Trabsmission Line Bid Document Khuppi To Tawang

GOVERNMENT OF ARUNACHAL PRADESH
DEPARTMENT OF POWER BID DOCUMENT PART-I

(BID GUARANTEE AND BID PROPOSAL) OF
CONSTRUCTION OF 132 KV SINGLE CIRCUIT TRANSMISSION LINE FROM KHUPPI TO TAWANG INCLUDING 132/33 KV SUB-STATION AT BOMDILA AND TAWANG WITH C/O 132 KV BAY (NEEPCO EXTENSION AT KHUPPI)
UNDER
SOCIAL INFRASTRUCTURE DEVELOPMENT FUND
SPECIFICATION NO:- DoP/TED/132 KV/KHUPPI-TWG
ESTIMATED COST: RS. 10130.03 LACS
TAWANG ELECTRICAL DIVISION
BID DOCUMENT PART-I

(BID GUARANTEE AND BID PROPOSAL)
LIST OF CONTENTS Sl. No. 1. Contents Section BPL: Bid Proposal Letter Page 1 to 4
Part-I
Section-Content
SPECIFICATION NO:- DoP/TED/132 KV/KHUPPI-TWG To The Executive Engineer (E) Tawang Electrical Division Department of Power Tawang - 790104 Bid Proposal Ref:
Page 1 of 4
Sub: Construction of 132 kV Single Circuit Transmission Line from Khuppi to Tawang i/c 132/33 kV Sub-Station at Bomdila and Tawang with C/O 132 KV Bay (NEEPCO Extension at Khuppi).
Dear Sirs, 1.0 We, the undersigned Bidder, have read and examined in detail the specifications and documents of the Bid Specification No. DoP/TED/132 KV/KHUPPI-TWG for Construction of 132 kV Single Circuit Transmission Line from Khuppi to Tawang i/c 132/33 kV Sub-Station at Bomdila and Tawang with C/O 132 KV Bay (NEEPCO Extension at Khuppi). and hereby propose to do the design, engineering, manufacture, testing at works, supply, transportation to and storage at site, insurance, erection, testing and commissioning of various sub-station equipments, equipment support structures and gantry structures etc. and associated civil works for the turn key works of Construction of 132 kV Single Circuit Transmission Line from Khuppi to Tawang i/c 132/33 kV Sub-Station at Bomdila and Tawang with C/O 132 KV Bay (NEEPCO Extension at Khuppi) as detailed in the specifications and documents of the subject bid. PRICES AND VALIDITY All the prices stated in the bid are firm and no price adjustment is applicable in line with the bidding documents. All the prices and other terms and conditions of this proposal are valid for a period of six (6) calendar months after the date of deadline of bid submission. We further declare that prices stated in our Proposal are in accordance with your "Instruction to Bidders" included in Condition of Contracts, Part-III (Vol-1/2) of bid documents. We do hereby confirm that our bid prices as quoted in Schedule 1 of Part-III (Vol-1/2) includes all the import duties and levies including license fees lawfully payable by us on imported items and all taxes, duties and levies applicable on bought-out components, materials, equipment and other items and confirm that any such taxes, duties and levies additionally payable shall be to our account. We further confirm that no tax & duties (except octroi/entry tax) in any form shall be payable by Owner for bought out items, which are dispatched by our sub-suppliers directly to the project site on sale-in-transit basis. We understand that the Owner shall provide us necessary Concessional Sales Tax Declaration Form, as concessional sales tax has been included in our bid price for such sale-in-transit transactions. Octroi/entry tax as applicable for destination site/state on bought/finished item, which shall be dispatched directly from our subvendor(s) works to your site (sale in transit) are not included in the bid price. The same has been indicated separately in Schedule-1 of Part-III (Vol-1/2). We understand that applicable octroi/entry tax in respect of such items of supply would also be reimbursed to us by the employer subject to furnishing of documentary proof. All taxes such as Excise Duty, Sales-Tax (but not surcharge in lieu of sales-tax), Octroi, local taxes, service tax and other levies, if any, applicable on the transaction between the Owner and Ourselves shall be to Owner's account and are not included in our bid price and are separately indicated at relevant columns in Schedule 1, 2, 3 & 4 of Part-III (Vol-1/2). The bid price, the price components of bid price viz., ex-works price, inland freight and insurance charges, erection price component, etc. are quoted by us in Schedule 1 to 4 of PartIII (Vol-1/2) of this proposal. We have studied Clause 14.0 of Section INB of Part-III (Vol-1/2), relating to Tax, and we hereby, declare that if any income-tax, surcharge on income-tax or any other corporate tax is attracted under the law, we agree to pay the same.
2.0 2.1
2.2
2.3
2.4
3.0
Part-I
Section-BPL
Page 2 of 4
4.0 4.1
CONSTRUCTION OF THE CONTRACT We declare that we are making the offer on the basis of a divisible supply-cum-erection contract on a single source responsibility basis. The supply portion of the contract will relate to supply of equipment/material on ex-works basis with freight and transportation including insurance; and the erection portion will relate to storage, erection, testing and commissioning etc. of equipment/material as defined in the bidding documents. However, we will have no objection in case owner decides to split the subject package into two separate contracts, one contract for supply of all equipment on ex-works basis with freight and insurance, and second contract on erection basis as defined in the bidding documents. We declare that the award of two contracts will not in any way dilute our responsibility for successful completion of the work as per the bidding documents and that both the contracts will have a cross-fall breach clause, viz. that a breach in one contract will automatically be considered as breach of other contract, which will confer on the owner the right to terminate the other contract at our risk and cost. BID GUARANTEE We have enclosed an STDR/TDR for an amount of Rs(in words) drawn on..(Name of Bank) pledge to you as Bid Guarantee as per clause 22.1 of Section INB Part III of contract conditions.
5.0
6.0
RIGHT TO ACCEPT/REJECT ANY OR ALL BIDS. We have studied and understood the clause 38.0 of Section INB part-III and declare that we will have no claim of any kind if any part or whole of our Bid is rejected or annul the bidding process at any time and at any stage prior to Award of contract, without assigning any reasons. Further such action of the Owner shall be without any liability or obligation to the affected Bidder.
7.0
BID PRICE We declare that our total price in Indian Rupees is given in para E of Schedule-1 of Part-III (Vol-1/2) for the entire scope of work as specified in your Bidding Documents.
8.0 8.1
DEVIATIONS We declare that the works shall be performed strictly in accordance with the specifications and documents except for the variations and deviations, all of which have been detailed out exhaustively in the following schedules, irrespective of whatever has been stated to the contrary anywhere else in our proposal. Sl. No. 1 2 Schedule Commercial Deviations Schedule Technical Deviations Schedule Schedule No. Schedule 2 of Part-II. Schedule 3 of Part-II
8.2
We confirm that specified stipulations of following clauses are acceptable to us and no deviation/exceptions are taken on any account, whatsoever in the following clauses. a) b) c) d) Terms of Payment Bid Guarantee Contract Performance Guarantee Liquidity Damages for Delay Clause Clause Clause Clause Clause Clause Clause Clause No. 34.7 of Section 'GCC, Part-III (Vol-1/2) and No. 7.0 of Section SCC, Part-III (Vol-1/2) No. 22 of Section 'INB, Part-III (Vol-1/2) and No. 10 of Section SCC, Part-III (Vol-1/2) No. 41 of Section 'INB, Part III (Vol-1/2) and No. 32 of Section GCC, Part III (Vol-1/2) No. 14.0 of Section GCC, part III (Vol-1/2) and No. 9 of Section SCC, Part-III (Vol-1/2) Section-BPL
Part-I
SPECIFICATION NO:- DoP/TED/132 KV/KHUPPI-TWG e) f) 8.3 9.0 Price basis and Payment Guarantees Clause Clause Clause Clause
Page 3 of 4
No. 13 of Section 'INB, Part-III (Vol-1/2) and No. 6 & 7 of Section SCC, Part-III (Vol-1/2) No. 15.0 of Section 'GCC', Part-III (Vol-1/2) No. 12 of Section SCC, Part III (Vol-1/2)
We have furnished herewith the Guarantee Declaration in Schedule-7 of Part-III (Vol-1/2). PERFORMANCE GUARANTEE We declare that the ratings/specifications and performance figures of the equipment to be supplied and erected by us for this package are guaranteed. The guaranteed particulars of different equipment in this package are enclosed in GTP.
10.0 BID PRICING We further declare that the prices stated in our proposal are in accordance with your 'Instruction to Bidders' included in Conditions of Contract, Part-III (Vol-1/2) of bid documents. 11.0 PRICE BASIS We declare that our price components are on FIRM BASIS AND DECLARED AT SCHEDULE 6 OF PART - II. 12.0 ADDITIONAL INFORMATION In addition to the information called for in these Proposal Sheets, we have included with this proposal information as listed in Schedule 4 of Part-II. We further confirm that such additional information does not imply any additional deviation beyond those covered in Schedule 2 & 3 of Part-II and in case of any contradiction between these additional information and other provisions of bid, the latter will prevail. 13.0 QUALIFICATION DATA We confirm having submitted the Qualification Data in three copies, as required by you in your 'Instruction to Bidders' in Part-III (Vol-1/2), and qualification requirement of Bidders in Part-II. Further, we have filled in information for qualifying requirement data in Schedule-1 of Part-II. In case, you require any further information in this regard, we agree to furnish the same in time. 14.0 WORK SCHEDULE If this proposal is accepted by you, we agree to submit engineering data, provide services and complete the entire work from time to time, in accordance with schedules indicated in the proposal. We fully understand that the Work Completion Schedule stipulated in this proposal is the essence of the contract, if awarded. The Completion Schedule of various major key phases of the work is indicated in Schedule 6 of Part-III (Vol-1/2). 15.0 CONTRACT PERFORMANCE GUARANTEE We further agree that if our proposal is accepted, we shall provide an irrevocable Contract Performance Guarantee, of value equivalent to fifteen percent (15%) of the Contract Price valid upto the end of ninety (90) days after the end of the contract warranty period in the form of an STDR/TDR drawn on any nationalized bank pledged in your favour within thirty (30) days from the date of issue of Letter of Award and formal agreement shall be signed thereafter not later than forty five (45) days from the Letter of Award (LoA).
16.0 BOUGHT OUT AND SUB-CONTRACTED ITEMS We are furnishing herewith in Schedule 5, of Part-III (Vol-1/2) the details of bought out items & sub-contracted items. 17.0 CHECK LIST We have included a Check List duly filled in, as Schedule 9 of Part-III (Vol-1/2).
Part-I
Section-BPL
Page 4 of 4
18.0 We, hereby, declare that only the persons or firms interested in this proposal as principals are named herein and that no other persons or firms other than those mentioned herein have any interest in this proposal or in the contract to be entered into, if we are awarded the contract, and that this proposal is made without any connection with any other persons, firm or party likewise submitting a proposal and that this proposal is in all respect for and in good faith, without collusion or fraud. 19.0 We have inspected the project site and got full acquaintance with the topography and other sites conditions, and accordingly submits our bid proposal as per instructions at Clause-9 of INB. Dated this .......................................... day of .................................... 200.
Signature: .......................................... in the capacity of ..........................................., duly authorized to sign for and on behalf of .....................................................................................
(IN BLOCK CAPITAL LETTERS) Bidders Name & Address: Person to be contacted: Phone landline: Mobile Number: Fax Numbers: E-Mail address:
Part-I
Section-BPL
DEPARTMENT OF POWER BID DOCUMENT PART-II

(PRE-QUALIFICATION DATA & DEVIATION STATEMENT) OF
UNDER
BID DOCUMENT PART-II

(PRE-QUALIFICATION DATA & DEVIATION STATEMENT)
LIST OF CONTENTS Sl. No. 1. Contents Section QR: Qualification Requirement. Page 1 to 3
2.
Section Annexure: A & B
4 to 6
3.
Section Schedule : 1, 2, 3, 4 , 5 & 6
7 to 18
Part-II
Section-Content
QUALIFYING REQUIREMENT
(QR)
Part-II
Section-QR
QUALIFYING REQUIREMENT (QR) OF THE BIDDER In addition to the general qualification requirement set forth in clause 2.0 of Section INB the bidder has to qualify the following criteria for selection to the next stage of the bid:
1.0 The bidder must have qualified the stage I ( Part-I) of the bid. 1.1
(i) the bidder must have successfully executed at least two Sub-Stations of 132 KV class or above voltage during the last 10 (ten) years as on the date of Bid opening and which must be in satisfactory operation for at least 2 (two) years as on the date of Bid opening. AND (ii) the bidder must have successfully executed at least 100 KM of 132 KV class or above voltage transmission line during the last 10 (ten) years as on the date of Bid opening and which must be in satisfactory operation for at least 2 (two) years as on the date of bid opening. AND The bidders must have successfully executed at-least one single power/electrical project costing not less than Rs 20.00 crores in hilly areas not below an altitude of 2000 meters MSL during last ten years and which must be in successful operation in the last 2 years from the date of opening the bid. AND
(iii)
(iv)
must have their Assessed Available Bid Capacity (herein after referred to as ABC) equal to or more than the total bid value. The ABC will be calculated as under:
ABC = (A*N*M - B) Bid Amount Where A = Annual average value of Works of similar nature executed during the last five years (updated to the price level of the last year at the rate of 8 percent a year) taking into account the completed as well as works in progress. N = Number of years prescribed for completion of the works for which bids are invited (period up to 6 months to be taken as half-year and more than 6 months as one year). M = 2.5 B = Value, at the current price level, of existing commitments and on-going works to be completed during the period of completion of the works for which bids are invited. Note: The statements showing the value of existing commitments and on-going works as well as the stipulated period of completion remaining for each of the works listed should be countersigned by the Engineer in charge, not below the rank of an Executive Engineer or equivalent.
Part-II Section-QR
(iv) Bidders meeting the above qualifying criteria shall face disqualification if they have: a) Made misleading or false representations in the forms, statements, affidavits and attachments submitted in proof of the qualification requirements; and/or Record of poor performance such as abandoning the works, not properly completing the contract, inordinate delays in completion, litigation history, or financial failures etc. Participated in the previous bidding for the same work and had quoted unreasonably high or low bid prices and could not furnish rational justification for it to the Employer.
b)
c)
1.2
The bidder(i) shall submit the bids as single firm and submit an affidavit to that effect as per clause-10 of section INB, Part-III. (ii) must be free from all legal encumbrance and submit an affidavit to that effect. (iii) must submit supporting documents of legal status namely like contractor registration/license/Company registration etc.
1.3 The average annual turn over of the bidders for the best three financial years out of last five (5) financial years of the bidder as annualized should be at least Rs. 5065.00 lacs. 1.4 The bidder shall have Liquid Assets (LA) and/or evidence of access to or availability of credit facilities of not less than 20% of bid amount. The bidder shall furnish documentary evidences in support of the qualifying requirement stipulated above as per Schedule-1 of Part-II and as per Annexure-B. 1.5 The bidder shall clearly list out all Commercial or Technical deviations from the bid stipulation as per Schedule-2 & Schedule-3 of this document. 1.6 The bidder shall list out all additional information furnished along with the bid as per Schedule-4 of this document. 1.7 1.8 The bidder shall list out all information regarding ex-employees of the Department of Power, Arunachal Pradesh, as per Schedule-5 of this document. The bidder shall declare that their prices are firm basis as per Schedule 6 of this document.
*********
Part-II
Section-QR
ANNEXURE
Part-II
Section-Annexure
ANNEXURE-A PROFORMA OF JOINT UNDERTAKING BY MANUFACTURER ALONGWITH THE BIDDER/CONTRACTOR (IN NON-JUDICIAL STAMP PAPER OF APPROPRIATE VALUE)
OMITTED
Part-II
Section-Annexure
Annexure-B
FORMAT FOR EVIDENCE OF ACCESS TO OR AVAILABILITY OF CREDIT FACILITIES
BANK CERTIFICATE This is to certify that M/s. ...................................., (Full Name & Address), who are submitting their bid to the Executive Engineer (E), Tawang Electrical Division, Department of Power, Tawang-790104, DoP/TED/132KV/KHUPPI-TWG
and
against their tender specification No.

notified vide No.
....................................., is our customer for the past . years.
Their financial transactions with our bank have been satisfactory. They enjoy the following fund based and non-fund based limits including for guarantees, L/C (Letter of Credit) and other credit facilities with us against which the extent of utilization as on date is also indicated below:
Sl. No. Sanctioned Limit as on date . Utilization as on date ............
Type of Facility
This letter is issued at the request of M/s ...................................................................................
Sd/Name of Bank: ........................................ Name of Authorized Signatory: ...................... Designation: ................................................................................ Phone No.: .............................................................................. Address: ......................................................................................
SEAL OF THE BANK ****
Part-II
Section-Annexure
SCHEDULES
Part-II
Section-Schedule
CONTENTS Sr. No. 1. 2. 3. 4. 5. 6. Description Schedule-1 Schedule-2 Schedule-3 Schedule-4 Schedule-5 Schedule-6 Page No. 9 14 15 16 17 18
Part-II
Section-Schedule
Schedule-1
Bidder's Name & Addres
To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790104
Dear Sirs, In support of our meeting the Qualifying Requirements (QR) for Bidders, stipulated in the QR Section of Part-II of Bidding Documents, we furnish herewith, the details/documents/confirmations etc. as follows: 1.0 Constitution or legal status of the Bidder 1.1 Copies of original constitution, place of registration and principal place of business are enclosed with our Bid at . (Attachment No. to be indicated). Written power of attorney of the signatory of the bid to commit the bidder is enclosed with our Bid at (Attachment No. to be indicated).
1.2
2.0 (Reference: Para 1.1 of QR-Section of Part-II) 2.1 We meet the stipulated QR, as mentioned at clause No. 1.1 through to 1.4 of Part II based on the following: 2.1.1 Qualifying informations: a). Table-A: Completed Works. Name of Bidder:
Sl. No.
Name of Project
No. of Sr. No of years of Name of Contract no Stipulated Actual date Description Value of satisfactory Certificate customer/E and date of Date of of of work Contract operation as enclosed as mployer Order completion completion on date of attachment bid opening
Part-II
Section-Schedule
10
b). Table B: Ongoing Works and Existing Commitments. Name of Bidder:
Sl. No.
Name of Project
Name of Description customer/E of work mployer
Value of Contract
Contract no and date of Order
Stipulated date of completion
Expected date of actual compltion
Sr. No of Certificate enclosed as attachment
*Name of the proposed sub-contractor is .

Documents in support of Para 2.1 above are enclosed with our bid at ... (Attachment No. to be indicated).
Note: Continuation sheets, of like size and format, may be used as per bidder's requirements and annexed to this Schedule and suitably put cross reference.
2.1.2 Calculation of ABC in pursuant to clause 1.1 (iii) of Section QR, part II. ABC = A*N*M-B Bid amount Note: The Bidder must calculate the ABC and indicate the calculation herein. 2.2 (Reference: Para 1.2 of QR Section of Part-II) 1.2.1 We have submitted our Bid as a Single Firm/Company who meets all the qualification requirement set forth in para 1.1 through to 1.4 of QR-Section of Part-II as per stipulated qualifying requirements are furnished in the format given at tables A and B along with customers certificate towards satisfactory operation.
1. Continuation sheets, of like size and format, may be used as per Bidders requirements and annexed to this Schedule.
Documents in support of above are enclosed with our Bid at . (Attachment No. to be indicated). Note:
2.3 (Reference: Para 1.3 & 1.4 of QR-Section of Part-II) [Single Firm] 2.3.1 The details/documents, required as per above are included/furnished in our bid as indicated below: i) We confirm that our Minimum Average Annual Turnover for the best three years out of last five financial years is Rs. . (in figures and words). ii) We hereby confirm that our Liquid Assets and/or evidence of access to or availability of Credit Facilities as on (Date) is Rs. .... (in figures and words).
Part-II
Section-Schedule
11
2.4 (Reference: Para 1.3, 1.4 of QR-Section of Part-II) 2.4.1 i) A certificate from the Banker(s) as per format, Annexure-B is enclosed (as stipulated in QR) with our Bid at (Attachment No. to be indicated). ii) Annual Reports/Profit & Loss Statement/Balance Sheets together with Additional Statements of Accounts for last five years are enclosed with our Bid at (Attachment Nos. to be indicated) iii)Details of data/documents, as stipulated in QR, is enclosed with our Bid at (Attachment No. to be indicated).
2.5 Following documents are furnished in our bid as indicated: i) Copies of original documents defining the constitution or legal status, place of registration and principal place of business are enclosed with our Bid at . (Attachment No. to be indicated). ii) Written power of attorney of the signatory of the bid to commit the bidder is enclosed with our Bid at (Attachment No. to be indicated). iii)The qualification and experience of key personnel proposed for carrying out the work are indicated in the format given at 1.6.3 of these Bid Proposal Sheets. Other documents enclosed at (Attachment No. to be indicated). 2.6 (a) Description of Plant
Item of equipment Equipment Information Current Status 1. Name of Manufacturer 3. Capacity 5. Current Location 6. Details of current commitments .. Source 7. Indicate source of the equipment (tick) Owned Rented Leased Specialy manufactured 2. Model and power rating 4. Year of manufacture
Omit the following information for equipment owned by the Bidder.
Owner
8. Name of Owner 9. Address of Owner: Telephone Contact name and title Fax Telex Details of rental/lease/manufacture agreements specific to the project. .
Agreement
For each manufacturer, separate sheet should be used.
Part-II
Section-Schedule
12
2.6 (b) Annual Turnover Data for the last Five years:
Year 1. 2. 3. 4. 5. Annual Turnover Data (Rs.) Turnover
2.6 (c) Details of Financial Standing:

Actual Financial information in Indian Rupees 1
1. 2. 3. 4. 5. 6.
Projected Next Five Years 2 3 4
Previous Five Years 2 3 4
Total Assets Current Assets Total Liabilities Current Liabilities Profit before Taxes Profit after Taxes
Proposed resources of financing to meet the cash flow demands of the Project, net of current commitments.
Sl. No.
Resources of Financing
Amount (Indian Rupees)
1. 2. 3. 4.
2.6 (d) Details of Bidders banks:

Banker Name of Banker Address of Banker: . Telephone Contact name and Title Fax Telex
Part-II
Section-Schedule
13
2.6 (e) Litigation History:

Year Award FOR or Name of client, cause of AGAINST the Bidder litigation and matter in dispute Disputed amount (Current Value in Indian Rupees)
2.7 Details of qualification and experience of key personnel proposed for carrying out the works.
Past Experience Name of Personnel Degree/ Diploma Responsibilities/ Relevant experience Name of Employer Year of Passing Position held
From
Date : Place :
(Signature) ........................................... (Printed Name) .................................... (Designation) ....................................... (Common Seal) ...................................
Note:
1.
Continuation sheets, of like size and format, may be used as per Bidders requirements and annexed to this Schedule.
Part-II
To
Sl. No.
Branch
Section-Schedule
14
Schedule-2
(Commercial Deviations) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790104
Dear Sirs, Subject: Commercial Deviations for Package. The following are the Commercial Deviations and variations from and exceptions to the specifications and documents for the subject package. These deviations and variations are exhaustive. Except for these deviations, the entire work shall be performed as per your specifications and documents.
Sl. Volume/ Ref./ Page As specified in No. Clause No. the specification
Commercial deviation and Withdrawal variation to the Price in Rupees specification
Date: Place:
(Signature).................................................. (Printed Name)............................................ (Designation)............................................. (Common Seal)...........................................
Note: Continuation sheets of like size and format may be used as per Bidder's requirements and annexed to this Schedule.
Part-II
Section-Schedule
15
Schedule-3
(Technical Deviations) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Department of Power Tawang - 790104
Dear Sirs, Sub. : Technical Deviations for the Package. The following are the Technical Deviations and variations from and exceptions to the specifications and documents for the subject package. These deviations and variations are exhaustive. Except for these deviations, the entire work shall be performed as per your specifications and documents.
Sl. No. Volume/ Clause Ref./ Page No. Technical deviation Withdrawal As specified in and variation to the Price in the specification specification Rupees
Date: Place:
Note: 1. 2.
Continuation sheets of like size and format may be used as per Bidder's requirements and annexed to this Schedule. The deviations and variations, if any, shall be brought out separately for each of the equipment.
Part-II
Section-Schedule
16
Schedule-4
(Additonal Information) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790104
Dear Sirs, We have enclosed with our proposal the following additional information for the subject package.
Sl. No. Brief description of information Reference & Page No.
Date: Place:
Note: Continuation sheets of like size and format may be used as per Bidder's requirements and annexed to this Schedule.
Part-II
Section-Schedule
17
Schedule-5
(Information regarding Organizational Set Up) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790104
We hereby furnish the details of ex-employees of Arunachal Pradesh Department of Power who had retired/resigned at the level of Executive Engineer and above from Arunachal Pradesh Department of Power and subsequently have employed by us:
Sl. No. 1 2 3
Name of Person with designation Date of Retirement/resignation in Arunachal pradesh from Arunachal Pradesh Department of Power Department of Power
Date of joining and designation in our Organization
Date: Place:
(Signature)................................................... (Printed Name)............................................ (Designation)............................................... (Common Seal)............................................
Part-II
Section-Schedule
18
Schedule-6
FIRM PRICE DECLARATION SCHEDULE Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790104
We hereby DECLARE THAT OUR PRICES ARE ON FIRM PRICE BASIS in pursuant to clause 6.15 of Section SCC and clauses 12.1 and 15 of Section INB.
Date: Place:
Part-II
Section-Schedule
DEPARTMENT OF POWER BID DOCUMENT PART-III

(Volume-1/2)
CONDITIONS OF CONTRACT (SUPPLY-CUM-ERECTION) FOR

UNDER
SPECIFICATION NO:- DoP/TED/ 132 KV/KHUPPI-TWG
BID DOCUMENT
Part-III (Volume-1/2) CONDITIONS OF CONTRACT (SUPPLY-CUM-ERECTION)
LIST OF CONTENTS
Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 Contents (Sections Containing Conditions of Contract) Section INV: Invitation to BID. Section INB: Instruction to Bidders. Section GCC: General Terms & Conditions of Contract. Section ECC: Erection Conditions of Contract. Section SCC: Special Conditions of Contract. Section - GTC: General Technical Condition. Section Annexure Section- Schedule Guaranteed Technical Particulars Single Line Diagram Page No. 1 to 4 5 to 25 26 to 51 52 to 74 75 to 83 84 to 93 94 to 115 116 to 174 175 to 230 231 to 233
Part-III (Vol-1/2)
Section-Content
INVITATION TO BID
(INV)
Part-III (Vol. 1/2)
Section-INV
INVITATION TO BID (INV) CONTENTS Clause No. 1.0 Description Notice Inviting Tender Page No. 3-4
Part-III (Vol. 1/2)
Section-INV
GOVERNMENT OF ARUNACHAL PRADESH OFFICE OF THE CHIEF ENGINEER (POWER) TRANSMISSION, PLANNING & MONITORING ZONE DEPARTMENT OF POWER, VIDYUT BHAWAN :::: ITANAGAR No. CE(P)/TP&M/W&C/CRT/DONER-SIDF-NLCPR/2012-13 Dtd.________
NOTICE INVITING TENDER On behalf of the Governor of Arunachal Pradesh, the Chief Engineer (Power), Transmission, Planning & Monitoring Zone, Itanagar, Deptt. of Power, Govt. of Arunachal Pradesh invites bids from eligible and reputed contractors/ companies for turnkey execution of the following work in the time frame given herein:Estimated cost of the work (Rs.lacs) Bid guarante e amount (Rs. lacs) Date and Time for Tender sale Last date and time of receipt of application for purchase of tender documents 24/11/12 upto 1500 hrs Last date & time for submission of tender documents Date & Time for opening of tender Cost of Tender (Non Refunda ble) Compl etion time
Sl. No Name of work
Construction of 132 KV Single Circuit Transmission line from Khuppi to Tawang including 132/33 KV SubStation at Bomdila and Tawang with C/o 132 KV Bay (NEEPCO Extension at Khuppi)
10130.03
111.30
12/11/12 to 26/11/12 upto 1600 hrs
17/12/12 at 1200 hrs
17/12/12 at 1500 hrs
15000.00
30 months
The non-transferable bid documents shall be available for sale in the office of the Executive Engineer (E), Tawang, Department of Power, on above specified date on all working days by paying the tender cost by Demand Draft drawn in favour of the Executive Engineer (E), Tawang payable at S.B.I., Tawang. The prospective bidder(s) shall have to apply for bid documents in writing on contractors/companys printed official letter pad with detailed postal address, telephone, mobile & fax numbers and e-mail etc. to the Executive Engineer (E) Tawang. The application must be accompanied by evidence of having experience of carrying out such similar works worth at-least equivalent to the estimated cost. Certified tender paper shall also be available in limited numbers, from SSW, O/o the Chief Engineer (P), (Transmission, Plg & Monitoring) with issue order from EE(E), Tawang, if advance request is received well in time at Tawang. The NIT and bid documents may be viewed at www.arunachalpower.org.in. However bids submitted in downloaded bid documents shall not be accepted. Prospective bidders should fulfill the GENERAL INFORMTION FOR PURCHASING BID DOCUMENT conditions as posted on the website. The bids shall be addressed to the Executive Engineer (E), Tawang Electrical Division and submitted in the office of the Chief Engineer (Power), Transmission, Planning & Monitoring Zone, Itanagar. General Information 1. The bid document shall consist of the following parts namely, Part-I (Bid Guarantee and Bid Proposal Letter), Part-II (Bid Qualification Data & Deviation Statement) and Part-III (Condition of Contract & Technical Specifications)
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2. The prospective bidder should satisfy themselves of the adequateness and proper sealing of the bid document done by the department before taking them away from the issuer. Any claim of improper sealing by the bidder at the time of opening shall not be entertained. 3. Prospective purchaser of the bid documents shall have to furnish letter of authority & proof of being genuine representative of the bidder along with copies of registration of company/proprietorship etc. 4. The application for tender document accompanying with the cost of bid document, along with a set of attested copies of the all supporting documents has to be addressed and submitted to the following address: The Executive Engineer (E) Tawang Electrical Division Department of Power Tawang- 790104 5. The Tender document shall be sold only to authorized representative in person on payment of tender cost by Demand Draft in favour of The Executive Engineer (E), Tawang, payable at SBI Tawang. 6. The tender documents shall not be sent or received through postal or courier services. 7. A pre-bid conference shall be taken by the Chief Engineer (P), Transmission, Planning & Monitoring , Deptt.of Power, Itanagar with the intending bidders at 1030 Hrs. on 3rd December 2012 to enable clarification, if any, with regard to the procedure for filling up the tender documents. 8. For any other information, Executive Engineer (E), Tawang Electrical Division, Department of Power, Tawang may be contacted at 03794-222249 (O), , 223745 (Fax) & email: electricaltawang@gmail.com The tender shall be opened & processed by a committee appointed for the purpose in the office of Chief Engineer (Power), Transmission, Planning & Monitoring Zone at the scheduled time & date. The Department of Power reserves all the rights to cancel/ withdraw the bid in full or part without assigning any reason for such decision and to place order in full or in part. Such decision will not incur any liability whatsoever on the part of Department of Power consequently.
Chief Engineer (Power) Transmission, Planning & Monitoring Zone Vidyur Bhawan, DoP, Itanagar (A.P) No.CE(P)/TP&M/W&C/CRT/DONER-SIDF-NLCPR/2012-13 Dtd.________ Copy to:1) PPS to HCM for information to the Honble Chief Minister. 2) PS to HMP, for information to the Honble Minister (Power). 3) The Honble Parliamentary Secretary (Power), for information 4) PS to Chief Secretary, Govt. of AP, Itanagar, for information. 5) The Secretary (Power), Govt. of AP, Itanagar, for information. 6) The Chief Engineer (Power), Eastern, Western, & Central Electrical Zone, Itanagar. 7) All Superintending Engineers, Department of Power, Arunachal Pradesh. 8) All Executive Engineers, Deptt. of Power, Arunachal Pradesh. 9) The Director of Information & Public Relations, Naharlagun, with a request to get the enclosed Press Notice (NIT) published as requested in endorsement. 10) Notice Board 11) I/T Section, O/o the CE(P), TP&M, for uploading of the NIT & other tender documents. Chief Engineer (Power) Transmission, Plg & Monitoring Zone Vidyur Bhawan, DoP, Itanagar (A.P)
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INSTRUCTIONS TO BIDDERS
(INB)
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CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0 35.0 36.0 37.0 38.0 39.0 40.0 41.0 42.0 43.0
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Description General Instruction Qualifying Requirements of Bidders Cost of Bidding Contents of Bidding Document Understanding of Bid Document Clarifications on Bid Documents Amendment to Bidding Document Language of Bid Local Conditions Documents Comprising the Bid Scope of the Proposal Bid Price Price Basis & Payments Taxes & Duties Price Basis Time Schedule Contract of Quality Assurance Insurance Maintenance Tools & Tackles Erection Tools & Tackles Brand Names Bid Guarantee Period of Validity of Bids Format of Bid Signature of Bids Sealing & Marking of Bids Deadline for Submission of Bids Late Bids Modifications & Withdrawal of Bids Information required with the proposal Opening of Bids Clarification of Bids Preliminary Examination Definitions and Meanings Comparison of Bids Contracting the Owner Award Criteria Right to Accept any Bid and to Reject any or all Bids Notification of Award Signing of Contract Contract Performance Guarantee Corrupt or Fraudulent Practices Acceptance of Award Appendices to INB
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Section-INB
SECTION INB INSTRUCTION TO BIDDERS A. INTRODUCTION

1.0 1.1 GENERAL INSTRUCTIONS The Department of Power, Government of Arunachal Pradesh (implementer of the project) hereinafter called Owner will receive bids in respect of equipment to be furnished and erected as set forth in the accompanying Specifications. All bids shall be prepared and submitted in accordance with these instructions. QUALIFYING REQUIREMENTS OF BIDDERS The essential qualifying requirement of this Bid Package has been stipulated in Part-II of this document. The bidder shall have to provide satisfactory evidence for both essential and general qualification requirements mentioned in part II and the following respectively. This Bidding is open to any manufacturer/erector/Contractor/Firm who provides satisfactory evidence concerning the following that he: a. is a qualified manufacturer/erector/Contractor/Firm who regularly manufactures or installs the equipment of the type specified and has adequate technical knowledge and practical experience; b. does not anticipate change in the ownership during the proposed period of work (if such a change is anticipated, the scope and effect thereof shall be defined); c. has adequate financial stability and status to meet the financial obligation pursuant to the scope of the works (the Bidders should submit at least 5 copies of their profit and loss account and balance sheet for the last five years); d. (i) For Manufacturer: has adequate plant and manufacturing capacity available to perform the works properly and expeditiously within the time period specified. The evidence shall consist of written details of the installed manufacturing capacities and present commitments (excluding the work under this Specification) of the Bidder or his principal. If the present commitments are such that the installed capacity results in inadequacy of the manufacturing capacities to meet the requirement of equipment corresponding to this bid, then the details of alternative arrangements to be organized by the Bidder for this purpose and which shall meet the Owners approval, shall also be furnished;
(ii) For Erector:
2.0 2.1
2.2
has adequate capacity for erection and installation to perform the works properly and expeditiously within the time period specified. The evidence shall consist of written details of the capacities and present commitments (excluding the work under this specification) of the Bidder or its principal. If the present commitments are such that may result in inadequacy to undertake the works corresponding to this bid (work under this specification), then the details of the alternative arrangements to be organized by the Bidder for this purpose and which shall meet the Owners approval, shall also be furnished;
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e. has adequate field services organization to provide the necessary field erection and management services required to successfully erect, test and commission the equipment as required by the Specifications and Documents; and f. has established quality assurance systems and organization designed to achieve high levels of equipment reliability, both during his manufacturing and field installation activities. 2.2.1 Majority publicly owned enterprises domiciled in India may be eligible to qualify if, in addition to meeting all the qualifying requirements, they also: a. are commercially oriented legal entities distinct from Department of Power and are not a government owned department; b. are financially autonomous, as demonstrated by requirements in their constitutions to provide separate audited accounts and return on capital, powers to raise loans and obtain revenues through the sale of goods or services; and c. are managerially autonomous. d. In addition, the qualifying requirements stated in the accompanying Special Condition of Contract also apply. 2.3 The above stated requirements are a minimum and Department of Power reserves the right to request for any additional information and also reserves the right to reject the Proposal of any Bidder, if in the opinion of Department of Power, the qualification data is incomplete or the Bidder is found not qualified to satisfactorily perform the Contract. COST OF BIDDING The Bidder shall bear all costs and expenses associated with preparation and submission of its bid including post-bid discussions, technical and other presentations etc, and Department of Power will in no case be responsible or liable for those costs, regardless of the conduct or outcome of the bidding process.
3.0 3.1
B. THE BIDDING DOCUMENTS

4.0 4.1 CONTENTS OF BIDDING DOCUMENT The goods and services required, bidding procedures and Contract terms are prescribed in the Bidding Document. In addition to the Invitation to Bids, the Bidding Documents of this part is a compilation of the following sections: a. Instructions to Bidders Section INB. b. General Conditions of Contract -Section GCC. c. Erection Conditions of Contract-Section ECC. d. Special Conditions of Contract-Section SCC. e. General Technical Condition-Section GTC. f. Guaranteed Technical Particulars GTP
g. Bid Form and Price Schedules. h. Technical Data Sheets. 5.0 UNDERSTANDING OF BID DOCUMENTS
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A prospective Bidder is expected to examine all instructions, forms, terms and specification in the Bid documents and fully inform himself as to all the conditions and matters which may in any way affect the scope of work or the cost thereof. Failure to furnish all information required by the Bid document or submission of a Bid not substantially responsive to the Bid document in every respect will be at the Bidders risk and may result in the rejection of its bid. CLARIFICATIONS ON BID DOCUMENTS If the prospective Bidder finds discrepancies or omissions, in specifications and document or is in doubt as to the true meaning of any part, he shall at once make a request, in writing, for an interpretation/clarification, to Department of Power in triplicate. The Department of Power, then, will issue interpretation(s) and clarification(s) as he may think fit in writing. After receipt of such interpretation(s) and clarification(s), the Bidder may submit his bid but within the time and date as specified in the Invitation to Bid. All such interpretations and clarifications shall form a part of the Bidding Document and shall accompany the Bidders Proposal. A prospective Bidder requiring any clarification on Bidding Document may notify Department of Power in writing. Department of Power will respond in writing to any request for such clarification of the Bidding Document which it receives not later than fifteen (15) days prior to the deadline for submission of bids prescribed by Department of Power. Written copies of Department of Powers response (including an explanation of the query but without identifying its source) will be sent to all prospective Bidders who have received the Bidding Document. Verbal clarification and information given by Department of Power or his owner(s) or his representative(s) shall not in any way be binding on Department of Power. AMENDMENT TO BIDDING DOCUMENT At any time prior to the deadline for submission of bids, Department of Power may, for any reason, whether at its own initiative or in response to a clarification requested by a prospective Bidder, modify the Bidding Document by amendment (s). The amendment will be notified in writing or by telex or cable to all prospective Bidders, which have received the Bidding Document at the address contained in the letter of request for issue of Bidding Document from the Bidders. Department of Power will bear no responsibility or liability arising out of non-receipt of the same in time or otherwise. In order to afford prospective Bidders reasonable time in which to take the amendment into account in preparing their Bids, Department of Power may, at its discretion, extend the deadline for the submission of bids by a maximum period of 15 days. Such amendments, clarifications, etc, shall be binding on the Bidders and will be given due consideration by the Bidders while they submit their bids and invariably enclose such documents as a part of the bid. C. PREPARATION OF BIDS
6.0 6.1
6.2
7.0 7.1
7.2
7.3
7.4
8.0 8.1
LANGUAGE OF BID The Bid prepared by the Bidder and all correspondences and documents relating to the Bid, exchanged by the Bidder and Department of Power shall be written in the English language, provided that any printed literature furnished by the Bidder may be written in another language so long as accompanied by an English translation of its pertinent passages. Failure to comply with this may disqualify a bid. For purposes of interpretation of the Bid, the English translation shall govern.
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9.0 9.1
LOCAL CONDITIONS It will be imperative on each Bidder to fully inform himself of all local conditions and factors, which may have any effect on the execution of the Contract covered under these documents and specifications. Department of Power shall not entertain any request for clarifications from the Bidders, regarding such local conditions. It must be understood and agreed that such factors have properly been investigated and considered while submitting the Proposals. No claim for financial adjustment to the Contract, awarded under these specifications and documents, will be entertained by Department of Power. Neither any change in the time schedule of the Contract nor any financial adjustments arising thereof shall be permitted by the Owner, which are based on the lack of such clear information or its effect on the cost of the Works to the Bidder.
9.2
10.0 DOCUMENTS COMPRISING THE BID The Bid document consists of Three (3) Part namely, Part-I, Part-II & Part-III. The Bid shall be submitted in 3 (three) parts in separate sealed envelops along with each part of the Bid volumes properly super-scribed as follows: Part-I: Bid Guarantee: This part of the tender shall Contain Bid Guarantee as per the stipulations of the Bid Documents. (As per format Annexure-1 of Part-I) and also Bid proposal letter. Part-II: Pre Qualification Bid Data & Deviation Statement: This part contains the Documentary Evidence of the Bidder fulfilling the Qualifying Requirements (Q.R.) stipulated in the NIT/Bid Document. The document to be submitted shall include copies of the relevant work order/ purchase order/Award letters/Agreements etc. and corresponding completion certificates issued by the concerned clients. The Bidder shall also furnish copies of the audited balance sheet and Profit and Loss Accounts for the last five financial years (w.r.t. the Bid Opening Date) in support of their meeting the Financial QR. The Bidder shall also submit all such other documents deemed necessary in support of their meeting the stipulated QR and its credentials. Further, any deviation from Technical Specification & Commercial terms shall be enclosed as per schedule 2 & 3 of Part-II. The Bidders shall submit an affidavit declaring that the bidder is a single firm and all the qualifying details are qualifications of the same firm submitting the bid. Part-III: Techno-Commercial Bid & Price Bid: This part shall contain priced Bid consisting of Bidders Technical Proposal i.e. GTP, Bid drawings etc. along with his Commercial Terms, Payment Terms in conformity with the Bid Documents. This part shall also contain prices as per the format indicated in the Bid Price Schedule both in figures and words. 10.1 The Bidding Documents are available for viewing at www.arunachalpower.org.in. However bids submitted in downloaded Bid Documents shall be unacceptable. 11.0 SCOPE OF THE PROPOSAL 11.1 The scope of the Proposal shall be on the basis of a single Bidders responsibility, completely covering all the equipments and their erection specified under the accompanying Technical Specifications. It will include the following: (i)
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Detailed design of the equipment.

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(ii) (iii) (iv) (v) (vi) (vii)
Complete manufacture including shop testing. Providing engineering drawing & operational manual etc. Packing & transportation from the manufactures works to the site. Reliability test and performance test on completion of commissioning. Erection, testing and commissioning of all the equipments. Submission of specifications, test certificates of all material supplied.
11.2 Bids containing deviations from provisions relating to the following clauses will be considered as non-responsive: a) Bid Guarantee: Clause 22.0, Section INB, Part-III, Conditions of Contract. b) Price Basis and Payments: Clause 13, Section INB, Part-III (Vol. ), Conditions of Contract. c) Contract Performance Guarantee: Clause 41.0, Section INB, Part-III (Vol. ), Conditions of Contract. d) Liquidated damages: Clause 14.0, Section GCC, Part-III (Vol. ), Conditions of Contract. e) Guarantee: Clause 15.0, Section GCC, Part - III (Vol. ), Conditions of Contract. f) Payment: Clause 34.0, Section GCC, Part - III (Vol. ), Conditions of Contract. Department of Powers determination of a Bids responsiveness is to be based on the contents of the Bid itself without recourse to extrinsic evidence. 11.3 Bids not covering the above entire scope of Works shall be treated as incomplete and hence rejected. 12.0 BID PRICE 12.1 The Bidder shall quote in the appropriate schedule of Bid Form lump-sum price for the entire scope of works (covered under the Bidding Document) and also the unit rates of the goods it proposes to supply under the Contract on FIRM PRICE BASIS 12.2 The Bidder shall also furnish the price break-up in the appropriate schedules of Bid Form to indicate the following: i Ex-works price of the equipment/materials (including tools and tackles etc.) delivery of the
ii. Charges for inland transportation and insurance for equipment/materials up to their final destinations.( i.e at site )
iii. Lump-sum charges towards unloading, storage, insurance, erection (including insurance during construction period), testing & commissioning. iv. Sales Tax and any other statutory levies payable on the transactions between Department of Power and the Bidder. v. Any other charges as per the requirement of Special Conditions of Contract/Technical Specifications. vi. In-case the price breakup is not given or unless specifically expressed otherwise, it will be treated as non responsive and shall be rejected. 12. 3 Based on their experience, capabilities and development works etc., the bidder may, in addition to base proposal, offer alternative proposal(s), for reasons of economy or better performance. But in all such cases, the base proposal shall be strictly in line with the requirements as stipulated in the Bid documents and only such base proposal shall be considered for the purpose of evaluation of proposals. Should the bid by the
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successful bidder contain such alternate proposal, then the owner at its discretion may accept the same at the time of award of contract. 13.0 PRICE BASIS AND PAYMENTS 13.1 The Bidders shall quote in their Proposals lump-sum price for the entire scope of works covered under the Technical Specifications as required in the Bid Proposal Sheets on FIRM PRICE BASIS unless otherwise specified in the Special Conditions of Contract. Bidders quoting a system of pricing other than that specified shall be rejected. 13.2 Bidder shall indicate Bid prices in Indian Rupees only. 14.0 TAXES AND DUTIES 14.1 All customs duties, excise duties, sales taxes and other statutory levies payable by the Bidders in respect of the transaction between the Bidders and their vendors/subsuppliers while procuring any components, sub-assemblies, raw materials and equipment shall be included in the Bid price and no claim on this behalf will be entertained by Department of Power. However, octroi/entry tax as applicable for destination site/state on all items of supply including bought-out finished items (as identified in the Contract), which shall be dispatched directly from the sub-vendors works to Employers site (sale-in-transit) shall not be included in the bid price. The applicable octroi/entry tax in respect of the said items of supply would be reimbursed to the Contractor separately by Department of Power subject to furnishing of documentary proof. Further, service tax as applicable on services that are not provided directly by the Contractor to Department of Power viz. transportation & insurance shall be included in the Bid price and any such taxes additionally payable will be to the Contractors account and no separate claim on this behalf will be entertained by Department of Power. However, applicability of service tax shall be ascertained and if applicable on services (for which the charges are payable by Department of Power) that are provided directly by the Contractor to the Employer viz. type tests, erection, testing and commissioning shall not be included in Bid price, but indicated separately, and the same shall be reimbursed to the Contractor by Department of Power subject to furnishing of documentary proof.
14.2 Sales tax, excise duties, local taxes and other levies in respect of the transactions between Department of Power and the Contractor under the Contract, if any, shall not be included in the Bid price but they should be indicated separately wherever applicable in the Bid Proposal Sheets. Whenever ex-works price is quoted exclusive of Excise duty applicable on the transaction between Department of Power and the Contractor, then the due credit under the MODVAT (Modified Value Added Tax) scheme, as per the relevant Government policies wherever applicable, shall be taken into account by the Bidder while quoting bid price.
14.3 In respect of transactions solely between Department of Power and the Contractor (for
dispatches made from the Contractors works under the Supply Contract), Sales Tax, Excise Duties, local taxes and other levies shall be paid/reimbursed by Department of Power at the applicable rate at the time of dispatch, scheduled or actual, whichever is lower. However, in case of advancement of supplies solely at the request of Department of Power, taxes and duties prevailing at the time of dispatch, shall be payable by Department of Power.
14.4 Concessional Sales Tax declaration forms, as admissible, would be issued to the Contractor, on request, for all items (as identified in the price schedule of the Bid) to be supplied directly by the Contractor as well as for the items to be supplied by the subsuppliers as sale in transit.
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14.5 Sales Tax on goods incorporated in the Works: The Bidder shall include the Sales Tax on Works Contract, Turnover Tax or any other similar taxes under the Sales Tax Act, as applicable in their quoted Bid price and Department of Power would not bear any liability on this account. Department of Power shall, however, deduct such taxes at source as per the rules and issue TDS Certificate to the Contractor. 14.6 For payment/reimbursement of Sales Tax, in respect of dispatches made directly from Contractors works, invoices raised by the Contractor shall be accepted as documentary evidence. Similarly, pre-numbered invoices duly signed by authorized signatory will be considered as evidence for payment of Excise Duty. 14.7 As regards the Income Tax, surcharge on Income Tax and other Corporate Taxes, the Bidder shall be responsible for such payment to the concerned authorities. 15.0 PRICE BASIS All price components shall remain FIRM and shall not be subjected to any adjustment, whatsoever, during the execution of the contract. 16.0 TIME SCHEDULE 16.1 The basic consideration and the essence of the Contract shall be strict adherence to the time schedule for performing the specified works. 16.2 Department of Powers requirement of completion schedule for the Works are mentioned in the accompanying Special Conditions of Contract. 16.3 The completion schedule as stated in the Special Conditions of Contract shall be one of the major factors in consideration of the Bids. 16.4 Department of Power reserves the right to request for a change in the work schedule during pre-award discussions with successful Bidder. 16.5 The successful Bidder will be required to prepare detailed PERT network and finalize the same with Department of Power as per the requirement of Clause 12.0, Section GCC. 17.0 CONTRACT QUALITY ASSURANCE 17.1 The Bidder shall include in his Proposal the Quality Assurance Programme containing the overall quality management and procedures, which he proposes to follow in the performance of the Works during various phases as detailed in relevant clause of the General Technical Conditions. 17.2 At the time of Award of Contract, the detailed Quality Assurance Programme to be followed for the execution of the Contract will be mutually discussed and agreed to and such agreed Programme shall form a part of the Contract. 18.0 INSURANCE The Bidders insurance liabilities pertaining to the scope of Works are detailed out in Clauses titled Insurance in General Terms and Conditions of Contract and in Erection Conditions of this volume of Part-III. Bidders attention is specifically invited to these clauses. Bid price shall include all the cost in pursuance of fulfilling all the insurance liabilities under the Contract.
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19.0 MAINTENANCE TOOLS AND TACKLES The Proposal shall include all special tools and tackles required for the operation and maintenance of the equipment in each equipment option. The Bidder shall indicate all the above items in the Proposal sheets in the form of a schedule given therein and the description and the quantity of each item. The lump sum price to be quoted by the Bidder shall include prices of these tools and tackles. These tools and tackles shall be delivered at site along with the last consignment of equipment and in no case earlier than this, unless otherwise specified in the Special Conditions of Contract and/or Technical Specifications, Part III (Vol. & Vol. 2/2). 20.0 ERECTION TOOLS & TACKLES The Bidder, under a separate schedule, in his Proposal shall include a list of all special equipment, tools & tackles etc. which he proposes to bring to site for the purpose of erection, handling, testing and commissioning including performance & guarantee tests of the equipment. If any such equipment is listed anywhere else in the Proposal and not specially mentioned in the above schedule, it shall be deemed to have been included in the Bidders proposed scope of supply. 21.0 BRAND NAMES 21.1 The specific reference in these specifications and documents to any material/ equipment by brand name, make or catalogue number shall be construed as establishing standards of quality and performance and not as limiting competition. However, Bidders may offer other similar material/equipment provided they meet the specified standard, design and performance requirements. The Bidder shall furnish adequate technical information about such alternative material/equipment to enable Department of Power to determine its acceptability. Department of Power shall be the sole judge on the acceptability or otherwise of such alternative material/equipment. 21.2 The Bidder shall note that standards for workmanship, material and equipment and reference to brand names or catalogue numbers designated by Department of Power in its Technical Specifications are intended to be descriptive only and not restrictive. The Bidder may substitute alternative standards, brand name and/or catalogue numbers in its Bid, provided that it demonstrates to Department of Powers satisfaction that the substitutions are substantially equivalent or superior to those designed in the Technical Specifications. 22.0 BID GUARANTEE 22.1 The Bidder shall furnish a Bid Guarantee as prescribed under CPWD Manual for an amount of Rs.111.3 lakhs in the form of TDR or STDR drawn on Bank pledged to the Executive Engineer (Elect), Tawang Electrical Division, in the Account of the bidder as part of its Bid, 22.2 The Bid security is required to protect Department of Power against the risk of Bidders conduct, which would warrant the guarantee forfeiture, pursuant to 22.7 this Section. The Bid Guarantee shall be made payable to Department of Power without any condition whatsoever. 22.3 The Bid Guarantee as stated above shall be denominated in Indian Rupees and obtained from any nationalized bank of India only. The Nationalized banks shall mean those banks which are listed in APPENDIX-II of Section INB. 22.4 Any bid not secured in accordance with paras 22.1 and 22.3 above will be rejected by Department of Power as non-responsive.
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22.5 Unsuccessful Bidders Bid guarantee will be discharged/returned as promptly as possible but not later than 60 days after the expiration of the period of bid validity prescribed by Department of Power. 22.6 The successful Bidders Bid Guarantee will be discharged upon the Bidders executing the Contract and furnishing the Performance Guarantee pursuant to Clause 41.0 of this Section. 22.7 The bid guarantee may be forfeited: a. If a Bidder withdraws/modifies its bid during the period of Bid validity specified by the Bidder on the Bid Form; or b. In case the Bidder does not withdraw the modification proposed by him, if any, at the cost of withdrawal stated by him in the bid; or c. If a Bidder does not accept the corrections to arithmetical errors identified during preliminary evaluation of his bid pursuant to Clause 33.2, Section-INB of this Section; or d. In the successful Bidder fails to sign the Contract within forty five (45) days from the date of Award; or e. The Bidder fails to furnish the Performance Guarantee within 30 days from the date of Letter of Award. 22.8 The Bid guarantee shall be submitted along with the bid in separate sealed envelope in one original and two copies. Any Bid not accompanied by the required Bid security in accordance with provisions of this clause will be rejected and shall not be opened. 22.9 No interest shall be payable by Department of Power on the above bid security. 23.0 PERIOD OF VALIDITY OF BIDS 23.1 Bids shall remain valid for 6 (six) calendar months after the date of bid opening prescribed by Department of Power unless otherwise specified in the accompanying Special Conditions of Contract. A bid valid for a shorter period will be rejected as non-responsive. 23.2 In exceptional circumstances, Department of Power may solicit the Bidders consent to an extension of the period of validity. The request and the response thereto shall be made in writing (including cable or telex). The bid security provided under Clause 22.0 of this Section shall also be extended by the same period as the extension in the validity of the Bid. A Bidder may refuse the request without forfeiting his Bid security. A Bidder granting the request will not be required or permitted to modify its Bid.
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D. SUBMISSION OF BIDS
24.0 FORMAT OF BID 24.1 The Bidder shall prepare five copies of the Bid, clearly marking each Original Bid and Copy of Bid, as appropriate. In the event of any discrepancy between them, the original shall govern. 24.2 The original and all copies of the bid shall be typed or written in indelible ink and shall be signed by the Bidder or a person or persons duly authorized to bind the Bidder to the Contract. The letter of authorization shall be indicated by written Powerof-Attorney accompanying the Bid. All pages of the Bid, except for un-amended printed literature, shall be initialed by the person or persons signing the bid. 24.3 The Bidders must submit the qualifying data in five copies, as required in this instruction to Bidders in a separate envelope sealed and enclosed in the envelope submitting Proposals, super-scribed as under: QUALIFYING DATA FOR THE CONSTRUCTION OF 132 KV SINGLE CIRCUIT TRANSMISSION LINE FROM KHUPPI TO TAWANG INCLUDING 132/33 KV SUB-STATION AT BOMDILA AND TAWANG WITH C/O 132 KV BAY (NEEPCO EXTENSION AT KHUPPI) 24.4 The Bid shall contain no interlineations, erasures or overwriting except as necessary to correct errors made by the Bidder, in which case such corrections shall be initialled by the person or persons signing the Bid. 24.5 ORIGINAL BID shall be submitted in the Original Bid document which was purchased from the department and shall be intact with the Original SEAL affixed by the Executive Engineer(E). Bid submitted on copies other than the original document as stated above or Bid Documents with mutilated or tempered SEAL shall be rejected. 25.0 SIGNATURE OF BIDS 25.1 The Bid must contain the name, residence and place of business of the person or persons making the Bid and must be signed and sealed by the Bidder with his usual signature. The names of all persons signing should also be typed or printed below the signatures. 25.2 Bid by a partnership must be furnished with full names of all partners and be signed with the partnership name, followed by the signature(s) and designation(s) of the authorized partner(s) or other authorized representative(s). 25.3 Bids by Corporation/Company must be signed with the legal name of the Corporation/Company by the President, Managing Director or by the Secretary or other person or persons authorized to Bid on behalf of such Corporation/Company in the matter. 25.4 A Bid by a person who affixes to his signature the word President, Managing Director, Secretary, Agent or other designation without disclosing his principal will be rejected. 25.5 Satisfactory evidence of authority of the person signing on behalf of the Bidder shall be furnished with the Bid. 25.6 The Bidders name stated on the Proposal shall be the exact legal name of the firm. 25.7 Bids not conforming to the above requirements of signing shall be disqualified.
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26.0 SEALING AND MARKING OF BIDS 26.1 The Bidders shall seal the original and each copy of the Copy of Bid separately as inner envelope and pack the Copies together in an outer envelope, duly marking the envelopes as Original and Copy. 26.2 The inner and outer envelopes shall be: a. Addressed to the Officer of Department of Power, Arunachal Pradesh, indicated in the cover page of this Bid document whose detailed address has been shown below:
The Executive Engineer (E) Tawang Electrical Division Department of Power
Tawang 790 104 b. and bear the name of the bid, the specification number, and the words DO NOT OPEN BEFORE . 26.3 The inner envelope shall indicate the name and address of the Bidder to enable the Bid to be returned unopened, in case it is declared late or rejected. 26.4 If the outer envelope is not sealed and marked as required by para 26.2 above, Department of Power will assume no responsibility for the bids misplacement or premature opening. 26.5 Premature opening shall lead to rejection of the Bid. 26.6 The Bid shall be submitted in a secured box preferably a strong steel trunk with two pad locks. The box shall be suitably and prominently labeled with Name of the Tender, full communication address of the bidder, name of the authorized representative with his contact numbers, DO NOT OPEN BEFORE.. and addressed to the Executive Engineer as stated above. Key set of one of the pad locks shall be handed over to Department at the time of submission. The bidder may suitably SEAL the box if so desired. 26.7 The Bidders have the option of sending the Bid by registered post or submitting the Bid in person. Bids submitted by telex/telegram will not be accepted. No request from any Bidder to collect the Proposals from airlines, cargo agents etc. shall be entertained. The Department shall not be responsible for any kind of damage, loss or mutilation of data; damage, loss, mutilation or misplacement of documents for those bids submitted in the mode and manner other than as prescribed in clause 26.6 above and shall be at the risk and responsibility of the Bidder.
26.8
27.0 DEADLINE FOR SUBMISSION OF BIDS 27.1 Bids must be received by Department of Power at the address specified under para 26.2 above, not later than the time & date mentioned in the Invitation to Bid. 27.2 Department of Power may, at its discretion, extend this deadline for the submission of Bids by amending the Bidding Document, in which case all rights and obligations of Department of Power and Bidders previously subject to the deadline will thereafter be subject to the deadline as extended.
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28.0 LATE BIDS 28.1 Any Bid received by Department of Power after the time & date fixed or extended for submission of Bids prescribed by Department of Power, will be rejected and/or returned unopened to the Bidder. 29.0 MODIFICATION AND WITHDRAWAL OF BIDS 29.1 The Bidder may modify or withdraw its bid after the Bids submission provided that written notice of the modification or withdrawal is received by Department of Power prior to the deadline prescribed for submission of Bids. 29.2 The Bidders modification or withdrawal notice shall be prepared, sealed, marked and dispatched in accordance with the provisions of Clause 26.0 above. 29.3 No Bid may be modified subsequent to the deadline for submission of bids. 29.4 No Bid may be withdrawn in the interval between the deadline for submission of Bids and the expiration of the period of Bid validity specified by the Bidder on the Bid Form. Withdrawal/modification of a Bid during this interval may result in the Bidders forfeiture of its bid security. 30.0 INFORMATION REQUIRED WITH THE PROPOSAL 30.1 The Bids must clearly indicate the name of the manufacturer, the type of model of each principal item of equipment proposed to be furnished and erected. The Bid should also contain drawings and descriptive materials indicating general dimensions, materials from which the parts are manufactured, principles of operation, the extent of pre-assembly involved, major construction equipment proposed to be deployed, method of erection and the proposed erection organizational structure. 30.2 The above information shall be provided by the Bidder in the form of separate sheets, drawings, catalogues, etc. in five copies. 30.3 Any bid not containing sufficient descriptive material to describe accurately the equipment proposed may be treated as incomplete and hence rejected. Such descriptive materials and drawings submitted by the Bidder will be retained. Any major departure from these drawings and descriptive material submitted will not be permitted during the execution of the Contract without specific written permission of Department of Power. 30.4 Oral statements made by the Bidder at any time regarding quality, quantity or arrangement of the equipment or any other matter will not be considered. 30.5 Standard catalogue pages and other documents of the Bidder may be used in the Bid to provide additional information and data as deemed necessary by the Bidder. 30.6 The Bidder, along with his Proposal, shall submit a list of recommended erection equipment and materials which will be required for the purpose of erection of equipment and materials supplied under the Contract. 30.7 In case if the proposal information contradicts specification requirements; the specification requirements shall govern, unless otherwise brought out clearly in the technical/commercial deviation schedule.
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E. BID OPENING AND EVALUATION

31.0 OPENING OF BIDS 31.1 First the cover containing Bid Guarantee and Bid Proposal letter (Part-I of the Bid) shall be opened and only those Bidders whose Bid contains Part-I bid as per the stipulations of the Bid Guarantee shall be considered eligible for opening of Part-II of the Bid which shall also be opened on the same day. Bidders found eligible on the basis of evaluation of the Part-II shall be invited for opening of the Part-III of the tender (Price and Techno-Commercial Bid) the date of which shall be notified by the owner to the bidders. 31.2 The Owner shall open Bids in the presence of Bidders representatives (up to 2 persons) who choose to attend at the date and time for opening of bids indicated in the Invitation to Bid, or in case any extension has been given thereto, on the extended bid opening date and time notified to all the Bidders, who have purchased the Bidding Documents. The Bidders representatives who are present shall sign a register evidencing their attendance. 31.3 The Bidders names, bid prices, modifications, bid withdrawals and the presence or absence of the requisite bid guarantee and such other details as the Owner, at its discretion, may consider appropriate shall be announced at the opening. 32.0 CLARIFICATION OF BIDS 32.1 To assist in the examination, evaluation and comparison of bids the Department of Power may, at its discretion, ask the Bidder for a clarification of its bid. The request for clarification and the response shall be in writing and no change in the price or substance of the bid shall be sought, offered or permitted. 33.0 PRELIMINARY EXAMINATION 33.1 Department of Power will examine the bids to determine whether they are complete, whether any computational errors have been made, whether required sureties have been furnished, whether the documents have been properly signed, and whether the bids are generally in order. 33.2 Arithmetical errors will be rectified on the following basis: If there is a 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 shall be corrected. If there is a discrepancy between words and figures, the amount in words will 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 forfeited. The Bidder should ensure that the prices furnished in various price schedules are consistent with each other. In case of any inconsistency in the prices furnished in the specified price schedules to be identified in Bid Form for this purpose, the Owner shall be entitled to consider the highest price for the purpose of evaluation and for the purpose of award of the Contract use the lowest of the prices in these schedules. 33.3 Prior to the detailed evaluation, Department of Power will determine the substantial responsiveness of each bid to the Bidding Document. For purpose of this Clause, a substantially responsive bid is one, which conforms to all the terms and conditions of the Bidding Document without material deviations. A material deviation is one which limits in any substantial way, inconsistent with the bidding documents, the Owners rights or the bidders obligation under the contract or whose rectification would affect unfairly the competitive position of other bidders presenting substantially responsive bids and which affects in any way the prices, quality, quantity or delivery period of the
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equipment or which limits in any way the responsibilities or liabilities of the Bidder of any right of the Department of Power as required in these specifications and documents. Department of Powers determination of a bids responsiveness shall be based on the contents of the bid itself without recourse to extrinsic evidence. 33.4 A bid determined as not substantially responsive will be rejected and may not subsequently be made responsive by the Bidder by correction of the non-conformity. 33.5 Department of Power may waive any minor informality or non-conformity or irregularity in a bid which does not constitute a material deviation, provided such waiver does not prejudice or affect the relative ranking of any Bidder. 34.0 DEFINITIONS AND MEANINGS 34.1 For the purpose of evaluation and comparison of bids, the following meanings and definitions will apply: a. Bid Price shall mean the base price quoted by each Bidder in his Proposal for the complete scope of works. b. Differential Price shall mean the summation of the equalizing elements of price for parameter differential or deficiencies in the equipment and services determined from the Bidders Proposal. c. Evaluated Bid Price shall be the summation of Bid Price and Differential Price. 34.2 Calculation of Differential Price:
34.2.1The Differential Price to be added to the Bid Price of each bid during evaluation and comparison shall be derived as under: Differential Price (DP)= n1F1 + n2F2+nnFn where F1, F2Fn are the various factors in Indian Rupees per unit of parameter differential or deficiency in the equipment and services offered as stipulated in these specifications; n1, n2..nn are the respective parameter differential or deficiency in the corresponding units to be determined from the Bidders Proposal. The above factors and corresponding units of parameter differential are brought out in the Technical Specifications and/or Special Conditions of Contract.
35.0 COMPARISON OF BIDS 35.1 The bids shall be compared on the basis of lump-sum prices (i.e. for supply portion and prices for services to be rendered as quoted by the Bidder) for the entire scope of the Proposal as defined in the Bidding Document. 35.2 For comparison purposes all the evaluated bid prices shall be in Indian Rupees as under: W = M + DP Where, W = Total Comparison Price M = Bid price in Indian Rupees (Ex-works value of equipment + Components of erection cost + mandatory spares and other components, if any). DP = Differential price in Indian Rupees calculated according to para 34.2.1 above. 35.3 All evaluated bid prices of all the Bidders shall be compared among themselves to determine the lowest evaluated bid and, as a result of this comparison, the lowest Bid will be selected for the award of the Contract.
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36.0 CONTACTING THE OWNER Bids shall be deemed to be under consideration immediately after they are opened and until such time official intimation of award/rejection is made by Department of Power to the Bidders. While the bids are under consideration, Bidders and/or their representatives or other interested parties are advised to refrain from contacting by any means, Department of Power and/or his employees/representatives on matters related to the bids under consideration. Department of Power, if necessary, will obtain clarifications on the bids by requesting for such information from any or all the Bidders, either in writing or through personal contacts as may be necessary. Bidders will not be permitted to change the substance of the bids after the bids have been opened.
F. AWARD OF CONTRACT
37.0 AWARD CRITERIA 37.1 Department of Power will award the Contract to the successful Bidder whose bid has been determined to be substantially responsive and has been determined as the lowest evaluated bid, provided further that the Bidder is determined to be qualified to perform the Contract satisfactorily. Department of Power shall be the sole judge in this regard. 37.2 In case of Supply Contract, the award shall be on the basis of FOR destination (site) basis. 37.3 Further, the Owner reserves the right to award separate Contracts to two or more parties in line with the terms and conditions specified in the accompanying Technical Specifications. 38.0 RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR ALL BIDS 38.1 Department of Power reserves the right to accept or reject any bid, and to annul the bidding process and reject all bids at any time prior to award of Contract, without thereby incurring any liability to the affected Bidder or Bidders or any obligation to inform the affected Bidder or Bidders of the grounds for Department of Powers action.
39.0 NOTIFICATION OF AWARD 39.1 Prior to the expiration of the period of bid validity and extended validity period, if any, Department of Power will notify the successful Bidder in writing by registered letter or by cable/telex/fax, to be confirmed in writing by registered letter that its bid has been accepted. 39.2 The notification of award will constitute the formation of the Contract. 39.3 Upon the successful Bidders furnishing of Contract Performance Guarantee pursuant to Clause 41.0 of this Section, Department of Power will promptly notify each unsuccessful Bidder and will discharge its bid security, pursuant to Clause 22.0 of this Section. 40.0 SIGNING OF CONTRACT 40.1 At the same time, as Department of Power notifies the successful Bidder that its bid has been accepted, Department of Power will send the Bidder the detailed Letter of Award (LOA), incorporating all agreements between the parties.
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40.2 Within 15 days of receipt of the detailed Letter of Award, the successful Bidder shall sign and date the same and return it to Department of Power as per clause 43 of this section. 40.3 The Bidder will prepare the Contract Agreement as per the Proforma enclosed at Annexure-VIII to this volume of Part-III and the same will be signed within 45 (forty five) days of Letter of Award. 40.4 The Contractor at his own cost shall provide the Department of Power with at least 10(Ten) true copies of Contract Agreement within 15(fifteen) days after signing of the Contract. 40.5 The Contractor shall have to furnish the Contract Performance Guaranty within 30 days from the letter of award before signing the agreement. 40.6 The contractor shall strictly abide by the SCHEDULE of important events to be executed as required under this Section and given in Appendix-I of Section INB for successful and timely Signing of the Contract. 41.0 CONTRACT PERFORMANCE GUARANTEE 41.1 As a Contract Performance Security, the successful Bidder, to whom the work is awarded, shall be required to furnish a Performance Guarantee from any nationalized bank in the form of TDR or STDR pledged to the Executive Engineer (E), Tawang Electrical Division in the account of the bidder. The guarantee (principal) amount shall be equal to fifteen percent (15%) of the Contract Price and it shall guarantee the faithful performance of the Contract in accordance with the terms and conditions specified in these documents and specifications. Maturity period of the Contract Performance Guarantee shall be at-least up to 12 months from the date of project completion Certificate as per clause 11.0 of Section GCC. 41.2 The Performance Guarantee shall cover additionally the following guarantees: a. The successful Bidder guarantees the successful and satisfactory operation of the equipment furnished and erected under the Contract, as per the specifications and documents. b. The successful Bidder further guarantees that the equipment provided and installed by him shall be free from all defects in design, material and workmanship and shall upon written notice from Department of Power fully remedy free of expenses such defects as developed under the normal use of the said equipment within the period of guarantee specified in the relevant clause of the General Terms and Conditions/Special Conditions of Contract in this Volume of Part-III. 41.3 The Contract Performance Guarantee is intended to secure the performance of the entire Contract. However, it is not to be construed as limiting the damages under clause entitled Equipment Performance Guarantee in Technical Specifications, Volume-II and damages stipulated in other clauses in the Bid documents. 41.4 The Performance Guarantee will be returned to the Contractor after 12 months of project completion certificate unless otherwise specified in the Special Conditions of Contract. 42.0 CORRUPT OR FRAUDULENT PRACTICES 42.1 Owner expects the bidders/suppliers/contractors observe the highest of ethics during the procurement and execution of such contracts. In pursuance of this policy, the owner,
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a. defines, for the purpose of this provision, the terms set forth below as follows: (i) Corrupt practice means offering, giving, receiving or soliciting of anything of value to influence the action of a public official in the procurement process or in contract execution, and (ii) Fraudulent practice means a misrepresentation of facts in order to influence a procurement process or the execution of a contract to the detriment of the owner, and includes collusive practice among bidders (prior to or after bid submission) designed to establish bid prices at artificial non-competitive levels and to deprive the owner of he benefits of free and open competition. b. will reject a proposal for award if it determines the bidder recommended for award has engaged a corrupt or fraudulent practice in competing for the contract in question. c. will declare a firm ineligible, either indefinitely or for a stated period of time, if owner any time determines that the firm has engaged a corrupt/fraudulent practices in competing for, or in executing the contract. 43. ACCEPTANCE OF AWARD The successful bidder (Contractor) on receipt of the Letter of Award issued as per provisions of clause 40.0 of this section shall acknowledge the receipt of the Award in the following manner: a. Within 15 (fifteen) days of receipt of the LOA, the bidder shall inform the owner of the acceptance of the Award as acknowledgement in writing as per ANNEXURE - IX. The Contractor shall sign, seal and date all the pages of LOA and return the same to the owner along with the acceptance letter. The contractor failing to so shall be treated as non responsive and the award shall be cancelled.
b. c.
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APPENDICES to INB APPENDIX-I 1. ACCEPTANCE OF LOA: 2. PERFORMANCE GUARANTEE: Within 15 (fifteen) days of LOA Date. Within 30 (Thirty) days of LOA Date before signing of the Agreement. 3. SIGNING OF AGREEMENT: Within 45 (forty five) days of LOA date.
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APPENDIX-II
List of Nationalized Banks. 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. State Bank of India State Bank of Bikaner State Bank of Hyderabad State Bank of Mysore State Bank of Patiala State Bank of Saurashtra State Bank of Travancore State Bank of Indore Allahabad Bank Andhra Bank Bank of Baroda Bank of India Bank of Maharashtra Canara Bank Central Bank of India Corporation Bank Dena Bank Indian Bank Indian Overseas Bank Oriental Bank of Commerce Punjab and Sind Bank Punjab National Bank Syndicate Bank UCO Bank Union Bank of India United Bank of India Vijaya Bank
END OF INB
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GENERAL TERMS AND CONDITIONS OF CONTRACT
(GCC)
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CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0
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Description Definition of Terms Application Standards Language and Measures Contract Documents Use of Contract Documents and Information Construction of the Contract Jurisdiction of Contract Manner of Execution of Contract Enforcement of Terms Completion of Contract Time-The Essence of Contract Effectiveness of Contract Liquidated Damages Guarantee Taxes, Permits and Licences Replacement of Defective Parts and Materials Patent Rights and Loyalties Defence of Suits Limitation of Liabilities Engineers Decision Power to Vary or Omit Work Assignment and Sub-letting of Contract Change of Quantity Packing, Forwarding and Shipment Co-operation with Other Contractors and Consulting Engineers No Waiver of Rights Certificate not to Affect Right of Owner and Liability of the Contractor Training of Owners Personnel Progress Reports and Photographs Taking-Over Contract Performance Guarantee Contract Price Adjustment Payment
Page No. 29 32 32 32 32 33 33 34 34 34 35 35 36 36 36 37 37 38 38 39 39 39 40 41 41 42 42 42 42 43 43 43 43 43
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35.0 36.0 37.0 38.0 39.0 40.0 41.0 42.0 43.0 44.0 45.0 46.0 47.0 48.0 49.0
Deductions from Contract Price Transfer of Title Insurance Liability for Accidents and Damages Delays by Employer or his Authorised Agents Demurrage, Wharfage, etc. Force Majeure Suspension of Work Contracts Default Termination of Contract on Owners Initiative Frustration of Contract Grafts and Commissions etc. Settlement of Disputes Arbitration Reconciliation of Accounts
46 46 46 47 47 48 48 48 48 49 50 50 50 51 51
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SECTION GCC GENERAL TERMS & CONDITIONS OF CONTRACT A. INTRODUCTION

1.0 DEFINITION OF TERMS 1.1 Contract means the agreement entered into between the Owner and the Contractor as per the Contract Agreement signed by the parties, including all attachments and appendices thereto and all documents incorporated by reference therein. Owner shall mean the Department of Power, Arunachal Pradesh and shall include its legal representatives, successors and assigns. Contractor or Manufacturer shall mean the Bidder whose bid will be accepted by the Owner for the award of the Works and shall include such successful Bidders legal representatives, successors and permitted assigns. Sub-Contractor shall mean the person named in the Contract for any part of the Works or any person to whom any part of the Contract has been sublet by the Contractor with the consent in writing of the Engineer and will include the legal representatives, successors and permitted assigns of such person. Engineer shall mean the officer appointed in writing by the Owner to act as Engineer from time to time for the purpose of the Contract. Consulting Engineer/ Consultant shall mean any firm or person duly appointed as such from time to time by the Owner. The terms Equipment, Stores and Materials shall mean and include equipment, stores and materials to be provided by the Contractor under the Contract. Works shall mean and include the furnishing of equipment, labour and services, as per the Specifications and complete erection, testing and putting into satisfactory operation including all transportation, handling, unloading and storage at the Site as defined in the Contract. Specifications shall mean the Specifications and Bidding Document forming a part of the Contract and such other schedules and drawings as may be mutually agreed upon. Site shall mean and include the land and other places on, into or through which the works and the related facilities are to be erected or installed and any adjacent land, paths, street or reservoir which may be allocated or used by the Owner or Contractor in the performance of the Contract. The term Contract Price shall mean the lump-sum price quoted by the Contractor in his bid with additions and/or deletions as may be agreed and incorporated in the Letter of Award, for the entire scope of the works. The term Equipment Portion of the Contract price shall mean the ex-works value of the equipment. The term Erection Portion of the Contract price shall mean the value of field activities of the works including erection, testing and putting into satisfactory operation including successful completion of performance and guarantee tests to be performed at Site by the Contractor including cost of insurances.
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1.4
1.5 1.6 1.7
1.8
1.9
1.10
1.11
1.12 1.13
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1.14
Manufacturers Works or Contractors Works, shall mean the place of work used by the manufacturer, the Contractor, their collaborators/associates or SubContractors for the performance of the Contract. Inspector shall mean the Owner or any person nominated by the Owner from time to time, to inspect the equipment; stores or Works under the Contract and/or the duly authorized representative of the Owner. Notice of Award of Contract/Letter of Award/Telex of Award shall mean the official notice issued by the Owner notifying the Contractor that his bid has been accepted. Date of Contract shall mean the date on which Notice of Award of Contract/Letter of Award has been issued. Month shall mean the calendar month. Day or Days unless herein otherwise expressly defined shall mean calendar day or days of 24 hours each. A Week shall mean continuous period of seven (7) days.
1.15
1.16
1.17 1.18
1.19 1.20
Writing shall include any manuscript, type written or printed statement, under or over signature and/or seal as the case may be. When the words Approved, Subject to Approval, Satisfactory, Equal to, Proper, Requested, As Directed, Where Directed, When Directed, Determined by, Accepted, Permitted, or words and phrases of like importance are used the approval, judgment, direction etc. is understood to be a function of the Owner/Engineer. Test on completion shall mean such tests as prescribed in the Contract to be performed by the Contractor before the work is taken over by the Owner. Start up shall mean the time period required to bring the equipment covered under the Contract from an inactive condition, when construction is essentially complete, to the state ready for trial operation. The start-up period shall include preliminary inspection and check-out of equipment and supporting sub-system, initial operation of the complete equipment covered under the Contract to obtain necessary pre-trial operation data, perform calibration and corrective action, shutdown, inspection and adjustment prior to the trial operation period. Initial Operation shall mean the first integral operation of the complete equipment covered under the contract with the sub-systems and supporting equipments in service or available for service Operation shall mean the integral operation of the complete equipment covered under the Contract with the sub-system and supporting equipment in service or available for service. The length of operation shall be as determined by the Engineer, unless otherwise specified elsewhere in the Contract. Performance and Guarantee Tests, shall mean all operational checks and tests required to determine and demonstrate capacity, efficiency, and operating characteristics as specified in the Contract Documents. The term Final Acceptance/Taking Over shall mean the Owners written acceptance of the Works performed under the Contract, after successful commissioning/completion of Performance and Guarantee Tests, as specified in the accompanying Technical Specifications or otherwise agreed in the Contract. Commercial Operation shall mean the condition of operation in which the complete equipment covered under the Contract is officially declared by the Employer to be available for continuous operation at different loads up to and
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1.21 1.22
1.23
1.24
1.24
1.25
1.26
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including rated capacity. Such declaration by the Owner, however, shall not relieve or prejudice the Contractor of any of his obligations under the Contract. 1.27 Guarantee Period/Maintenance Period shall mean the period during which the Contractor shall remain liable for repair or replacement of any defective part of the works performed under the Contract. Latent Defects shall mean such defects caused by faulty designs, material or work-man-ship which cannot be detected during inspection, testing etc. based on the technology available for carrying out such tests. Drawing, Plans, shall mean all: a) Drawings furnished by the Owner/Consultant as a basis of Bid/Proposals. b) Supplementary drawings furnished by the Owner/Consultant to clarify and to define in greater detail the intent of the Contract. c) Drawings submitted by the Contractor with his bid provided such drawings are acceptable to the Owner/Consultant. d) Drawings furnished by the Owner/Consultant to the Contractor during the progress of the work; and e) Engineering data and drawings submitted by the Contractor during the progress of the work provided such drawings are acceptable to the Engineer/Owner. 1.30 Codes shall mean the following including the latest amendments and/or replacements, if any: a) Indian Electricity Act, 1910 and Rules and Regulations made there under. b) Indian Factory Act, 1948 and Rules and Regulations made there under. c) Indian Explosives Act, 1884 and Rules and Regulations made there under. d) Indian Petroleum Act, 1934 and Rules and Regulations made there under. e) Indian Electricity Act, 2003 and Rules and Regulations made there under. f) A.S.M.E. Test Codes. g) A.I.E.E. Test Codes. h) American Society of Materials Testing Codes. i) Standards of the Indian Standards Institution. j) Other Internationally approved standards and/or rules and regulations touching the subject matter of the Contract. 1.31 1.32 1.33 Words imparting the singular only shall also include the plural and viceversa where the context so requires. Words imparting Person shall include firms, companies, corporations and associations or bodies of individuals, whether incorporated or not. Terms and expressions not herein defined shall have the same meaning as are assigned to them in the Indian Sale of Goods Act (1930), failing that in the Indian Contract Act (1872) and failing that in the General Clauses Act (1897) including amendments thereof, if any. The various Acts and Regulations are normally available for sale from the following addresses or with leading authorized Government of Indian Book Sellers:
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1.29
32
i) Deputy Controller Publication Department Government of India Civil Lines, New Delhi-110 0006 ii) Deptt. of Publication Government of India Kitab Mahal, Unit No.21, Emporia Building Baba Kharak Singh Marg, New Delhi-110 001 1.34 In addition to the above the following definitions shall also apply: a) All equipment and materials to be supplied shall also mean Goods. b) Constructed shall also mean erected and installed. c) Contract Performance Guarantee shall also mean Contract Performance Security. d) Bid Guarantee shall also means Earnest money or Bid security 2.0 APPLICATION These General Conditions shall apply to the extent that they are not superseded by provisions in other parts of the Contract. 3.0 STANDARDS The goods supplied under this Contract shall conform to the standards mentioned in the Technical Specifications, and, when no applicable standard is mentioned, to the authoritative standard appropriate to the goods and such standards shall be the latest issued by the concerned institution. 4.0 LANGUAGE AND MEASURES All documents pertaining to the Contract including specifications, schedules, notices, correspondences, operating and maintenance instructions, drawings or any other writing shall be written in English language. The Metric System of measurement shall be used exclusively in the Contract. 5.0 CONTRACT DOCUMENTS 5.1 The term Contract Documents shall mean and include the following, which shall be deemed to form an integral part of the Contract: a) Invitation to Bid including letter forwarding the Bidding Documents, Instructions to Bidders, General Terms & Conditions of Contract, Special Conditions of Contract and all other documents included under Part-I, PartII and Part-III of the Bid document. b) Specifications of the equipment to be furnished and erected under the Contract as brought out in the accompanying Technical Specifications in Part-III (Vol. ). c) Contractors Bid Proposal and the documents attached thereto including the letters of clarifications thereto between the Contractor and the Owner/Consultant prior to the Award of Contract except to the extent of repugnancy.
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d) All the materials, literature, data and information of any sort given by the Contractor along with his Bid, subject to the approval of the Owner/Consultant. e) Letter of Award and any agreed variations of the conditions of the documents and special terms and conditions of Contract, if any. 5.2 In the event of any conflict between the above-mentioned documents, the matter shall be referred to the Engineer whose decision shall be considered as final and binding upon the parties.
6.0 USE OF CONTRACT DOCUMENTS AND INFORMATION 6.1 The Contractor shall not, without the Owners prior written consent, disclose the Contract, or any provision thereof, or any specification, plan, drawing, pattern, sample or information furnished by or on behalf of the Owner in connection therewith, to any person other than a person employed by the Contractor in the performance of the Contract. Disclosure to any such employed person shall be made in confidence and shall extend only as far as it may be necessary for the purpose of such performance. The Contractor shall not, without the Owners prior written consent, make use of any document or information enumerated in various Contract documents except for the purpose of performing the Contract. The Contractor shall not communicate or use in advertising, publicity, sales releases or in any other medium, photographs or other reproduction of the Works under this Contract, or descriptions of the site, dimensions, quantity, quality or other information, concerning the works unless prior written permission has been obtained from the Owner. Any document, other than the Contract itself, enumerated in various Contract documents shall remain the property of the Employer and shall be returned (in all copies) to the Owner on completion of the Contractors performance under the Contract if so required by the Owner.
6.2
6.3
6.4
7.0 CONSTRUCTION OF THE CONTRACT 7.1 Notwithstanding anything stated elsewhere in the Bid documents, the Contract to be entered into will be a single Contract on TURNKEY BASIS having elements of Supply and Erection as divisible Components within the Contract. Award shall be placed on the successful Bidder on TURNKEY BASIS as a Single Contract for Supply and Erection having the following elements as distinct components: i) For Ex-Works Supply of all equipment and materials. ii) For Erection of all supplied equipments and materials including storage, handling at site, installation, testing and commissioning, providing all other services like inland transportation, insurance for delivery at site, unloading, performance testing in respect of all the equipment supplied under the Contract and any other services specified in the Bid Documents. iii) For other provisions like levies, taxes and duties etc admissible as per clause 14.0 of Section INB and clause 7.3 of Section SCC. iii) All these Components shall be severely interlinked and shall have cross-fall breach clause specifying that failure on the part of bidder in one or more Components of contract will constitute breach of the entire Contract.
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7.2
In case, where the Owner hands over his equipment to the Contractor for executing the contract, then the Contractor shall at the time of taking delivery of the equipment/dispatch documents be required to execute an Indemnity Bond in favour of the Owner in the form acceptable to the Owner for keeping the equipment in safe custody and to utilize the same exclusively for the purpose of the said Contract. Samples of Proforma for the Indemnity Bond are enclosed as Annexure VI & VII to this Part-III. The Contract shall in all respect be construed and governed according to Indian Laws. It is clearly understood that the total consideration for the Contract(s) has been broken up into various components only for the convenience of payment of advance under the Contract(s) and for the measurement of deviations or modifications under the Contract(s). TURNKEY concept shall mean execution of contract from concept to successful commissioning and operation of the project which shall comprise of Survey, Investigation and Design, efficient planning and project management, quality control, supply, erection, construction, supervision, monitoring and overseeing of the performance and operation of the project and handing over the project as a successful product of the Contract at the time of Closing the contract.
7.3 7.4
7.5
8.0 JURISDICTION OF CONTRACT 8.1 The laws applicable to the Contract shall be the laws in force in India. The Guwahati High Courts Permanent Bench at Naharlagun of Arunachal Pradesh shall have exclusive jurisdiction in all matters arising under this Contract.
9.0 MANNER OF EXECUTION OF CONTRACT 9.1 9.2 The Owner, after the issue of the Letter of Award to the Contractor, will send one copy of the final agreement to the Contractor for his scrutiny and approval. The Agreement, unless otherwise agreed to, shall be signed within 45 (forty five) days of the acceptance of the Letter of Award, at the office of the Owner on a date and time to be mutually agreed. The Contractor shall provide for signing of the Contract, Performance Guarantee in six copies, appropriate power of attorney and other requisite materials. In case the Contract is to be signed beyond the stipulated time, the Bid Guarantee submitted with the Proposal will have to be extended accordingly. The Agreement will be signed in six originals and the Contractor shall be provided with one signed original and the rest will be retained by the Owner. The Contractor shall provide free of cost to the Owner all the Engineering data, drawings, and descriptive materials submitted with the bid, in at least six (6) copies to form a part of the Contract immediately after issue of Letter of Award Subsequent to signing of the Contract, the Contractor at his own cost shall provide the Owner with at least ten (10) ten true copies of agreement within thirty (30) days after the signing of the Contract.
9.3 9.4
9.5
10.0 ENFORCEMENT OF TERMS 10.1 The failure of either party to enforce at any time any of the provisions of this Contract or any rights in respect thereto or to exercise any option therein provided, shall in no way be construed to be a waiver of such provisions, rights
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or options or in any way to affect the validity of the Contract. The exercise by either party of any of its rights herein shall not preclude or prejudice either party from exercising the same or any other right it may have under the Contract. 11.0 CLOSURE OF CONTRACT 11.1 Unless otherwise terminated under the provisions of any other relevant clause, this Contract shall be deemed to have been closed on the expiry of the contract performance guarantee period as provided for under the clause 41 of Section INB of the Part-III (Vol. ). Project completion shall mean completion of all supplies, erection, testing, commissioning and taking over of the entire project as a finished product as envisaged in the turnkey contract. It shall not be synonymous with contract completion which is link with other contractual obligations.
11.2
B. GUARANTEES & LIABILITIES

12.0 TIME THE ESSENCE OF CONTRACT 12.1 The time and the date of completion of the Contract as stipulated in the Contract by the Owner without or with modifications, if any, and so incorporated in the Letter of Award, shall be deemed to be the essence of the Contract. The Contractor shall so organize his resources and perform his work as to complete it not later than the date agreed to. The Contractor shall submit a detailed PERT network/bar chart within the time frame agreed consisting of adequate number of activities covering various key phases of the work such as design, procurement, manufacturing, shipment and field erection activities within fifteen (15) days of the date of Notification of Award. This network shall also indicate the interface facilities to be provided by the Owner and the dates by which such facilities are needed. The Contractor shall discuss the network so submitted with the Owner and the agreed network shall form part of the Contract documents. As provided in the clause of Terms of Payment in this Section, finalization of the network/bar charts will be precondition to release of any initial advance to the Contractor. During the performance of the Contract, if in the opinion of the Engineer, proper progress is not maintained, suitable changes shall be made in the Contractors operations to ensure proper progress without any cost implication to the Owner. The interface facilities to be provided by the Owner in accordance with the agreed network shall also be reviewed while reviewing the progress of the Contractor. Based on the above-agreed network/bar chart fortnightly reports shall be submitted by the Contractor as directed by the Engineer. Subsequent to the finalization of the network, the Contractor shall make available to the Engineer a detailed manufacturing programme in line with the agreed Contract network. Such manufacturing programme shall be reviewed, updated and submitted to the Engineer once every two months thereafter.
12.2
12.3 12.4
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12.5
The above bar charts/manufacturing programme shall be compatible with the Owners computer environment and furnished to the Owner on such media as may be desired by the Owner.
13.0 EFFECTIVENESS OF CONTRACT The Contract shall be considered as having come into force from the date of the notification of award unless otherwise provided in the notification of award. 14.0 LIQUIDATED DAMAGES 14.1 For Equipment Portion 14.1.1 If the Contractor fails to successfully complete the commissioning within the time fixed under the Contract, the Contractor shall pay to the Owner as liquidated damages and not as penalty a sum specified for each specified period of delay. The details of such liquidated damages are brought out in the accompanying Special Conditions of Contract. 14.1.2 Equipment and materials shall be deemed to have been delivered only when all its components, parts are also delivered. If certain components are not delivered in time the equipment and materials will be considered as delayed until such time the missing parts are also delivered. 14.1.3 Total amount of liquidated damages for delay under the Contract will be subject to a maximum of 10% of the Contract price. 14.3 Liquidated damages for not meeting performance guarantee during the performance and guarantee tests shall be assessed and recovered from the Contractor as detailed in Technical Specifications/Special Conditions of Contract. Such liquidated damages shall be without any limitation whatsoever and shall be in addition to damages, if any, payable under any other clause of Conditions of Contract.
15.0 GUARANTEE 15.1 The Contractor shall warrant that the equipment will be new, unused and in accordance with the Contract documents and free from defects in material and workmanship for a period of twelve (12) calendar months commencing immediately upon the satisfactory commissioning. The Contractors liability shall be limited to the replacement of any defective parts in the equipment of his own manufacture or those of his Sub-Contractors under normal use and arising solely from faulty design, materials and/or workmanship provided always that such defective parts are repairable at the site and are not in meantime essential in the commercial use of the equipment. Such replaced/defective parts shall be returned to the Contractor unless otherwise arranged. No repairs or replacement shall normally be carried out by the Engineer when the equipment is under the supervision of the Contractors supervisory Engineer. In the event of any emergency where in the judgment of the Engineer, delay would cause serious loss or damages, repairs or adjustment may be made by the Engineer or a third party chosen by the Engineer without advance notice to the Contractor and the cost of such work shall be paid by the Contractor. In the event such action is taken by the Engineer, the Contractor will be notified promptly and he shall assist wherever possible in making necessary corrections.
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This shall not relieve the Contractor of his liabilities under the terms and conditions of the Contract. 15.3 If it becomes necessary for the Contractor to replace or renew any defective portions of the works the provision of this clause shall apply to portion of the works so replaced or renewed until the expiry of twelve (12) months from the date of such replacement or renewal. If any defects are not remedied within a reasonable time, the Engineer may proceed to do the work at the Contractors risk and cost but without prejudice to any other rights, which the Owner may have against the Contractor in respect of such defects. The repaired or new parts will be furnished and erected free of cost by the Contractor. If any repair is carried out on his behalf at the site, the Contractor shall bear the cost of such repairs. The cost of any special or general overhaul rendered necessary during the maintenance period due to defects in the equipment or defective work carried out by the Contractor, the same shall be borne by the Contractor. The acceptance of the equipment by the Engineer shall in no way relieve the Contractor of his obligations under this clause
In the case of those defective parts, which are not repairable at site but are essential for the commercial operation of the equipment, the Contractor and the Engineer shall mutually agree to a program of replacement or renewal, which will minimize interruption to the maximum extent in the operation of the equipment.
15.4
15.5
15.6
15.7
15.8
At the end of the guarantee period, the Contractors liability ceases except for latent defects. For latent defects, the Contractors liability as mentioned in Clauses 15.1 through 15.7 above shall remain till the end of 5 years from the date of completion of guarantee period. In respect of goods supplied by SubContractors to the Contractor, where a longer guarantee (more than 12 months) is provided by such Sub-Contractor, the Owner shall be entitled to the benefits of such longer guarantee. The provisions contained in this clause will not be applicable: a) If the Owner has not used the equipment according to generally approved industrial practice and in accordance with the conditions of operations specified and in accordance with operating manuals, if any. b) In cases of normal wear and tear of the parts to be specifically mentioned by the Contractor in the offer.
15.9
16.0 TAXES, PERMITS & LICENCES The Contractor shall be liable and pay all non-Indian taxes, duties, levies lawfully assessed against the Owner or the Contractor in pursuance of the Contract. In addition, the Contractor shall be responsible for payment of all Indian duties, levies and taxes lawfully assessed against the Contractor for his personal income & property only. This clause shall be read in conjunction with Clause 14.0 of Section INB of this volume of Part-III. 17.0 REPLACEMENT OF DEFECTIVE PARTS AND MATERIALS 17.1 If during the performance of the Contract, the Engineer shall decide and inform in writing to the Contractor that the Contractor has manufactured any equipment, material or part of equipment unsound and imperfect or has furnished any equipment inferior to the quality specified, the Contractor on receiving details of such defects or deficiencies shall at his own expense within
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seven (7) days of his receiving the notice, or otherwise, within such time as may be reasonably necessary for making it good, proceed to alter, reconstruct or remove such works and furnish fresh equipment/materials up to the standards of the specifications. In case, the Contractor fails to do so, the Engineer may on giving the Contractor seven (7) days notice in writing of his intentions to do so, proceed to remove the portion of the works so complained of and at the cost of the Contractor perform all such Works or furnish all such equipment/ material provided that nothing in this clause shall be deemed to deprive the Employer of or affect any rights under the Contract which the Employer may otherwise have in respect of such defects and deficiencies. 17.2 The Contractors full and extreme liability under this clause shall be satisfied by the payment to the Owner of extra cost, of such replacement procured including erection as provided for in the Contract, such extra cost being the ascertained difference between the price paid by the Owner for such replacements and the Contract Price by portion for such defective equipment/materials/works and repayments of any sum paid by the Owner to the Contractor in respect of such defective equipment/material. Should the Owner not so replace the defective equipment/materials the Contractors extreme liability under this clause shall be limited to repayment of all sums paid by the Owner under the Contract for such defective equipment/materials.
18.0 PATENT RIGHTS AND ROYALTIES Royalties and fees for patents covering materials, articles, apparatus, devices, equipment or processes used in the works shall be deemed to have been included in the Contract Price. The Contractor shall satisfy all demands that may be made at any time for such royalties or fees and he alone shall be liable for any damages or claims for patent infringements and shall keep the Owner indemnified in that regard. The Contractor shall, at his own cost and expense, defend all suits or proceedings that may be instituted for alleged infringement of any patents involved in the Works, and, in case of an award of damages, the Contractor shall pay for such award. In the event of any suit or other proceedings instituted against the Owner, the same shall be defended at the cost and expense of the Contractor who shall also satisfy/comply with any decree, order or award made against the Owner. But it shall be understood that no such machine, plant, work, material or thing has been used by the Owner for any purpose or any manner other than that for which they have been furnished and installed by the Contractor and specified under these specifications. Final payment to the Contractor by the Owner will not be made while any such suit or claim remains unsettled. In the event any apparatus or equipment, or any part thereof furnished by the Contractor, is in such suit or proceedings held to constitute infringement, and its use is enjoined, the Contractor shall at his option and at his own expense, either procure for the Owner, the right to continue the use of said apparatus, equipment or part thereof, replace it with non-infringing apparatus or equipment or modify it, so it becomes noninfringing. 19.0 DEFENCE OF SUITS If any action in court is brought against the Owner or Engineer or an officer or agent of the Owner, for the failure, omission or neglect on the part of the
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Contractor to perform any acts, matters, covenants or things under the Contract, or for damage or injury caused by the alleged omission or negligence on the part of the Contractor, his agents, representatives or his Sub-Contractors, or in connection with any claim based on lawful demands of Sub-Contractors, workmen, suppliers or employees, the Contractor shall in all such cases indemnify and keep the Owner, and the Engineer and/or his representative, harmless from all losses, damages, expenses or decrees arising of such action. 20.0 LIMITATION OF LIABILITIES The final payment by the Owner in pursuance of the Contract shall mean the release of the Contractor from all his liabilities under the Contract. Such final payment shall be made only at the end of the Guarantee/Warranty period, and till such time as the Contractual liabilities and responsibilities of the Contractor, shall prevail. All other payments made under the Contract shall be treated as on-account payments. 21.0 ENGINEERS DECISION 21.1 In respect of all matters which are left to the decision of the Engineer including the granting or with-holding of the certificates, the Engineer shall, if required to do so by the Contractor, give in writing a decision thereon. If, in the opinion of the Contractor, a decision made by the Engineer is not in accordance with the meaning and intent of the Contract, the Contractor may file with the Engineer, within fifteen (15) days after receipt of the decision, a written objection to the decision. Failure to file an objection within the allotted time will be considered as an acceptance of the Engineers decision and the decision shall become final and binding. The Engineers decision and the filing of the written objection thereto shall be a condition precedent to the right to request arbitration. It is the intent of the Agreement that there shall be no delay in the execution of the works and the decision of the Engineer as rendered shall be promptly observed.
21.2
21.3
22.0 POWER TO DEVIATE, VARY OR OMIT WORK 22.1 No alterations, amendments, omissions, suspensions or deviations of the Works (hereinafter referred to as deviation) under the Contract as detailed in the Contract Documents, shall be made by the Contractor except as directed in writing by the Engineer, but the Engineer shall have full powers subject to the provisions hereinafter contained, from time to time during the execution of the Contract, by notice in writing to instruct the Contractor to make such deviation without prejudice to the Contract. The Contractor shall carry out such deviation and be bound by the same conditions as far as applicable as though the said deviations occurred in the Contract Documents. If any suggested deviations would, in the opinion of the Contractor, if carried out, prevent him from fulfilling any of his obligations or guarantees under the Contract, he shall notify the Engineer thereof in writing and the Engineer shall decide forthwith whether or not, the same shall be carried out and if the Engineer confirms his instructions, the Contractors obligations and guarantees shall be modified to such an extent as may be mutually agreed. Any agreed difference in cost occasioned by any such deviation shall be added to or deducted from the Contract Price as the case may be. In the event of Engineer requiring any deviation, a reasonable and proper notice shall be given to the Contractor to enable him to work his arrangement
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accordingly, and in cases where goods or materials are already prepared or any design, drawings or pattern made or work done requires to be altered, a reasonable and agreed sum in respect thereof shall be paid to the Contractor. 22.3 In any case in which the Contractor has received instructions from the Engineer as to the requirement of carrying out the alterations or additional or substituted work which either then or later on, will in the opinion of the Contractor, involve a claim for additional payment, the Contractor shall immediately and in no case later than thirty (30) days, after receipt of the instructions aforesaid and before carrying out the instructions, advise the Engineer to that effect. But the Engineer shall not become liable for payment of any charges in respect of any such deviations, unless the instructions for the performance of the same shall be confirmed in writing by the Engineer. If any deviation in the Works results in reduction of Contract Price, the parties shall agree, in writing, so to the extent of any change in the price, before the Contractor proceeds with the change. In all the above cases, in the event of a disagreement as to the reasonableness of the said sum, the decision of the Engineer shall prevail. Notwithstanding anything stated above in this clause, the Engineer shall have the full power to instruct the Contractor, in writing, during the execution of the Contract to vary the quantities of the items or groups of items in accordance with the provisions of clause entitled Change of Quantity in section GCC of this volume of Part-III. The Contractor shall carry out such deviations and be bound by the same conditions as though the said deviations occurred in the Contract Documents. However, the Contract Price shall be adjusted at the rates and the prices provided for the original quantities in the Contract.
22.4
22.5 22.6
23.0 ASSIGNMENT AND SUBCONTRACT 23.1 The Contractor may, after informing the Engineer and getting his written approval, Sub-Contract any parts thereof but shall not assign the Contract through execution of Power Of Attorney. Suppliers of the equipment not identified in the Contract or any change in the identified suppliers shall be subjected to approval by the Engineer. The approved vendors list as per clause 17.0 of section SCC under consideration by the Contractor for this Contract shall be furnished to the Engineer for approval prior to procurement of all such items/equipment. Such sub-contracting shall not relieve the Contractor of any obligation, duty or responsibility under the Contract. Any subcontract as above, without prior written approval of Engineer, shall be void. For components/equipment procured by the Contractor for the purposes of the Contract, after obtaining the written approval of the Employer, the Contractors purchase specifications and enquiries shall call for quality plan to be submitted by the suppliers along with their Proposals. The quality plans called for from the Vendors shall set out, during the various stages of manufacture and installation, the quality practices and procedures followed by the Vendors quality control organization, the relevant reference document/standard used, acceptance level, inspection documentation raised, etc. Such quality plans of the successful vendors shall be discussed and finalized in consultation with the Engineer and shall form a part of the Purchase Order/Contract between the Contractor and the Vendor. Within three weeks of the release of the Purchase Orders/Contracts for such bought out items/components a copy of the same without price details but together with detailed purchase specifications, quality
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plans and delivery conditions shall be furnished to the Engineer by the Contractor. 23.3 The Contractor shall not require any approval from the Employer for: a. the provision for labour, or labour component. b. the purchase of Materials which are in accordance with the standards specified in the Contract from approved vendors. purchase of machineries and equipment for carrying out the contract.
c.
24.0 CHANGE OF QUANTITY 24.1 During the execution of the Contract, the Owner reserves the right to increase or decrease the quantities of items under the Contract but without any change in unit price or other terms & conditions. Such deviations unless otherwise specified in the accompanying Special Conditions of Contract and/or Technical Specifications, shall be subject to the specific provision for the individual items but the total deviations in all such items under the Contract shall be limited to a percentage of the Contract price as specified in the Special Conditions of Contract. The Contract price shall accordingly be adjusted based on the unit rates available in the Contract for the change in quantities as above. The base unit rates, as identified in the Contract shall however remain constant during the currency of the Contract, except as provided for in Clause 33.0 below. In case the unit rates are not available for the change in quantity, the same shall be subjected to mutual agreement.
24.2
25.0 PACKING, FORWARDING AND SHIPMENT 25.1 The Contractor, wherever applicable, shall after proper painting, pack and crate all equipment in such a manner as to protect them from deterioration and damage during rail and road transportation to the Site and storage at the site till the time of erection. The Contractor shall be held responsible for all damages due to improper packing. The Contractor shall notify the Owner of the date of each shipment from his works, and the expected date of arrival at the Site for the information of the Owner. The Contractor shall also give all shipping information concerning the weight, size and content of each packing including any other information the Owner may require. The following documents shall be sent by registered post to the Owner within three days from the date of shipment, to enable the Owner to make progressive payments to the Contractor: Application for payment in the standard format of the Owner (3 copies) Invoice (6 copies) Packing list (6 copies) Pre-dispatch clearance certificate, if any (3 copies) Test Certificate, wherever applicable (3 copies)
25.2
25.3
25.4
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Insurance Certificate (3 copies) 25.5 The Contractor shall prepare detailed packing list of all packages and containers, bundles and loose materials forming each and every consignment dispatched to Site. The Contractor shall further be responsible for making all necessary arrangements for loading, unloading and other handling right from his works up to the Site and also till the equipment is erected, tested and commissioned. He shall be solely responsible for proper storage and safe custody of all equipment. COOPERATION WITH OTHER CONTRACTORS & CONSULTING ENGINEERS The Contractor shall agree to cooperate with the Owners other Contractors and Consulting Engineers and freely exchange with them such technical information as is necessary to obtain the most efficient and economical design and to avoid unnecessary duplication of efforts. The Engineer shall be provided with three copies of all correspondence addressed by the Contractor to other Contractors and Consulting Engineers of the Owner in respect of such exchange of technical information. 27.0 NO WAIVER OF RIGHTS Neither the inspection by the Owner or the Engineer or any of their officials, employees, or agents nor any order by the Employer or the Engineer for payment of money or any payment for or acceptance of, the whole or any part of the Works by the Owner or the Engineer, nor any extension of time, nor any possession taken by the Engineer shall operate as a waiver of any provision of the Contract, or of any power herein reserved to the Owner or any right to damages herein provided nor shall any waiver of any breach in the Contract be held to be a waiver of any other or subsequent breach. 28.0 CERTIFICATE NOT TO AFFECT RIGHT OF OWNER AND LIABILITY OF THE CONTRACTOR. No interim payment certificate of the Engineer, nor any sum paid on account by the Owner, nor any extension of time for execution of the Works granted by the Engineer shall affect or prejudice the rights of the Employer against the Contractor or relieve the Contractor of his obligation for the due performance of the Contract, or be interpreted as approval of the Works done or of the equipment furnished and no certificate shall create liability for the Owner to pay for alterations, amendments, deviations or additional works not ordered, in writing , by the Engineer or discharge the liability of the Contractor for the payment of damages whether due, ascertained, or certified or not or any sum against the payment of which he is bound to indemnify the Owner, nor shall any such certificate nor the acceptance by him of any sum paid on account or otherwise affect or prejudice the rights of the Owner against the Contractor. 29.0 TRAINING OF OWNERS PERSONNEL 29.1 The Contractor shall undertake to train free of cost, Engineering personnel selected and sent by the Owner at the works of the Contractor unless otherwise specified in the Technical Specifications. The period and the nature of training for the individual personnel shall be agreed upon mutually between the Contractor and the Owner. These Engineering personnel shall be given special training in the shops, where the equipment will be manufactured and/or in their Collaborators works and where possible, in any other plant where equipment
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manufactured by the Contractor or his collaborator is under installation, operation, or testing to enable those personnel to become familiar with the equipment being furnished by the Contractor. The details of the number of persons to be trained, period of training, nature of training etc. shall be as outlined in accompanying Technical Specifications/Special Conditions of Contract. 29.2 All traveling and living expenses for the Engineering personnel to be trained during the total period of training will be borne by the Owner. These Engineering personnel, while undergoing training, shall be responsible to the Contractor for discipline. The Owner shall not be entitled for any rebate, whatsoever, on any account in the event of his failing to avail of the training facilities, for any reason.
29.3
30.0 PROGRESS REPORTS AND PHOTOGRAPHS During the various stages of the work in pursuance of the Contract, the Contractor shall at his own cost submit periodic progress reports as may be reasonably required by the Engineer with such materials as, charts, net-works, photographs, test certificates, etc. Such progress reports shall be in the form and size as may be required by the Engineer and shall be submitted in at least three (3) copies. 31.0 TAKING-OVER Upon successful commissioning of the work as defined in clause 19 of Section SCC, the Engineer shall issue to the Contractor a Taking-over Certificate as a proof of the final acceptance of the equipment. Such certificate shall not unreasonably be withheld nor will the Engineer delay the issuance thereof on account of minor omissions or defects, which do not affect the commercial operation and/or cause any serious risk to the equipment. Such certificate shall not relieve the Contractor of any of his obligations which otherwise survive, by the terms and conditions of the Contract after issue of such certificate.
C. CONTRACT SECURITY AND PAYMENTS

32.0 CONTRACT PERFORMANCE GUARANTEE The Contractor shall furnish Contract Performance Guarantee(s) as a security for the proper fulfillment of the Contract in the prescribed format within thirty (30) days of Notice of Award of Contract. The performance guarantee(s) shall be as per terms prescribed in Clause 41 of Section INB.
33.0
CONTRACT CONTRACT)
PRICE
ADJUSTMENT
(NOT
APPLICABLE
IN
THIS
34.0 PAYMENT 34.1 The payment to the Contractor for the performance of the works under the Contract will be made by the Owner as per the guidelines and conditions specified herein. All payments made during the Contract shall be on account payments only. The final payment will be made on completion of all Works and on fulfillment by the Contractor of all his liabilities under the Contract. Currency of Payment All payments under the Contract shall be in Indian Rupees only.
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34.3
Due Dates for Payments The initial advance amount shall be payable after fulfilment of all the conditions laid down in the General Terms and Conditions of Contract, Clause 34.7.1 below and receipt of the Contractors invoice along with all necessary supporting documents for such advance payment. The price component of the initial advance amount will become due for payment within thirty (30) days of receipt of the Contractors invoice. The Owner will make progressive payment as and when the payment is due as per the terms of payment set forth in the accompanying Special Conditions of Contract. Progressive payments other than those under the letter of credit will become due and payable by the Owner within thirty (30) days of the date of receipt of Contractors bill/invoice/debit note by the Owner provided the documents submitted are complete in all respects.
34.4
Payment Schedule The Contractor shall prepare and submit to the Engineer for approval, a break up of the Contract Price. This Contract Price break-up shall be interlinked with the agreed detailed PERT network of the Contractor setting forth his starting and completion dates for the various key phases of Works prepared as per conditions in Clause 12.0 of this Section GCC of Part-III (Vol. ). Any payment under the Contract shall be made only after the Contractors price break up is approved by the Engineer. The aggregate sum of the Contractors price break up shall be equal to the lump sum Contract Price. A price break-up over valuing those items of supply, which will be shipped first will not be accepted.
34.5
Application for Payment 34.5.1 The Contractor shall submit application for the payment in the prescribed proforma of the Owner. Proforma for application for payment is enclosed as Annexure-IV of Part-III (Vol. ). 34.5.2 Each such application shall state the amount claimed and shall set forth in detail, in the order of the Payment Schedule, particulars of the Works including the Works executed at Site and of the equipment shipped/brought on to the site pursuant to the Contract up to the date mentioned in the application and for the period covered since the last preceding certificate, if any. 34.5.3 Every interim payment certificate shall certify the Contract value of the Works executed up to the date mentioned in the application for the payment certificate, provided that no sum shall be included in any interim payment certificate in respect of the works that, according to the decision of the Engineer, does not comply with the Contract or has been performed, at the date of certificate prematurely.
34.6
Mode of Payment 34.6.1 Payment due on dispatch of equipment shall be made by the Owner through the Owners Bank or directly to the Contractor as per the payment schedule. 34.6.2 The payment of the advance, test charges, if any, price adjustment, any other supply payment, taxes and duties (whenever admissible) inland transportation (including port handling), insurance and the erection portion of the Works shall be made direct to the Contractor by the Owner.
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34.7
Terms Of Payment The terms of payments for various activities under the Contract are as under: 34.7.1 Ex-works Price and Erection The terms of payments for Ex-works price-components of the equipment and erection are detailed in Special Conditions of Contract, for each equipment package. A certain percentage of the equipment and erection costs of each package shall be paid as initial advance on fulfillment of the following by the Contractor. i) For Ex-works price component of Equipment: a. Acknowledgement of Letter of Award. a. Submission of TDR or STDR of principal amount not lesser than eligible advance proposed. Such TDR/STDR should be drawn on any Nationalized Bank pledged in favour of the Executive Engineer(E), Tawang in the account of the bidder. The maturity period of such STDR shall not be less than the Contract period. c. Submission of Contract Performance Guarantee in accordance with clause 41.0 of Section INB of Part-III (Vol. ). d. Submission of a detailed PERT network/bar chart based on the work schedule stipulated in the Letter of Award and its approval by the Owner. ii) For Erection Component: No advance shall be admissible separately for erection works. 34.7.2 All further payments under the Contract shall be made as stipulated in the Special Conditions of Contract after signing the Contract Agreement. The payments linked with the dispatch of materials shall only be made after production of all dispatch documents as specified in L/C conditions and/or in the relevant Contract conditions which will inter-alia include the Material Inspection Clearance Certificate (MICC) issued by the Owners Corporate QA&I representatives. Progressive payments linked with erection shall only be made after the issue of certificates by the Engineer, one for the quantum of work completed and the other by the Engineers Field Qualify surveillance representative for the successful completion of quality check points involved in the quantum of work billed. 34.7.3 Inland Transportation & Insurance Inland transportation (including port handling) and inland insurance charges shall be paid to the Contractor on pro-rata to the value of the equipment received at site and on production of the invoices by the Contractor. However, wherever equipment wise inland transportation charges have been called for in the Bid Proposal Sheets and have been furnished by the Contractor, the payment of inland transportation charges shall be made after receipt of equipment at site based on the charges thus identified by the Contractor in his Proposal and incorporated in the Contract. The aggregate of all such pro-rata payments shall however not exceeds the total amount quoted by the Bidder in his Bid and incorporated in the Contract.
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34.7.4 Price adjustment/Contract Deviation (NOT APPLICABLE IN THIS CONTRACT) 35.0 DEDUCTIONS FROM CONTRACT PRICE All costs, damages or expenses that the Owner may have paid, for which under the Contract the Contractor is liable, will be claimed by the Owner. All such claims shall be billed by the Owner to the Contractor regularly as and when they fall due. Such bills shall be supported by appropriate and certified vouchers or explanations, to enable the Contractor to properly identify such claims. Such claims shall be paid by the Contractor within thirty (30) days of the receipt of the corresponding bills and if not paid by the Contractor within the said period, the Owner may then deduct the amount, from any moneys due or becoming due by him to the Contractor under the Contract or may be recovered by sections of Law or otherwise.
D. RISK DISTRIBUTION
36.0 TRANSFER OF TITLE 36.1 Transfer of title in respect of equipment and materials supplied by the Contractor to the Owner pursuant to the terms of the Contract shall pass on to the Owner with negotiation of dispatch documents. This Transfer of Title shall not be construed to mean the acceptance and the consequent Taking Over of equipment and materials. The Contractor shall continue to be responsible for the quality and performance of such equipment and materials and for their compliance with the specifications until Taking Over and the fulfillment of guarantee provisions of this Contract. This Transfer of Title shall not relieve the Contractor from the responsibility for all risks of loss or damage to the equipment and materials as specified under the clause entitled Insurance of this Section.
36.2
36.3
37.0
INSURANCE 37.1 The Contractor at his cost shall arrange, secure and maintain all insurance as may be pertinent to the Works and obligatory in terms of law to protect his interest and interests of the Owner against all perils detailed herein. The form and the limit of such insurance as defined herein together with the under-writer in each case shall be acceptable to the Owner. However, irrespective of such acceptance, the responsibility to maintain adequate insurance coverage at all time during the period of Contract shall be of Contractor alone. The Contractors failure in this regard shall not relieve him of any of his contractual responsibilities and obligations. The insurance covers to be taken by the Contractor shall be in the joint name of the Owner and the Contractor. The Contractor shall, however, be authorized to deal directly with Insurance Company or Companies and shall be responsible in regard to maintenance of all insurance covers. Further the insurance should be in freely convertible currency. Any loss or damage to the equipment during handling, transportation, storage, erection, putting into satisfactory operation and all activities to be performed till the successful completion of commissioning of the equipment shall be to the account of the Contractor. The Contractor shall be responsible for preference of all claims and make good the damages or loss by way of repairs and/or replacement of the equipment, damaged or lost. The transfer of title shall not in
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any way relieve the Contractor of the above responsibilities during the period of Contract. The Contractor shall provide the Owner with copies of all insurance policies and documents taken out by him in pursuance of the Contract. Such copies of documents shall be submitted to the Owner immediately after such insurance coverage. The Contractor shall also inform the Owner in writing at least sixty (60) days in advance regarding the expiry/cancellation and/or change in any of such documents and ensure revalidation, renewal etc., as may be necessary well in time. 37.3 The perils required to be covered under the insurance shall include, but not be limited to fire and allied risks, miscellaneous accidents (erection risks) workman compensation risks, loss or damage in transit, theft, pilferage, riot and strikes and malicious damages, civil commotion, weather conditions, accidents of all kinds, etc. The scope of such insurance shall be adequate to cover the replacement/reinstatement cost of the equipment for all risks up to and including delivery of goods and other costs till the equipment is delivered at Site. The insurance policies to be taken should be on replacement value basis and/or incorporating escalation clause. Notwithstanding the extent of insurance cover and the amount of claim available from the underwriters, the Contractor shall be liable to make good the full replacement/rectification value of all equipment/materials and to ensure their availability as per project requirements. All costs on account of insurance liabilities covered under the Contract will be on Contractors account and will be included in Contract Price. However, the Owner may from time to time, during the pendency of the Contract, ask the Contractor in writing to limit the insurance coverage, risks and in such a case, the parties to the Contract will agree for a mutual settlement, for reduction in Contract price to the extent of reduced premium amount. The Contractor, while arranging the insurance shall ensure to obtain all discounts on premium, which may be available for higher volume or for reason of financing arrangement of the project. The clause entitled Insurance under the Section ECC of this Part-III (Vol. ) covers the additional insurance requirements for the portion of the works to be performed at the Site.
37.4
37.5
38.0
LIABILITY FOR ACCIDENTS AND DAMAGES Under the Contract, the Contractor shall be responsible for loss or damage to the plant until the successful completion of commissioning as defined else where in the Bid document.
39.0 DELAYS BY EMPLOYER OR HIS AUTHORISED AGENTS 39.1 In case the Contractors performance is delayed due to any act of omission on the part of the Owner or his authorized agents, then the Contractor shall be given due extension of time for the completion of the Works, to the extent such omission on the part of the Owner has caused delay in the Contractors performance of the Contract. In addition, the Contractor shall be entitled to claim demonstrable and reasonable compensation if such delays have resulted in any increase in cost. The Owner shall examine the justification for such a request for claim and if satisfied, the extent of compensation shall be mutually agreed depending upon the circumstances at the time of such an occurrence.
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40.0 DEMURRAGE, WHARFAGE, ETC. All demurrage, wharfage and other expenses incurred due to delayed clearance of the material or any other reason shall be to the account of the Contractor. 41.0 FORCE MAJEURE 41.1 Force Majeure is herein defined as any cause which is beyond the control of the Contractor or the Owner as the case may be, which they could not foresee or with a reasonable amount of diligence could not have foreseen and which substantially affects the performance of the Contract, such as: a. Natural phenomena, including but not limited to floods, droughts, earthquakes and epidemics; b. Acts of any Government, domestic or foreign, including but not limited to war, declared or undeclared, priorities, guarantees, and embargoes. Provided either party shall within fifteen (15) days from the occurrence of such a cause notify the other in writing of such causes. 41.2 The Contractor or the Owner shall not be liable for delays in performing his obligations resulting from any Force Majeure cause as referred to and/or defined above: The date of completion will, subject to hereinafter provided, be extended by a reasonable time even though such cause may occur after Contractors performance of obligation has been delayed due to other causes. 42.0 SUSPENSION OF WORK 42.1 The Owner reserves the right to suspend and reinstate execution of the whole or any part of the Works without invalidating the provisions of the Contract. Orders for suspension or reinstatement of the Works will be issued by the Engineer to the Contractor in writing. The time for completion of the works will be extended for a period equal to duration of the suspension. Any necessary and demonstrable cost incurred by the Contractor as a result of such suspension of the works will be paid by the Owner, provided such costs are substantiated to the satisfaction of the Engineer. The Owner shall not be responsible for any liabilities if suspension or delay is due to some default on the part of the Contractor or his Sub-Contractor.
42.2
43.0
CONTRACTOR`S DEFAULT 43.1 If the Contractor shall neglect to execute the works with due diligence and expedition or shall refuse or neglect to comply with any reasonable order given to him, in writing by the Engineer in connection with the works or shall contravene the provisions of the Contract, the Owner may give notice in writing to the Contractor to make good the failure, neglect or contravention complained of. Should the Contractor fail to comply with the notice within thirty (30) days from the date of serving the notice, then and in such case the Owner shall be at liberty to employ other workmen and forthwith execute such part of the works as the Contractor may have neglected to do or if the Owner shall think fit, without prejudice to any other right he may have under the Contract to take the work wholly or in part out of the Contractors hands and re-contract with any other person or persons to complete the works or any part thereof and in that event the Owner shall have free use of all Contractors equipment that may have been at the time on the Site in connection with the works without being
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responsible to the Contractor for fair wear and tear thereof and to the exclusion of any right of the Contractor over the same, and the Owner shall be entitled to retain and apply any balance which may otherwise be due on the Contract by him to the Contractor, or such part thereof as may be necessary, to the payment of the cost of executing the said part of the Works or of completing the Works as the case may be. If the cost of completing of works or executing part thereof as aforesaid shall exceed the balance due to the Contractor shall pay such excess. Such payment of excess amount shall be independent of the liquidated damages for delay, which the Contractor shall have to pay if the completion of works is delayed. 43.2 In addition, such action by the Owner as aforesaid shall not relieve the Contractor of his liability to pay liquidated damages for delay in completion of Works as defined in Clause 14.0 of this Section. Such action by the Owner as aforesaid the termination of the Contract under this clause shall not entitle the Contractor to reduce the value of the Contract Performance Guarantee nor the time thereof. The Contract Performance Guarantee shall be valid for the full value and for the full period of the Contract including guarantee period.
43.3
44.0 TERMINATION OF CONTRACT ON OWNER`S INITIATIVE 44.1 The Owner reserves the right to terminate the Contract either in part or in full due to reasons other than those mentioned under clause entitled Contractors Default. The Owner shall in such an event give fifteen (15) days notice in writing to the Contractor of his decision to do so. 44.2 The Contractor upon receipt of such notice shall discontinue the work on the date and to the extent specified in the notice, make all reasonable efforts to obtain cancellation of all orders and Contracts to the extent they are related to the work terminated and terms satisfactory to the Owner, stop all further subcontracting or purchasing activity related to the work terminated, and assist Owner in maintenance, protection, and disposition of the works acquired under the Contract by the Owner. In the event of such a termination; the Contractor shall be paid compensation, equitable and reasonable, dictated by the circumstances prevalent at the time of termination. 44.3 If the Contractor is an individual or a proprietary concern and the individual or the proprietor dies and if the Contractor is a partnership concern and one of the partners dies then unless the Owner is satisfied that the legal representatives of the individual Contractor or of the proprietor of the propriety concerned and in the case of partnership, the surviving partners, are capable of carrying out and completing the Contract the Owner shall be entitled to cancel the Contract as to its incomplete part without being in any way liable to payment of any compensation to the estate of deceased Contractor and/or to the surviving partners of the Contractors firm on account of the cancellation of the Contract. The decision of the Owner that the legal representatives of the deceased Contractor or surviving partners of the Contractors firm cannot carry out and complete the Contract shall be final and binding on the parties. In the event of such cancellation the Owner shall not hold the estate of the deceased Contractor and/or the surviving partners of the estate of the deceased Contractor and/or the surviving partners of the Contractors firm liable to damages for not completing the Contract.
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45.0 FRUSTRATION OF CONTRACT 45.1 In the event of frustration of the Contract because of supervening impossibility in terms of Section 56 of the Indian Contract Act, parties shall be absolved of their responsibility to perform the balance portion of the Contract, subject to provisions contained in sub-clause 45.3 below. In the event of non-availability or suspension of funds for any reasons, whatsoever (except for reason of willful or flagrant breach by the Owner) and/or Contractor then the works under the Contract shall be suspended. Furthermore, if the Owner is unable to make satisfactory alternative arrangements for financing to the Contractor in accordance with the terms of the Contract within three months of the event, the parties hereto shall be relieved from carrying out further obligations under the Contract treating it as frustration of the Contract. 45.3 In the event referred to in sub-clauses 45.1 & 45.2 above the parties shall mutually discuss to arrive at reasonable settlement on all issues including amounts due to either party for the work already done on Quantum merit basis, which shall be determined by mutual agreement between the parties.
45.2
46.0 GRAFTS AND COMMISSIONS ETC. Any graft, commission, gift or advantage given, promised or offered by or on behalf of the Contractor or his partner(s), agent(s), officer(s), director(s), employee(s) or servant(s) or any one on his or their behalf in relation to the obtaining or to the execution of this or any other Contract with the Owner, shall in addition to any criminal liability which it may incur, subject the Contractor to the cancellation of this and all other Contracts and also to payment of any loss or damage to the Owner resulting from any cancellation. The Owner shall then be entitled to deduct the amount so payable from any monies otherwise due to Contractor under the Contract.
E. RESOLUTION OF DISPUTES
47.0 SETTLEMENT OF DISPUTES 47.1 47.2 Any dispute(s) or difference(s) arising out of or in connection with the Contract shall, to the extent possible, be settled amicably between the parties. If any dispute or difference of any kind, whatsoever, shall arise between the Owner and the Contractor, arising out of the Contract for the performance of the Works whether during the progress of the Works or after its completion or whether before or after the termination, abandonment or breach of the Contract, it shall, in the first place, be referred to and settled by the Engineer, who, within a period of thirty (30) days after being requested by either party to do so, shall give written notice of his decision to the Owner and the Contractor. Save as hereinafter provided, such decision in respect of every matters so referred shall be final and binding upon the parties until the completion of the Works and shall forthwith be given effect to by the Contractor who shall proceed with the Works with all due diligence, whether he or the Owner requires arbitration as hereinafter provided or not. If after the Engineer has given written notice of his decision to the parties, no claim to arbitration has been communicated to him by either party within thirty (30) days from the receipt of such notice, the said decision shall become final and binding on the parties.
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47.5
In the event of the Engineer failing to notify his decision as aforesaid within thirty (30) days after being requested as aforesaid, or in the event of either the Owner or the Contractor being dissatisfied with any such decision, or within thirty (30) days after the expiry of the first mentioned period of thirty days, as the case may be, either party may require that the matters in dispute be referred to arbitration as hereinafter provided.
48.0
ARBITRATION 48.1 All disputes or differences in respect of which the decision, if any, of the Engineer has not become final or binding as aforesaid shall be settled by arbitration in the manner hereinafter provided.
48.1.1 The arbitration shall be conducted by three arbitrators, one each to be nominated by the Contractor and the Owner and the third to be appointed as an umpire by both the arbitrators in accordance with the Indian Arbitration Act. If either of the parties fails to appoint its arbitrator within sixty (60) days after receipt of a notice from the other party invoking the Arbitration clause, the arbitrator appointed by the party invoking the arbitration clause shall become the sole arbitrator to conduct the arbitration. 48.1.2 The arbitration shall be conducted in accordance with the provisions of the Indian Arbitration Act, 1940 or any statutory modification thereof. The venue of arbitration shall be Itanagar. 48.2 The decision of the majority of the arbitrators shall be final and binding upon the parties. The arbitrators may, from time to time with the consent of all the parties enlarge the time for making the award. In the event of any of the aforesaid arbitrators dying, neglecting, resigning or being unable to act for any reason, it will be lawful for the party concerned to nominate another arbitrator in place of the outgoing arbitrator. The arbitrator shall have full powers to review and/or revise any decision, opinion, direction, certification or valuation of the Engineer in accordance with the Contract, and neither party shall be limited in the proceedings before such arbitrators to the evidence or arguments put before the Engineer for the purpose of obtaining the said decision. No decision given by the Engineer in accordance with the foregoing provisions shall disqualify him as being called as a witness or giving evidence before the arbitrators on any matter whatsoever relevant to the dispute or difference referred to the arbitrators as aforesaid. During settlement of disputes and arbitration proceedings, both parties shall be obliged to carry out their respective obligations under the Contract.
48.3
48.4
48.5
49.0 RECONCILIATION OF ACCOUNTS The Contractor shall prepare and submit every six months, a statement covering payments claimed and the payments received vis--vis the works executed, for reconciliation of accounts with the Owner. The Contractor shall also prepare and submit a detailed account of Owner Issue Materials, received and utilized by him for reconciliation purpose in a format to be discussed & finalized with the Owner before the award of Contract.
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ERECTION CONDITIONS OF CONTRACT
(ECC)
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CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0 35.0 36.0 37.0
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Description General Regulation of Local Authorities and Statutes Owners Lien on Equipment Inspection, Testing and Inspection Certificates Access to Site and Works on Site Contractors Site Office Establishment Co-Operation with Other Contractors Discipline of Workman Contractors Field Operation Photographs and Progress Report Man-Power Report Protection of Work Employment of Labour Facilities to be Provided by the Owner Facilities to be Provided by the Contractor Line and Grades Fire Protection Security Contractors Area Limits Contractors Co-Operation with the Owner Pre-Commissioning Trials and Initial Operations Materials Handling and Storage Construction Management Field Office Records Contractors Materials brought on to Site Protection of Property and Contractors Liability Painting Insurance Unfavourable Working Conditions Protection of Monuments and Reference Points Work and Safety Regulations Code Requirements Foundation, Dressing and Grouting Shaft Alignments Dowelling Check out of Contract Systems Cabling
Page No. 54 54 54 54 55 55 55 55 56 56 56 56 57 60 60 61 61 62 62 62 63 63 64 64 65 65 65 66 67 67 67 71 71 73 73 73 73
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SECTION ECC ERECTION CONDITIONS OF CONTRACT

1.0 GENERAL 1.1 The following shall supplement the conditions already contained in other parts of these specifications and document and shall govern the portion of the work of this Contract to be performed at Site. 1.2 The Contractor upon signing of the Contract shall, in addition to a Project Coordinator, nominate another responsible officer as his representative at Site suitably designated for the purpose of overall responsibility and coordination of the works to be performed at Site. Such person shall function from the Site office of the Contractor during the pendency of Contract.
2.0 REGULATION OF LOCAL AUTHORITIES AND STATUTES 2.1 The Contractor shall comply with all the rules and regulations of local authorities during the performance of his field activities. He shall also comply with the Minimum Wages Act, 1948 and the Payment of Wages Act (both of the Government of India) and the rules made there under in respect of any employee or workman employed or engaged by him or his Sub-Contractor. 2.2 All registration and statutory inspection fees, if any, in respect of his work pursuant to this Contract shall be to the account of the Contractor. However, any registration, statutory inspection fees lawfully payable under any statutory laws and its amendments from time to time during erection in respect of the equipment ultimately to be owned by the Owner, shall be to the account of the Owner. Should any such inspection or registration need to be re-arranged due to the fault of the Contractor or his Sub Contractor, the additional fees to such inspection and/or registration shall be borne by the Contractor.
3.0 OWNERS LIEN ON EQUIPMENT The Owner shall have lien on all equipment including those of the Contractor brought to the Site for the purpose of erection, testing and commissioning of the equipment to be supplied & erected under the Contract. The Owner shall continue to hold the lien on all such equipment throughout the period of Contract. No material brought to the Site shall be removed from the Site by the Contractor and/or his Sub-Contractors without the prior written approval of the Engineer. 4.0 INSPECTION, TESTING AND INSPECTION CERTIFICATES The provisions of the clause entitled Inspection, Testing and Inspection Certificates under Technical Specifications; Section GTR shall also be applicable to the erection portion of the Works. The Engineer shall have the right to re-inspect any equipment though previously inspected and approved by him at the Contractors works, before and after the same are erected at Site. If by the above inspection, the Engineer rejects any equipment, the Contractor shall make good for such rejections either by replacement or modifications/repairs as may be necessary to the satisfaction of the Engineer. Such replacement will also include the replacements or re-execution of such of those works of other Contactors and/or agencies, which might have got damaged or affected by the replacements or re-work done to the Contractors work.
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5.0 ACCESS TO SITE AND WORKS ON SITE 5.1 Suitable access to and possession of the Site shall be afforded to the Contractor by the Owner in reasonable time. 5.2 The Owner shall have the necessary foundations to be provided by him ready, as per the agreed schedule for the execution of the individual phases of works 5.3 The works so far as it is carried out on the Owners premises, shall be carried out at such time as the Owner may approve and the Owner shall give the Contractor reasonable facilities for carrying out the works. 5.4 In the execution of the works, no person other than the Contractor or his duly appointed representative, Sub- Contractor and workmen, shall be allowed to do work on the Site, except by the special permission, in writing of the Engineer or his representative.
6.0 CONTRACTORS SITE OFFICE ESTABLISHMENT ( at least in two locations) The Contractor shall establish a Site Office at the site and keep posted an authorized representative for the purpose of the Contract. Any written order or instruction of the Engineer or his duly authorized representative shall be communicated to the said authorised resident representative of the Contractor and the same shall be deemed to have been communicated to the Contractor at his legal address. 7.0 CO-OPERATION WITH OTHER CONTRACTORS 7.1 The Contractor shall co-operate with all other Contractors or tradesmen of the Owner, who may be performing other works on behalf of the Owner and the workmen who may be employed by the Owner and doing work in the vicinity of the Works under the Contract. The Contractor shall also so arrange to perform his work as to minimize, to the maximum extent possible, interference with the work of other Contractors and their workmen. Any injury or damage that may be sustained by the employees of the other Contractors and the Owner, due to the Contractors work shall promptly be made good at the Contractors own expense. The Engineer shall determine the resolution of any difference or conflict that may arise between the Contractor and other Contractors or between the Contractor and the workmen of the Owner in regard to their work. If the work of the Contractor is delayed because of any acts of omission of another Contractor, the Contractor shall have no claim against the Owner on that account other than an extension of time for completing his Works. 7.2 The Engineer shall be notified promptly by the Contractor of any defects in the other Contractors works that could affect the Contractors Works. The Engineer shall determine the corrective measures, if any, required to rectify this situation after inspection of the works and such decision by the Engineer shall be binding on the Contractor.
8.0
DISCIPLINE OF WORKMEN 8.1 The Contractor shall adhere to the disciplinary procedure set by the Engineer in respect of his employees and workmen at Site. The Engineer shall be at liberty to object to the presence of any representative or employee of the Contractor at the Site, if in the opinion of the Engineer the conduct of the employee is not satisfactory or is incompetent or negligent or otherwise undesirable and then the Contractor shall remove such a person objected to and provide in his place a competent replacement.
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8.2 The Contractor shall employ personnel for construction works after satisfying themselves of the satisfactory character and antecedents of all personnel specially those imported from other states. Any breach of peace, faith or harmony of the local area or any act of unlawful nature or any act that causes or potential to cause breach of law and order by such personals employed by the contractor shall solely and entirely on contractors responsibility. 9.0 CONTRACTORS FIELD OPERATION 9.1 The Contractor shall keep the Engineer informed in advance regarding his field activity plans and schedules for carrying-out each part of the works. Any review of such plan or schedule or method of work by the Engineer shall not relieve the Contractor of any of his responsibilities towards the field activities. Such reviews shall also not be considered as an assumption of any risk or liability by the Engineer or the Owner or any of his representatives and no claim of the Contractor will be entertained because of the failure or inefficiency of any such plan or schedule or method of work reviewed. The Contractor shall be solely responsible for the safety, adequacy and efficiency of plant and equipment and his erection methods. 9.2 The Contractor shall have the complete responsibility for the conditions of the Work-site including the safety of all persons employed by him or his Sub Contractor and all the properties under his custody during the performance of the work. This requirement shall apply continuously till the completion of the Contract and shall not be limited to normal working hours. The construction review by the Engineer is not intended to include review of Contractors safety measures in, on or near the Work-Site, and their adequacy or otherwise.
10.0 PHOTOGRAPHS AND PROGRESS REPORT 10.1 The Contractor shall furnish three (3) prints each to the Engineer of progress photographs of the work done at site. Photographs shall be taken as and when indicated by the Engineer or his representative. Photographs shall be adequate in size and number to indicate various stages of erection. Each photograph shall contain the date, the name of the Contractor and the title of the photograph. 10.2 The above photographs shall accompany the monthly progress report detailingout the progress achieved on all erection activities as compared to the schedules. The report shall also indicate the reasons for the variance between the scheduled and actual progress and the action proposed for corrective measures, wherever necessary. 11.0 MAN-POWER REPORT 11.1 The Contractor shall submit to the Engineer, on the first day of every month, a man hours schedule for the month, detailing the man hours scheduled for the month, skill-wise and area-wise. 11.2 The Contractor shall also submit to the Engineer, on the first day of every month, a man-power report of the previous month detailing the number of persons scheduled to have been employed and actually employed, skill-wise and the areas of employment of such labour. 12.0 PROTECTION OF WORK The Contractor shall have total responsibility for protecting his works till it is finally taken over by the Engineer. No claim will be entertained by the Owner or by the Engineer for any damage or loss to the Contractors works and the Contractor shall be
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responsible for complete restoration of the damaged works to original conditions to comply with the specification and drawings, should any such damage to the Contractors works occur because of any other party not being under his supervision or control. The Contractor shall make his claim directly with the party concerned. If disagreement or conflict or dispute develops between the Contractor and the other party or parties concerned regarding the responsibility for damage to the Contractors works, the same shall be resolved as per the provisions of the Clause 7.0 above entitled Cooperation with other Contractors. The Contractor shall not cause any delay in the repair of such damaged works because of any delay in the resolution of such dispute. The Contractor shall proceed to repair the Work immediately and no cause thereof will be assigned pending resolution of such disputes. 13.0 EMPLOYMENT OF LABOUR 13.1 The Contractor will be expected to employ on the work only his regular skilled employees with experience of his particular work. No female labour shall be employed after darkness. No person below the age of eighteen years shall be employed. 13.2 All traveling expenses including provisions of all necessary transport to and from site, lodging allowances and other payments to the Contractors employees shall be the sole responsibility of the Contractor. 13.3 The hours of work on the Site shall be decided by the Owner and the Contractor shall adhere to it. Working hours will normally be eight (8) hours per dayMonday through Saturday. 13.4 The Contractors employees shall wear identification badges while on work at Site. 13.5 In case the Owner becomes liable to pay any wages or dues to Labour or any Government agency under any of the provisions of the Minimum Wages Act, Workmen Compensation Act, Contract Labour Regulation Abolition Act or any other law due to act of omission of the Contractor, the Owner may make such payment and shall recover the same from the Contractors bills. 13.6 The contractor shall be responsible for obtaining Inner Line Permits from local authorities for importing personals from outside the State as required under Bengal Frontier Regulation Act 1863.
13.7
Compliance with Labour Regulations 13.7.1 During continuance of the contract, the Contractor and his sub-contractors shall abide at all times by all applicable existing labour enactments and rules made there-under, regulations, notifications and byelaws of the State or Central Government or local authority and any other labour law (including rules), regulations, bye laws that may be passed or notification that may be issued under any labour law in future either by the State or the Central Government or the local authority. The employees of the Contractor and the Sub-contractor in no case shall be treated as the employees of the Owner at any point of time. 13.7.2 The Contractor shall keep the Owner indemnified in case any action is taken against the Owner by the competent authority on account of contravention of any of the provisions of any Act or rules made there under, regulations, or notifications including amendments.
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13.7.3 If the Owner is caused to pay under any law as Principal Employer such amount as may be necessary to cause or observe, or for non-observance of the provisions stipulated in the Notifications/Byelaws/Acts/Rules/Regulations including amendments, if any, on the part of the Contractor, the Owner shall have the right to deduct any money due to the Contractor under this contract or any other contract with the Owner including his amount of Performance Security for adjusting the aforesaid payment. The Owner shall also have right to recover from the Contractor any sum required or estimated to be required for making good the loss or damage suffered by the Owner. 13.7.4 Salient features of some major laws applicable to establishments engaged in building and other construction works: (a) Workmen Compensation Act 1923: The Act provides for compensation in case of injury by accident arising out of and during the course of employment. (b) Payment of Gratuity Act 1972: Gratuity is payable to an employee under the Act on satisfaction of certain conditions on separation if an employee has completed 5 years service or more or on death at the rate of 15 days wages for every completed year of service. The Act is applicable to all establishments employing 10 or more employees. (c) Employee P.F. and Miscellaneous Provision Act 1952: The Act provides for more contribution by the Employer plus workers @ 10% or 8.33%. The benefits under these are : i) ii) iii) iv) Pension or family pension on retirement or death, as the case may be. Deposit linked insurance on death in harness of the worker. Payment of P.F. accumulation on retirement/death etc. Maternity Benefit Act 1951: The Act provides for leave and some other benefit for women employees in case of confinement or miscarriage etc.
(d) Contract Labour (Regulation & Abolition) Act 1970: The Act provides for certain welfare measures to be provided by the Contractor to contract labour and in case contractor fails to provide, the same are required to be provided, by the Principal Employer by law. The Principal Employer is required to take Certification of Registration and the Contractor is required to take license from the designated Officer. The Act applicable to the establishments or contractor of Principal Employer if they employ 20 or more contract labour. (e) Minimum Wages Act 1948: The Employer is supposed to pay not less than the Minimum Wages fixed by appropriate Govt. as per provision of the Act if the employment is scheduled employment. (f) Payment of Wages Act 1936: It lays down as to by what date the wages are to be paid, when it will be paid and what deductions can be made from the wages of the workers. (g) Equal Remuneration Act 1979: The Act provides for payment of equal wages for work of equal nature to male and female workers and for not making discrimination against female employees in the matters of transfer, training and promotions etc. (h) Payment of Bonds Act 1965: The Act is applicable to all establishments employing 20 or more employees. The Act provides for payments of annual
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bonus subject to a minimum of 8.33% of wages and maximum of 20% of wages to employees drawing Rs. 3500/- per month or less. The bonus is to be paid to employees getting Rs. 2500 per month or above up to Rs. 3500/per month shall be worked out by taking wages of Rs. 2500/- per month only. The Act does not apply to certain establishments. The newly set-up establishments are exempted for five years in certain circumstances. Some of the State Governments have reduced the employment size from 20 to 10 for the purpose of applicability of this Act. (i) Industrial Dispute Act 1947: The act lays down the machinery and procedure for resolution of industrial disputes, in what situations as strike or lock-out becomes illegal and what are the requirements for laying off or retrenching the employees or closing down the establishment. (j) Industrial Employment (Standing Orders) Act 1946: It is applicable to all establishments employing 100 or more workmen (employment size reduced by some of the States and Central Government to 50). The Act provides for laying down rules governing the conditions of employment by the Employer on matters provided in the Act and gets the same certified by the designated Authority. (k) Trade Unions Act 1926: The Act lays down the procedure for registration of Trade Unions of workmen and Employers. The Trade Unions registered under the Act have been given certain immunities from civil and criminal liabilities. (l) Child Labour (Prohibition & Regulation) Act 1986: The Act prohibits employment of children below 14 years of age in certain occupations and processes and provides for regulations of employment of children in all other occupations and processes. Employment of Child Labour is prohibited in building and Construction Industry. (m) Inter-State Migrant Workmens (Regulation of Employment & Conditions of Service) Act 1979: The Act is applicable to an establishment which employs 5 or more inter-state migrant workmen through an intermediary (who has recruited workmen in one state for employment in the establishment situated in another state). The Inter-State migrant workmen, in an establishment to which this Act becomes applicable, are required to be provided certain facilities such as; housing, medical aid, traveling expenses from home up to the establishment and back, etc. (n) The Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act 1996 and the Cess Act of 1996: All the establishments who carry on any building or other construction work and employ 10 or more workers are covered under this Act. All such establishments are required to pay cess at the rate not exceeding 2% of the cost of construction as may be modified by the Government. The Employer of the establishment is required to provide safety measures at the building or construction work and other welfare measures, such as canteens, first-aid facilities, ambulance, housing accommodations for workers near the work place etc. The Employer to whom the Act applies has to obtain a registration certificate from the Registering Officer appointed by the Government. (o) Factories Act 1948: The Act lays down the procedure for approval at plans before setting up a factory, health and safety provisions, welfare provisions, working hours, annual earned leave and rendering information regarding
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accidents or dangerous occurrences to designated authorities. It is applicable to premises employing 10 persons or more with aid of power or 20 or more persons without the aid of power engaged in manufacturing process.
14.0 FACILITIES TO BE PROVIDED BY THE OWNER 14.1 Space Land for Contractors Office, Store, Workshop etc. a) The Engineer shall at his discretion and for the duration of execution of the Contract make available at site, land for construction of Contractors field office, workshop, stores, magazines for explosives in isolated locations, assembling yard etc. required for execution of the Contract. Any construction of temporary roads, offices, workshop etc. as per plan approved by the Engineer shall be done by the Contractor at his cost. b) On completion of work the Contractor shall hand over the land duly cleaned to the Engineer. Until and unless the Contractor has handed over the vacant possession of land allotted to him for the above purpose, the payment of his final bill shall not be made. The Contractor shall be made liable to pay for the use and occupation at the rates to be determined by the Engineer if the Contractor over stays in the land after the Contract is completed. 14.2 Electricity: Power supply: Where power supply is available with the Owner for construction purpose the same will be provided at the job site at one point of the distribution system as may be decided by Engineer free of charge for consumption in works. Electricity furnished will be 440 volts, 3 phase, 50 cycles and 230 volts, 1 phase, 50 cycles. Each Contractor shall provide and install all necessary transformers, switchgears, wiring fixtures, bulbs and other temporary equipment for further distribution and utilisation of energy for power and lighting and shall remove the same on completion of the work. Should, however, electricity be used in the Contractors labour/staff colony, the power so consumed shall be charged at the prevailing tariff rate of Department of Power, Arunachal Pradesh as prevalent for that area at the time of award of work; the supply may be withdrawn if the power is used for purposes other than for the work of the project and the Contractor shall not be entitled to any claim whatsoever on account of any such action taken by the Engineer. 14.3 Water Free supply of water will be made available for the construction purpose wherever water is available and the same shall be given at an agreed single point at the Site. Any further distribution will be the responsibility of the Contractor. Free drinking water if available will also be provided at one agreed point in the Site. Further distribution either to his labour colony or his work Site or to his office shall be the responsibility of the Contractor. 15.0 FACILITIES TO BE PROVIDED BY THE CONTRACTOR 15.1 Tools, tackles and scaffoldings The Contractor shall provide all the construction equipment, tools, tackles and scaffoldings required for pre-assembly, erection, testing and commissioning of the equipment covered under the Contract. He shall submit a list of all such
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materials to the Engineer before the commencement of pre-assembly at Site. These tools and tackles shall not be removed from the Site without the written permission of the Engineer.
15.2 Communication The contractor will arrange their own telephone and telex facilities from the local service provider, for the purpose of Contract at their own cost and expenses. The owner shall facilitate with the certification for application etc. if required in obtaining such connections. 15.3 First-aid 15.3.1 The Contractor shall provide necessary first-aid facilities for all his employees, representatives and workmen working at the Site. Enough number of Contractors personnel shall be trained in administering firstaid. 15.3.2 The Owner will provide the Contractor, in case of any emergency, the services of an ambulance for transportation to the nearest hospital. 15.4 Cleanliness 15.4.1 The Contractor shall be responsible for keeping the entire area allotted to him clean and free from rubbish, debris etc. during the period of Contract. The Contractor shall employ enough number of special personnel to thoroughly clean his work-area at least once in a day. All such rubbish and scrap material shall be stacked or disposed off in a place to be identified by the Engineer. Materials and stores shall be so arranged to permit easy cleaning of the area. In areas where equipment might drip oil and cause damage to the floor surface, a suitable protective cover of a flame resistant, oil proof sheet shall be provided to protect the floor from such damage. 15.4.2 Similarly the labour colony, the offices and the residential areas of the Contractors employees and workmen shall be kept clean and neat to the entire satisfaction of the Engineer. Proper sanitary arrangement shall be provided by the Contractor, in the work areas, office and residential areas of the Contractor. 16.0 LINES AND GRADES All the works shall be performed to the lines, grades and elevations as would be indicated on the drawings. The Contractor shall be responsible to locate and lay-out the works. Basic horizontal and vertical control points will be established and marked by the Engineer at site at suitable points. These points shall be used as datum for the works under the Contract. The Contractor shall inform the Engineer well in advance of the times and places at which he wishes to do work in the area allotted to him so that suitable datum points may be established and checked by the Engineer to enable the Contractor to proceed with his works. Any work done without being properly located may be removed and/or dismantled by the Engineer at Contractors expense. 17.0 FIRE PROTECTION 17.1 The work procedures that are to be used during the erection shall be those, which minimize fire hazards to the extent practicable. Combustible materials,
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combustible waste and rubbish shall be collected and removed from the Site at least once each day. Fuels, oils and volatile or inflammable materials shall be stored away from the construction and equipment and materials storage areas in safe containers. Un-treated materials shall not at all be used at Site for any other purpose unless otherwise specified. If any such materials are received with the equipment at the Site, the same shall be removed and replaced with acceptable materials before moving into the construction or storage area. 17.2 Similarly, corrugated paper fabricated cartons etc. will not be permitted in the construction area either storage or for handling of materials. All such materials used shall be of waterproof and flame resistant type. All other materials such as working drawings, plans etc., which are combustible but are essential for the works to be executed shall be protected against combustion resulting from welding sparks, cutting flames and other similar fire sources. 17.3 All the Contractors supervisory personnel and sufficient number of workers shall be trained for fire fighting and shall be assigned specific fire protection duties. Enough of such trained personnel must be available at the Site during the entire period of the Contract. 17.4 The Contractor shall provide enough fire protection equipment of the types and numbers for the warehouses, office, temporary structures, labour colony area etc. Access to such fire protection equipment shall be easy and kept open at all times. 18.0 SECURITY: The Contractor shall have total responsibility for all equipment and materials in his custody/stores, loose, semi-assembled and/or erected by him at Site. The Contractor shall make suitable security arrangements including employment of security personnel to ensure the protection of all materials, equipment and works from theft, fire, pilferage and any other damages and loss. All materials of the Contractor shall enter and leave the project site only with the written permission of the Engineer in the prescribed manner. 19.0 CONTRACTORS AREA LIMITS The Engineer will mark-out the boundary limits of access roads, parking spaces, storage and construction areas for the Contractor and the Contractor shall not trespass the areas not so marked out for him. The Contractor shall be responsible to ensure none of his personnel move out of the areas marked out for his operations. In case of such a need for the Contractors personnel to work out of the areas marked out for him, the same shall be done only with the written permission of the Engineer. 20.0 CONTRACTORS CO-OPERATION WITH THE OWNER In case where the performance of the erection work by the Contractor affects the operation of the system facilities of the Owner, such erection work of the Contractor shall be scheduled to be performed only in the manner stipulated by the Engineer and the same shall be acceptable at all times to the Contractor. The Engineer may impose such restrictions on the facilities provided to the Contractor such as electricity, water, etc. as he may think fit in the interest of the Owner and the Contractor shall strictly adhere to such restrictions and co-operate with the Engineer. It will be the responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring devices required during start-up and operation of the equipment systems, which are erected by him. The Contractor shall also be responsible for flushing and initial filling of all the oil and lubricants required for the equipment furnished and erected by him, so as to make such equipment ready for operation. The
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Contractor shall be responsible for supplying such flushing oil and other lubricants unless otherwise specified elsewhere in the document and specifications. 21.0 PRE-COMMISSIONING TRIALS AND INITIAL OPERATIONS The pre-commissioning trials and initial operations of the equipment furnished and erected by the Contractor shall be the responsibility of the Contractor as detailed in relevant clauses in Technical Specifications, Section GTR. The Contractor shall provide, in addition, test instruments, calibrating devices etc. and labour required for successful performance of these trials. If it is anticipated that the above test may prolong for a long time, the Contractors workmen required for the above test shall always be present at Site during such trials. 22.0 MATERIALS HANDLING AND STORAGE 22.1 All the equipments furnished under the Contract and arriving at Site shall be promptly received, unloaded, transported and stored in the storage spaces by the Contractor. Contractor shall be responsible for examining all the shipment and notify the Engineer immediately of any damages, storage, discrepancy etc. for the purpose of Engineers information only. The Contractor shall submit to the Engineer every week a report detailing all the receipts during the week. However, the Contractor shall be solely responsible for any shortages or damages in transit, handling and/or in storage and erection of the equipment at Site. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor. The Contractor shall maintain an accurate and exhaustive record detailing out the list of all equipments received by him for the purpose of erection and keep such record open for the inspection of the Engineer in-charge. All equipment shall be handled very carefully to prevent any damage or loss. No bare wire ropes, slings etc. shall be used for unloading and/or handling of the equipment without the specific written permission of the Engineer. The equipment stored shall be properly protected to prevent damage either to the equipment or to the floor where they are stored. The equipment from the store shall be moved to the actual location at the appropriate time so as to avoid damage of such equipment at Site. All electrical panels, control gears, motors and such other devices shall be properly dried by heating before they are installed and energized. Motor bearings, slip rings, commutators and other exposed parts shall be protected against moisture ingress and corrosion during storage and periodically inspected. All the electrical equipment such as motors, generators, etc. shall be tested for insulation resistance at least once in three months from the date of receipt till the date of commissioning and a record of such measured insulation values maintained by the Contractor. Such records shall be opened for inspection by the Engineer. The Contractor shall ensure that all the packing materials and protection devices, used for various equipments during transit and storage, are removed before the equipment is installed.
22.2
22.3
22.4
22.5
22.6
22.7
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22.8
The consumable and other supplies likely to deteriorate due to storage must be thoroughly protected and stored in a suitable manner to prevent damage or deterioration in quality by storage. All the materials stored in the open or dusty location must be covered with suitable weatherproof and flame proof covering material wherever applicable.
22.9
22.10 If the materials belonging to the Contractor are stored in areas other than those earmarked for him, the Engineer will have the right to get it moved to the area earmarked for the Contractor at the Contractors cost. 22.11 The Contractor shall be responsible for making suitable indoor storage facilities to store all equipments, which require indoor storage. Normally all the electrical equipments such as motors, control gears, generators, exciters and consumables like electrodes, lubricants etc. shall be stored in the closed storage space. The Engineer, in addition, may direct the Contractor to move certain other materials, which in his opinion will require indoor storage, to indoor storage areas, which the Contractor shall strictly comply with. 23.0 CONSTRUCTION MANAGEMENT 23.1 The field activities of the Contractors, working at Site, will be coordinated by the Engineer and the Engineers decision shall be final in resolving any disputes or conflicts between the Contractor and other Contractors and the tradesmen of the Employer regarding scheduling and coordination of work. Such decision by the Engineer shall not be a cause for extra compensation or extension of time for the Contractor. The Engineer shall hold weekly meetings of all the Contractors working at Site, at a time and place to be designated by the Engineer. The Contractor shall attend such meetings and take notes of discussions during the meeting and the decision of the Engineer and the contractor shall strictly adhere to those decisions in performing his works. In addition to the above weekly meeting, the Engineer may call for other meetings either with individual Contractor or with selected number of Contractors and in such a case the Contractor if called, will also attend such meetings. Time is the essence of the Contract and the Contractor shall be responsible for performance of his works in accordance with the specified construction schedule. If at any time, the Contractor is falling behind the schedule, he shall take necessary action to make good for such delays by increasing his work force or by working overtime or otherwise accelerate the progress of the work to comply with the schedule and shall communicate such actions in writing to the Engineer, satisfying that his action will compensate for the delay. The Contractor shall not be allowed any extra compensation for such action. The Engineer shall, however, not be responsible for provision of additional labour and/or materials or supply or any other services to the Contractor except for the coordination work between various Contractors as set out earlier.
23.2
23.3
23.4
24.0 FIELD OFFICE RECORDS The Contractor shall maintain at his Site office up to date copies of all drawings, specifications and other Contract Documents and any other supplementary data complete with all the latest revisions thereto. The Contractor shall also maintain in addition the continuous record of all changes to the above Contract Documents, drawings, specifications, and supplementary data etc. effected at the field and on completion of his total assignment under the Contract shall incorporate all such
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changes on the drawings and other Engineering data to indicate as installed conditions of the equipment furnished and erected under the Contract. Such drawings and Engineering data shall be submitted to the engineer in required number of copies. 25.0 CONTRACTORS MATERIALS BROUGHT ON TO SITE 25.1 The Contractor shall bring to Site all equipments, components, parts, materials, including construction equipments, tools and tackles for the purpose of the works under intimation to the Engineer. All such goods shall, from the time, of their being brought vest in the Owner, but may be used for the purpose of the works only and shall not on any account be removed or taken away by the Contractor without the written permission of the Engineer. The Contractor shall nevertheless be solely liable and responsible for any loss or destruction thereof and damage thereto. The Owner shall have a lien on such goods for any sum or sums which may at any time be due or owing to him by the Contractor, under, in respect of or by reasons of the Contract. After giving a fifteen (15) days notice in writing of his intention to do so, the Owner shall be at liberty to sell and dispose off any such goods, in such manner as he shall think fit including public auction or private treaty and to apply the proceeds in or towards the satisfaction of such sum or sums due as aforesaid. After the completion of the Works, the Contractor shall remove from the Site under the direction of the Engineer the materials such as construction equipments, erection tools and tackles, scaffolding etc. with the written permission of the Engineer. If the Contractor fails to remove such materials, within fifteen (15) days of issue of a notice by the Engineer to do so then the Engineer shall have the liberty to dispose off such materials as detailed under Clause 25.2 above and credit the proceeds thereto to the account of the Contractor.
25.2
25.3
26.0 PROTECTION OF PROPERTY AND CONTRACTORS LIABILITY 26.1 The contractor shall be responsible for any damage resulting from his operations. He shall also be responsible for protection of all persons including members of public and employees of the Owner and the employees of other Contractors and Sub-Contractors and all public and private property including structures, buildings, other plants and equipments and utility either above or below the ground. The Contractor will ensure provision of necessary safety equipments such as barriers, signboards, warning lights and alarms, etc. to provide adequate protections to persons and property. The contractor shall be responsible to give reasonable notice to the engineer and the owner of public or private property and utilities when such property and utilities are likely to get damaged or injured during the performance of his works and shall make all necessary arrangements with such Owners, related to removal and/or replacement or protection of such property and utilities.
26.2
27.0 PAINTING All exposed metal parts of the equipment including piping, structures, railing etc. wherever applicable, after installation unless otherwise surface protected, shall be first painted with at least one coat of suitable primer which matches the shop primer paint used, after thoroughly cleaning all such parts of all dirt, rust, scales, grease, oil and
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other foreign materials by wire brushing, scraping or sand blasting and the same being inspected and approved by the Engineer for painting. Afterwards, the above parts shall be finished painted with two coats of allowed resin machinery enamel paints. The quality of the finish paint shall be as per the standards of ISI or equivalent and shall be of the colour as approved by the Engineer. 28.0 INSURANCE 28.1 In addition to the conditions covered under the Clause entitled Insurance in General Terms and Conditions of Contract of this Volume of Part-III, the following provisions will also apply to the portion of works to be done beyond the Contractors own or his Sub-Contractors manufacturing Works. Workmens Compensation Insurance This insurance shall protect the Contractor against all claims applicable under the Workmens Compensation Act, 1948 (Government of India). This policy shall also cover the Contractor against claims for injury, disability, disease or death of his or his Sub-Contractors employee, which for any reason are not covered under the Workmens Compensation Act, 1948. The liabilities shall not be less than: Workmens Compensation Employees Liability 28.3 : : As per statutory Provisions As per statutory Provisions
28.2
Comprehensive Automobile Insurance This insurance shall be in such a form to protect the Contractor against all claims for injuries, disability, disease and death to members of public including the Owners men and damage to the property of others arising from the use of motor vehicles during, on or off the Site operations, irrespective of the Employership of such vehicles. The liability covered shall be as herein indicated: Fatal Injury : Rs. 1,00,000.00 each person Rs. 2,00,000.00 each occurrence Rs. 1,00,000.00 each occurrence
Property Damage: 28.4
Comprehensive General Liability Insurance 28.4.1 The insurance shall protect the Contractor against all claims arising from injuries, disabilities, disease or death of members of public or damage to property of others, due to any act of omission on the part of the Contractor, his agents, his employees, his representatives and SubContractors or from riots, strikes and civil commotion. This insurance shall also cover all the liabilities of the Contractor arising out of the Clause entitled Defence of Suits under General Terms and Conditions of Contract of Part-III (1/2). 28.4.2 The hazards to be covered will pertain to all the works and areas where the Contractor, his Sub-Contractors, his agents and his employees have to perform work pursuant to the Contract. 28.5 The above are only illustrative list of insurance covers normally required and it will be the responsibility of the Contractors to maintain all necessary insurance coverage to the extent both in time and amount
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to take care of all his liabilities either direct or indirect, in pursuance of the Contract. 29.0 UNFAVOURABLE WORKING CONDITIONS The Contractor shall confine all his field operations to those works, which can be performed without subjecting the equipment and materials to adverse effects during inclement weather conditions, like monsoon, storms etc. and during other unfavorable construction conditions. No field activities shall be performed by the Contractor under conditions, which might adversely affect the quality and efficiency thereof, unless special precautions or measures are taken by the Contractor in a proper and satisfactory manner in the performance of such Works and with the concurrence of the Engineer. Such unfavorable construction conditions will in no way relieve the Contractor of his responsibility to perform the Works as per the schedule. 30.0 PROTECTION OF MONUMENTS AND REFERENCE POINTS The Contractor shall ensure that any finds such as relic, antiquity, coins, fossil etc. which he may come across during the course of performance of his Works either during excavation or elsewhere, are properly protected and handed over to the Engineer. Similarly the Contractor shall ensure that the bench marks, reference points etc. which are marked either with the help of engineer or by the Engineer shall not be disturbed in any way during the performance of his Works. If any work is to be performed which disturbs such reference the same shall be done only after these are transferred to other suitable locations under the direction of the Engineer. The Contractor shall provide all necessary materials and assistance for such relocation of reference points etc. 31.0 WORK & SAFETY REGULATIONS 31.1 The Contractor shall ensure proper safety of all the workmen, materials, plant and equipment belonging to him or to the Owner or to others, working at the Site. The Contractor shall also be responsible for provision of all safety notices and safety equipment required both by the relevant legislations and the Engineer, as he may deem necessary. The Contractor will notify well in advance to the Engineer of his intention to bring to the Site any container filled with liquid or gaseous fuel or explosive or petroleum substance or such chemicals which may involve hazards. The Engineer shall have the right to prescribe the conditions, under which such container is to be stored, handled and used during the performance of the works and the Contractor shall strictly adhere to and comply with such instructions. The Engineer shall have the right at his sole discretion to inspect any such container or such construction plant/equipment for which material in the container is required to be used and if in his opinion, its use is not safe, he may forbid its use. No claim due to such prohibition shall be entertained by the Owner and the Owner shall not entertain any claim of the Contractor towards additional safety provisions/conditions to be provided for/constructed as per the Engineers instructions. Further, any such decision of the Engineer shall not, in any way, absolve the Contractor of his responsibilities and in case, use of such a container or entry thereof into the Site area is forbidden by the Engineer, the Contractor shall use alternative methods with the approval of the Engineer without any cost implication to the Owner or extension of work schedule.
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31.3
Where it is necessary to provide and/or store petroleum products or petroleum mixtures and explosives, the Contractor shall be responsible for carrying out such provision and/or storage in accordance with the rules and regulations laid down in Petroleum Act 1934, Explosives Act, 1948 and Petroleum and Carbide of Calcium Manual published by the Chief Inspector of Explosives of India. All such storage shall have prior approval of the engineer. In case, any approvals are necessary from the Chief Inspector (Explosives) or any statutory authorities, the Contractor shall be responsible for obtaining the same. All equipment used in construction and erection by Contractor shall meet Indian/International Standards and where such standards do not exist, the Contractor shall ensure these to be absolutely safe. All equipment shall be strictly operated and maintained by the Contractor in accordance with manufacturers Operation Manual and safety instructions and as per Guidelines/rules of the Owner in this regard. Periodical examinations and all tests for all lifting/hoisting equipment & tackles shall be carried out in accordance with the relevant provisions of Factories Act 1948, Indian Electricity Act 1910 and associated Laws/Rules in force from time to time. A register of such examinations and tests shall be properly maintained by the Contractor and will be promptly produced as and when desired by the Engineer or by the person authorised by him. The Contractor shall be fully responsible for the safe storage of his and his SubContractors radioactive sources in accordance with BARC/DAE Rules and other applicable provisions. All precautionary measures stipulated by BARC/DAE in connection with use, storage and handling of such material will be taken by the Contractor. The Contractor shall provide suitable safety equipment of prescribed standard to all employees and workmen according to the need, as may be directed by the Engineer who will also have right to examine these safety equipment to determine their suitability, reliability, acceptability and adaptability. Where explosives are to be used, the same shall be used under the direct control and supervision of an expert, experienced, qualified and competent person strictly in accordance with the Code of Practice/Rules framed under Indian Explosives Act pertaining to handling, storage and use of explosives. The Contractor shall provide safe working conditions to all workmen and employees at the Site including safe means of access, railings, stairs, ladders, scaffoldings etc. The scaffoldings shall be erected under the control and supervision of an experienced and competent person. For erection, good and standard quality of material only, shall be used by the Contractor.
31.4
31.5
31.6
31.7
31.8
31.9
31.10 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical equipment belonging to the Owner or other Contractors under any circumstances, whatsoever, unless expressly permitted in writing by the Owner to handle such fuses, wiring or electrical equipment 31.11 Before the Contractor connects any electrical appliances to any plug or socket belonging to the other Contractor or Owner, he shall: a. Satisfy the Engineer that the appliance is in good working condition; b. Inform the Engineer of the maximum current rating, voltage and phases of the appliances;
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c. Obtain permission of the Engineer detailing the sockets to which the appliances may be connected. 31.12 The Engineer will not grant permission to connect until he is satisfied that; a. The appliance is in good condition and is fitted with suitable plug; b. The appliance is fitted with a suitable cable having two earth conductors, one of which shall be an earthed metal sheath surrounding the cores. 31.13 No electric cable in use by the Contractor/Owner will be disturbed without prior permission. No weight of any description will be imposed on any cable and no ladder or similar equipment will rest against or attached to it. 31.14 No repair work shall be carried out on any live equipment. The equipment must be declared safe by the Engineer and a permit to work shall be issued by the Engineer before any repair work is carried out by the Contractor. While working on electric lines/equipment, whether live or dead, suitable type and sufficient quantity of tools will have to he provided by the Contractor to electricians/workmen/officers. 31.15 The Contractors shall employ necessary number of qualified, full time electricians/electrical supervisors to maintain his temporary electrical installation. 31.16 The Contractor employing more than 250 workmen whether temporary, casual, probationer, regular or permanent or on contract, shall employ at least one full time officer exclusively as safety officer to supervise safety aspects of the equipment and workmen, who will coordinate with the Project Safety Officer. In case of work being carried out through Sub-Contractors, the SubContractors workmen/employees will also be considered as the Contractors employees/workmen for the above purpose. The name and address of such Safety Officers of the Contractor will be promptly informed in writing to Engineer with a copy to Safety Officer-inCharge before he starts work or immediately after any change of the incumbent is made during currency of the Contract. 31.17 In case any accident occurs during the construction/erection or other associated activities undertaken by the Contractor thereby causing any minor or major or fatal injury to his employees due to any reason, whatsoever, it shall be the responsibility of the Contractor to promptly inform the same to the Engineer in prescribed form and also to all the authorities envisaged under the applicable laws. 31.18 The Engineer shall have the right at his sole discretion to stop the work, if in his opinion the work is being carried out in such a way that it may cause accidents and endanger the safety of the persons and/or property, and/or equipment. In such cases, the Contractor shall be informed in writing about the nature of hazards and possible injury/accident and he shall comply to remove shortcomings promptly. The Contractor after stopping the specific work can, if felt necessary, appeal against the order of stoppage of work to the Engineer within 3 days of such stoppage of work and decision of the Engineer in this respect shall be conclusive and binding on the Contractor. 31.19 The Contractor shall not be entitled for any damages/compensation for stoppage of work due to safety reasons as provided in clause 31.18 above and the period of such stoppage of work will not be taken as an extension of time
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for completion of work and will not be the ground for waiver of levy of liquidated damages. 31.20 It is mandatory for the Contractor to observe during the execution of the works, requirements of Safety Rules which would generally include but not limited to following: Safety Rules a) Each employee shall be provided with initial indoctrination regarding safety by the Contractor, so as to enable him to conduct his work in a safe manner. b) No employee shall be given a new assignment of work unfamiliar to him without proper introduction as to the hazards incident thereto, both to himself and his fellow employees. c) Under no circumstances shall an employee hurry or take unnecessary chance when working under hazardous conditions. d) Employees must not leave naked fires unattended. Smoking shall not be permitted around fire prone areas and adequate fire fighting equipment shall be provided at crucial location. e) Employees under the influence of any intoxicating beverage, even to the slightest degree shall not be permitted to remain at work. f) There shall be a suitable arrangement at every work site for rendering prompt and sufficient first aid to the injured. g) The staircases and passageways shall be adequately lighted. h) The employees, when working around moving machinery, must not be permitted to wear loose garments. Safety shoes are recommended when working in shops or places where materials or tools are likely to fall. Only experienced workers shall be permitted to go behind guard rails or to clean around energized or moving equipment. i) The employees must use the standard protection equipment intended for each job. Each piece of equipment shall be inspected before and after it is used. j) Requirements of ventilation in underwater working to licensed and experienced divers, use of gum boots for working in slushy or in inundated conditions are essential requirements to be fulfilled. k) In case of rock excavation, blasting shall invariably be done through licensed blasters and other precautions during blasting and storage/transport of charge material shall be observed strictly. 31.21 The Contractor shall follow and comply with the Owners Safety Rules, relevant provisions of applicable laws pertaining to the safety of workmen, employees, plant and equipment as may be prescribed from time to time without any demur, protest or contest or reservations. In case of any discrepancy between statutory requirement and Owners Safety Rules referred above, the latter shall be binding on the Contractor unless the statutory provisions are more stringent. 31.22 If the Contractor fails in providing safe working environment as per Owners Safety Rules or continues the work even after being instructed to stop work by the Engineer as provided in clause 31.18 above, the Contractor shall promptly pay to the Owner, on demand by the Owner, compensation at the rate of Rs. 5, 000/- per day or part thereof till the instructions are complied with and so
71
certified by the Engineer. However, in case of accident taking place, causing injury to any individual, the provisions contained in Clause 31.23 shall also apply in addition to compensation mentioned in this clause. 31.23 If the Contractor does not take all safety precautions and/or fails to comply with the Safety Rules as prescribed by the Owner or under the applicable law for the safety of the equipment and plant and for the safety of personnel and the Contractor does not prevent hazardous conditions which cause injury to his own employees or employees of other Contractors or Owners employees or any other person who are at Site or adjacent thereto, the Contractor shall be responsible for payment of compensation to the Owner as per the following schedule (These are applicable for death/injury to any person, whatsoever):
a. Fatal injury or accident causing death b. Major injuries or accident causing death 25% or more permanent disablement toworkmen or employees. Rs. 1,00,000/- per person. Rs. 20,000/- per person.
Permanent disablement shall have same meaning as indicated in Workmens Compensation Act. The compensation mentioned above shall be in addition to the compensation payable to the workmen/employees under the relevant provisions of the Workmens Compensation Act and rules framed there under or any other applicable laws as applicable from time to time. In case the Owner is made to pay such compensation then the Contractor is liable to reimburse the Owner such amount in addition to the compensation indicated above. 31.24 If the Contractor observes all the Safety Rules and Codes, Statutory Laws and Rules during the currency of Contract awarded by the Owner and no accident occurs then the Owner may consider the performance of the Contractor and award suitable ACCIDENT FREE SAFETY MERITORIOUS AWARD as per scheme as may be announced separately from time to time. 32.0 CODE REQUIREMENTS The erection requirements and procedures to be followed during the installation of the equipment shall be in accordance with the relevant Codes and accepted good engineering practice, the Engineers drawings and other applicable Indian recognized codes and laws and regulation of the Government of India. 33.0 FOUNDATION DRESSING & GROUTING 33.1 The surfaces of foundation shall be dressed to bring the top surface of the foundation to the required level, prior to placement of equipment/equipment bases on the foundation. All the equipment bases and structural steel base plates shall be grouted and finished as per these specifications unless otherwise recommended by the equipment manufacturer. The concrete foundation surfaces shall be properly prepared by chipping and/or grinding as required to bring the type of such foundation to the required level to provide the necessary roughness for bondage and to ensure enough bearing strength. All laitance and surface film shall be removed and cleaned. Grouting Mix The grouting mixture shall be composed of Portland cement, sand and water. The Portland cement to be used shall conform to ISI: 269 or equivalent. Sand
33.2
33.3
33.4
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shall conform to ISI: 383/2386 or equivalent. The grout proportions for flat bases where the grouting space does not exceed 35 mm shall be 50 Kg bag of cement to 75 Kg of sand. Only the required quantity of water shall be added so as to make the mix quaky and flowable and the mix shall not show excess water on top when it is being puddled in place. For thicker grout beds up to 65 mm, the amount of sand shall be increased to 105 Kg per bag of cement. Bases which are hollow and are to be filled full of grouting shall be filled to a level of 25 mm above the outside rim with a mortar mix in the volumetric proportion of one part of cement and 1.5 part sand and 1.5 part 6 mm granite gravel. An acceptable plasticizer may be added to the grout mixes in a proportion recommended by the plasticizers manufacturer. All such grouts shall be thoroughly mixed for not less than five minutes in an approved mechanical mixer and shall be used immediately after mixing. 33.5 Placing of Grout 33.5.1 After the base has been prepared, its alignment and level has been checked and approved and before actually placing the grout a low dam shall be set around the base at a distance that will permit pouring and manipulation of the grout. The height of such dam shall be at least 25 mm above the bottom of the base. Suitable size and number of chains shall be introduced under the base before placing the grout, so that such chains can be moved back and forth to push the grout into every part of the space under the base. 33.5.2 The grout shall be poured either through grout holes provided or shall be poured at one side or at two adjacent sides giving it a pressure head to make the grout move in a solid mass under the base and out in the opposite side. Pouring shall be continued until the entire space below the base is thoroughly filled and the grout stands at least 25mm higher all around than the bottom of the base. Enough care should be taken to avoid any air or water pockets beneath the bases. 33.6 Finishing of the Edges of the Grout The poured grout should be allowed to stand undisturbed until it is well set. Immediately thereafter, the dam shall be removed and grout, which extends beyond the edges of the structural or equipment base plates shall be cut off, flushed and removed. The edges of the grout shall then be pointed and finished with 1:2 cement mortar pressed firmly to bond with the body of the grout and smoothened with a tool to present a smooth vertical surface. The work shall be done in a clean and scientific manner and the adjacent floor spaces, exposed edges of the foundations, and structural steel and equipment base plates shall be thoroughly cleaned of any spillage of the grout. 33.7 Checking of Equipment after Grouting After the grout is set and cured, the Contractor shall check and verify the alignment of equipment, alignment of shafts of rotating machinery, the slopes of all bearings, pedestals, centering of rotors with respect to their sealing bores, couplings etc. as applicable and the like items to ensure that no displacement has taken place during grouting. The values recorded prior to grouting shall be used during such post grouting checkup and verification. Such pre and post grout records of alignment details shall be maintained by the Contractor in a manner acceptable to the Engineer.
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34.0 SHAFT ALIGNMENTS All the shafts of rotating equipment shall be properly aligned to those of the matching equipment to as perfect and accurate as practicable. The equipment shall be free from excessive vibration so as to avoid overheating of bearings or other conditions, which may tend to shorten the life of the equipment. All bearings, shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated before starting. 35.0 DOWELLING All the motors and other equipment shall be suitably dowelled after alignment of shafts with tapered machined dowels as per the direction of the Engineer. 36.0 CHECK OUT OF CONTROL SYSTEMS After completion of wiring, cabling furnished under separate specification and laid and terminated by the Owner, the Contractor shall check out the operation of all control system for the equipment furnished and installed under these specifications and documents. 37.0 CABLING 37.1 All cables shall be supported by conduits or cable trays run in air or in cable channels. These shall be installed in exposed runs parallel or perpendicular to dominant surface with right angle turn made of symmetrical bends for fittings. When cables are run on cable trays, they shall be clamped at minimum intervals of 2000 mm or otherwise as directed by the Engineer. Each cable, whether power or control, shall be provided with a metallic or plastic tag of an approved type, bearing a cable reference number indicated in the cable and conduit list (prepared by the Contractor), at every 5 metre run or part thereof and at both ends of the cable adjacent to the terminations. Cable routing is to be done in such a way that cables are accessible for any maintenance and for easy identification. Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC insulated cables 1100 V grade shall be 15 D where D is the overall diameter of the cable. Installation of other cables like high voltage, coaxial, screened compensating, mineral insulated shall be in accordance with the cable manufacturers recommendations. Wherever cables cross roads and water, oils, sewage or gas lines, special care should be taken for the protection of the cables in designing the cables channels. In each cable run some extra length shall be kept at a suitable point to enable one or two straight through joints to be made, should the cable develop fault at a later date. Control cable terminations shall be made in accordance with wiring diagrams, using identifying codes subject to Engineers approval. Multi-core control cable jackets shall be removed as required to train and terminate the conductors. The cable jacket shall be left on the cable, as far as possible, to the point of the first conductor branch. The insulated conductors from which the jacket is removed shall be neatly twined in bundles and terminated. The bundles shall be firmly, but not tightly, tied utilizing plastic or nylon ties or specially treated fungus protected cord made for this purpose. Control cable conductor insulation shall be secure and even. The connectors for control cables shall be covered with a transparent insulating sleeve so as to prevent accidental contact with ground or adjacent terminals and
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37.3
37.4
37.5
37.6
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shall preferably be terminated in elmex terminals and washers. The insulating sleeve shall be fire resistant and shall be long enough to over pass the conductor insulation. All control cables shall be fanned out and connection made to terminal blocks and test equipment for proper operation before cables are corded together.
END OF ECC
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SPECIAL CONDITIONS OF CONTRACT
(SCC)
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CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 Description General Information Scope Qualifying Requirements Basis of Bid Evaluation and Bidding Schedule Work Schedule Prices and Price Basis Terms of Payment Erection Insurance Liquidated Damages for Delay in Completion Bid Guarantee to be Submitted by the Bidder in a Separate Sealed Cover Quantity Variation Guarantee Storage Guiding Code Completeness of Work Drawing & Design Approved Vendor Establishment of Project Office Commissioning Page No. 77 77 78 78 78 79 80 81 81 81
11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0
81 81 82 82 82 82 82 82 82
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SECTION-V
SPECIAL CONDITION OF CONTRACT
1.0 GENERAL INFORMATION The following Special Conditions of Contract shall supplement the General Terms & Conditions of Contract (GCC). Wherever there is a conflict the provision herein shall prevail over those in the General Conditions of Contract. 1.1 The requirement, conditions, etc. stated in different volumes shall apply to and shall be considered as part of this Volume, as if bound together. In case of any discrepancy between the provisions of this Section and other Section(s) of any Part(s) and Volume(s), the provision of this Volume shall prevail. However, for scope of work, Technical Specification in Volume: 2/2 of Part-III shall prevail over all other Volume(s)/Section(s) of Bid document. Unless brought out clearly, the Bidder shall be deemed to conform strictly to the provisions of the bidding documents. All deviations to the specification shall be clearly brought out in respective schedules of deviations. Any discrepancy between specification and bid if not clearly brought out in the schedule, will not be considered as a valid deviation. Unless defined or specified elsewhere in this document, the terms OWNER, EMPLOYER, DEPARTMENT shall mean Department of Power, Government of Arunachal Pradesh and represented by the Executive Engineer (Elect) Tawang.
1.2
1.3
2.0
SCOPE Detailed scope of work is specified in the Schedule 3 & 4 of Volume 1/2 of part-III of the Bid documents, which inter-alia includes the following: 2.1 Scope of work covered under the package broadly includes design, engineering, manufacture, testing at works, supply on FOR destination site basis, including transportation & insurance, unloading, storage, erection including associated civil works, testing and commissioning of various equipments and systems of the following: (i) Detailed survey, route alignment, profiling, tower spotting, optimization of tower locations, soil resistivity measurement, geotechnical investigation i/c soil investigation, detail design of equipments, ROW clearance and check survey. (ii) Excavation, benching, casting of foundation i/c foundation for tower footings as per the approved designed and drawing by the owner. (iii) Packing, transportation & handling of line materials and machineries & equipments from manufacturers works to the site including receipt, storage, preservation, conservation of the equipments/materials at site and insurance. (iv) Erection of towers, tack welding of bolts & nuts i/c supply and application of zinc rich primer and enamel paint, Painting of towers for aviation requirements (wherever applicable), tower earthing, fixing of required insulators, supplying & stringing of conductors, earth wire along with all necessary line accessories. (v) Testing & commissioning of the erected transmission line. (vi) Providing of type and destruction test at the manufacturer premises.
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(vii) Complete manufacture including shop testing; (viii) Providing engineering drawing, data, operational manual etc. for the owners approval; (ix) Project management and site organization, providing detailed work plan, PERT, Bar chart etc. (x) Obtaining clearances from Statutory Agencies, Govt. Depts., etc. (xi) Pre-assembly, if any, erection, testing and commissioning of all equipments and systems installed viz. Circuit Breakers of different types, C & R panels, Switchyard and equipment earthing, Battery Bank and Chargers, 132/33 kV Power Transformers; (xii) Reliability tests and performance guarantee tests on completion of commissioning; (xiii) Submission of Specifications/Test Certificates of all materials supplied. (xiv) Submission of any other information/documents in respect of the project as and when asked for. and (xv) Furnishing of standard spares. Scope of work given above is only indicative. The detailed scope has been described in the Schedule 3 & 4 of Part-III (Vol-1/2) of Bid documents. 3.0 QUALIFYING REQUIREMENTS 3.1 The Qualifying Requirements for the packages are as per QR Section of Part-II of Bid document.
4.0
BASIS OF BID EVALUATION AND BIDDING SCHEDULE 4.1 The quantities of various items for the package are indicated in the respective sections of Bid Proposal Sheets (BPS), of the Bidding documents, which are only provisional. For evaluation purpose, total prices for ex-works, transportation & insurance charges, erection charges etc. will be considered on the basis of such provisional quantities specified under the respective Schedules of BPS. However, the Contractor shall be paid for actual quantity of items supplied & erected based on the unit rates quoted by the Bidder & incorporated in the Contract. For this purpose unit rates for each item as required in the Bid Proposal Sheets are also to be quoted. Further, the brief description shall not be construed to limit the scope of work, and the same shall be read in conjunction with corresponding Sections of Technical section including amendments/errata, if any, thereto. Conditional rebates, if any, offered by any Bidder shall not be considered in Bid evaluation. Bidder has to quote for the complete scope of work for the package. Bids for individual items or incomplete services shall be treated as incomplete and nonresponsive, and are liable to be rejected. Basis of Comparison Pursuant to Clause 35.0, Section-INB, of Volume-1/2 of Part-III, Bids shall be compared on the basis of lump sum price for entire scope of work under the packages, which shall include ex-works price, transportation & insurance charges and erection charges and all applicable taxes & duties such as excise duty, sales tax, service tax and any other taxes/duties/levies etc. applicable solely on the transaction between the contractor and the Owner and octroi/entry tax on boughtout finished items, as applicable on the date of Bid opening.
4.2 4.3
4.4
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5.0
WORK PLAN AND SCHEDULE 5.1 The broad outline of the milestone to be achieved in the project and their respective completion period of the project components are indicated below and the contractor shall make detailed PERT and submit the Critical Path duly identified for the owner to monitor the progress during the execution. The time period required for each of the milestone is only indicative of maximum length of time the bidder must spent to achieve without any reference to initial time but all must be phased to complete the entire project within 30 ( thirty) months. The bidders are to phase chronologically each of the milestone in the PERT.
Milestone Activities Time Period
5.2
Survey, investigation, design and submission of design data, drawing, and Vendors list etc for approval.
3 months from Award
Procurement of steel for foundation works and tower materials including placement at site store. Preliminary Erection works like associated civil works, site development, human resource, site office, store, labour shades, taking over of sites etc. Placement of materials, equipments , tools& plant at work site Procurement of tower materials Procurement of line materials Erection of towers Erection of line materials. Procurement of sub-station machineries and equipments. Erection of sub-station machineries and equipments. Testing and commissioning.
3 (three) months
6 months
D E F G H I J K
6 months 6 months 6 months 12 months 12 months 8 months 6 months 3 months
6.0 PRICES AND PRICE BASIS 6.1 Prices 6.1.1 The Bidder shall indicate on the appropriate Price Schedules attached to these documents, the
unit prices and total Bid prices of the goods and services, it proposes to provide under the contract. 6.1.2 Price indicated in the Price Schedules shall be entered separately in the following manner:
(i) The price of the goods, quoted ex-works; (ii) Applicable Taxes & Duties such as excise duty, sales tax, octroi, service tax, entry tax and other taxes which shall be payable on the goods, if the contract is awarded;
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(iii) Charges for inland transportation & insurance and incidental to delivery of the goods to their final destination; (iv) Erection charges
6.1.3 Erection charges shall include the cost of all services to be performed at site viz. unloading, handling, storage, erection, testing and commissioning of all equipment to be provided under the contract. The Bidders separation of price components in accordance with para 6.1.2 above shall be solely for the purpose of facilitating the comparison of bids by the owner and shall not in any way limit the Owners right to contract on any of the terms offered. All prices and price component quoted by the Bidder shall be firm and no price
6.1.4
6.15
adjustment shall be applicable for any of the price components. 7.0

TERMS OF PAYMENT The payment to the Contractor for the performance of the contract shall be made by the Owner as per Clause 34.7 Section GCC, Conditions of Contract of the bidding documents and as per conditions specified herein. Not withstanding anything contained therein the advance payment to the successful bidder shall be released only after submission of complete & detailed/check survey report within 2(two) months for approval of the owner by the successful bidder.
7.1
Ex-works price component Ex-works price component of the Contract price can be availed as under: a) An initial advance of 15% (fifteen percent) of the Ex-works price of equipment/materials can be availed subject to the conditions specified in clause 34.7.1 (i) and (ii) of Section GCC of Contract against submission of TDR or STDR of principal amount not lesser than the advance amount drawn on any Nationalized Bank pledged in favor of the Executive Engineer(E), Tawang in the account of the Contractor. b) Thereafter, all interim payments shall be made against works done as per the following formula: IP = 0.5*MS+EM/MS*(MS+EC) Not exceeding IP = 0.75*MS+0.9EC Where IP = Interim Payment MS = Cost of Material supplied (Ex Work cost +Inland Cost of F&I) EM = Cost of materials Erected (Ex Work cost +Inland Cost of F&I) EC = Cost of Erection of supplied materials (Base rate of erection excluding Service tax and VAT if any).
c) The contractor shall be eligible for final payment of the balance dues against the contract
only on the claim of last and final bill to be submitted to the owner with a request for project completion certificate as defined in clause 11.2 of Section GCC.
7.2 Erection Price Component No advance shall be admissible separately for erection works. 7.3 Taxes & Duties
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Taxes, levies and duties, applicable as per Indian or Non Indian Tax Laws, shall be dealt as per clause 14 of Section INB and claiuse 16 of Section GCC.
7.4 Freight & Insurance Charges

Full Freight & Insurance charges shall be paid to the Contractor pro-rata, as per the unit rate indicated in the Letter of Award, after receipt of equipment/materials at site and production of the invoices by the Contractor.
7.5 Mode of Payment All payments under the contract shall be released directly to the Contractor.
8.0 ERECTION INSURANCE In addition to conditions specified in Clause 37.0, Section-GCC, following shall also apply:
All the equipment and materials being supplied by the Contractor shall be kept completely insured by the Contractor at his cost from the time of dispatch from the Contractor's/sub-vendor's works, up to the completion of erection and final checking, testing and commissioning at site and subsequent taking over by the Owner. It shall be the responsibility of the Contractor to lodge, pursue and settle all claims with the insurance company in case of any damage, loss, theft, pilferage or fire and the Owner shall be kept informed about it. The Contractor shall replace the lost/damaged equipment/materials promptly irrespective of the settlement of the claims by the underwriters and ensure that the work progress is as per agreed schedule. The losses, if any, in such replacement shall have to be borne by the Contractor. 9.0 9.1 LIQUIDATED DAMAGES FOR DELAY IN COMPLETION If the erection and testing & commissioning and handing over of the equipments by the contractor is delayed beyond the Scheduled date, as stipulated in clause 5.0 or above or any time extensions granted thereof by the Owner, the Contractor shall pay to the Owner as liquidated damages and not as penalty @ 0.5% (Half percent) of the total Contract Price for the Package for each week of delay or part thereof in the handing over of the project. The above amount of liquidated damages shall be subject to a maximum of ten percent (10%) of the total Contract price for the respective package.
9.2
10.0 BID GUARANTEE TO BE SUBMITTED BY THE BIDDER IN A SEPARATE SEALED COVER 10.1 A Bid Guarantee shall accompany the bid in the original and three copies of the original for the
amount of Rs.111.3 lakhs only and in the manner as set forth in Clause 22.0, Section-INB of Part-III, Conditions of contract of the Bidding documents. 10.2 Any Bid not accompanied by a Bid Guarantee as set forth in Clause 22.0, Section INB of PartIII (Vol. 1/2), General Terms & Conditions of Contract & herein above shall be rejected by the Owner as non-responsive. 11.0 QUANTITY DEVIATION 11.1 The quantities of all equipment/materials given in the Bid Proposal Sheets of the Bidding documents are provisional. The final quantity shall depend on the actual quantities those would be required as per actual survey and erected at site. The Contractor shall be responsible for supply and execution of such final quantities for completion of the work and they shall be paid for such finalized quantity at the unit rate indicated in the Letter of Award. 11.2 The owner reserves the right to increase or decrease the quantity of good to the extent of +50% & -25% (plus fifty percent & minus twenty five percent) of the contract price, by way of suitable amendments to the contract, without any change of unit rate/price and /or other terms & conditions of the contract.
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11.3 For the purpose of calculating the deviations of GI structures or such other structures whose rates are based on tonnage of the item rather than number of structures, the tonnage shall be taken for assessing the deviation instead of the numbers of structures. 11.4 Meaning of quantity deviation in this document shall be interpreted as defined in CPWD Manual for all purpose. 12.0 GUARANTEE (Stipulated in GCC Clause 15) 12.1 The guarantee period of all the equipments to be supplied under the package shall be 1 (One) year from the date of handing over to owner after successful testing and commissioning to the satisfaction of the Engineer-in-Charge/Owner. 13.0 STORAGE 13.1 The owner shall provide suitable space for storing of the equipments at his own premises. However the contractor shall be responsible for safety and security of the equipments. The contractor shall maintain a proper record of all materials stored and taken out from the store for installation purpose. Before taking out any material from the store, proper authorization from the owner shall be taken by the contractor. 14.0 GUIDING CODE The terms and conditions of this contract are self defining without any probable ambiguities. However, in the event of any difficulties in implementations of this contract due to some discovered ambiguities or certain situation not stipulated or explained in this contract in some rare cases, the CPWD code shall be treated as a guiding code for the purpose. 15.0 COMPLETENESS OF WORK All such missed out or discovered items of works/supplies not listed in the Bill of quantities (with or without deviations) of the contract, but forming an integral part as per specifications and scope of the project without which the system can not be considered complete for commercial operation, shall have to be supplied and erected by the contractor without any extra cost to the owner. 16.0 DRAWING AND DESIGN The bidders shall submit the design & drawing of sub-station and bay including control room to the department for necessary approval. The bidders shall also to submit the detail design & drawing of all residential buildings as per standard specification of P.W.D (Govt.of Arunachal Pradesh) for approval of the owner. 17.0 APPROVED VENDOR 17.1 The bidders shall ensure supply of Conductors, transformers, tower structures, insulators and all other allied items and Sub Station equipments, control and protective switch gears etc procured only from latest approved Vendors of PGCIL (Power Grid Corporation of India Ltd). 17.2 In pursuant to above clause the Bidder shall submit such approved Vendors list from which the bidder intends to pick and procure the said items at the time of bid. 17.3 In case of unavailability of some of the items in such approved vendors list, the bidder shall require to obtain Prior Approval of the Vendors before actually supply is initiated. 18.0 ESTABLISHMENT OF PROJECT OFFICE 18.1 It shall be mandatory for the contractor to establish project offices at following locations: i. ii. iii. Site office in Divisional HQ at Tawang and Bomdila within 30 days of Award. Project Office at Dirang within 3 months of Award Project Office in Itanagar within 6 months of Award.
18.2 The contractor shall within 30 days of award inform the owner in writing the following: i. ii. Full address of Project/Site office. Phone, mobile and Fax no of the Site/Project office.
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iii. iv.
Name of staff who would be heading each of the offices Full communication address with the name of competent contact person, his designation etc in the corporate office.
19.0 COMMISSIONING For the purpose of clear understanding of the contract the word commissioning shall have the following meanings: 19.1 Sub- Station: A sub station shall be considered Commissioned when all the items of sub station in entirety such as Transformers, switchgears, control panels, control rooms, measuring instruments, all accessories and allied structures to put the sub station in commercial operation without any portion of the scope of work of the sub station as defined in the agreement undone at that point of time. 19.2 Line: An electrical line shall be considered commissioned when all the activities of erection of structures, conductors, Earth wires etc associated with the line are completed in all respect as per agreement to put the line for commercial operation with flow of electricity.
END OF SCC
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GENERAL TECHNICAL CONDITIONS
(GTC)
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CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Description General Information Scope Weights and Measures General Technical Conditions Technical Description Tests and Standards Guaranteed Technical Particulars Service Conditions Page No. 86 86 86 86 91 91 92 93
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SECTION-GTC
GENERAL TECHNICAL CONDITIONS
1.0 GENERAL INFORMATION
1.1
The material/equipment covered in this specification shall be used for C/O 4 X 5 MVA, 132/33 KV Sub-Station each at Tawang and Bomdila with 1 No 132 KV Bay (NEEPCO Extension at Khuppi) under the Social Infrastructure Development Fund sponsored project of Construction of 132 kV Single Circuit Transmission Line from Khuppi to Tawang i/c 132/33 kV Sub-Station at Bomdila and Tawang with C/O 132 KV Bay (NEEPCO Extension at Khuppi).
2.0 SCOPE 2.1 The material/equipment to be supplied on final destination at site basis as covered in this volume of Part-III shall be designed, manufactured and tested as per the requirements specified. Final Destination shall mean the stores established by the Contractor in the work site. 2.2 The materials/equipment covered here under this option shall be supplied complete in all respects, including all components, fittings and accessories which are necessary or are usual for their efficient performance and satisfactory maintenance under the various operating and atmospheric conditions. Such parts shall be deemed to be within the scope of the Contract, whether specifically included or not in the Specification or in the Contract Schedules. The Contractor shall not be eligible for any extra charges for such fittings etc. The details of the materials/equipment required for the C/O 4 X 5 MVA, 132/33 KV Sub-Station each at Tawang and Bomdila with 1 No 132 KV Bay (NEEPCO Extension at Khuppi) have been elaborated in Schedules 3 & 4 of Part-III (Vol. ) of the Bid document. They are briefly listed in the scope of work in Clause-1.0 of Part-II. 3.0 WEIGHTS AND MEASURES All weights and measures shall be in System International (S.I.) units. All fasteners shall be of Metric size only. 4.0 GENERAL TECHNICAL CONDITIONS 4.1 The following provisions shall supplement all the detailed technical specifications and requirements brought out in the accompanying Technical Specifications. The Bidders proposal shall be based on the use of equipment and materials complying fully with the requirements, specified herein. The Bidder shall furnish clause-by-clause commentary (with detailed technical data as required) on the Technical Specifications demonstrating the goods substantial responsiveness to the specifications or deviation and exceptions to the provisions of the Technical Specification unless and until advised contrary to this in the bidding document.
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4.2 Equipment Performance Guarantee 4.2.1 The performance requirements of the items are detailed separately in this Specification. These guarantees shall supplement the general performance guarantee provisions covered under General Terms and Conditions of Contract in clause entitled Guarantee. 4.2.2 Liquidated damages for not meeting specified performance shall be assessed and recovered from the Contractor. Such liquidated damages shall be without any limitation whatsoever and shall be in addition to damages, if any payable under any other clause of Conditions of Contract. 4.3 Engineering Data 4.3.1 The furnishing of engineering data by the Contractor shall be in accordance with the appropriate Schedule appended to this document. The review of these data by the Owner shall cover only general conformance of the data to the specifications and drawings. This review by the Owner may not indicate a thorough review of all dimensions, quantities and details of the equipment, materials, any devices or items indicated or the accuracy of the information submitted. This review and/or approval by the Owner shall not be considered by the Contractor, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these Specifications and documents. 4.3.2 All engineering data submitted by the Contractor after final process including review and approval by the Owner shall form part of the Contract Document and the entire works performed under these Specifications shall be performed in strict conformity, unless otherwise expressly requested by the owner in writing. 4.4 Drawings 4.4.1 All drawings submitted by the Contractor including those submitted at the time of bid shall be in sufficient detail to indicate the type, size, arrangement, dimensions, material description, Bill of Materials, weight of each component, break-up for packing and shipment, fixing arrangement required, the dimensions required for installation and any other information specifically requested in the Specifications. 4.4.2 Each drawing submitted by the Contractor shall be clearly marked with the name of the Purchaser, the unit designation, the Specification title, the Specification number and the name of the Project. All titles, notings, markings and in writings on the drawing shall be in English. All the dimensions should be to the scale and in metric units. 4.4.3 The drawings submitted by the Contractor shall be reviewed by the Owner as far as practicable within four (4) weeks and shall be modified by the Contractor if any modifications and/or corrections are required by the Owner in compliance with the Specifications. The Contractor shall incorporate such modifications and or corrections and submit the final drawings for approval. Any delays arising out of failure by the Contractor to rectify the drawings in good time shall not alter the Contract completion date. 4.4.4 The drawings submitted for approval to the Owner shall be in quadruplicate. One print of such drawings shall be returned to the
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Contractor by the Owner marked Approved/Approved with corrections. The Contractor shall thereupon furnish the Owner additional print as stipulated in Technical Specification along with one reproducible in original of the drawings after incorporating all corrections. 4.4.5 Further work by the Contractor shall be strictly in accordance with these drawings and no deviation shall be permitted without the written approval of the Purchaser, if so required. 4.4.6 All manufacturing and fabrication work in connection with the equipment/material prior to the approval of the drawings shall be at the Contractors risk. The Contractor may make any changes in the design which are necessary to make the equipment conform to the provisions and intent of the Contract and such changes shall again be subject to approval by the Owner. Approval of Contractors drawing or work by the Owner shall not relieve the Contractor of any of his responsibilities and liabilities under the Contract. 4.4.7 All rights of the design/drawing shall be strictly reserved with the Owner only and any designs/drawings/data sheets submitted by the contractor from time to time shall become the property of the Owner. Under no circumstances, the Contractor shall be allowed to user/offer above designs/drawings/data sheets to any other authority without prior written permission of the Owner. Any deviation to above is not acceptable and may be a cause of rejection of the bid. 4.4.8 Design Co-ordination Wherever, the design is in the scope of Contractor, the Contractor shall be responsible for the selection and design of appropriate material/item to provide the best co-coordinated performance of the entire system. The basic design requirements are detailed out in this Specification. The design of various components, sub-assemblies and assemblies shall be so done that it facilitates easy field assembly and maintenance. 4.5 Manufacturing Schedule The Contractor shall submit to the Owner his manufacturing, testing and delivery schedules of various items within thirty (30) days from the date of the Letter of Award in accordance with the delivery requirements stipulated. Schedules shall also include the materials and items purchased from outside Contractors, if any. 4.6 Reference Standards 4.6.1 The Codes and/or Standards referred to in Specifications shall govern, in all cases wherever such references are made. In case of a conflict between such Codes and/or Standards and the specifications, latter shall govern. Such Codes and/or Standards, referred to shall mean the latest revisions, amendments/changes adopted and published by the relevant agencies. 4.6.2 Other internationally acceptable Standards which ensure equivalent or better performance than those specified shall also be accepted. 4.7 Design Improvements 4.7.1 The Owner or the Contractor may propose changes in the
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Specification of the equipment or quality thereof and if the parties agree upon any such changes, the Specification shall be modified accordingly. 4.7.2 If any such agreed upon change is such that it affects the price and schedule of completion, the parties shall agree in writing as to the extent of any change in the price and/or schedule of completion before the Contractor proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amended accordingly. 4.8 Quality Assurance 4.8.1 To ensure that the equipment under the scope of this Contract whether manufactured within the Contractors Works or at his SubContractors premises is in accordance with the specifications, the Contractor shall adopt suitable Quality Assurance Programme to control such activities at all points necessary. Such programme shall be outlined by the Contractor and shall be finally accepted by the Owner after discussions before the award of Contract. A Quality Assurance Programme of the Contractor shall generally cover but not limited to the following: (a) (b) (c) (d) His organization structure for the management and implementation of the proposed Quality Assurance Programme. Documentation control system. Qualification data for key personnel; The procedure for purchases of materials, parts/components and selection of sub-Contractors services including vendor analysis, source inspection, incoming raw material inspection, verification of material purchases etc. System for shop manufacturing including process controls. Control of non-conforming items and system for corrective action. Control of calibration and testing of measuring and testing equipments. Inspection and test procedure for manufacture. System for indication and appraisal of inspection status. System for quality audits. System for authorising release of manufactured product to the Purchaser. System for maintenance of records.
(e) (f) (g) (h) (i) (j) (k) (l)
(m) System for handling storage and delivery and (n) A Quality Plan detailing out the specific quality control procedure adopted for controlling the quality characteristics of the product.
The Quality Plan shall be mutually discussed and approved by the Owner after incorporating necessary corrections by the Contractor as may be required.
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4.8.2 Quality Assurance Documents The Contractor shall be required to submit all the Quality Assurance Documents as stipulated in the Quality Plan at the time of Owners inspection of equipment/material. 4.8.3 The owner or his duly authorised representatives reserves the right to carry out Quality Audit and Quality surveillance of the systems and procedures of the Contractors/his vendors Quality Management and Control Activities. 4.9 Owners Supervision 4.9.1 To eliminate delays and avoid disputes and litigation it is agreed between the parties to the Contract that all matters and questions shall be resolved in accordance with the provisions of this document. 4.9.2 The manufacturing of the product shall be carried out in accordance with the specifications. The scope of the duties of the Owner, pursuant to the contract, shall include but not be limited to the following: (a) (b) (c) Interpretation of all the terms and conditions of these Documents and Specifications. Review and interpretation of all the Contractors drawings, engineering data etc. Witness or authorise his representative to witness tests at the manufacturers works or at site, or at any place where work is performed under the Contract. Inspect, accept or reject any equipment, material and work under the Contract, in accordance with the Specifications. Issue certificate of acceptance and/or progressive payment and final payment certificate. Review and suggest modification and improvement in completion schedules from time to time; and Supervise the Quality Assurance Programme implementation at all stages of the Works.
(d) (e) (f) (g)
4.10 Inspection, Testing & Inspection Certificate 4.10.1 The Owner, his duly authorised representative and/or outside inspection agency acting on behalf of the Owner shall have at all reasonable times access to the Contractors premises or Works and shall have the power at all reasonable times to inspect and examine the materials and workmanship of the product during its manufacture and if part of the product is being manufactured or assembled at other premises or works, the Contractor shall obtain from the Owner and/or his duly authorised representative permission to inspect as if the equipment/materials were manufactured or assembled on the Contractors own premises or works. 4.10.2 The Contractor shall give the Owner or authorized representative or inspecting agency 15 (fifteen) days written notice of any material being ready for testing. Such tests shall be to the Contractors account except for the expenses of the Inspector. The Owner or his authorized representative or inspecting agency unless witnessing of the tests is
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virtually waived, shall attend such tests within fifteen 15 (fifteen) days of the date of which the equipment is notified as being ready for test/inspection or on a mutually agreed date, failing which the Contractor may proceed with the test which shall be deemed to have been made in the owner or his authorized representative or inspecting agency's presence and he shall forthwith forward to the owner or his authorized representative or inspecting agency duly certified copies of tests in triplicate. 4.10.3 The Owner or his authorized representative or inspecting agency shall, within 15 (fifteen) days from the date of inspection as defined herein give notice in writing to the Contractor, of any objection to any drawings and all or any equipment and workmanship which in his opinion is not in accordance with the Contract. The Contractor shall give due consideration to such objections and shall make the modifications that may be necessary to meet the said objections. 4.10.4 When the factory tests have been completed at the Contractors or Sub-Contractors works, the Purchaser Inspector shall issue a certificate to this effect within 15 (fifteen) days after completion of tests but if the tests are not witnessed by the Owner or his authorized representative or inspecting agency the certificate shall be issued within fifteen (15) days of receipt of the Contractors Test certificate by the Owner or his authorized representative or inspecting agency. The completion of these tests or the issue of the certificate shall not bind the Owner to accept the equipment should it, on further tests after erection, be found not to comply with the Contract. 4.10.5 In all cases where the Contract provides for tests whether at the premises or works of the Contractor or of any Sub-Contractor, the Contractor except where otherwise specified shall provide free of charge such item as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Owner or his authorized representative or inspecting agency to carry out effectively such tests of the equipment in accordance with the Contract and shall give facilities to the Owner or to his authorised representative or inspecting agency to accomplish testing. 4.10.6 The inspection by Owner or his authorized representative or inspecting agency and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the agreed Quality Assurance Programme forming a part of the Contract. 5.0 TECHNICAL DESCRIPTION 5.1 The technical description of various materials/equipment has been specified in the respective volumes of technical specifications or as per the latest amendments of specification prescribed by the owner.
6.0 TESTS AND STANDARDS 6.1 Tests All equipments to be supplied under this package must have been type tested. The following acceptance and routine tests and tests during manufacture shall be carried-out on the material. For the purpose of this clause:
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6.1.1 Acceptance Tests shall mean those tests, which are to be carried out on samples taken from each lot offered for pre-dispatch inspection, for the purposes of acceptance of that lot.
6.1.2 Routine Tests shall mean those tests, which are to be carried out on the material to check requirements, which are likely to vary during production. 6.1.3 Tests during Manufacture shall mean those tests, which are to be carried out during the process of manufacture and end inspection by the Contractor to ensure the desired quality of the end product to be supplied by him. 6.1.4 The norms and procedure of sampling for these tests shall be as per the Quality Assurance Programme to be mutually agreed to by the Contractor and the Owner. 6.1.5 The standards and norms to which these tests shall be carried out are listed against them. Where a particular test is a specific requirement of this Specification, the norms and procedure of the test shall be as specified in a mutually agreed manner between the Contractor and the Owner in the Quality Assurance Programme. 6.1.6 For all acceptance tests, the acceptance values shall be the values specified in this Specification or guaranteed by the Bidder, as applicable. The tests and standards for various materials/equipments have been specified in the respective volumes of technical specifications. 6.2 Testing Expenses 6.2.1 The entire cost of testing for the acceptance test and routine tests and tests during manufacture specified in the technical specifications for materials/equipment shall be treated as included in the quoted unit price except for the expenses of the Inspector/Owners representative. 6.3 Additional Tests 6.3.1 The Owner reserves the right of having at his own expenses any other test(s) of reasonable nature carried out at contractors premises, at site, or in any other place in addition to the specified type, acceptance and routine tests to satisfy himself that the materials/equipment comply with the Specifications. 6.3.2 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 Contractors premises or at any other test center. In case of evidence of non compliance, it shall be binding on the part of contractor to prove the compliance of the items to the technical specifications by repeat tests, or correction of deficiencies, or replacement of defective item all without any extra cost to the Owner. 7.0 GUARANTEED TECHNICAL PARTICULARS 7.1 The Guaranteed Technical Particulars of the various items shall be furnished by the Bidders in one original and Four (4) copies in the prescribed schedules of the Specifications. The Bidder shall also furnish any other schedule information as in his opinion is needed to give full description and details to
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judge the item(s) offered by him. 7.2 The data furnished in Guaranteed Technical Particulars should be the minimum or maximum value (as per the requirement of the specification) required. A Bidder may guarantee a value more stringent than the specification requirement. However, for testing purpose or from performance point of view, the material shall be considered performed successfully if it achieves the minimum/maximum value required as per the technical specification. No preference whatsoever shall be given to the bidder offering better/more stringent values than those required as per specification.
8.0 SERVICE CONDITIONS 8.1 All out door Equipment/material to be supplied against this specification shall be suitable for satisfactory continuous operation under tropical conditions as specified below: 1. Maximum ambient temperature (C): 2. Minimum ambient temperature (C): 3. Relative Humidity Range (%): 4. Maximum wind velocity (Mtr./Sec.): 5. Maximum altitude above Mean Sea Level (Mtr.): 6. Isoceraunic level (Days/Year): 7. Moderately hot and humid tropical, climate, conducive to rust and fungus growth: 8. Seismic Zone: 9. Rainfall: 10. Transportation/accessibility: 30 -10 52.17 78.98 47 4242.42 (approx) 50 Yes Zone V 1232.20 mm. Hostile & Difficult
For indoor equipment/material the requirements are specified in the respective volumes of technical specification.
END OF GTC
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ANNEXURE
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CONTENTS Annexure I Description Performance of Bank Guarantee for Contract Performance Proforma of Extension of Bank Guarantee Proforma of Letter of Undertaking Proforma of Application for Payment Proforma of Bank Guarantee for Advance Payment Proforma of Indemnity Bond to be Executed by the Contractor for Equipment Handed over for Performance for its Contract Proforma of Indemnity Bond to be Executed by the Contractor for the Equipment(s) Handed over in Installments for Performance of its Contract Proforma of Agreement Page No. 96
II III IV V VI
98 99 101 103 105
VII
108
VIII
111
IX
Format for acceptance of LOA
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Annexure-I PROFORMA OF BANK GUARANTEE FOR CONTRACT PERFORMANCE (To be stamped in accordance with Stamp Act) Bank Guarantee No. .. Ref. .. To The Executive Engineer (E) Tawang Electrical Division Department of Power Tawang 790 104 Dear Sir(s), In consideration of Department of Power, Government of Arunachal Pradesh, (hereinafter 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 its Registered/Head office at ., (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. , Dated, ., and the same having been acknowledged by the Contractor, resulting in a Contract, bearing No. Dated , valued at Rs. for Turn Key job of CONSTRUCTION
OF 132 KV SINGLE CIRCUIT TRANSMISSION LINE FROM KHUPPI TO TAWANG INCLUDING 132/33 KV SUB-STATION AT BOMDILA AND TAWANG WITH C/O 132 KV BAY (NEEPCO EXTENSION AT KHUPPI), and the Contractor having agreed to provide a
Date ...
Contract Performance Guarantee for the faithful performance of the entire Contract equivalent to 15% (Fifteen per cent) of the said value of the Contract to the Owner. We .... (Name & Address 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 on demand any and all monies payable by the Contractor to the extent of as aforesaid at any time up to $$ (days/month/year) 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 not withstanding any difference between the Owner and 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 Employer discharges 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 extend the time for performance of 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 powers 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 or to forbear to enforce any covenants, contained or
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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 of 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 hereinabove, our liability under this guarantee is restricted to .. and this guarantee is valid up to . and we shall be released and discharged from all liabilities here under unless a written claim within 90 days for payment under this guarantee is lodged on us on or before . irrespective of whether or not the original guarantee is return to us. Dated this ... Day of .. 200 at WITNESS . (Signature) .. (Name) ... (Official Address) (Signature) (Name) (Designation with Bank Stamp)
Attorney as per Power of Attorney No. Date ..
$$ The date will be ninety (90) days after the end of Warranty Period as specified in the Contract.
Note: The stamp papers of appropriate value shall be purchased in the name of issuing Bank.
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Annexure-II PROFORMA OF EXTENSION OF BANK GUARANTEE (To be stamped in accordance with Stamp Act) Ref. ... To The Executive Engineer (E) Tawang Electrical Division Department of Power Tawang 790 104 Date ..
Dear Sirs, 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).
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 Guarantee No. , Dated , for a further period of years/months from . to expire on .. Except 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 which has issued the Bank Guarantee.
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Annexure-III PROFORMA OF LETTER OF UNDERTAKING (To be submitted by the Bidder along with his Bid) (To be executed on non-judicial stamp paper of requisite value) Ref. ... Date ..
To The Executive Engineer (E) Tawang Electrical Division Department of Power Tawang 790 104 Dear Sir,
1. I*/We* have read and examined the following bid documents relating to the Specification No. DoP/TED/132 KV/KHUPPI-TWG for CONSTRUCTION OF 132
KV SINGLE CIRCUIT TRANSMISSION LINE FROM KHUPPI TO TAWANG
INCLUDING 132/33 KV SUB-STATION AT BOMDILA AND TAWANG WITH C/O 132 KV BAY (NEEPCO EXTENSION AT KHUPPI).
a) Notices Inviting Tender b) Conditions of Contract (Non-IDA Supply-cum-Erection containing Sections Invitation to Bid (INV), Instructions to Bidders (INB), General Terms & Conditions of Contract (GCC) and Erection Conditions of Contract (ECC)). c) Special Conditions of Contract along with Annexure . to . d) Drawing Nos. .... e) Technical Specifications.
2. I*/We* hereby submit our Bid and undertake to keep our Bid valid for a period of six (6) calendar months from the date of bid i.e. up to . I*/We* hereby further undertake that during the said period I/We shall not vary/alter or revoke my/our Bid.
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This undertaking is in consideration of Department of Power, Arunachal Pradesh agreeing to open my/our* Bid and consider and evaluate the same for the purpose of award of Work in terms of provisions of Clause entitled Award of Contract, Section INB, Conditions of Contract in the Bid Documents, Volume-1/2 of Part-III.
Should this Bid be accepted, *I/we* also agree to abide by and fulfill all the terms & conditions of provisions of the above mentioned bid documents.
Signature along with Seal of Company .

(Duly authorized to sign the Bid on behalf of the Contractor)
Name: ..... Designation: ... Name of Company: (in Block Letters) WITNESS Signature . Date & Postal Address: Date: .. Name & Address: ... Telephone No: .... Fax No.: ..
*Strike out whichever is not applicable.
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Annexure-IV PROFORMA OF APPLICATION FOR PAYMENT Project Equipment package : : Date :
Name of Contractor : Contract Value Unit Reference : :
Contract No. : Contract Name: Application Serial number:
To The Executive Engineer (E) Tawang Electrical Division Department of Power Tawang 790 104 Dear Sir, APPLICATION FOR PAYMENT Pursuant to the above-referred Contract Dated .., the undersigned hereby applies for payment of the sum of .. (.) (Specify amount and currency in which claim is made). 2. The above amount is on account of: [TICK () whichever is applicable] Initial advance (Schedule $$) Interim payment as advance (Schedule$$) Progressive payment against dispatch of equipment (Schedule$$) Progressive payment against receipt of equipment at site (Schedule$$) Progressive payment against Erection (Schedule$$) Ocean freight & marine insurance (Schedule$$) Inland transportation (Schedule$$) Inland insurance Price adjustment Extra work not specified in Contract (Ref. Contract change order No. ...) Other (specify) Final payment (Schedule$$) as detailed in the attached Schedule(s) which form an integral part of this application.
3. The payment claimed is as per item(s) No.(s) .. of the payment schedule annexed to the above-mentioned Contract.
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4. The application consists of this page, a summary of claim statement (Schedule$$), and the following signed schedule: 1. . 2. . 3. . The following documents are also enclosed: 1. . 2. . 3. .
Signature of Contractor/ Authorized Signatory
Application for payment will be made to Engineer to be designated for this purpose at the time of award of the Contract.
$$ Proforma for the Schedules will be mutually discussed and agreed to during the finalization of the
Contract Agreement.
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AnnexureV PROFORMA OF BANK GUARANTEE FOR ADVANCE PAYMENT (To be stamped in accordance with Stamp Act) Bank Guarantee No. .. Ref. .. To The Executive Engineer (E) Tawang Electrical Division Department of Power Tawang 790 104 Date ...
Dear Sir, In consideration of Department of Power (hereinafter referred to as the Employer, which expression 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 Employers Letter of Award No. , Dated .., and the same having been acknowledged by the Contractor, resulting in a Contract bearing No. , Dated ., valued at Rs. . for the turn key job of CONSTRUCTION OF 132 KV SINGLE CIRCUIT TRANSMISSION LINE FROM KHUPPI TO TAWANG INCLUDING 132/33 KV SUB-STATION AT BOMDILA AND TAWANG WITH C/O 132 KV BAY (NEEPCO EXTENSION AT KHUPPI) (hereinafter called the Contract) and the Employer having agreed to make an advance payment to the Contractor for performance of the above Contract amounting Rs. . (Rupees) 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 Employer, immediately on demand any, or all monies payable by the Contractor to the extent of as aforesaid at any time up to @ without any demur, reservation, contest, recourse or protest and/or without any reference to the Contractor. Any such demand made by the Employer on the Bank shall be conclusive and binding notwithstanding any difference between the Employer 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 Employer discharges this guarantee. The Employer 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 extend the time for performance of the Contract by the Contractor. The Employer shall have the fullest liberty without affecting this guarantee, to postpone from time to time the exercise of any powers 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 or to forbear to enforce any covenants, contained or implied, in the Contract between the Employer and the Contractor or any other course or remedy or security available to the Employer. The Bank shall not be released of its obligations under these presents by any exercise by the Employer of its liberty with reference to the matters aforesaid or any of them or by reason of any other act or
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forbearance or other acts of omission or commission on the part of the Employer or any other indulgence shown by the Employer 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 Employer 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 notwithstanding any security or other guarantee that the Employer may have in relation to the Contractors liabilities. Notwithstanding anything contained hereinabove our liability under this guarantee is limited to .. and it shall remain in force up to and including ....@ and shall be extended from time to time for such period (not exceeding one year), as may be desired by M/son whose behalf this guarantee has been given. Dated this . Day of . at.. WITNESS (Signature) (Name) .. (Official Address) . (Signature) . (Name) Designation.. (with Bank Stamp)
Attorney as per Power of Attorney No. . Dated,
@ The date will be ninety (90) days after the date of completion of the Contract.
Note: The non-judicial stamp papers of appropriate value shall be purchased in the name of Bank, which issues the Bank Guarantee.
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Annexure-VI PROFORMA OF INDEMNITY BOND TO BE EXECUTED BY THE CONTRACTOR FOR EQUIPMENT HANDED OVER FOR PERFORMANCE OF ITS CONTRACT (Entire Equipment(s) consignment in one lot) (On non-Judicial stamp paper of appropriate Value) INDEMNITY BOND THIS INDEMNITY BOND is made this . day of .. 200.. by , a Company registered under the Companies Act, 1956/Partnership Firm/Proprietary Concern having its Registered Office at .. (hereinafter called as Contractor or Obligor which expression shall include its successors and permitted assigns) in favour of Department of Power, having its Registered Office at Vidyut Bhawan, 0-Point, Itanagar-791 111, (hereinafter called Department of Power which expression shall include its successors and assigns): WHEREAS Department of Power has awarded to the Contractor a Contract for vide its Letter of Award/Contract No. .... dated . and its Amendment No. . (applicable when amendments have been issued) (hereinafter called the Contract) in terms of which Department of Power is required to hand over various equipment(s) to the Contractor for execution of the Contract. And WHEREAS by virtue of Clause No. 7.2 of Section GCC of Part-III (Vol. ) of Bid document of the said Contract, the Contractor is required to execute an Indemnity Bond in favor of Department of Power for the Equipment handed over to it by Department of Power for the purpose of performance of the Contract/Erection portion of the Contract {hereinafter called the Equipment(s)}. NOW THEREFORE, This Indemnity Bond witnesseth as follows: 1. That in consideration of various equipment(s) as mentioned in the Contract, valued at Rs. ................ (Rupees .) handed over to the Contractor for the purpose of performance of the Contract, the Contractor hereby undertakes to indemnify and shall keep Department of Power indemnified, for the full value of the Equipment(s). The Contractor hereby acknowledges receipt of the Equipment as per dispatch title documents handed over to the Contractor duly endorsed in their favour and detailed in the Schedule appended hereto. It is expressly understood by the Contractor that handing over of the dispatch title documents in respect of the said Equipment duly endorsed by Department of Power in favour of the Contractor shall be construed as handing over of the Equipment purported to be covered by such title documents and the Contractor shall hold such Equipment in trust as a Trustee for and on behalf of Department of Power. 2. That the Contractor is obliged and shall remain absolutely responsible for the safe transit/protection and custody of the Equipment(s) at Department of Power Project Site against all risks, whatsoever, till the Equipment(s) are duly used/erected in accordance with the terms of the Contract and the Plant/Package duly erected and commissioned in accordance with the terms of the Contract, is taken over by Department of Power. The Contractor undertakes to keep Department of Power harmless against any loss or damage that may be caused to the Equipment(s). 3. The Contractor undertakes that the Equipment shall be used exclusively for the performance/execution of the Contract strictly in accordance with its terms and conditions and no part of the equipment shall be utilized for any other work or purpose
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whatsoever. It is clearly understood by the Contractor that non-observance of the obligations under this Indemnity Bond by the Contractor shall inter-alia constitute a criminal breach of trust on the part of the Contractor for all intents and purpose including legal/penal consequences. 4. That Department of Power is and shall remain the exclusive Employer/Owner of the Equipment(s) free from all encumbrances, charges or liens of any kind, whatsoever. The Equipment shall at all times be open to inspection and checking by Engineer-inCharge/Engineer or other employees/agents authorized by him in this regard. Further, Department of Power shall always be free at all times to take possession of the Equipment(s) in whatever form the Equipment(s) may be, if in its opinion the Equipment(s) are likely to be endangered, mis-utilised or converted to uses other than those specified in the Contract, by any acts of omission or commission on the part of the Contractor or any other person or on account of any reason, whatsoever, and the Contractor binds himself and undertakes to comply with the direction of demand of Department of Power to return the Equipment without any demur or reservation. 5. That this indemnity Bond is irrevocable. If at any time any loss or damage occurs to the Equipment(s) or the same or any part thereof is misutilised in any manner whatsoever, then the Contractor hereby agrees that the decision of the Engineer-in-Charge/Engineer of Department of Power as to assessment of loss or damage to the Equipment(s) shall be final and binding on the Contractor. The Contractor binds itself and undertakes to replace the lost and/or damaged Equipment(s) at its own cost and/or shall pay the amount of loss of Department of Power without demur, reservation or protest. This is without prejudice to any other right or remedy that may be available to Department of Power against the Contractor under the Contract and under this Indemnity Bond. 6. NOW THE CONDITION of this Bond is that if the Contractor shall duly and punctually comply with terms and conditions of this Bond to the satisfaction of Department of Power, THEN, the above Bond shall be void, but otherwise, it shall remain in full force and virtue. IN WITNESS WHEREOF, the Contractor has hereunto set its hand through its authorised representative under the common seal of the Company, the day, month and year first above mentioned.
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Schedule (to the Indemnity Bond of Annexure-VI) Particulars of the Equipment handed over Quantity Particulars of Despatch Title Documents RR/GR Carrier No./ Date of Bill of Lading Value of the Equipment Signature of Attorney (authorised representative) as a token of receipt
For and on behalf of M/s .......................................................... WITNESS 1. 1. 2. 3. 2. 1. 2. 3. Signature ..................................... Name ........................................... Address ....................................... Signature .................................. Name ........................................ Address .................................... (Common Seal in case of Company) Signature .......................................... Name ................................................. Designation ....................................... Authorised representative$
$ Indemnity Bonds are to be executed by the authorized person and (i) in case of Contracting Company
under common seal of the Company or (ii) having the Power of Attorney issued under common seal of the company with authority to execute Indemnity Bonds, (iii) In case of (ii), the original Power of Attorney if it is specifically for this Contract or a Photostat copy of the Power of Attorney, if it is General Power of Attorney, and such documents should be attached to Indemnity Bond.
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Annexure-VII PROFORMA OF INDEMNITY BOND TO BE EXECUTED BY THE CONTRACTOR FOR THE EQUIPMENT(S) HANDED OVER IN INSTALMENTS FOR PERFORMANCE OF ITS CONTRACT (On non-judicial stamp paper of appropriate value) INDEMNITY BOND THIS INDEMNITY BOND is made this ................. day of .................... 200. by ....................................., a Company registered under the Companies Act, 1956/Partnership Firm/Proprietary Concern having its Registered Office at .............................................. (hereinafter called as 'Contractor' or 'Obligor' which expression shall include its successors and permitted assigns) in favour of Department of Power, having its Registered Office at Vidyut Bhawan, 0-Point, Itanagar-791 111, (hereinafter called Department of Power which expression shall include its successors and assigns). WHEREAS Department of Power has awarded to the Contractor a Contract for ......................... vide its Letter of Award/Contract No. ..........................., Dated ...................., and Amendment No. .., and Amendment No. . (applicable when amendments have been issued) (hereinafter called the 'Contract') in terms of which Department of Power is required to hand over various Equipment to the Contractor for execution of the Contract. AND WHEREAS by virtue of Clause No. 7.1 of Section-GGG of Part-III (Vol. ) of Bid documents of the said Contract, the Contractor is required to execute an Indemnity Bond in favour of Department of Power for the Equipment(s) handed over to it by Department of Power for the purpose of performance of the Contract/Erection portion of the Contract {hereinafter called the 'Equipment(s)'}. NOW THEREFORE, This Indemnity Bond witnesseth as follows: 1. That in consideration of various Equipment(s) as mentioned in the Contract, valued at Rs. ........................................... (Rupees ..................................................) to be handed over to the Contractor in instalments from time to time for the purpose of performance of the Contract, the Contractor hereby undertakes to indemnify and shall keep Department of Power indemnified, for the full value of the Equipment(s). The Contractor hereby acknowledges receipt of the initial instalment of the equipments as per details in the Schedule appended hereto. Further, the Contractor agrees to acknowledge receipt of the subsequent instalments of the Equipment(s) as required by Department of Power in the form of Schedules consecutively numbered which shall be attached to this Indemnity Bond so as to form integral parts of this Bond. It is expressly understood by the Contractor that handing over the dispatch title documents in respect of the said Equipment(s) duly endorsed by Department of Power in favour of the Contractor shall be construed as handing over the Equipment(s) purported to be covered by such title documents and the Contractor shall hold such Equipment(s) in trust as a Trustee for and on behalf of Department of Power. 2. That the Contractor is obliged and shall remain absolutely responsible for the safe transit/protection and custody of the Equipment at Department of Power project Site against all risks, whatsoever, till the Equipment(s) are duly used/erected in accordance with the terms of the Contract and the Plant/Package duly erected and commissioned in accordance with the terms of the Contract, is taken over by Department of Power. The
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Contractor undertakes to keep Department of Power harmless against any loss or damage that maybe caused to the Equipment(s). 3. The Contractor undertakes that the Equipment(s) shall be used exclusively for the performance/execution of the Contract strictly in accordance with its terms and conditions and no part of the equipment shall be utilised for any other work or purpose, whatsoever. It is clearly understood by the Contractor that non-observance of the obligations under this Indemnity Bond by the Contractor shall inter-alia constitute a criminal breach of trust on the part of the Contractor for all intents and purpose including legal/penal consequences. 4. That Department of Power is and shall remain the exclusive Employer of the Equipment(s) free from all encumbrances, charges or liens of any kind, whatsoever. The Equipment(s) shall at all times be open to inspection and checking by Engineer-inCharge/Engineer or other employees/agents authorised by him in this regard. Further, Department of Power shall always be free at all times to take possession of the Equipment(s) in whatever form the Equipment(s) may be, if in its opinion the Equipment(s) are likely to be endangered, mis-utilised or converted to use other than those specified in the Contract, by any acts of omission or commission on the part of the Contractor or any other person or on account of any reason, whatsoever, and the Contractor binds himself and undertakes to comply with the directions of demand of Department of Power to return the equipment without any demur or reservation. 5. That this Indemnity Bond is irrevocable. If at any time any loss or damage occurs to the Equipment(s) or the same or any part thereof is mis-utilised in any manner whatsoever, then the Contractor hereby agrees that the decision of the Engineer-in-Charge/Engineer of Department of Power as to assessment of loss or damage to the Equipments) shall be final and binding on the Contractor. The Contractor binds itself and undertakes to replace the lost and/or damaged Equipment(s) at its own cost and/or shall pay the amount of loss to Department of Power without any demur, reservation or protest. This is without prejudice to any other right or remedy that may be available to Department of Power against the Contractor under the Contract and under this Indemnity Bond. 6. NOW THE CONDITION of this Bond is that if the Contractor shall duly and punctually comply with the terms and conditions of this Bond to the satisfaction of Department of Power, THEN above Bond shall be void, but otherwise, it shall remain in full force and virtue. IN WITNESS WHEREOF, the Contractor has hereunto set its hand through its authorised representative under the common seal of the Company, the day, month and year first above mentioned.
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Schedule No. 1 (to the Annexure-VII) Particulars of the Equipment handed over Quantity Particulars of Despatch Title Documents RR/GR Carrier No./Date of Bill of Lading Value of the Equipment Signature of Attorney (authorised representative) as a token of receipt
(Please number subsequent schedules) For and on behalf of M/s .......................................................... WITNESS 1. 1. 2. 3. 2. 1. 2. 3. Signature ..................................... Name ........................................... Address ....................................... Signature .................................. Name ........................................ Address .................................... (Common Seal in case of Company) Signature .......................................... Name ................................................. Designation ....................................... Authorised representative$
$ Indemnity Bonds are to be executed by the authorized person and (i) in case of Contracting Company
under common seal of the Company or (ii) having the Power of Attorney issued under common seal of the company with authority to execute Indemnity Bonds, (iii) In case of (ii), the original Power of Attorney if it is specifically for this Contract or a Photostat copy of the Power of Attorney, if it is General Power of Attorney, and such documents should be attached to Indemnity Bond.
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Annexure-VIII PROFORMA OF 'AGREEMENT' (To be executed on non-judicial stamp paper of appropriate value) This Agreement made this ....................... day of ...................... two thousand between Department of Power, having its Registered Office at Vidyut Bhawan, 0-Point, Itanagar-791 111 (hereinafter called Department of Power which expression shall include its administrators, successors, executors and permitted assigns) of the one part and M/s .., a company incorporated under the Companies Act, 1956, having its Registered Office at ............................................., [hereinafter referred to as the Contractor or X (name of the Contracting Co.) which expression shall include its administrators, successors, executors and permitted assigns] of the other part. WHEREAS Department of Power desirous of executing a project of Construction of 132 kV Single Circuit Transmission Line from Khuppi to Tawang i/c 132/33 kV SubStation at Bomdila and Tawang with C/O 132 KV Bay (NEEPCO Extension at Khuppi), under sponsorship of Social Infrastructure Development Fund, Ministry of DoNER, Govt. of India and invited bids for the above work against its Bid Specification No. DoP/TED /132 KV/KHUPPI-TWG AND WHEREAS ......... "X" ......... had participated in the above referred bidding vide their Proposal No. ......................, Dated ....................., and Department of Power has awarded the Contract to ........ "X" .... on terms and conditions of the documents referred to therein, which have been acknowledged by ........... "X" ............. resulting into a "Contract". NOW THEREFORE THIS DEED WITNESSETH AS UNDER: 1.0 Article 1.1 Award of Contract The Department of Power has 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 expressions used in this Agreement shall have the same meaning as are assigned to them in the Contract Documents referred to in the succeeding Article. 2.0 Contract Documents 2.1 The Contract shall be performed strictly as per the terms and conditions stipulated herein and in the following documents attached herewith (hereinafter referred to as Contract Documents). i) Department of Powers Bidding Documents in respect of Specification No. DoP/TED/PACKAGE-B/132 KV/SS/BDL-TWG, issued vide its letter No. ................, Dated ................, consisting of Invitation to Bid, Instructions to Bidders, General Terms & Conditions of Contract, Special Conditions of Contract and all other Sections entitled "Conditions of Contract" including all amendments issued vide its letter(s) No. (s) ............, Dated .................. (Volume-I) ii) Department of Power's Technical Specifications including Amendments issued vide its Letter No. .................................................., Dated ..................
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(Volume-II) iii) "X"s Proposal No. ........................................., dated ............, along with Bid Proposal Sheets, Data Requirements, payment terms and Work Schedules submitted by "X" entitled as "................................................................................" (Volume-III) iv) Agreed Minutes of the meeting held on ................... between ---------- and "X". (Volume-IV) v) Department of Powers Letter of Award No. ...................., Dated .............., duly acknowledged by "X". (Volume-V) vi) Quality Plans for manufacturing and field activities entitled Quality Plan. (Volume-VI) vii) Contract Network (Volume-VII) All the aforesaid Contract Documents shall form an integral part of this Agreement, in so far as the same or any part conforms to the Bidding Documents (Vol. I & II) and what has been specifically agreed to by the Department of Power in its Letter of Award. Any matter inconsistent therewith, contrary or repugnant thereto or any deviations taken by the Contractor in its Proposal (Vol. of Part-III) but not agreed to specifically by the Department of Power in its Letter of Award shall be deemed to have been withdrawn by 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 Adjustment, if any, Taxes wherever applicable, Insurance, Liquidated Damages, Performance Guarantee and all other terms and conditions are contained in Department of Powers Letter of Award No. ...................., Dated, .................., read in conjunction with other aforesaid Contract documents. The Contract shall be duly performed by the Contractor strictly and faithfully in accordance with the terms of the Agreement. 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 & 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 schedule as given in Volume - V & VI of Contract documents [Clause 2.1 (v & vi) above]. 3.4 Quality Plans 3.4.1 The Contractor is responsible for the proper execution of the Quality Plans enclosed in Volume-VI. The work beyond the Customer Inspection Points (CIP) will progress only with the Department of Powers consent. The Department of Power 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 Employers
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approval. The Contractor shall also perform all quality control activities, inspection and tests agreed with the Department of Power to demonstrate full compliance with the Contract requirements. 3.4.2 The Contractor also agrees to provide the Department of Power with the necessary facilities for carrying out inspection, quality audit and quality surveillance of Contractors and its Sub-Contractors Quality Assurance Systems and manufacturing activities. These shall include but not limited to the following: i) Relevant plant standards, drawing and procedures; ii) Detailed Quality Assurance System manuals for manufacturing activities; iii) Storage procedures and instructions weld, NDT, heat treatment prior to commencement of manufacture; iv) Complete set of log sheets (blank) mentioned in the quality plan. 3.4.3 It is expressly agreed to by the Contractor that the quality tests and inspection by the Employer shall not in any way relieve the Contractor of its responsibilities for quality standards, and performance guarantee and their other obligations under the Agreement. 3.4.4 X agrees to submit Quality Assurance Documents package to Department of Power for review and record after completion and within three weeks of dispatch of material. The package will include the following: i) Factory test result/inspection reports for testing required by this Contract or applicable codes and standards; ii) Two copies of inspection reports duly signed by Quality Assurance personnel of both Department of Power and X for the agreed Customer Inspection Points; iii) 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 sales 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 entirety and nonperformance of any part or portion of the Contract shall be deemed to be a breach of the entire Contract. 3.6 The Contractor guarantees that the equipment supplied under the Contract shall meet the ratings and performance parameters as stipulated in the Technical Specifications (Volume 2/2 of Part-III) and in the event of any deficiencies found in the requisite performance figures, the Department of Power 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 documents and without any limitation. It is further agreed by the Contractor that the Contract Performance Guarantee shall in no way be construed to limit or restrict the Department of Powers right to recover the damages/compensation due to short-fall 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 deductions from the Contract price, Contract Performance Guarantee and/or otherwise.
3.7
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The Contract Performance Guarantee furnished by the Contractor is irrevocable and unconditional and the Department of Power shall have the powers to invoke it notwithstanding any dispute or difference between the Employer 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 presents. It shall supercede any 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 authorised representative of both the parties. SETTLEMENT OF DISPUTES It is specifically agreed by and between the parties that all the differences or disputes arising out of the Agreement or touching the subject matter of the Agreement shall be decided by the process of Settlement & Arbitration as specified in Clause 7, 8, 47 and 48 of the General Terms & Conditions of the Contract and the provisions of the Indian Arbitration Act, 1940 shall apply and Guwahati High Court through its Permanent Bench at Itanagar alone shall have exclusive jurisdiction over the same. 4.2 Notice of Default Notice of default given by either party to the other party under Agreement shall be in writing and shall be deemed to have been duly and properly served upon the parties hereto if delivered against acknowledgment or by telex or by registered mail with acknowledgment due addressed to the signatories at the addresses mentioned herein above. IN WITNESS WHEREOF, the parties through their duly authorised representatives have executed these presents (execution whereof has been approved by the competent authorities of both the parties) on the day, month and year first above mentioned at Itanagar. WITNESS: 1. ..................................................(Signature of Department of Power) (Printed Name) .......................................................... (Designation) (Department's Stamp) ........................................................... (Contractor's signature) (Printed Name) .......................................................... (Designation) (Company's Stamp)
Applicable in case single award is placed on one party on Supply-cum-Erection basis. In case 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.
4.0
2.
1.
2.
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ANNEXURE-IX FORMAT FOR ACCEPTANCE OF LOA To The Executive Engineer (Elect) Tawang Electrical Division Tawang. Subject: Acceptance of Award Reference: Your LOA No: Sir, With reference to your LOA no. Cited above we acknowledge the receipt of the said LOA. Having carefully studied and clear understanding of the details and contents of the award we do hereby accept the Award as required under clause 43 of section INB. Accordingly we have signed, sealed and dated the copy of LOA and is being enclosed herewith for further necessary action. In accordance with clause 40.0 and 43.0 of Section INB we shall perform the following events as per schedule prescribed as follows: 1. Submission of Contract performance Guarantee: Please specify date (Within 30 days from date of LOA issue) 2. Signing of Agreement( (within 45 days of LOA) : Please specify date In case if you find any of the above dates unsuitable please inform us accordingly. Yours faithfully
END OF ANNEXURE
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SCHEDULES
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CONTENTS Sr. No. 1 2 3 4 5 6 7 8 9 10 Description Schedule-1 Schedule-2 (Summary Price Proposal) (Summary Price Components) Page No. 118 119 121 122 164 (Bought-out and Sub-Contracted Items) (Work Completion Schedule) (Guarantee Declaration) (List of Special Tools & Tackles) (Check List) 170 171 172 173 174
Abstract of Schedule-3 & 4 Schedule-3 & 4 Schedule-3 A Schedule-5 Schedule-6 Schedule-7 Schedule-8 Schedule-9
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Schedule-1
(Summary Price Proposal) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790 104
Dear Sirs, We declare that in terms of Clause 13.0, Section-INB, Part-III (Vol. ) of Bidding Documents, the following are our lump sum bid price for the entire scope of work as specified in the Specifications and the Bidding Documents. A. Lump sum Price (excluding sales tax, excise duties and levies other than sales tax): Rs. ................... (Rupees ..............................................................................................) [Summary price component of the Lump Sum bid price are given in Schedule-2 (E)] B. Applicable Taxes & duties and other levies, payable additionally, in respect of the transaction between Owner and ourselves (i.e., direct supply items), if the Contract is awarded to us: 1. Excise duty .......................................... 2. Sales Tax .......................................... 3. Other levies: (i) Octroi ............................................ estimated @ ....................... estimated @ ........................ estimated @ ........................ estimated @ ....................... estimated @ .......................
(ii) Entry tax ....................................... (iii) Others (please specify) ..................
4. Total taxes & duties (1+2+3): .............................................................................. [Item wise break up of above is indicated in Schedules-2, 3 & 4] C. Applicable Octroi/Entry tax payable additionally in respect of bought-out finished items which shall be dispatched directly from our sub-vendor's works to Owner's site (sale-in-transit): (i) Octroi ........................................ estimated @ ............................................ (ii) Entry tax ................................ estimated @ ............................................ (iii) Total levies [(i)+(ii)] .. D. E. Service Tax estimated @ Total Lump sum Bid Price including Taxes & Duties and other levies, if the Contract is awarded to us i.e., sum of A+B+C+D above Rs. ................. (Rupees ...).
Date
(Signature) ............................................ (Printed Name) ...................................... (Designation) ......................................... (Common Seal) .....................................
Place :
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Schedule-2
(Summary Price Componentsl) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790 104
Summary of Price Component as per the scope identified in accompanying specifications: Sr. No. A. B. C. D. E. Description
Total Equipment Ex-works Price Total Freight and Insurance Charges Total FOR Site Price (A+B) Total Erection Charges (including civil works) Total bid price = C + D
Amount (Rs.)
[as per Schedule-3A] [as per Schedule-4]
In Figure: In Words:
Amount of Taxes, Duties and levies indicated at F below are not included in the Total Bid Price indicated at E.
F. Taxes/Duties/Levies additionally payable by the DoP (Arunachal Prradesh): Description of applicable Taxes/Duties/Levies F-I 1. Excise Duty (as per B.1 of Schedule-1) a. @ . b. @ . c. @ . 2. Sales Tax (as per B.2 of Schedule-1) @ . 2. Other Levies: a. Octroi for direct transaction [as per B.3 (i) of Schedule-1] @ . b. Entry Tax for direct transaction [as per B.3(ii) of Schedule-1] @ . c. Others (Specify) for direct transaction [as per B.3 (iii) of Schedule-1] @ .
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Items
Item Sr. No. as per Schedule 3 &4
Value of Bid Price on which applicable (Rs.)
Total amount towards Tax/Duty/Levy (Rs.)
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d. Octroi for bought-out items (Sale-in-transit) [as per C. (i) of Schedule-1] @ . e. Entry tax for boughtout items (Sale-intransit) [as per C. (ii) of Schedule-1] @ . Total F-I: (1+2+3): F-II: Service Tax for the services which shall be provided directly by us if the Contract is awarded to us [as per B.3. (iii)) of Schedule-1] Description of price component on which Service Tax is applicable Value of the price component in Rupees, on which Service Tax is applicable Rate & Amount of Service Tax, if applicable & payable by the Department of Power
Total F-II: Total F: (F-I + F-II):
(Signature) . Date: (Printed Name) .. Place: (Designation) . (Common Seal) .

Note: 1. The figures given at E & F of this Schedule shall match with the lump sum price given at Schedule-1. 2. Item-wise break-up of the figures given in this schedule is indicated in Schedule-3 & 4.
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ABSTRACT OF COST
SL. DESCRIPTION OF ITEMS No. 1 2 132 KV Line from Khuppi 1 to Tawang 2 133/33 KV Bay at Khuppy 133/33, 4x5 MVA Substation at Bomdila 133/33, 4x5 MVA Sub4 station at Tawang 3 SUPPLY 3 ERECTION 4 TOTAL (Rs.) 5
GRAND TOTAL
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CONSTRUCTION OF 132 KV SINGLE CIRCUIT TRANSMISSION LINE FROM KHUPPI TO TAWANG I/C 132/33 KV S/S AT BOMDILA & TAWANG WITH C/O 132 KV BAY (NEEPCO EXTENSION AT KHUPPI) (Price Break-up of Ex-works Prices) SPECTIFICATION NO: DOP/TED/132 KV/KHUPPI-TWG Bidder's Name & Address : The Executive Engineer (E), Tawang Electrical Division Department of Power, Tawang
Price Break-up of Ex-works price for supply of individual items for construction of 132 kV Single Circuit Transmission Line from Khuppi to Tawang . (Bidder shall quote prices for the following items. Prices of all accessories, assemblies, components, parts etc. associated with these items are to be included in ( All Prices in Rs) Sl. No. 1 Other Taxes & Duties Unit ExTotal Ex-works applicable not included in the price at Column(6) works price price Other Excise Duty CST 5 6 = (4x5) 7 8 Applicable VAT/Entry Tax 9 Freight & Insuran ce charges 10
Description of Item
Unit
Qty.
Total Price
11
132 KV Line from Khuppi to Tawang

A SUPPLY OF MATERIALS 1.0 TOWER STEEL a Design, Fabrication, galvanizing and supply of various type of towers and its body extention / unequal leg extensions etc parts complete excluding stubs, bolts and nuts (fasteners) etc. b Design, Fabrication, galvanising & supply of Stubs, bolts and nuts i/c templates of various types of towers.
MT
1904.89
MT
44.20
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Sl. No.
Description of Item
Unit
Qty.
1 2 2.0 ACSR Conductor of size 30/7/3.00 mm ( Panther ) 3.0 90 kN Anti fog Disc insulator 4.0 HARDWARE & ACCESSORIES FOR ACSR CONDUCTOR Manufacturing & Supply of Single tension type hardware fitting with bolted type clamp. ii Manufacturing and Supply of Midspan compression joints. iii Manufacturing & Supply of Repair sleeves. iv Manufacturing & Supply of Vibration damper stock bridge type. v Manufacturing & Supply of Anti climbing device 5.0 Manufacturing & Supply of Hot dip galvanized ground wire 7/3.15 mm dia. 6.0 Manufacturing & Supply of tower accessories Danger Notice plate i ii Number plate iii Phase sequence plate (set of 3 pcs) iv Manufacturing & supply of Armour Rod. i
3 KM Nos
4 472.54 42264
Other Taxes & Duties Unit ExTotal Ex-works applicable not included in the price at Column(6) works price price Other Excise Duty CST 5 6 = (4x5) 7 8
Applicable VAT/Entry Tax 9
Freight & Insuran ce charges 10
Total Price
11
Set Set Set Set Kg kM
3522 530 1600 3522 40000 165.00
Nos Nos Set Set
2348.00 587.00 587.00 3516
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Sl. No. 1 v
Description of Item
Unit
Qty.
2 Manufacturing & Supply of Bird guard. 7.0 ACCESSORIES FOR 7/3.15MM EARTH WIRE Manufacturing & Supply of i Midspan compression joints. ii Manufacturing & Supply of Vibration damper stock bridge type. iii Manufacturing and Supply of Tension clamp. iv Manufacturing & Supply of Suspension clamp. COST OF SUPPLY (i)
3 Set
4 3516
Other Taxes & Duties Unit ExTotal Ex-works applicable not included in the price at Column(6) works price price Other Excise Duty CST 5 6 = (4x5) 7 8
Applicable VAT/Entry Tax 9
Freight & Insuran ce charges 10
Total Price
11
Nos Nos Nos Nos
587 531 1056 118
Note: 1 In case of discrepancy between unit price & total, the unit price shall prevail. 2 Brief description of item/work mentioned in this schedule shall not be construed to limit the scope of work and the same shall be read in conjunction with corresponding section of TS including amendments/errata, if any thereto.
Schedule-4
125
CONSTRUCTION OF 132 KV SINGLE CIRCUIT TRANSMISSION LINE FROM KHUPPI TO TAWANG I/C 132/33 KV S/S AT BOMDILA & TAWANG WITH C/O 132 KV BAY (NEEPCO EXTENSION AT KHUPPI) Price Break up of Erection Charges To, Bidder's Name & Address: The Executive Engineer (E), Tawang Electrical Division, Department of Power, Tawang - 790104 (All Prices in Rupees) Erection Charges Price Service Tax Total Price 6 7 8
Sl.No 1 1.0 1.1 1.2 2.0 i. ii. iii. iv. 3.0 4.0 a) b) c)
Description of Items 2 132 KV LINE ERECTION AND CIVIL WORKS SURVEY & INVESTIGATION. Detailed survey including route allignment profiling, tower spotting and Final Peg marking. Check survey DETAILED SOIL INVESTIGATION Sandy soil Mixed soil Clay soil Hard Rock Funishing Bore log data BENCHING. Normal soil Fissured soil/Soft Rock Hard rock
Unit 3
Qty. 4
Unit Rate 5
KM KM Loc. Loc. Loc. Loc. Loc. Cum Cum Cum
70.251 159.811 73.00 123.00 221.00 170.00 373.00 21390.70 18073.29 29431.96
Schedule-4
126
Sl.No 1 5.0 5.1 a) b) c) 5.2
Description of Items 2 Tower Foundation Work Excavation work in various types of soil Normal Dry soil Dry Fissured rock Hard rock Design & concreting of Tower footing work with Normal mix ratio 1:2:4 (M15) on 100% full rate (i.e supply & erection RCC works with cement & concrete) Design & concreting of Tower footing work with Normal mix ratio 1:1.5:3 (M10) on 100% full rate (i.e supply & erection RCC works with cement & concrete) Protection of Tower footing Random rubble stone masonary including excavation Stone bound in galvanised wire netting including excavation Erection of various type of towers and its body leg extensions etc. (complete) i/c bolts and nuts, step bolts, hangers, D-shackles etc. and i/c tack welding and supply and application of enamel and Zinc rich paint.
Unit 3
Qty. 4
Unit Rate 5
Erection Charges Price Service Tax 6 7
Total Price 8
Cum Cum Cum Cum
12508.995 5440.884 1696.026 8413.907
5.3
Cum
5745.280
6.0 i ii 7.0
Cum Cum
7750.37 7785.95
MT
2177.292
Schedule-4
127
Sl.No 1 8.0 i) ii) iii) 9.0 10.0
Description of Items 2 Installation of following tower accessories Danger Notice plate Number plate Phase sequence plate (set of 3 pcs) Installation of Stubs Installation of insulators strings (complete fitting) with arching horns and necessary hardware fittings, installing and stringing of conductor & earthwire(i/c fixing of accessories for conductors and earth wire )for 3 Phase single circuit line. Installation of earthing of towers i/c supply of all required materials i/c coal & salt etc. 4 Nos Pipe earthing with 1 No Counter poise earthing per Tower = 1 Set COST OF ERECTION (ii) TOTAL COST OF LINE (i) + (ii) = A
Unit 3 Nos Nos Set KM
Qty. 4 2348.00 587.00 587.00 147.126
Unit Rate 5
Total Price 8
Ckt KM
159.811
11.0 i
Set
587.00
Schedule-3
128
Construction of 132 kV Single Circuit Transmission Line from Khuppi to Tawang i/c 132/33 kV Sub-Station at Bomdila and Tawang with C/O 132 KV Bay (NEEPCO Extension at Khuppi). Specification No: DoP/TED/132 KV/KHUPPI-TWG Bidder's Name & Address: To, The Executive Engineer (E) Tawang Electrical Division Department of Power, Tawang
Price Break-up of Ex-works price for supply of individual items for construction of 132 KV Bay at Khuppi & 4 x 5 MVA, 132/33 kV Sub-Station at Bomdila and Tawang.
(Bidder shall quote prices for the following items. Prices of all accessories, assemblies, components, parts etc. associated with these items are to be included in bidder's quoted prices for all these items). (All Prices in Rs.) Other Taxes & Duties applicable Total Ex-works not included in the price price at Column(6) Excise Duty 7 CST 8 9 Freigh t& Insura nce charg es 10
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Applicable VAT/Entry Tax
Total Price
6 (4x5)
11
132 KV Bay at Khuppi A Material Ex-Works Cost 1.0 GI STRUCTURES (i) Design, fabrication and supplying of hot dip galvanised latticed type tower made with angle iron including nuts and bolts, spring washers etc. as required for 132 KV and 33 KV tower gantry, 132 KV CTs, PTs LA's and isolators structures. 2.0 145 KV EQUIPMENTS (a) Circuit Breaker
MT
3.00
Schedule-3
129
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Other Taxes & Duties applicable Total Ex-works not included in the price price at Column(6) Excise Duty 7 CST 8
Freigh t& Insura nce charg es 10
Total Price
6 (4x5)
11
(i) 145 KV, 1250 A, 31.5KA, SF6,3-Phase circuit breaker along with support structure No. (b) Current Transforers (i) 145 KV, 150 A, 31.5 KA, 1-Phase, 3-Core current transformer with 120% extended current rating complete in all respects along with associated and common MB No. (c) Isolators (i) 145 KV, 1250 A, 31.5KV, 3-Phase Horizontal Centre Break isolator with earthswitch. (ii) 145 KV, 1250 A, 31.5 KV, 3-Phase Horizontal Centre Break isolator without earthswitch(Tandem) (d) Surge Arrestor (i) 120 KV, 1-Phase, gapless Surge Arrestor complete in all respects with insulating base and surge monitor. (e) Capacitor voltage Transformers (i) 145 KV, 4400PF, 1-, CVT having three secondaries along with Main Bus(MB) 6 2
No.
No.
No.
No.
Schedule-3
130
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Price
6 (4x5)
11
(f) 132 KV Control, Ralay and protection panels. (i) Control Panel for 1 bay(SMT Type ) (ii) Circuit Breakers Relay Panel for 132 KV Breakers without auto recloser (iii) Line protection panel 3.0 Bus Bar Materials(Hardware) 3.1 Bus post insulators & insulator strings, Disc Insulators, Hardware, spacers, conductor(s), bus bar materials, cable trays, bay MB clamps, conectors including equipment conectors, junction box, Earthwire, earthing materials, risers, auxiliary earthmat buried/RCC cable trenches / pipes for equipment & lighting all accessories etc. for the following. (a) 132 KV "SMT" Type (i) 132 KV Line bay 4.0 Cables along with glands, lugs and straight joints etc. (a) Power Cable(1.1 KV grade PVC aluminium conductor) (i) 4 Cores of 6 Sq.mm. (ii) 2 Core of 6 Sq.mm. (b) Control Cable (1.1KV Grade PVC Copper Conductor) (i) 5 Cores of 2.5 Sq.mm. (ii) 2 Cores of 4 Sq.mm. (iii) 4 Cores of 4 Sq.mm.
Set Set Set
2 2 2
Set
KM KM
1.00 0.90
KM KM KM
1.60 2.00 1.00
Schedule-3
131
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Price
3 MT
4 2.86
6 (4x5)
11
(c) Steel for foundation of equipments structurects of various sizes (d) Foundation Bolts for equipments structures Cost of 132 KV Bay supply (iii)
MT
0.52
Schedule-4
132
Construction of 132 kV Single Circuit Transmission Line from Khuppi to Tawang i/c 132/33 kV Sub-Station at Bomdila and Tawang with C/O 132 KV Bay (NEEPCO Extension at Khuppi). Price Break up of Erection Charges Specification No: DoP/TED/132 KV/KHUPPI-TWG Bidder's Name & Address:
To The Executive Engineer (E) Tawang Electrical Division Department of Power Tawang - 790104
Price Break-up towards Erection of Materials for construction of 132 KV Bay at Khuppi & 4 x 5 MVA, 132/33 kV Sub-Station at Bomdila and Tawang Sl. No. 1 B i Erection Charges Price Service Tax 6 7
Description of Items 2 132 KV Bay at Khuppi ERECTION PORTION Erection of various type of towers and its body leg extensions etc. (complete) i/c bolts and nuts, step bolts, hangers, D-shackles etc. and i/c tack welding and supply and application of enamel and Zinc rich paint as required for 132 and 33 kV gantry, 132 KV CTs, PTs,LAs and Isolator structures.
Unit 3
Qty. 4
Unit Rate 5
Total Price 8
MT 2.0 145 KV EQUIPMENTS (a) Circuit Breaker (i) 145 KV, 1250 A, 31.5KA, SF6,3-Phase circuit breaker along with support structure (b) Current Transforers (i) 145 KV, 150 A, 31.5 KA, 1-Phase, 3-Core current transformer with 120% extended current rating complete in all respects along with associated and common MB (c) Isolators (i) 145 KV, 1250 A, 31.5KV, 3-Phase Horizontal Centre Break isolator with earthswitch.
3.00
No.
No.
No.
Schedule-4
133
Sl. Description of Items No. 1 2 (ii) 145 KV, 1250 A, 31.5 KV, 3-Phase Horizontal Centre Break isolator without earthswitch(Tandem) (d) Surge Arrestor (i) 120 KV, 1-Phase, gapless Surge Arrestor complete in all respects with insulating base and surge monitor. (e) Capacitor voltage Transformers (i) 145 KV, 4400PF, 1-, CVT having three secondaries along with Main Bus(MB) (f) 132 KV Control, Relay and protection panels. (i) Control Panel for 1 bay(SMT Scheme) (ii) Circuit Breakers Relay Panel for 132 KV Breakers without auto recloser (iii) Line protection panel 3.0 Bus Bar Materials(Hardware) 3.1 Bus post insulators & insulator strings, Disc Insulators, Hardware, spacers, conductor(s), bus bar materials, cable trays, bay MB clamps, conectors including equipment conectors, junction box, Earthwire, earthing materials, risers, auxiliary earthmat buried/RCC cable trenches / pipes for equipment & lighting all accessories etc. for the following. (a) 132 KV "SMT" Type (i) 132 KV Line bay 4.0 Cables along with glands, lugs and straight joints etc. (a) Power Cable(1.1 KV grade PVC aluminium conductor) (i) 4 Cores of 6 Sq.mm. (ii) 2 Core of 6 Sq.mm.
Unit 3 No.
Qty. 4 4
Unit Rate 5
Total Price 8
No.
No. Set Set Set
6 2 2 2
Set
KM KM
1.00 0.90
Schedule-4
134
Sl. No. 1 (b) (i) (ii) (iii) C (a) (b) (c) (d) g) h) i)
Description of Items
Unit
Qty. 4 1.60 2.00 1.00 50.00 4.00 30.00 1 200 300
j) k)
l)
(i) (ii) (iii)
2 3 Control Cable (1.1KV Grade PVC Copper Conductor) 5 Cores of 2.5 Sq.mm. KM 2 Cores of 4 Sq.mm. KM 4 Cores of 4 Sq.mm. KM CIVIL WORKS Execavation works for equipments structures Cum. RCC 1:3:6 for foundfation works of equpment support structures. Cum. RCC 1:2:4 for foundation works of equipment support structures. Cum. Cable Trenches and other civil works Job M Roads 3.75 m wide (i/c all crossings) M Water Drainage Security wall around the Sub-Station with angle iron post of size 100 x 100 x 8 mm by providing chain link and barbed wire at the top etc as required. RM Job Providing and installation of Gate, Gate Pillar & Security Room C/O RCC Control room i/c glazing,false ceiling, internal water supply, internal wiring (concealed conduit), air conditioning etc. (Plinth area: 15 mtr. x 10.5 Sqm mtr.= 157.50 sq. mtr. ) Full furnished RCC building with bricks wall height of 2.75 Meters as prescribed in the Technical Specifications and approved design & drawing etc. Sqm 5 Man barrack - 1 No. 139.5 Sq mtr Sqm Type - I Qtr- 1 No. 35 Sq mtr Sqm Type - II Qtr- 1 No. 46 Sq mtr
Unit Rate 5
Total Price 8
400 1
157.5
139.5 35 46
Schedule-4
135
Sl. No. 1 (iv) (v) m) n)
Description of Items 2 Type - III Qtr- 1No. 55 Sq mtr Type - IVQtr- 1 No. 212 Sq mtr D.G.set building (Plinth area: 5 mtr. x 4 mtr.= 20 sq. mtr. ) Land Development
Unit 3 Sqm Sqm Sqm
Qty. 4 55 212 20
Unit Rate 5
Total Price 8
i Land development i/c earth cutting / filling, filling with sand, stone aggregate etc.
Job
Cost of 132 KV Bay Erection (iv) COST OF BAY (iii) + (iv) = B
Schedule-3
136
(All Prices in Rs.) Freigh Other Taxes & t& Duties applicable Applicable Insura not included in the VAT/Entry nce price at Column(6) Tax charg Excise CST es Duty 7 8 9 10
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
Total Price
6 (4x5)
11
132 /33 KV 4 x 5 MVA S/S at Bomdila B MATERIALS EX WORKS COST 1.0 GI STRUCTURES i Design, fabrication and supplying of hot-dip galvanised latticed type tower made with angle iron i/c nuts and bolts, spring washer etc.as required for 132 kV and 33 kv tower gantry, 132 kV CT's, PT's, LA's and isolators structures 2.0 145 KV equipments a Transformer i 1-ph 5 MVA, 132/33 kV Transformers b Circuit Breaker i 145 kV, 1250 A 31.5 KA, SF6, 3-phase circuit breaker along with support structure c Current Transformer & Potential Transformer i 145 kV, 150 A, 31.5 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB ii 145 kV , 1-phase 3 core potential transformer with all accesssories etc as reqd.
MT
105.00
No.
No.
No. No.
12 2
Schedule-3
137
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
6 (4x5)
Freigh Other Taxes & t& Duties applicable Applicable Insura not included in the VAT/Entry nce price at Column(6) Tax charg Excise CST es Duty 7 8 9 10
Total Price
11
d) Isolators i 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator with earth switch ii 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator without earth switch (Tandem) e) Surge Arrestors i 120 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor f) Capacitor Voltage Transformers i 145 kV, 4400 pF, 1-phase,CVT having Three secondaries along with main bus (MB) g) 132 KV Control, Relay and Proctection panel i Control panel for 2 bays (SMT Type ) ii Control panel for Transformer bay iii. Circuit Breaker Relay Panel for 132 KV breakers without auto recloser iv. v vi vii viii Protection panel for 132/33 kV transformer Main and transfer Bus Protection panel Circuit Breaker relay panel for transfer bus coupler Line protection panel Synchronizing trolley
Set Set
6 10
No.
12
No. No. Set No. No. Set Set Set. No.
9 2 1 4 1 1 1 2 1
Schedule-3
138
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
1 3.0 a i b i
6 (4x5)
Total Price
11
33 kV Equipments Transformer 250 kVA, 33/0.433 kV, 3-phase Transformers Circuit Breaker 36 kV, 630 A, 25KA, VCB,3 -Phase circuit breaker along with support structure c Current Transformer i 36 kV, 300 A, 25 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB d) Isolators i 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator with earth switch ii 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator without earth switch e) Surge Arrestors i 30 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor f) i Potential Transformer 36 kV, 25 KA, 1-phase potential Transformer
No.
No.
No.
21
No. No.
6 8
No. No.
21 21
Schedule-3
139
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
6 (4x5)
Total Price
11
g) 33 kV Control, Relay and Protection panels and associated equipments (Simplex type) a) Control and Relay pannel for 33 kV side of 5 MVA transformer No. b) Control and Relay pannel for 4 nos of 33 kV feeders No. c) Control and Relay pannel for 6 nos of 33 kV SF6 Circuit No. Breakers. 4.0 Bus Bar materials (Hardware) 4.1 Bus post insulators and insulator strings, disc insultors, hardware, spacers, conductor(s), bus bar materials, cable trays, Bay MB, clamps, connectors i/c equipment connectors, junction box, Earthwire, earthing materilas, risers, auxilliary earthmat (excluding main earth mat), buried / RCC cable trenches / pipes for equipments and lighting all accessories for the following. a) i ii iii. iv. v 132 KV "SMT" Type Transformer bays 132 KV main and transfer buses Transformer Bus Coupler Bay Line bays Stringing for coupling of both transfer buses Set Set Set Set Set
1 4 6
1 2 1 2 1
Schedule-3
140
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
1 b) i ii iii. 5.0 i ii iii. 6.0 i ii iii. 7.0 a) i ii iii. iv b) i ii iii. iv 8.0
2 33 KV "SMT" Type Line bays Transformer Bay Main bus & other Fire Protection System 9 litre water type 4.5 kG carbon di-oxide type 5 kG dry chemical powder type Switch yard and buiding Illumination System Switchyard lighting Street lighting D.G.set building illumination Other Accesssories Direct Current Distribution System Battery Bank of 110 Volts, 200AH of 2V lead acid batteries (10% uncharged spare cells) Battery Bank of 50 Volts, 200AH of 2V lead acid batteries (10% uncharged spare cells) 110 Volts Float cum Boost Battery Charger 50 Volts Float cum Boost Battery Charger LT Switchgears system 415 Volts Main Switch board with panel, fuse switch combined unit for LT feeders 415 V ACDB 110V DCDB 50 V DCDB 100 KVA, 415 Volts D.G.Set with control panel
3 Set Set Set No. No. No. S/S S/S S/S
4 4 2 1 10 15 15 1 1 1
6 (4x5)
Total Price
11
Nos Nos Set Set
61 28 1 1
Set Set Set Set Set
1 1 1 1 1
Schedule-3
141
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
6 (4x5)
Total Price
11
9.0 Cables with glands, lugs and straight joints etc. a) Power cables (1.1 KV grade XLPE, Alu. Conductor) i 3.5 Core of 185 Sq.mm b) Power cables (1.1 KV grade PVC Alu. Conductor) 4 Cores of 6 Sq.mm 2 Cores of 6 Sq.mm Control cables (1.1 KV grade PVC Copper Conductor) i 5 Cores of 2.5 Sq.mm ii 7 Cores of 2.5 Sq.mm iii. 9 Cores of 2.5 Sq.mm iv 2 Cores of 4 Sq.mm v 4 Cores of 4 Sq.mm 10.0 PLCC equipments a) 1250 A Line traps b) Coupling devices c) HF cables d) Carrier terminals (for use of speech + telex + data) e) Carrier terminals (for use of speech + Protection) e) Protection Coupler f) EPAX (24/8 lines) g) 2 wire telephone equipment with necessary connection cable h) 4 wire telephone equipment with necessary connection cable f) Testing and maintenance equipments for PLCC i ii c) KM 0.20
KM KM
0.50 0.45
KM KM KM KM KM No. No. KM Set Set No. Set No. No. Set
0.80 1.00 0.40 0.50 0.45 2 1 1.5 1 1 1 1 5 3 1
Schedule-3
142
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
3 MT
4 8.53
6 (4x5)
Total Price
11
11.0 STEEL FOR FOUNDATION OF EQUIPMENTS STRUCTURES 12.0 FOUNDATION BOLTS FOR EQUIPMENTS STRUCTURES i Foundation bolts Cost of Bomdila S/S - (v)
MT
2.80
Schedule-4
143
Sl. No. 1 A:: 1.0 i. ii. iii. iv. 3.0 4.0 a) b) c) C i
Description of Items
Unit
Qty. 4
2.0 a i b i c i
2 3 132 /33 KV 4 x 5 MVA S/S at Bomdila SOIL INVESTIGATION. Detailed soil investigation Sandy soil Job Mixed soil Job Clay soil Job Hard Rock Job Job Funishing Bore log data BENCHING. Normal soil Cum Fissured soil Cum Hard rock Cum ERECTION PORTION Erection of various type of towers and its body leg extensions etc. (complete) i/c bolts and nuts, step bolts, hangers, D-shackles etc. and i/c tack welding and supply and application of enamel and Zinc rich paint as required for 132 and 33 kV gantry, 132 kV CT's,PT's, LA's and isolator structures. MT 145 KV equipments Transformer No. 1-ph 5 MVA, 132/33 kV Transformers Circuit Breaker 145 kV, 1250 A 31.5 KA, SF6, 3-phase circuit breaker along with support No. structure
Current Transformer & Potential Transformer
Unit Rate 5
Total Price 8
1 1 1 1 1 1.00 1.00 1.00
105.00
145 kV, 150 A, 31.5 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB
145 kV , 1-phase 3 core potential transformer with all accesssories etc as reqd.
ii
No. No.
12 2
Schedule-4
144
Sl. Description of Items No. 1 2 d) Isolators i 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator with earth switch ii 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator without earth switch (Tandem) e) Surge Arrestors i 120 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor f) Capacitor Voltage Transformers i 145 kV, 4400 pF, 1-phase,CVT having Three secondaries along with main bus (MB) g) 132 KV Control, Relay and Proctection panel i Control panel for 2 bays (SMT scheme) ii Control panel for Transformer bay iii. Circuit Breaker Relay Panel for 132 KV breakers without auto recloser iv. Protection panel for 132/33 kV transformer v Main and transfer Bus Protection panel vi Circuit Breaker relay panel for transfer bus coupler vii Line protection panel viii Synchronizing trolley 3.0 33 kV Equipments a Transformer i 250 kVA, 33/0.433 kV, 3-phase Transformers b Circuit Breaker i 36 kV, 630 A, 25KA, VCB,3 -Phase circuit breaker along with support structure c Current Transformer i 36 kV, 300 A, 25 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB
Unit 3
Qty. 4
Unit Rate 5
Total Price 8
Set Set
6 10
No.
12
9 2 1 4 1 1 1 2 1
No.
No.
No.
21
Schedule-4
145
Sl. Description of Items No. 1 2 d) Isolators i 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator with earth switch ii 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator without earth switch e) Surge Arrestors i 30 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor f) Potential Transformer i 36 kV, 25 KA, 1-phase potential Transformer g) 33 kV Control, Relay and Protection panels and associated equipments (Simplex type) a) Control and Relay pannel for 33 kV side of 5 MVA transformer b) Control and Relay pannel for 4 nos of 33 kV feeders c) Control and Relay pannel for 6 nos of 33 kV SF6 Circuit Breakers. 4.0 Bus Bar materials (Hardware) 4.1 Bus post insulators and insulator strings, disc insultors, hardware, spacers,
conductor(s), bus bar materials, cable trays, Bay MB, clamps, connectors i/c equipment connectors, junction box, Earthwire, earthing materilas, risers, auxilliary earthmat (excluding main earth mat), buried / RCC cable trenches / pipes for equipments and lighting all accessories for the following.
Unit 3
Qty. 4
Unit Rate 5
Total Price 8
No. No.
6 8
No. No.
21 21
No. No. No.
1 4 6
a) i ii iii. iv. b) i ii iii. 5.0
132 KV "SMT" Type Transformer bays 132 KV main and transfer buses Transformer Bus Coupler Bay Line bays 33 KV "SMT" Type Line bays Transformer Bay Main bus & other Fire Protection System
Set Set Set Set Set Set Set
1 2 1 2 4 2 1
Schedule-4
146
Sl. No. 1 i ii iii. 6.0 i ii iii. 7.0 a) b)
Description of Items 2 9 litre water type 4.5 kG carbon di-oxide type 5 kG dry chemical powder type Switch yard and buiding Illumination System Switchyard lighting Street lighting D.G.set building illumination Earthing: Mat earthing for entire switchyard with 65/6mm and 50/5 mm MS flat iron including 32 mm dia MS rod and other accessories as reqd. Copper plate earthing of transformer, CB's,RCPs and Battery Charger i/c cost of copper plate and copper strips of 15 m long & other accessories as reqd. GI plate earting of Las,CTs,PTS,isolators, gantry tower, ACDB and DCDB i/c cost of GI earth plate and GI strip of 15 mtr long & other accessories as reqd. Other Accesssories Direct Current Distribution System Battery Bank of 110 Volts, 200AH of 2V lead acid batteries (10% uncharged spare cells) Battery Bank of 50 Volts, 200AH of 2V lead acid batteries (10% uncharged spare cells) 110 Volts Float cum Boost Battery Charger 50 Volts Float cum Boost Battery Charger LT Switchgears system 415 Volts Main Switch board wwith panel, fuse switch combined unit for LT feeders 415 V ACDB 110V DCDB 50 V DCDB 100 KVA, 415 Volts D.G.Set with control panel Cables with glands, lugs and straight joints etc.
Unit 3 No. No. No. S/S S/S S/S
Qty. 4 10 15 15 1 1 1
Unit Rate 5
Total Price 8
Set
40
Set
40
c)
Set
50
8.0 a) i ii iii. iv b) i ii iii. iv 9.0 10.0
Nos. Nos. Set Set
61 28 1 1
Set Set Set Set Set
1 1 1 1 1
Schedule-4
147
Sl. No. 1 a) i b) i ii c) i ii iii. iv v 10.0 a) b) c) d) e) e) f) g) h) f) D a) b) c) d)
Description of Items 2 Power cables (1.1 KV grade XLPE, Alu. Conductor) 3.5 Core of 185 Sq.mm Power cables (1.1 KV grade PVC Alu. Conductor) 4 Cores of 6 Sq.mm 2 Cores of 6 Sq.mm Control cables (1.1 KV grade PVC Copper Conductor) 5 Cores of 2.5 Sq.mm 7 Cores of 2.5 Sq.mm 9 Cores of 2.5 Sq.mm 2 Cores of 4 Sq.mm 4 Cores of 4 Sq.mm PLCC equipments 1250 A Line traps Coupling devices HF cables Carrier terminals (for use of speech + telex + data) Carrier terminals (for use of speech + Protection) Protection Coupler EPAX (24/8 lines) 2 wire telephone equipment with necessary connection cable 4 wire telephone equipment with necessary connection cable Testing and maintenance equipments for PLCC CIVIL WORKS Foundation for 1-phase, 5 MVA,132/33 V Transformer Foundation for 3-phase, 250 KVA,33/0.433 KV Transformer Excavation works for equipments and gantry towers RCC 1:3:6 for foundation works of gantry tower and equipment structures
Unit 3 KM KM KM KM KM KM KM KM No. No. KM Set Set No. Set No. No. Set No. No. Cum Cum
Qty. 4 0.20 0.50 0.45 0.80 1.00 0.40 0.50 0.45 2 1 1.5 1 1 1 1 5 3 1 4 1 975.0 45.0 225
Unit Rate 5
Total Price 8
e) RCC 1:2:4 for foundation works of gantry tower and equipment structures Cum f) Cable trenches i/c all types of crossings
Schedule-4
148
Sl. No. 1 i i ii iii. g) h) i)
Description of Items 2 Section 2-2 Section 2-2 Section 3-3 Section 4-4 Roads 3.75 m wide (i/c all crossings) Water Drainage Security wall around the Sub-Station with angle iron post of size 100 x 100 x 8 mm by providing chain link and barbed wire at the top etc as required.
Unit 3 M M M M M M
Qty. 4 50.00 50.00 65.00 80.00 200 300
Unit Rate 5
Total Price 8
j) Providing and installation of Gate, Gate Pillar & Security Room k) C/O RCC Control room i/c glazing,false ceiling, internal water supply, internal wiring (concealed conduit), air conditioning etc. (Plinth area: 21 mtr. x 15 mtr.= 315 sq. mtr. ) l) Full furnished RCC building with bricks wall height of 2.75 Meters as prescribed in the Technical Specifications and approved design & drawing etc. (i) 5 Man barrack - 4 No. 558 Sq mtr (ii) Type - I Qtr- 5 No. 175 Sq mtr (iii) Type - II Qtr- 5 No. 230 Sq mtr (iv) Type - III Qtr- 4 No. 220 Sq mtr (v) Type - I VQtr- 1 No. 212 Sq mtr m) D.G.set building (Plinth area: 5 mtr. x 4 mtr.= 20 sq. mtr. ) n) Providing and Installation of 60LB/yd ratio for transformer track (Rail) . o) Land Development i land development i/c earth cutting / filling, filling with sand, stone aggregate etc.
RM Job
400 1
Sqm
315
Sqm Sqm Sqm Sqm Sqm Sqm Mtr
558 175 230 220 212 20 24.20
Job
Erection Cost of Bomdila S/S - (vi) TOTAL COST OF BOMDILA SUB-STATION (v + vi) - C
Schedule-3
149
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
6 (4x5)
Total Price
11
132 /33 KV 4 x 5 MVA S/S at Tawang B MATERIALS EX WORKS COST 1.0 GI STRUCTURES Design, fabrication and supplying of hot-dip galvanised latticed type tower made with angle iron i/c nuts and bolts, spring washer etc.as required for 132 kV and 33 kv tower gantry, 132 kV CT's, PT's, LA's and isolators structures 2.0 145 KV equipments a Transformer i 1-ph 5 MVA, 132/33 kV Transformers b Circuit Breaker i 145 kV, 1250 A 31.5 KA, SF6, 3-phase circuit breaker along with support structure c Current Transformer & Potential Transformer i 145 kV, 150 A, 31.5 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB ii 145 kV , 1-phase 3 core potential transformer with all accesssories etc as reqd. d) Isolators i 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator with earth switch ii 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator without earth switch (Tandem) e) Lightning Arrestors
MT
105.00
No.
No.
No. No.
9 1
Set Set
4 8
Schedule-3
150
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
1 i f) i g) i ii iii. iv. v vi vii viii ix)
2 120 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor Capacitor Voltage Transformers 145 kV, 4400 pF, 1-phase,CVT having Three secondaries along with main bus (MB) 132 KV Control, Relay and Proctection panel Control panel for 2 bays (SMT scheme) Control panel for Transformer bay Circuit Breaker Relay Panel for 132 KV breakers without auto recloser Protection panel for 132/33 kV transformer Main and transfer Bus Protection panel Circuit Breaker relay panel for transfer bus coupler Line protection panel Synchronizing trolley Surge counter to be installed in the incoming feeder with accessories etc. complete.
3 No.
4 9
6 (4x5)
Total Price
11
No. No. Set No. No. Set Set Set. No. Set
6 2 1 4 1 2 1 2 1 1
Schedule-3
151
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
6 (4x5)
Total Price
11
3.0 33 kV Equipments a Transformer i) Suppy installation testing and commissioning of power transformer 33/11KV, 5MVA, three phase , 50Hz , ONAN cooled delta/star connected with accessories. 250 kVA, 33/0.433 kV, 3-phase Transformers Circuit Breaker 36 kV, 630 A, 25KA, VCB,3 -Phase circuit breaker along with support structure c Current Transformer i 36 kV, 300 A, 25 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB d) Isolators i 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator with earth switch ii 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator without earth switch e) Lightning Arrestors i 30 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor f) Potential Transformer i 36 kV, 25 KA, 1-phase potential Transformer g) 33 kV Control, Relay and Protection panels and associated equipments (Simplex type) ii) b i
No No.
0 1
No.
No.
21
No. No.
6 8
No. No.
21 21
Schedule-3
152
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
1 a) b) c)
2 Control and Relay pannel for 33 kV side of 5 MVA transformer Control and Relay pannel for 4 nos of 33 kV feeders
3 No. No. No. No.
4 1 4 6 2
6 (4x5)
Total Price
11
Control and Relay pannel for 6 nos of 33 kV SF6 Circuit Breakers. d) Bus bar PT panel. 4.0 Bus Bar materials (Hardware) 4.1 Bus post insulators and insulator strings, disc insultors, hardware, spacers, conductor(s), bus bar materials, cable trays, Bay MB, clamps, connectors i/c equipment connectors, junction box, Earthwire, earthing materilas, risers, auxilliary earthmat (excl) a) 132 KV "SMT" Type i Transformer bays ii 132 KV main and transfer buses iii Transformer Bus Coupler Bay iv Line bays v Stringing for coupling of both transfer buses b) 33 KV "SMT" Type i Line bays ii Transformer Bay iii Main bus & other
Set Set Set Set Set Set Set Set
1 2 1 2 1 4 2 1
Schedule-3
153
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
1 5.0
2 Suppy installation testing and commissioning of high voltage 3 core XLPE insulated armoued cable. 33KV XLPE cable 120mm size 11KV XLPE cable 70sq mm size Suppy installation testing of cable terminal with epoxy resin based compound and kits. 3 core 33KV XLPE cable 120/95 Sq mm indoor type.
6 (4x5)
Total Price
11
a) b) 6 a) b)
Mtr Mtr
50.00 100.00
Nos Nos No. No. No. S/S S/S S/S
3 3 10 15 15 1 1 1
11KV XLPE cable 70sq mm and termination indoor type 7.0 Fire Protection System i 9 litre water type ii 4.5 kG carbon di-oxide type iii 5 kG dry chemical powder type 8.0 Switch yard and buiding Illumination System i Switchyard lighting ii Street lighting iii D.G.set building illumination
Schedule-3
154
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
6 (4x5)
Total Price
11
9.0 Other Accesssories a) Direct Current Distribution System i Battery Bank of 110 Volts, 200AH of 2V lead acid batteries (10% uncharged spare cells) ii Battery Bank of 50 Volts, 200AH of 2V lead acid batteries (10% uncharged spare cells) iii 110 Volts Float cum Boost Battery Charger iv 50 Volts Float cum Boost Battery Charger b) LT Switchgears system i 415 Volts Main Switch board wwith panel, fuse switch combined unit for LT feeders ii 415 V ACDB iii 110V DCDB iv 50 V DCDB 10.0 100 KVA, 415 Volts D.G.Set with control panel 11.0 Cables with glands, lugs and straight joints etc. a) Power cables (1.1 KV grade XLPE, Alu. Conductor)
Nos Nos Set Set
61 28 1 1
Set Set Set Set Set
1 1 1 1 1
i 3.5 Core of 185 Sq.mm b) Power cables (1.1 KV grade PVC Alu. Conductor) i ii 4 Cores of 6 Sq.mm 2 Cores of 6 Sq.mm
KM
0.20
KM KM
0.50 0.45
Schedule-3
155
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
1 c) i ii iii iv v vi) vii) viii) 12 a) b) 13.0 a) b) c) d) e) e) f) g) h) f)
2 Control cables (1.1 KV grade PVC Copper Conductor) 5 Cores of 2.5 Sq.mm 7 Cores of 2.5 Sq.mm 9 Cores of 2.5 Sq.mm 2 Cores of 4 Sq.mm 4 Cores of 4 Sq.mm 16 Cores of 2.5 Sq.mm 4 Cores of 2.5 Sq.mm 2 Cores of 2.5 Sq.mm LT cable PVC insulated PVC sheathed ground aluminium conductor cable 1.1KV grade. 3 and 1/2 core 95Sq mm 2 core 2.5 Sq mm PLCC equipments 1250 A Line traps Coupling devices HF cables Carrier terminals (for use of speech + telex + data) Carrier terminals (for use of speech + Protection) Protection Coupler EPAX (24/8 lines) 2 wire telephone equipment with necessary connection cable 4 wire telephone equipment with necessary connection cable Testing and maintenance equipments for PLCC
6 (4x5)
Total Price
11
KM KM KM KM KM KM KM KM
0.80 1.00 0.40 0.50 0.45 0.10 0.25 0.20
Mtr Mtr No. No. KM Set Set No. Set No. No. Set
50.00 500.00 2 1 1.50 1 1 1 1 5 3 1
Schedule-3
156
Sl. No.
Description of Item
Unit
Qty.
Unit Ex-works price
Total Exworks price
3 MT
4 8.53
6 (4x5)
Total Price
11
14.0 STEEL FOR FOUNDATION OF EQUIPMENTS STRUCTURES 15.0 FOUNDATION BOLTS FOR EQUIPMENTS STRUCTURES i Foundation bolts Cost of Tawang S/S - (vii)
MT
2.80
Schedule-4
157
Sl. No. 1 A:: 1.0 i. ii. iii. iv. 2.0 3.0 a) b) c) C 1.0
Description of Items 2 132 /33 KV 4 x 5 MVA S/S at Tawang SOIL INVESTIGATION. Detailed soil investigation Sandy soil Mixed soil Clay soil Hard Rock Funishing Bore log data BENCHING. Normal soil Fissured soil Hard rock ERECTION PORTION Erection of various type of towers and its body leg extensions etc. (complete) i/c bolts and nuts, step bolts, hangers, D-shackles etc. and i/c tack welding and supply and application of enamel and Zinc rich paint as required for 132 and 33 kV gantry, 132 145 KV equipments Transformer 1-ph 5 MVA, 132/33 kV Transformers Circuit Breaker 145 kV, 1250 A 31.5 KA, SF6, 3-phase circuit breaker along with support structure
Current Transformer & Potential Transformer
Unit 3
Qty. 4
Unit Rate 5
Total Price 8
Job Job Job Job Job Cum Cum Cum
1 1 1 1 1 1.00 1.00 1.00
MT
105.00
2.0 a i b i c i
No.
No.
145 kV, 150 A, 31.5 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB
145 kV , 1-phase 3 core potential transformer with all accesssories etc as reqd.
ii
No. No.
9 1
d) Isolators i 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator with earth switch ii 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator without earth switch (Tandem)
Set Set
4 8
Schedule-4
158
Sl. Description of Items No. 1 2 e) Lightning Arrestors i 120 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor f) Capacitor Voltage Transformers i 145 kV, 4400 pF, 1-phase,CVT having Three secondaries along with main bus (MB) g) 132 KV Control, Relay and Proctection panel i Control panel for 2 bays (SMT scheme) ii Control panel for Transformer bay iii Circuit Breaker Relay Panel for 132 KV breakers without auto recloser iv Protection panel for 132/33 kV transformer v Main and transfer Bus Protection panel vi Circuit Breaker relay panel for transfer bus coupler vii Line protection panel viii Synchronizing trolley 3.0 33 kV Equipments i) Erection,Testing and commissioning of power transformer 33/11KV, 5MVA, three phase , 50Hz , ONAN cooled delta/star connected with accessories. a i b i c i Transformer 250 kVA, 33/0.433 kV, 3-phase Transformers Circuit Breaker 36 kV, 630 A, 25KA, VCB,3 -Phase circuit breaker along with support structure Current Transformer 36 kV, 300 A, 25 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB
Unit 3
Qty. 4
Unit Rate 5
Total Price 8
No.
6 2 1 3 1 1 1 2 1
No. No.
0 1
No.
No.
21
Schedule-4
159
Sl. Description of Items No. 1 2 d) Isolators i 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator with earth switch ii 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator without earth switch e) Surge Arrestors i 30 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor f) Potential Transformer i 36 kV, 25 KA, 1-phase potential Transformer g) 33 kV Control, Relay and Protection panels and associated equipments (Simplex type) a) Control and Relay pannel for 33 kV side of 5 MVA transformer b) Control and Relay pannel for 4 nos of 33 kV feeders c) Control and Relay pannel for 6 nos of 33 kV SF6 Circuit Breakers. 4.0 Bus Bar materials (Hardware) Bus post insulators and insulator strings, disc insultors, hardware, spacers, conductor(s), bus bar materials, cable trays, Bay MB, clamps, connectors i/c equipment connectors, junction box, Earthwire, earthing materilas, risers, auxilliary earthmat (excl a) 132 KV "SMT" Type i Transformer bays ii 132 KV main and transfer buses iii Transformer Bus Coupler Bay iv Line bays b) 33 KV "SMT" Type i Line bays ii Transformer Bay iii Main bus & other
Unit 3
Qty. 4
Unit Rate 5
Total Price 8
No. No.
6 8
No. No.
21 21
No. No. No.
1 4 6
Set Set Set Set Set Set Set
1 2 1 2 4 2 1
Schedule-4
160
Sl. No. 1 5.0 i ii iii 6.0 i ii iii 7.0 a)
Description of Items 2
Unit 3 No. No. No. S/S S/S S/S
Qty. 4 10 15 15 1 1 1
Unit Rate 5
Total Price 8
Fire Protection System 9 litre water type 4.5 kG carbon di-oxide type 5 kG dry chemical powder type Switch yard and buiding Illumination System Switchyard lighting Street lighting D.G.set building illumination Earthing: Mat earthing for entire switchyard with 65/6mm and 50/5 mm MS flat iron including 32 mm dia MS rod and other accessories as reqd. b) Copper plate earthing of transformer, CB's,RCPs and Battery Charger i/c cost of copper plate and copper strips of 15 m long & other accessories as reqd. c) GI plate earting of Las,CTs,PTS,isolators, gantry tower, ACDB and DCDB i/c cost of GI earth plate and GI strip of 15 mtr long & other accessories as reqd.
Set
40
Set
40
Set 8.0 a) i ii iii iv b) i Other Accesssories Direct Current Distribution System Battery Bank of 110 Volts, 200AH Battery Bank of 50 Volts, 200AH 110 Volts Float cum Boost Battery Charger 50 Volts Float cum Boost Battery Charger LT Switchgears system 415 Volts Main Switch board wwith panel, fuse switch combined unit for LT feeders ii 415 V ACDB iii 110V DCDB iv 50 V DCDB 9.0 100 KVA, 415 Volts D.G.Set with control panel
50
Set Set Set Set
1 1 1 1
Set Set Set Set Set
1 1 1 1 1
Schedule-4
161
Sl. No. 1 10.0 a) i b) i ii c) i ii iii iv v 11.0 a) b) c) d) e) f) g) h) i) j)
Description of Items 2 Cables with glands, lugs and straight joints etc. Power cables (1.1 KV grade XLPE, Alu. Conductor) 3.5 Core of 185 Sq.mm Power cables (1.1 KV grade PVC Alu. Conductor) 4 Cores of 6 Sq.mm 2 Cores of 6 Sq.mm Control cables (1.1 KV grade PVC Copper Conductor) 5 Cores of 2.5 Sq.mm 7 Cores of 2.5 Sq.mm 9 Cores of 2.5 Sq.mm 2 Cores of 4 Sq.mm 4 Cores of 4 Sq.mm PLCC equipments 1250 A Line traps Coupling devices HF cables Carrier terminals (for use of speech + telex + data) Carrier terminals (for use of speech + Protection) Protection Coupler EPAX (24/8 lines) 2 wire telephone equipment with necessary connection cable 4 wire telephone equipment with necessary connection cable Testing and maintenance equipments for PLCC
Unit 3
Qty. 4
Unit Rate 5
Total Price 8
KM KM KM KM KM KM KM KM No. No. KM Set Set No. Set No. No. Set
0.20 0.50 0.45 0.80 1.00 0.40 0.50 0.45 2 1 1.50 1 1 1 1 5 3 1
D CIVIL WORKS a) Foundation for 1-phase, 5 MVA,132/33 V Transformer b) Foundation for 3-phase, 250 KVA,33/0.433 KV Transformer
No. No.
4 1
Schedule-4
162
Sl. Description of Items No. 1 2 c) Excavation works for equipments and gantry towers d) RCC 1:3:6 for foundation works of gantry tower and equipment structures e) RCC 1:2:4 for foundation works of gantry tower and equipment structures f) Plain cement concrete for equipment structures. g) Providing and Installation of 60LB/yd ratio for transformer track (Rail) . h) Installation of ground met consisting of 32 mm dia 3m long ground rods, 100x10mm MS ground conductors and 50x6mm below ground level as per CEA/CBIB standared includig excavation back filling i Ground rod i) Cable trenches i/c all types of crossings i Section 2-2 ii Section 3-3 iii Section 4-4 j) Roads 3.75 m wide (i/c all crossings) k) Water Drainage l) Security wall around the Sub-Station with angle iron post of size 100 x 100 x 8 mm by providing chain link and barbed wire at the top etc as required.
Unit 3 Cum Cum Cum Cum Mtr
Qty. 4 975.00 45.00 225 6.26 24.20
Unit Rate 5
Total Price 8
Nos M M M M M
16 50.00 65.00 80.00 200 300 400 1
RM Job m) Providing and installation of Gate, Gate Pillar & Security Room. n) C/O RCC Control room i/c glazing,false ceiling, internal water supply, internal wiring (concealed conduit), air conditioning etc. (Plinth area: 21 mtr. x 15 mtr.= Sqm 315 sq. mtr. ) o) Full furnished RCC building with bricks wall height of 2.75 Meters as prescribed in the Technical Specifications and approved design & drawing etc. Sqm (i) 5 Man barrack - 4 No. 558 Sq mtr Sqm (ii) Type - I Qtr- 5 No. 175 Sq mtr
315
558 175
Schedule-4
163
Sl. No. 1 (iii) (iv) (v) p) q) i
Description of Items 2 Type - II Qtr- 5 No. 230 Sq mtr Type - III Qtr- 4 No. 220 Sq mtr Type - I VQtr- 1 No. 212 Sq mtr D.G.set building (Plinth area: 5 mtr. x 4 mtr.= 20 sq. mtr. ) Land Development Land development i/c earth cutting / filling, filling with sand, stone aggregate etc.
Unit 3 Sqm Sqm Sqm Sqm
Qty. 4 230 220 212 20
Unit Rate 5
Total Price 8
Job
Erection Cost of Tawang S/S - (viii) Total Cost of S/S (vii) + (viii) = D
GRAND TOTAL COST OF SUPPLY & ERECTION ( A+B+C+D)
Schedule-3 A
CONSTRUCTION OF 132 KV SINGLE CIRCUIT TRANSMISSION LINE FROM KHUPPI TO TAWANG I/C 132/33 KV S/S AT BOMDILA & TAWANG WITH C/O 132 KV BAY (NEEPCO EXTENSION AT KHUPPI)
Specification No: DoP/TED/132 KV/KHUPPI-TWG Bidder's Name & Address: To The Executive Engineer (E) Tawang Electrical Division Department of Power Tawang - 790104
164
Price Break-up of Freight & Insurance Price for supply of individual items for supply of materials for construction of 132 KV Bay at Khuppi & 4 x 5 MVA, 132/33 kV Sub-Station at Bomdila and Tawang (Bidder shall quote prices for the following items. Prices of all accessories, assemblies, components, parts etc. associated with these items are to be included in bidder's quoted prices for all these items). Sl. No. 1 A 1.0 a Description of Items 2 132 KV Line from Khuppi to Tawang SUPPLY OF MATERIALS TOWER STEEL Design, Fabrication, galvanizing and supply of various type of towers and its body extention / unequal leg extensions etc parts complete excluding stubs, bolts and nuts (fasteners) etc. Design, Fabrication, galvanising & supply of Stubs, bolts and nuts i/c templates of various types of towers. ACSR Conductor of size 30/7/3.00 mm ( Panther ) 90 kN Anti fog Disc insulator HARDWARE & ACCESSORIES FOR ACSR CONDUCTOR Manufacturing & Supply of Single tension type hardware fitting with bolted type clamp. Manufacturing and Supply of Midspan compression joints. Manufacturing & Supply of Repair sleeves. Manufacturing & Supply of Vibration damper stock bridge type. Manufacturing & Supply of Anti climbing device Manufacturing & Supply of Hot dip galvanized ground wire 7/3.15 mm dia. Manufacturing & Supply of tower accessories Danger Notice plate Number plate Phase sequence plate (set of 3 pcs) Manufacturing & supply of Armour Rod. Manufacturing & Supply of Bird guard. ACCESSORIES FOR 7/3.15MM EARTH WIRE Manufacturing & Supply of Midspan compression joints. Manufacturing & Supply of Vibration damper stock bridge type. Manufacturing and Supply of Tension clamp. Manufacturing & Supply of Suspension clamp. Total F&I Charge of 132 KV Line from Khuppi to Tawang A 1 (i) 132 KV Bay at Khuppi Material Ex-Works Cost GI STRUCTURES Design, fabrication and supplying of hot dip galvanised latticed type tower made with angle iron including nuts and bolts, spring washers etc. as required for 132 KV and 33 KV tower gantry, 132 KV CTs, PTs LA's and isolators structures. 145 KV EQUIPMENTS Circuit Breaker 145 KV, 1250 A, 31.5KA, SF6,3-Phase circuit breaker along with support structure Current Transforers 145 KV, 150 A, 31.5 KA, 1-Phase, 3-Core current transformer with 120% extended current rating complete in all respects along with associated and common MB Isolators 145 KV, 1250 A, 31.5KV, 3-Phase Horizontal Centre Break isolator with earthswitch. Unit 3 Quantity 4 Freight & Insurance Unit Total Charges Charges 5 6
MT MT KM Nos
1904.89 44.20 472.54 42264
b 2 3 4 i ii iii iv v 5 6 i ii iii iv v 7.0 i ii iii iv
Set Set Set Set Kg kM Nos Nos Set Set Set Nos Nos Nos Nos
3522 530 1600 3522 40000 165.00 2348 587 587 3516 3516 587 531 1056 118
MT
3.00
2 (a) (i) (b)
No.
(i) (c) (i)
No.
No.
Schedule-3 A
Freight & Insurance Unit Total Charges Charges 5 6
165
Sl. No. 1 (ii) (d) (i) (e) (i) (f) (i) (ii) (iii) 3 3.1
Description of Items 2 145 KV, 1250 A, 31.5 KV, 3-Phase Horizontal Centre Break isolator without earthswitch(Tandem) Surge Arrestor 120 KV, 1-Phase, gapless Surge Arrestor complete in all respects with insulating base and surge monitor. Capacitor voltage Transformers 145 KV, 4400PF, 1-, CVT having three secondaries along with Main Bus(MB) 132 KV Control, Ralay and protection panels. Control Panel for 1 bay(SMT Type ) Circuit Breakers Relay Panel for 132 KV Breakers without auto recloser Line protection panel Bus Bar Materials(Hardware) Bus post insulators & insulator strings, Disc Insulators, Hardware, spacers, conductor(s), bus bar materials, cable trays, bay MB clamps, conectors including equipment conectors, junction box, Earthwire, earthing materials, risers, auxiliary earthmat buried/RCC cable trenches / pipes for equipment & lighting all accessories etc. for the following. 132 KV "SMT" Type 132 KV Line bay Cables along with glands, lugs and straight joints etc. Power Cable(1.1 KV grade PVC aluminium conductor) 4 Cores of 6 Sq.mm. 2 Core of 6 Sq.mm. Control Cable (1.1KV Grade PVC Copper Conductor) 5 Cores of 2.5 Sq.mm. 2 Cores of 4 Sq.mm. 4 Cores of 4 Sq.mm. Steel for foundation of equipments structurects of various sizes Foundation Bolts for equipments structures Total F&I Charge of 132 KV Bay at Khuppi 132 /33 KV 4 x 5 MVA S/S at Bomdila MATERIALS EX WORKS COST GI STRUCTURES Design, fabrication and supplying of hot-dip galvanised latticed type tower made with angle iron i/c nuts and bolts, spring washer etc.as required for 132 kV and 33 kv tower gantry, 132 kV CT's, PT's, LA's and isolators structures 145 KV equipments Transformer 1-ph 5 MVA, 132/33 kV Transformers Circuit Breaker 145 kV, 1250 A 31.5 KA, SF6, 3-phase circuit breaker along with support structure Current Transformer & Potential Transformer 145 kV, 150 A, 31.5 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB 145 kV , 1-phase 3 core potential transformer with all accesssories etc as reqd. Isolators 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator with earth switch 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator without earth switch (Tandem) Surge Arrestors 120 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor Capacitor Voltage Transformers 145 kV, 4400 pF, 1-phase,CVT having Three secondaries along with main bus (MB) 132 KV Control, Relay and Proctection panel Control panel for 2 bays (SMT Type ) Control panel for Transformer bay Circuit Breaker Relay Panel for 132 KV breakers without auto recloser
Unit 3 No.
Quantity 4 4
No.
No. Set Set Set
6 2 2 2
(a) (i) 4 (a) (i) (ii) (b) (i) (ii) (iii) (c) (d)
Set
KM KM KM KM KM MT MT
1.00 0.90 1.60 2.00 1.00 2.86 0.52
B 1 i
MT
105.00
2 a i b i c i
No.
No.
No. No.
12 2
ii d) i ii e) i f) i g) i ii iii.
Set Set
6 10
No.
12
No. No. Set No.
9 2 1 4
Schedule-3 A
166
Sl. No. 1 iv. v vi vii viii 3.0 a i b i c i
Description of Items 2 Protection panel for 132/33 kV transformer Main and transfer Bus Protection panel Circuit Breaker relay panel for transfer bus coupler Line protection panel Synchronizing trolley 33 kV Equipments Transformer 250 kVA, 33/0.433 kV, 3-phase Transformers Circuit Breaker 36 kV, 630 A, 25KA, VCB,3 -Phase circuit breaker along with support structure Current Transformer 36 kV, 300 A, 25 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB Isolators 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator with earth switch 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator without earth switch Surge Arrestors 30 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor Potential Transformer 36 kV, 25 KA, 1-phase potential Transformer 33 kV Control, Relay and Protection panels and associated equipments (Simplex type) Control and Relay pannel for 33 kV side of 5 MVA transformer Control and Relay pannel for 4 nos of 33 kV feeders Control and Relay pannel for 6 nos of 33 kV SF6 Circuit Breakers. Bus Bar materials (Hardware) Bus post insulators and insulator strings, disc insultors, hardware, spacers, conductor(s), bus bar materials, cable trays, Bay MB, clamps, connectors i/c equipment connectors, junction box, Earthwire, earthing materilas, risers, auxilliary earthmat (excluding main earth mat), buried / RCC cable trenches / pipes for equipments and lighting all accessories for the following. 132 KV "SMT" Type Transformer bays 132 KV main and transfer buses Transformer Bus Coupler Bay Line bays Stringing for coupling of both transfer buses 33 KV "SMT" Type Line bays Transformer Bay Main bus & other Fire Protection System 9 litre water type 4.5 kG carbon di-oxide type 5 kG dry chemical powder type Switch yard and buiding Illumination System Switchyard lighting Street lighting D.G.set building illumination Other Accesssories Direct Current Distribution System Battery Bank of 110 Volts, 200AH of 2V lead acid batteries (10% uncharged spare cells) Battery Bank of 50 Volts, 200AH of 2 V lead acid batteries (10% uncharged spare cells) 110 Volts Float cum Boost Battery Charger 50 Volts Float cum Boost Battery Charger LT Switchgears system 415 Volts Main Switch board with panel, fuse switch combined unit for LT feeders 415 V ACDB 110V DCDB 50 V DCDB
Unit 3 No. Set Set Set. No.
Quantity 4 1 1 1 2 1
No.
No.
No.
21
d) i ii e) i f) i g) a) b) c) 4.0 4.1
No. No.
6 8
No. No.
21 21
No. No. No.
1 4 6
a) i ii iii. iv. v b) i ii iii. 5.0 i ii iii. 6.0 i ii iii. 7.0 a) i ii iii. iv b) i ii iii. iv
Set Set Set Set Set Set Set Set No. No. No. S/S S/S S/S
1 2 1 2 1 4 2 1 10 15 15 1 1 1
Nos Nos Set Set
61 28 1 1
Set Set Set Set
1 1 1 1
Schedule-3 A
167
Sl. No. 1 8 9 a) i b) i ii c) i ii iii. iv v 10 a) b) c) d) e) e) f) g) h) f) 11 12 i
Description of Items 2 100 KVA, 415 Volts D.G.Set with control panel Cables with glands, lugs and straight joints etc. Power cables (1.1 KV grade XLPE, Alu. Conductor) 3.5 Core of 185 Sq.mm Power cables (1.1 KV grade PVC Alu. Conductor) 4 Cores of 6 Sq.mm 2 Cores of 6 Sq.mm Control cables (1.1 KV grade PVC Copper Conductor) 5 Cores of 2.5 Sq.mm 7 Cores of 2.5 Sq.mm 9 Cores of 2.5 Sq.mm 2 Cores of 4 Sq.mm 4 Cores of 4 Sq.mm PLCC equipments 1250 A Line traps Coupling devices HF cables Carrier terminals (for use of speech + telex + data) Carrier terminals (for use of speech + Protection) Protection Coupler EPAX (24/8 lines) 2 wire telephone equipment with necessary connection cable 4 wire telephone equipment with necessary connection cable Testing and maintenance equipments for PLCC STEEL FOR FOUNDATION OF EQUIPMENTS STRUCTURES FOUNDATION BOLTS FOR EQUIPMENTS STRUCTURES Foundation bolts Total F&I Charge of Bomdila S/S
Unit 3 Set
Quantity 4 1
KM KM KM KM KM KM KM KM No. No. KM Set Set No. Set No. No. Set MT MT
0.20 0.50 0.45 0.80 1.00 0.40 0.50 0.45 2 1 1.50 1 1 1 1 5 3 1 8.53 2.80
B 1
2 a i b i c i
ii d) i ii e) i f) i g) i ii iii. iv. v vi vii viii
132 /33 KV 4 x 5 MVA S/S at Tawang MATERIALS EX WORKS COST GI STRUCTURES Design, fabrication and supplying of hot-dip galvanised latticed type tower made with angle iron i/c nuts and bolts, spring washer etc.as required for 132 kV and 33 kv tower gantry, 132 kV CT's, MT PT's, LA's and isolators structures 145 KV equipments Transformer No. 1-ph 5 MVA, 132/33 kV Transformers Circuit Breaker 145 kV, 1250 A 31.5 KA, SF6, 3-phase circuit breaker along with No. support structure Current Transformer & Potential Transformer 145 kV, 150 A, 31.5 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated No. and common MB No. 145 kV , 1-phase 3 core potential transformer with all accesssories etc as reqd. Isolators 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator with Set earth switch 145 kV, 1250 A, 31.5 KA, 3-phase horizontal Centre Break Isolator Set without earth switch (Tandem) Lightning Arrestors 120 kV, 1-phase, gapless Surge arrestor complete in all respect with No. insulating base and surge monitor Capacitor Voltage Transformers 145 kV, 4400 pF, 1-phase,CVT having Three secondaries along with No. main bus (MB) 132 KV Control, Relay and Proctection panel No. Control panel for 2 bays (SMT scheme) Set Control panel for Transformer bay Circuit Breaker Relay Panel for 132 KV breakers without auto recloser Protection panel for 132/33 kV transformer Main and transfer Bus Protection panel Circuit Breaker relay panel for transfer bus coupler Line protection panel Synchronizing trolley No. No. Set Set Set. No.
105.00
9 1
4 8
6 2 1 4 1 2 1 2 1
Schedule-3 A
168
Sl. No. 1 ix) 3.0 a i)
Description of Items 2 Surge counter to be installed in the incoming feeder with accessories etc. complete. 33 kV Equipments Transformer Suppy installation testing and commissioning of power transformer 33/11KV, 5MVA, three phase , 50Hz , ONAN cooled delta/star connected with accessories. 250 kVA, 33/0.433 kV, 3-phase Transformers Circuit Breaker 36 kV, 630 A, 25KA, VCB,3 -Phase circuit breaker along with support structure Current Transformer 36 kV, 300 A, 25 KA, 1-phase 3 core current transformer with 120% extended current rating complete in all respect along with associated and common MB Isolators 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator with earth switch 36 kV, 630 A, 25 KA, 3-phase horizontal double Break Isolator without earth switch Lightning Arrestors 30 kV, 1-phase, gapless Surge arrestor complete in all respect with insulating base and surge monitor Potential Transformer 36 kV, 25 KA, 1-phase potential Transformer 33 kV Control, Relay and Protection panels and associated equipments (Simplex type) Control and Relay pannel for 33 kV side of 5 MVA transformer Control and Relay pannel for 4 nos of 33 kV feeders Control and Relay pannel for 6 nos of 33 kV SF6 Circuit Breakers. Bus bar PT panel. Bus Bar materials (Hardware) Bus post insulators and insulator strings, disc insultors, hardware, spacers, conductor(s), bus bar materials, cable trays, Bay MB, clamps, connectors i/c equipment connectors, junction box, Earthwire, earthing materilas, risers, auxilliary earthmat (excl) 132 KV "SMT" Type Transformer bays 132 KV main and transfer buses Transformer Bus Coupler Bay Line bays Stringing for coupling of both transfer buses 33 KV "SMT" Type Line bays Transformer Bay Main bus & other Suppy installation testing and commissioning of high voltage 3 core XLPE insulated armoued cable. 33KV XLPE cable 120mm size 11KV XLPE cable 70sq mm size Suppy installation testing of cable terminal with epoxy resin based compound and kits. 3 core 33KV XLPE cable 120/95 Sq mm indoor type. 11KV XLPE cable 70sq mm and termination indoor type Fire Protection System 9 litre water type 4.5 kG carbon di-oxide type 5 kG dry chemical powder type Switch yard and buiding Illumination System Switchyard lighting Street lighting D.G.set building illumination Other Accesssories Direct Current Distribution System Battery Bank of 110 Volts, 200AH of 2V lead acid batteries (10% uncharged spare cells) Battery Bank of 50 Volts, 200AH of 2V lead acid batteries (10% uncharged spare cells)
Unit 3 Set
Quantity 4 1
ii) b i c i
No No.
0 1
No.
No.
21
d) i ii e) i f) i g) a) b) c) d) 4.0 4.1
No. No.
6.00 8
No. No.
21 21
No. No. No. No.
1 4 6 2
a) i ii iii iv v b) i ii iii 5.0 a) b) 6 a) b) 7 i ii iii 8.0 i ii iii 9.0 a) i ii
Set Set Set Set Set Set Set Set
1 2 1 2 1 4 2 1
Mtr Mtr
50.00 100.00
Nos Nos No. No. No. S/S S/S S/S
3 3 10 15 15 1 1 1
Nos Nos
61 28
Schedule-3 A
169
Sl. No. 1 iii iv b) i ii iii iv 10 11 a) i b) i ii c) i ii iii iv v vi) vii) viii) 12 a) b) 13 a) b) c) d) e) e) f) g) h) f) 14 15 i
Description of Items 2 110 Volts Float cum Boost Battery Charger 50 Volts Float cum Boost Battery Charger LT Switchgears system 415 Volts Main Switch board wwith panel, fuse switch combined unit for LT feeders 415 V ACDB 110V DCDB 50 V DCDB 100 KVA, 415 Volts D.G.Set with control panel Cables with glands, lugs and straight joints etc. Power cables (1.1 KV grade XLPE, Alu. Conductor) 3.5 Core of 185 Sq.mm Power cables (1.1 KV grade PVC Alu. Conductor) 4 Cores of 6 Sq.mm 2 Cores of 6 Sq.mm Control cables (1.1 KV grade PVC Copper Conductor) 5 Cores of 2.5 Sq.mm 7 Cores of 2.5 Sq.mm 9 Cores of 2.5 Sq.mm 2 Cores of 4 Sq.mm 4 Cores of 4 Sq.mm 16 Cores of 2.5 Sq.mm 4 Cores of 2.5 Sq.mm 2 Cores of 2.5 Sq.mm LT cable PVC insulated PVC sheathed ground aluminium conductor cable 1.1KV grade. 3 and 1/2 core 95Sq mm 2 core 2.5 Sq mm PLCC equipments 1250 A Line traps Coupling devices HF cables Carrier terminals (for use of speech + telex + data) Carrier terminals (for use of speech + Protection) Protection Coupler EPAX (24/8 lines) 2 wire telephone equipment with necessary connection cable 4 wire telephone equipment with necessary connection cable Testing and maintenance equipments for PLCC STEEL FOR FOUNDATION OF EQUIPMENTS STRUCTURES FOUNDATION BOLTS FOR EQUIPMENTS STRUCTURES Foundation bolts Total F&I Charge of Tawang S/S Total F&I Charge of 132 KV Bay & S/S Grand Total F&I Charge of 132 KV Line & S/S
Unit 3 Set Set
Quantity 4 1 1
Set Set Set Set Set
1 1 1 1 1
KM KM KM KM KM KM KM KM KM KM KM
0 0.50 0.45 0.80 1.00 0.4 0.5 0.45 0.1 0.25 0.20
Mtr Mtr No. No. KM Set Set No. Set No. No. Set MT MT
50.00 500.00 2 1 1.5 1 1 1 1 5 3 1 8.53 2.8
Specification No: DoP/TED/132 KV/KHUPPI-TWG
170
Schedule-5 (Bought-Out & Sub-Contracted Items) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790104
We hereby furnish the details of the items/sub-assemblies amounting to more than 10% of our bid price; we propose to buy for the purpose of subject package. Sl. Item Description Qty. Proposed Source of Supply No. to be bought/ Sub-contracted 1. ....................................... ........................................... .................................. 2. 3. 4. 5. 6. 7. 8. ....................................... ....................................... ....................................... ....................................... ....................................... ....................................... ....................................... ........................................... .................................. ........................................... .................................. ........................................... .................................. ........................................... .................................. ........................................... .................................. ........................................... .................................. ........................................... ..................................
Date: Place:
(Signature): .................................................. (Printed Name): ........................................... (Designation): .............................................. (Common Seal)............................................
Part-III (Vol. 1/2)
Section-Schedule
171
Schedule-6 (Work Completion Schedule) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790104
We hereby declare that the following Work Completion Schedule shall be followed by us for the subject package. Sl. No. Description of Work Period in Months (from the date of LOA) 1. Completion of detailed engineering 2. 3. Procurement of raw materials Manufacturing a) b) 4. Commencement Completion
Shipments a) b) Commencement Completion
5. 6.
Establishment of site office Erection a) b) Commencement Completion
7.
Testing & Pre-commissioning a) b) Commencement Completion
8.
Commissioning
Date: Place: (Signature)................................................... (Printed Name)............................................ (Designation)............................................... (Common Seal)............................................
Part-III (Vol. 1/2)
Section-Schedule
172
Schedule-7 (Guarantee Declaration) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790 104
Dear Sirs, We declare that the ratings and performance figures of the Power Transformer, Circuit Breakers, Distribution Transformer and other equipments furnished by us under this Package are guaranteed. We further declare that in the event of any deficiencies in meeting the guarantees in respect of the characteristics mentioned below as established after conducting the factory test, you may at your discretion, reject or accept the equipment after assessing the liquidated damages as specified in relevant clause of Bid Document. Guaranteed Maximum losses at rated output (kW)/unit Differential Differential Cooler Loss Copper Iron
Equipment
1. 2. 3. 4. 5.
5 MVA, 132/33 kV Power Transformer. 250 kVA, 33/0.415 kV Distribution Transformer
-----------------
-----------------
--------------------
-----------------
-----------------
NA
Date: Place:
(Signature): ..................................................... (Printed Name): .............................................. (Designation): ................................................. (Common Seal): ..............................................
Part-III (Vol. 1/2)
Section-Schedule
173
Schedule-8
(List of Special Tools & Tackles) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790 104
We are furnishing below the list of special tools & tackles for installation & commissioning of the equipments for subject package. The prices for these tools & tackles are already included in the lump sum bid price. Sl. No. Equipment Item Description Unit Qty.
Date: Place:
Part-III (Vol. 1/2)
Section-Schedule
174
Schedule-9
(Check List) Bidder's Name & Addres To The Executive Engneer (E) Tawang Electrical Division Department of Power Tawang - 790 104
Sl. No. Item Description Reference Declaration (Strike out whichever is not applicable) 1. 2. 3. 4. 1. Summary Price Proposal Schedule-1 Part-III (Vol. ) Schedule filled in Yes/No 2. 3. 4. 5. 6. 7. 8. Summary Price Components Schedule filled in Price Components Schedule filled in Brought out and SubContracted Item filled in Work Completion Schedule filled in Guarantee Declaration Schedule filled in List of Special tools & Tackles schedule Check List Schedule-2 Part-III (Vol. ) Yes/No Schedule-3 & 4 of Part-III (Vol. ) Schedule -5 of Part-III (Vol. ) Schedule-6 of Part-III (Vol. ) Schedule-7 of Part-III (Vol. ) Schedule-8 of Part-III (Vol. ) Schedule-9 of Part-III (Vol. ) Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No
Date: Place:
END OF SCHEDULE
Part-III (Vol. 1/2)
Section-Schedule
175
GURANTEED TECHNICAL PARTICULARS
(GTP)
Part-III (Vol. 1/2)
Section-GTP
176
GUARANTEED TECHNICAL PARTICULARS (GTP)
CONTENTS
Sr. No. Description Page No. 177 182 186 188 190 192 194 195 197 198 199 200 203 204 205 213 214 216
Transformer Circuit Breakers Current Transformer Capacitor Voltage Transformer Isolators Surge Arrester LT Transformer 1.1 kV Power & Control Cables LT Switch Gear Lightning System Battery & Battery Charger Insulators, Hardware & Accessories Air Conditioning System Fire Protection System Control & Relay Panel Power Line Carrier Communication Power Line Carrier Terminal for Speech & Data Transmission GTP 132 KV Line Materials
Part-III (Vol. 1/2)
Section-GTP
177
TRANSFORMER
... (Bidders Name) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Manufacturers Name & Address Rating (MVA) Voltage ratio (kV) Winding connection Vector group Number of phases Frequency (Hz) Type of cooling Rating available at different cooling (%) Impedance Data a) Positive sequence impedance between HV-LV at 75 C with 100% rating at i) ii) iii) Principal tap Maximum tap Minimum tap i) -----------------------ii) -----------------------iii) -----------------------b) -----------------------11. -----------------------a) -----------------------b) -----------------------c) -----------------------12. -----------------------a) -----------------------b) -----------------------c) -----------------------d) -----------------------13. -----------------------a) -----------------------b) -----------------------1. ----------------------2. ----------------------3. -----------------------4. -----------------------5. -----------------------6. -----------------------7. -----------------------8. -----------------------9. -----------------------10. ------------------------
b) Zero sequence impedance at principal tap 11. Guaranteed losses a) b) c) 12. Maximum no load loss on principal tap at rated voltage and frequency (KW) Maximum load loss at rated current at principal tap at 75 C (KW) Maximum cooler loss (K/W)
Cooling Equipment Details a) b) c) d) Number of radiator bank and its rating as % of transformer cooling Type of mounting Material Thickness
13.
Thermal Data a) b) Temperature rise in top oil over an ambient of 50 C (C) Temperature rise in winding by resistance measurement method over an ambient of 50 C. (C) Thermal time constant (Hours)
c) 14.
c) -----------------------14. ------------------------
Withstand time for three phase short circuit at terminals (secs.)
Part-III (Vol. 1/2)
Section-GTP: Transformer
178
15.
Over excitation withstand time (secs.) i) ii) iii) 125% 140 % 150 %
15. ---------------------i) ---------------------ii) ---------------------iii) ---------------------16. ---------------------a) ---------------------i) ---------------------ii) ---------------------iii) ---------------------iv) ---------------------v) ---------------------vi) ----------------------b) -----------------------i) -----------------------ii) ----------------------iii) ---------------------iv) ----------------------v) ----------------------vi) ----------------------17. ---------------------18. a) ----------------------b) -----------------------c) -----------------------d) ----------------------e) ----------------------f) ------------------------g) -----------------------h) -----------------------i ) -----------------------19. ---------------------a) ----------------------i) ------------------------ii) -----------------------
16.
Bushings a) High Voltage i) ii) iii) iv) v) vi) b) Manufacturer Type Total creepage distance (mm) Protected creepage distance (mm) Mounting Rated current (Amps)
Low Voltage i) ii) iii) iv) v) vi) Manufacturer Type Total creepage distance (mm) Protected creepage distance (mm) Mounting Rated current (Amps)
17. 18.
Proposed method of transformer transportation Tap changing Equipment rating a) b) c) d) e) f) g) h) i) Voltage class & current Number of steps Range Step voltage Type Rated voltage of drive motor (volts) No. of revolutions to complete one step Time to complete one step on manual/auto operation (secs.) Power required (kW)
19.
Insulation Level a) HV Winding i) ii) iii) Lightning impulse withstand voltage (kVp) Switching Surge withstand voltage (kVp)
Power Frequency withstand voltage (kV rms) iii) ----------------------
Part-III (Vol. 1/2)
179
b)
LV Winding i) ii) Lightning impulse withstand voltage (kVp)
b) ----------------------i) -------------------------
Power Frequency withstand voltage (kV rms) ii) ----------------------c) ----------------------i) -----------------------ii) ------------------------
c)
HV Bushings i) ii) iii) Lightning impulse withstand voltage (kVp) Switching Surge withstand voltage (kVp)
Power Frequency withstand voltage (kV rms) iii) ---------------------d) -----------------------i) -------------------------
d)
LV Bushings i) ii) Lightning impulse withstand voltage (kVp)
Power Frequency withstand voltage (kV rms) ii) -----------------------e) ----------------------i) ------------------------
e)
Neutral Bushings i) ii) Lightning impulse withstand voltage (kVp)
Power Frequency withstand voltage (kV rms) ii) -----------------------20. ---------------------a) ----------------------b) ----------------------c) ----------------------d) ----------------------e) ----------------------21. ---------------------a) ----------------------b) ----------------------c) ----------------------d) ----------------------e) ----------------------f) -----------------------g) ----------------------h) ----------------------i) ------------------------j) -----------------------22. ---------------------23. ---------------------a) -----------------------i) -----------------------ii) ----------------------b) -----------------------
20.
Approximate dimensions a) b) c) d) e) Tank (lxbxh) (mm) Overall dimensions with coolers (lxbxh) Shipping dimensions (lxbxh) Height for un-tanking (mm) Dimensions of largest (mm) package (lxbxh)
21.
Weights of Transformer Components a) b) c) d) e) f) g) h) i) j) Core (kg) Windings (Kg) Insulation (Kg) Tank and fittings (Kg) Oil (Kg) Untanking weight (heaviest piece) (Kg) Total weight (Kg) Weight of heaviest package (Kg) Total shipping weight (Kg) Parts detached for transport (furnish list)
22. 23.
Permissible overload (% of rating and time) Clearances a) Minimum clearance between phases and phase to earth i) ii) b) In oil (mm) In air (mm)
Minimum clearance of HV winding to tank in oil (mm)
Part-III (Vol. 1/2)
180
c) d) e) f) 24.
Minimum clearance of HV winding of earth in oil (mm) Clearance between Core and Coil (mm) Clearance between coils (mm) Clearance between neutral to ground in air (mm)
c) ----------------------d) ----------------------e) ---------------------f) -----------------------24. ---------------------a) ----------------------b) ----------------------25. ---------------------a) -----------------------b) ----------------------26.a) -------------------b) ----------------------c) ----------------------27 a) -------------------b) ----------------------28. ----------------------
Conservator a) b) Total volume (Litres) Volume between highest and lowest levels
25.
Capacitance Values a) b) HV to earth (pF) LV to earth (pF) Type of oil preservation Material of air cell Continuous temp. withstand capability of the air cell No. of pressure relief device provided Operating pressure of pressure relief device
26.
a) b) c)
27.
a) b) Oil a)
28.
Quality of Oil
Before Before First commissioning Filling i) -------------------------------ii) -------------------------------iii) ------------------------------iv) ------------------------------v) -------------------------------c) -------------------------------29. ------------------------------
i) ii) iii) iv) v) b) 29. Core a) b) c) d) e) f) g)
Moisture Content (ppm) Max. tan-delta value (at 90 C.) Resistivity (ohm-cm) Breakdown Strength (kV) Interfacial tension at 20 C (min.)
Standards applicable
Type of construction (core/shell) Net core area (mm ) Core material and grade used Type of joint between core and yoke Thickness of stamping (mm) Percentage silicon content (%) Maximum flux density in core at rated frequency and at i) ii) iii) 90% voltage (wb/sq.m) 100% voltage (wb/sq.m) 110% voltage (wb/sq.m)
2
a) -------------------------------b) -------------------------------c) -------------------------------d) -------------------------------e) -------------------------------f) -------------------------------g) -------------------------------i) -------------------------------ii) -------------------------------iii) ------------------------------Section-GTP: Transformer
Part-III (Vol. 1/2)
181
30.
Winding a) b) i) ii) c) Type of winding Current density at rated load HV (A/sq.mm) LV (A/sq. mm) Conductor area i) ii) d) HV (A/sq.mm) LV (A/sq.mm)
30. -----------------------------a) -------------------------------b) -------------------------------i) -------------------------------ii) -------------------------------c) -------------------------------i) -------------------------------ii) -------------------------------d) -------------------------------i) -------------------------------ii) ------------------------------e) -------------------------------f) -------------------------------i) -------------------------------ii) -------------------------------iii) ------------------------------g) -------------------------------h) -------------------------------i) -------------------------------ii) --------------------------------
Maximum current density under short circuit i) ii) HV (A/sq.mm) LV (A/sq. mm)
e) f)
Magnetizing inrush current (Amps) No load current (Amps) at rated frequency and at i) ii) iii) 90% voltage (wb/sq.m) 100% voltage (wb/sq.m) 110% voltage (wb/sq.m)
g) h)
Magnetising current at rated frequency and at rated voltage Leakage reactance i) i) HV (ohms) LV (ohms)
i)
Leakage resistance i) ii) HV (ohms) LV (ohms) i) -------------------------------ii) -------------------------------31. -----------------------------Tank cover Conventional/Bell Type Material Approximate thickness of i) ii) iii) Sides (mm) Bottom (mm) Cover (mm) a) -------------------------------b) -------------------------------c) -------------------------------i) -------------------------------ii) -------------------------------iii) ------------------------------32. -----------------------------a) -------------------------------b) -------------------------------33. -----------------------------a) -------------------------------b) --------------------------------
31.
Tank a) b) c)
32.
Vaccum withstand capability of a) b) Main tank (torr) Radiators and accessories (torr)
33.
Pressure withstanding capability of a) b) Main tank (torr) Radiators and accessories (torr)
Part-III (Vol. 1/2)
182
34.
Gasket a) b) Material Temperature withstand capability (C)
34. -----------------------------a) -------------------------------b) -------------------------------35. -----------------------------36. -----------------------------37. -----------------------------a) -------------------------------Manufacturer Range Accuracy i) -------------------------------ii) -------------------------------iii) -------------------------------
35. 36. 37.
Minimum draw bar pull required to move the transformer on level track (kg) Size of filter hose (mm) Temperature Indicators a) OTI i) ii) iii) b) WTI i) ii) iii) c) Manufacturer Range Accuracy
i) -------------------------------ii) -------------------------------iii) ------------------------------
RWTI i) ii) iii) iv) Manufacturer Range Accuracy Auxiliary supply used i) -------------------------------ii) -------------------------------iii) ------------------------------iv) -------------------------------
... (Bidders Signature)
Part-III (Vol. 1/2)
183
CIRCUIT BREAKER
.. (Bidders Name) 1. 2.a.) b) 3. 4. 5. 6. 7. 8. 9. 10. i) ii) .. iii) . 11. i) ... ii) 12.i)
1. 2.
Name of the Manufacturer & Address a) b) Type of Circuit Breaker Type of tank (Live/Dead)
3. 4. 5. 6. 7. 8. 9. 10.
Manufacturer's type designation Standards Applicable Rated Voltage (kV rms) Rated continuous current at design temperature of 50 C (Amps) Rated frequency (Hz) Number of breaks per poles Whether 3 pole or single pole unit Rated short circuit breaking current i) ii) iii) Symmetrical component at highest system voltage (kA) DC Component (%) Asymmetrical breaking current at highest system voltage (kA)
11.
Rated Making Capacity i) ii) at higher rated voltage (kAp) at lower rated voltage (kAp) Maximum total break time under any duty condition for any current up to rated breaking current with limiting conditions of voltage and pressure (ms) Rated break time as per IEC condition (ms) Closing time (ms) Maximum opening time under any condition with limiting voltage and pressures (ms)
12.
i)
ii) iii) iv)
ii) iii) .. iv)
v) 13. 14. 15. 16. 17.
Maximum close open time under any (ms) v) condition with limiting voltages and pressures. 13. .. 14. 15. 16. 17.i)
Section-GTP: Circuit Breaker
First pole to clear factor Short time current rating for 1 second (kA) Rated operating duty Maximum line charging breaking current with temporary over voltage upto 1.4 p.u (kA) i) Maximum period between closing of first contact & last contact in a pole (ms)
Part-III (Vol. 1/2)
184
ii) 18. 19. 20. 21.
Maximum pole discrepancy (ms)
ii) 18. .. 19. .. 20. .. 21. i) ii) .. 22.
Small fault current breaking capacity (Amps) Maximum temperature rise for main contacts over design ambient temperature of 50C (C) Rated pressure and limits of pressure of extinguishing medium (kg/sq.cm) Minimum dead time for i) ii) Three phase reclosing (ms) Single phase reclosing (ms)
22.
Dielectric Withstand Voltage of Complete Breaker i) One minute dry & wet power frequency withstand voltage a) b) ii)
Between live terminal and ground (kV rms)a) Between terminals with breaker contacts b) Open (kV rms)
1.2/50 micro second impulse withstand test voltage. a) b) Between live terminals and ground (kVp) a) Between terminals with breaker contacts b) Open (kVp)
iii)
250/2500 micro second switching surge withstand test voltage a) b) Between live terminals and ground (kVp) a) Between terminals with breaker contacts b) Open (kVp) iv) .. v)
iv) v) vi)
Corona extinction voltage Maximum radio interference voltage at 1.1 Ur/root 3 Total creepage distance a) b) To ground Between terminals
a) b) 23.
23.
Operating Mechanism a) Type of operating mechanism for i) ii) Closing Opening
i) ii) 24. a) b)
24.
SF6 Circuit Breakers a) b) Quantity of SF6 per pole at rated Pressure (cu. m) Guaranteed maximum leakage rate per year (kg/sq. cm)
Part-III (Vol. 1/2)
185
c) d) e) 25.
Rated pressure of SF6 in operating chamber (kg/sq. cm) Limits of pressure at which breaker operates correctly (kg/sq. cm) Mimimum time interval between each Make / break operation (ms)
c) d) e) 25. a) b)
General a) b) c) d) e) f) Weight of complete 3 phase breaker for foundation design (kg) Impact loading Foundation design
Seismic level for which Breaker is designed (g) c) Min. safety clearance from earthed objects Noise level in Base of the breaker (dB) and upto 50m distance from base Minimum clearance in air i) ii) iii) between live parts (mm) live parts to earth (mm) live parts to ground level (mm) d) e) f) i) . ii) iii) .. g) i) ii) iii) iv) 26. a) YES / NO YES / NO YES / NO YES / NO
g)
Compliance to technical specification w.r.t parameters specified for i) ii) iii) iv) Control Cabinet Bushing/support Insulator Terminal connector. SF6 Gas
26.
Detailed Literature a) Whether similar equipment are type tested as per IEC/IS and are in successful operation for atleast 2 (two) years (If yes, furnish type test reports). Furnish data on capabilities of circuit breaker in terms of time and number of operations at duties ranging from 100 % fault currents to load currents of the lowest possible value without requiring any maintenance or checks. Furnish details of effect of non simultaneity between contacts within a pole or between poles and also show how it is covered in the guaranteed rated break time. Overall General Arrangement drawing of circuit breaker is to be enclosed.
b)
b)
c)
c)
d)
d) .. -------------------------------(Bidders Signature)
Part-III (Vol. 1/2)
186
CURRENT TRANSFORMER
... (Bidders Name)
1.
Name and address of manufacturer Standards applicable Type of CT (Live or Dead Tank Type) Rated frequency (Hz) Rated voltage Ur (kV) Rated current i) ii) Rated continuous current (Amps) Rated extended primary current (Amps)
1 .. 2. . 3. . 4. . 5. . 6. i) . ii) . 7. . 8. 9. .... 10. .. 11. ... 12. 13. 14. 15. 16. 17. 18. . 19. .. 20. .. 21. .. 22. .. 23. .. 24. .. 25. ..
2. 3. 4. 5. 6.
7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Short time thermal current withstand for 1 sec (kA) Dynamic current withstand (kAp) 1.2/50 micro sec impulse withstand voltage (kVp) 250/2500 micro sec switching surge withstand voltage (dry and wet) (kVp) One minute dry and wet power frequency withstand voltage (kV rms) No. of primary winding No. of cores per CT Current ratio (for all cores) Output Burden (for all cores) Accuracy class (for all cores) Knee point voltage at different taps (V) (for all cores) Maximum exciting current at Knee point voltage at different ratios (for all cores) (mA) Secondary winding resistance for all ratios and cores. Instrument security factor at different ratios for metering cores Radio interference voltage at 1.1 Ur/3 at 1.0 MHz (Micro Volts) Corona extinction voltage (kV rms) Partial discharge level (PC) Standard to which oil conforms generally Total weight (kg)
Part-III (Vol. 1/2)
Section-GTP: Current Transformer
187
26.
Confirm whether similar equipment are type tested and in successful operation for at least 2 years ratios (for all cores) (Ohms) (Furnish type test report) Overall General arrangement drawing of CT is to be enclosed.
26. .
27.
27. .
---------------------------------(Bidders Signature)
Part-III (Vol. 1/2)
Section-GTP: Current Transformer
188
CAPACITOR VOLTAGE TRANSFORMERS

(Bidders Name) 1.
Name and address of Manufacturer Manufacturer's type designation Standards applicable Rated primary voltage Ur (kV) Rated secondary voltages (kV) Number of secondaries Rated frequency (Hz) Rated output of each secondary winding (VA) Total simultaneous burden (VA) Rated total thermal burden (VA) Highest system voltage (kV) Rated voltage factor and corresponding rated time Accuracy class of each secondary winding Capacitance i. ii. of high voltage capacitor (pF) of intermediate voltage capacitor (pF)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. i) ii) 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. YES / NO
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.
Carrier frequency coupling (pF) Band width (kHz) One minute power frequency test voltage of secondary winding (kV rms) One minute power frequency test voltage of H.F. terminal (kV rms) One minute power frequency test voltage of capacitor (kV rms) (dry & wet) 1.2/50 micro sec impulse withstand test voltage of Capacitor (kVp) Corona extinction voltage (kV rms) Max. Radio Interference voltage at 1.1 Ur/ Root 3 at 1.0 MHz (Micro volts) Total weight (kg) Quantity of oil (litres) Whether CVTs are hermetically sealed. If so. Furnish arrangement of sealing. Whether similar equipment is type tested as per IEC 186 and in successful operation for at least.
Part-III (Vol. 1/2)
Section-GTP: Capacitor Voltage Transformers
189
2 (two) years (Furnish type test report) 31. Overall General Arrangement drawing of CVT is to be enclosed. 31.
.. (Bidders Signature)
Part-III (Vol. 1/2)
Section-GTP: Capacitor Voltage Transformers
SPECIFICATION NO:- DoP/TED//132 KV/KHUPPI-TWG
190
ISOLATORS
(Bidders Name) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Name and address of the Manufacturer Manufacturers type designation Standard applicable Rated Voltage, Ur Rated Current under site conditions at 50 C ambient (Amps) Rated frequency (Hz) Number of poles Whether all 3 poles are ganged /mechanically coupled. Pole to pole spacing (mm) Rated short time current of isolator and Earth switch for 1(one) second and dynamic current Opening time of isolator and earth switch Closing time of isolator and earth switch Rated mechanical terminal load Dielectric withstand capacity of completely assembled isolator/earth switch One minute dry power frequency withstand test voltage i) ii) 16. against ground (kVrms) across isolating distance (kVrms) 1. 2. 3. 4. 5. 6. 7. 8. Yes/No
9. 10.
11. 12. 13. 14. 15.
11. 12. 13. 14. 15. i) ii) 16. i) ii) 17. 18. 19. i) ii) 20.
1.2/50 micro sec impulse withstand test voltage i) ii) against ground (kVp) across isolating distance (kVp)
17. 18. 19.
Corona Extinction voltage (kVrms) Radio interference level at 1.1 Ur/ root 3 (in micro volts) at 1 MHz Operating Mechanism i) ii) For main blades For earth switches
20.
Confirm whether similar equipment are type tested as per IEC / IS and are in successful operation for at least 2 (two) years( furnish type test report)
Part-III (Vol. 1/2)
Section: GTP: Isolators
SPECIFICATION NO:- DoP/TED//132 KV/KHUPPI-TWG
191
21.
Overall General Arrangement drawing of Isolator/ Earth switch is to be enclosed.
21.
(Bidders Signature)
Part-III (Vol. 1/2)
Section: GTP: Isolators
192
SURGE ARRESTER
.. (Bidders Name) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Name and address of Manufacturer Manufacturers type designation Applicable standards Arrester class and type Rated arrester voltage (kV) Rated system voltage (kV) Maximum continuous operating voltage (COV) at 50 C ambient temperature (kV) Nominal discharge current (8/20 micro sec. wave) (kA) Minimum discharge capability (kJ / kV) a) b) 11. a) b) 12. 13. 14. Maximum residual voltage at nominal discharge current (kV peak) Minimum residual voltage at nominal discharge current (kV peak) Maximum residual voltage at 50 % nominal discharge current (kV peak) Maximum residual voltage at 200% nominal discharge current (kV peak) 1. 2. 3. 4. .. 5. 6. 7. 8. 9. 10.a) 10.b) 11.a) 11.b) 12. 13. 14. a) b) 15. 16. 17. 18. 19. 20. 21.
Steep fronted wave residual voltage at 1 KA (kV peak) Long duration discharge class Impulse current withstand a) b) High current short duration (4/10 micro-sec wave) in kV peak Low current long duration (2000 micro sec.)
15. 16. 17. 18. 19. 20. 21.
Current for pressure relief test (kA) Pressure relief class (as per IEC 99) One minute power frequency (dry) withstand voltage of arrester housing (kV rms) Lightning Impulse withstand test voltage of arrester housing with 1.2/50 micro sec wave (kVp) Total creepage distance of whole arrester housing (mm) Cantilever strength of complete arrester (N) Total height of the arrestor (mm)
Part-III (Vol. 1/2)
Section-GTP: -Surge Arrestor
193
22. 23. 24. 25. 26.
Total weight of the arrestor (Kg) Maximum radio interference voltage at 1.1 Ur/ root 3 voltage at 1 MHz (microvolts) Partial discharge at 1.05 continuous operating Voltage (pC) Minimum prospective symmetrical fault current (kArms) ZnO block details a) Confirm whether equipment type tested with offered type of ZnO block
22. 23. 24. 25. 26 a) 27
27.
Confirm whether similar equipment are type tested as per IEC/IS or equivalent standard and are in successful operation for at least two years. Overall General Arrangement drawing of Surge arrester is to enclosed.
28.
28.
(Bidders Signature)
Part-III (Vol. 1/2)
Section-GTP: -Surge Arrestor
194
LT TRANSFORMER
.. (Bidders Name) 1. 2. 3. 4. 5. 6. 7. 8. 9. i) . ii) 10. a) b) c) 11. a) b) 12. a ) b) 13. .. 14. a) i. ..... ii.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Name & Address of Manufacturer Voltage Ratio Rating Standards applicable Rated frequency Number of phases Vector Group Type of cooling Tap changing equipment i) Type ii) No. of steps & tap range
10. a) b) c) 11.
Positive sequence Impedance at 75 C with 100% rating at Principal tap Maximum tap Minimum tap Temperature rise over an ambient of 50 C a) Top oil C
b) 12.
Windings (by resistance measurement method) C Guaranteed losses a) Maximum no load loss on principal tap at rated voltage and frequency.(kW) b) Maximum load loss at rated current at principal tap at 75 C(kW)
13. 14.
Withstand time for three phase short circuit at terminals (secs.) Insulation level a) Full wave lightning impulse withstanding i. HV Winding (kVp) ii. LV Winding (kVp)
15. 16.
Confirm whether similar equipment are type tested 15. and are in successful operation for atleast two years. Confirm whether similar equipment is tested for dynamic short circuit withstand capability. (furnish details) 16. ..
Part-III (Vol. 1/2) Section-GTP: LT Transformer
195
1.1 KV POWER & CONTROL CABLES

.. (Bidders Name) 1.
Manufacturer's name and address Type of cable Applicable standards Rated Voltage (Volts) Suitable for earthed or unearthed system? Continuous current rating when laid in air in an ambient temp. of 50 C and for maximum conductor temp. of 70 C for PVC cable Short Circuit Capacity i. ii. iii. iv. Short Circuit Current (kA rms) Duration of short circuit. (Sec.) Conductor temp. allowed for the short circuit duty (C) Formula relating short circuit current (rms) and duration (Sec.)
1. ...... 2. ...... 3. ...... 4. ...... 5. ...... 6. ......
2. 3. 4. 5. 6.
7.
7. i. ...... ii. ...... iii. ...... iv. ...... 8. i. ..... ii. ...... iii. ...... iv. ...... 9. i. ...... ii. ...... 10. i. ...... ii. ...... iii. ...... 11. i. ...... ii. ...... iii. ...... iv. ...... v. ......
8.
Conductor i. ii. iii. iv. Material (Copper or aluminium) Grade Normal cross section area (Sq. mm) Number and diameter of wire (No./mm)
9.
Insulation i. ii. Composition of insulation Nominal thickness of insulation (mm)
10.
Inner Sheath i. ii. iii. Material Calculated diameter over the laid up cores, (mm) Thickness of Sheath (minimum) mm
11.
Armour i.
ii.
Type and material of armour (wire/strip) Calculated diameter under armour (mm) Nominal diameter of round armour wire Nominal size of wire/strip Short circuit capacity armour along with formulae
iii. iv. v.
Part-III (Vol. 1/2)
Section-GTP: 1.1 kV Power & Control Cables
196
vi. 12.
Maximum D.C. resistance at 20 C
vi. ...... 12. i. ...... ii. ...... 13. ...... 14. ...... i. ..... ii. ..... 15. ...... 16.
Outer Sheath i. ii. Material Calculated diameter under sheath
13. 14.
Safe pulling force when pulled by pulling eye on the conductor (kG) Test Voltage i. ii. High Voltage test voltage (kV) Water immersion test voltage (kV)
15. 16.
Minimum bending radius permissible Confirm that are all the cables approved by BIS or other international standard organizations and marked as such Whether the cables are type tested as per IS/ international Standard.
17.
17.
Yes/No
Part-III (Vol. 1/2)
Section-GTP: 1.1 kV Power & Control Cables
197
LT SWITCHGEAR
.. (Bidders Name) 1. 2. Manufacturers Name & Address Confirm whether Manufacturers have supplied 50 Nos. draw out Air circuit breaker Panels out of which 5 Nos. are with CT and relaying scheme. Confirm whether Manufacturers have supplied 50 Nos. MCC panels similar to the offered panels. Confirm whether 100 nos. (at least) circuit breakers of the make and type being offered are already been operating satisfactorily. Rated short circuit current Symmetrical short circuit withstand current at rated voltage of switchgear cubicle Peak short circuit withstand current Degree of protection Breaker/MCC/AC & DC Distribution Cubicles Busbar chamber Standard height, width & depth of typical panel Circuit Breaker Panel MCC panel AC/DC Distribution Board Width of cable alley Confirm whether equipment offered are from manufacturer and they are type tested as per IS/ International standard and are in successful operation for two years. 1. 2.
3.
3.
4.
5. 5.1
5. 5.1.
5.2 6. 6.1 6.2 6.3 7. 7.1 7.2 7.3 8. 9.
5.2. 6. 6.1. 6.2 6.3 7. 7.1 7.2 7.3 8. 9
Part-III (Vol. 1/2)
Section-GTP: LT Switchgear
198
LIGHTING SYSTEM
.. (Bidders Name) A. Lighting Fixtures & Accessories 1. Manufacturer's Name and address a) b) 2 Fixtures Accessories A. 1. a). b). 2. a). b). B. 1. 2. C.
Applicable Standards for a) b) Fixtures Accessories
B.
Conduits & Accessories (For each type & size) 1. 2. Manufacturer's name and address Applicable standard
C.
Junction Boxes (For each type & size) 1. 2. Manufacturer's name and address Degree of protection for enclosure.
1. 2. D. 1. 2. E. 1. 2. 3. 4. F. 1. 2. G. 1. 2. 3.
D.
Lighting Panels (For each type & size) 1. 2. Manufacturer's name and address Degree of Protection
E.
Lighting Transformer 1. 2. 3. 4. Manufacturer's name and address Rating (KVA) Standards Applicable Degree of protection for enclosure
F.
Lighting poles 1. 2. Manufacturer's name and address Dimensions
G.
Lighting Wires 1. 2. 3. Manufacturer's name and address Voltage grade Cross section of conductor
Part-III (Vol. 1/2)
Section-GTP: Lighting System
199
BATTERY & BATTERY CHARGERS

. (Bidders Name) A: 1. 2. BATTERIES Manufacturers Name and address Confirm whether Manufacturers have manufactured, tested, supplied, installed and commissioned batteries of 220 V, 600AH capacity similar to be the offered batteries and are in operation for at least 2 (Two) years. Type of battery Capacity of battery at 27 C Confirm whether batteries are type tested as per IS Recommended value of float charging voltage 1. ------------------------------2. -------------------------------
3. 4. 5. 6.
3. -------------------------------4. -------------------------------5. 6. --------------------------------
BATTERIES CHARGERS 1. 2. Manufacturers Name and address Confirm whether Manufacturers have manufactured, tested, supplied, installed and commissioned battery Chargers to 10 Kw capacity similar to the offered battery Chargers. Capacity of battery chargers (AH) Charger rate/output current Float charging mode (A) Boost Charging Mode (A) Ripple content in output voltage (%) Confirm whether battery chargers are type tested as per specification. 1. -------------------------------2. --------------------------------
3. 4 5. 6. 7. 8.
3. -------------------------------4. -------------------------------5. -------------------------------6. --------------------------------7. -------------------------------8. ---------------------------------
. (Bidders Signature)
Part-III (Vol. 1/2)
Section-GTP: Battery & Battery Chargers
200
INSULATORS, HARDWARE & ACCESSORIES

(Bidders Name)
A.
INSULATOR STRINGS 1. Manufacturers name and address 2. 3. 4. Applicable Standards No. of Units per String Weight a) b) 5. Each Disc (Kg) Complete string (Kg)
1. ... .. 2. ..... 3. . .. 4. (a) . ... (b) . .. 5. (a) . .. (b) . .. 6.
Creepage Distance a) b) Each Disc (mm) Complete String (mm)
6.
Power Frequency Withstand Voltage of the complete string with corona control ring i. ii. Dry (KV rms) Wet (KV rms)
i. . . .. ii. . ..
7.
Lightning Impulse (dry) Withstand 7. . .. Voltage of the complete string for both positive and negative peaks. (kVp) Switching Surge withstand Voltage of the complete string with corona control (Wet) (kVp) Power Frequency Puncture Withstand Voltage (Dry & Wet) of each Disc (KV rms) Electro Mechanical Strength of each Disc (Kg) 8. . ..
8.
9.
9. . ..
10. 11.
10. ..
Minimum Corona extinction (kV rms) 11. .. voltage level of the complete string with corona control ring (Dry Condition)
12. RIV level of the complete (micro-volts) 12. .. String with corona control ring at 1 MHz when subjected to a test voltage. 13. Confirm whether string type tested with 13. offered disc insulator as per IS B. INSULATOR 1. 2. 3. Manufacturers Name and Address Applicable Standards Ultimate Strength a) Complete assembly (kg)
Part-III (Vol. 1/2)
1. . .. 2. . .. 3. a) . ..
Section-GTP: Insulators
201
b) Suspension/drop clamp (kg) C. TUBULAR BUS CONDUCTOR 1. 2. 3. 5. Manufacturers name and address Applicable Standards Material Size of Tubular Bus i. Standard pipe size- IPS (mm) ii. Outside diameter (mm) iii. Tolerance on outside iv. Thickness (mm) v. Tolerance on Thickness 6. 7. 8. 9. 10. 11. D. D.C. Resistance of 20 C Current rating at ambient temperature of 50 C Short circuit current rating for 1 sec. duration (kA) Radio Interference at rated voltage (micro volts ) Weight (kg/m) Final allowable tubular bus conductor temperature due to short circuit
b) . .........
1. . 2. .. 3. .. 5. i. ii. iii. .. iv. .. v. 6. 7. 8. 9. 10. .. 11. ..
MARSHALLING KIOSK 1. 2. 3. Manufacturer's Name and address Thickness of sheet steel (mm) Degree of protection provided 1. 2. 3.
BUS POST INSULATORS 1. 3. 4. 5. 6. 7. Manufacturers name and address Applicable Standards No. of Units per Stack Whether corona ring provided or not Diameter (mm) Creepage Distance a. b. 8. Total (mm) Protected (mm) 1. .. 3. . ... 4. . ... 5. . ... 6. . ... 7. a. .. b. .... 8. . .. a. i. . ... ii. . ..........
Section-GTP: Insulators
Power Frequency withstand Voltage of Insulator a. One complete stack i. Dry (kV rms) ii. Wet (kV rms)
Part-III (Vol. 1/2)
202
9. 10.
1.2/50 micro sec. impulse withstand Voltage on complete stack (kVp) 250/2500 micro second switching Surge withstand voltage a. One complete stack i. Dry (kV peak) ii. Wet (kV peak)
9. . .... 10. .... a. i. . ... ii. . ......... 11. i. . .... ii. . ....... 12. ....
11.
Radio interference Voltage of complete stack i. ii. Test Voltage (kVrms) Radio interference voltage (micro volt)
12. 13. 15. 16. 17.
Weight-of complete stack (Kg)
Cantilever Strength of Complete Stack 13. . ... Torsional Strength (Kg. m) Compression Strength (Kg) 15. . .. 16. . ..
Confirm whether type tested as per IS/ 17. IEC and are in successful operation for at least 2 (Two) years.
ACSR CONDUCTOR 1. 2. 3. 4. 5. 6. 7. Name and address of manufacturer Standards Applicable Name & Type of Conductor No. & diameter of various strands 1. . 2. . 3. . 4. .
Overall diameter of the conductor (mm) 5. . Current rating capacity of the Conductor at 75 C (Amps) Confirm whether type tested as per IS 6. . 7..
GALVANISED STEEL EARTH WIRE 1. 2. Name and Address of the Manufacturer 1. . Standards Applicable 2. . 3.1 . 3.2 . 3.3 . 3.4 . 3.5 .
(Bidders Signature)
Part-III (Vol. 1/2) Section-GTP: Insulators
3.1 UTS of the Earth wire (kN) 3.2 Lay length of outer steel layer (mm) 3.3 3.4 DC Resistance of earth wire at 20 C (ohms) Standard length of earth wire in the drum (metres)
3.5 Diameter of earth wire
SPECIFICATION NO:- DoP/TED/132 KVKHUPPI-TWG
203
AIR CONDITIONING SYSTEM

.. (Bidders Name) 1. 2. Name and Address of Air Conditioning system supplier Number of A/C system executed by the supplier and duration of successful operation as on date of bid opening. Window type air conditioning Unit a) b) c) d) e) Make & Model Nominal Capacity (TR/Kcal/Hr.) Nominal Air quantity (cu. m/hr -CFM) Number of units offered Guaranteed power consumption for each unit 1. 2.
3.
3. a) . b) c) . d) e).
(Bidders Signature)
Part-III (Vol. 1/2)
Section-GTP: Air Conditioning System
204
FIRE PROTECTION SYSTEM

. (Bidders Name)
1. 2.
Name and Address of the fire protection system supplier Number of Fire Protection System executed by the supplier and duration of successful operation as on date of bid opening for each type fire protection system a) b) Automatic HVW/MVW spray type fire protection system Automatic Hydrant type fire protection system
1. 2.
a) b) 3 ..
3.
Confirm that fire protection system supplier have designed, erected, tested & commissioned fire protection system of each type as in 2(a), (b) & (c) above as per the recommendations of TAC of India or any other international reputed authority like (FOC, London or NFPA, USA et) and are in successful operation for at least two years.
(Bidders Signature)
Part-III (Vol. 1/2)
Section-GTP: Fire Protection System
205
CONTROL AND RELAY PANELS

(Bidders Name)
1. 2. 3. 4.
Name and address of Manufacturer of panels Manufacturer's type and designation Type of construction (Simplex/duplex) Thickness of sheet steel (i) Front (ii) Back (iii) Sides Degree of protection Name of the manufacturer of relays DC voltage of the relays Make and Model of static (0.2 accuracy Class type) energy meters Confirm whether offered manufacturer of C&R panels and protective relays have tested commissioned & they are in successful operation for at least two years in 400 kV system.
1. 2... 3. . 4. i) . ii) ... iii) . 5. .. 6. .. 7. .. 8. .. 9. ..
5. 6. 7. 8. 9.
TRANSMISSION LINE PROTECTION Numerical Distance protection Scheme -I 1. 2. 3. Name and address of Manufacturer Manufacturer's type and designation Switched or Non- switched type (is it with separate measurements for single/three phase faults) Setting range of offset feature Whether the relay is having self monitoring feature Whether relay is compatible for PLCC equipment and can be used for Permissive Under reach/over reach /Blocking scheme etc Suitable for single and three phase Trip? Type of shaped characteristic No of tripping contacts with making capacity of 30 amp for 0.2 seconds In case 16 contacts as per above clause are not available with the distance relay offered, type of tripping relay being offered Maximum operating time for at 50% of the reach setting of 2 ohms and 10/20 ohms (with CVT) including all trip relays ,if any 1.... 2 3
4.. 5. 6.
4 5 6
7. 8. 9. 10
7 8 9.... 10..
11
11..
Part-III (Vol. 1/2)
Section-GTP: Control & Relay Panel
206
(Bidder is required to enclose isochronic curve with CVT on line) a) b) c) 12 at SIR=4 at SIR=15, (3 phase faults) at SIR=15 (other faults) a).. b).. c).. 12.
IDMT earth fault relay Meeting Normal Inverse Characteristics as per IEC 60253 is being offered ass built in feature for 220 KV lines If no, type of IDMT relay being offered Built in features offered with the relay (YES/NO) a) b) c) d) Disturbance recorder Fault locator Over voltage (one stage only) Auto reclose along with Dead line charging and check synchronisng
13. 14.
13. 14. a)...... b).. c).. d)..
Numerical Distance protection Scheme -II 1. 2. 3. Name and address of Manufacturer Manufacturer's type and designation Switched or Non- switched type (is it with separate measurements for single/three phase faults) Setting range of offset feature Whether the relay is having self monitoring feature Whether relay is compatible for PLCC equipment and can be used for Permissive Under reach/over reach /Blocking scheme etc Suitable for single and three phase Trip? Type of shaped characteristic No of tripping contacts with making Capacity of 30 amp for 0.2 seconds In case 16 contacts as per above Clause are not available with the distance relay offered, type of tripping relay being offered Maximum operating time for at 50% of the reach setting of 2 ohms and 10/20 ohms (with CVT) including all trip relays, if any (Bidder is required to enclose isochronic curve with CVT on line) a) b) c) at SIR=4 at SIR=15, (3 phase faults) at SIR=15 (other faults) 1... 2 3
4.. 5. 6.
4 5 6
7. 8. 9. 10.
7 8 9. 10..
11.
11..
a). b). c).

Part-III (Vol. 1/2)
207
12.
13. 14.
IDMT earth fault relay Meeting Normal Inverse Characteristics as per IEC: 60253 is being offered ass built in feature for 220 KV lines If no, type of IDMT relay being offered Built in features offered with the relay (YES/NO) a) b) c) d) Disturbance recorder Fault locator Over voltage (one stage only) Auto reclose along with Dead line charging and check synchronisng
12
13 14. a). b). c).. d).
BACKUP DIRECTIONAL OVER CURRENT AND EARTH FAULT PROTECTION SCHEME 1. 2. 3. 4. 5. 6. 7. 8. 9. Name and address of Manufacturer Manufacturers type and designation Three over current and one E/F elements are whether independent or composite unit Type of relay (Elecro mechanical/static/Numerical) Directional sensitivity Whether characteristic conform to IEC: 255-3 Over current unit setting range inverse time Earth fault unit setting range inverse time VT Fuse failure relay/feature included for alarm 1.. 2.. 3. 4.. 5.. 6.. 7.. 8.. 9..
LINE OVER VOLTAGE PROTECTION RELAY 1. 2. 3. 4. 5. 6. 7. 8. Name and address of Manufacturer Manufacturers type and designation Type of relay (Elecro mechanical/static/Numerical) Operation indicator provided? Operating time Resetting time Whether monitors all three phases? Built in feature of Main1/Main 2 distance relay is offered . If so, which stage is offered as built in 1.. 2.. 3.. 4.. 5.. 6.. 7.. 8...
DISTANCE TO FAULT LOCATOR 1. 2. 3. 4. Name and address of Manufacturer Manufacturers type and designation Built in feature of Main1/Main 2 distance relay is offered Maximum registering time 1. 2. 3. 4.
Part-III (Vol. 1/2)
208
5. 6. 7. 8.
Whether direct display unit provided? Whether both phase to phase fault and phase to earth fault measuring units included? Whether On-Line type Accuracy for the typical conditions defined under technical specification
5. 6. 7. 8.
DISTURBANCE RECORDER a. 1. 2. 3. 4. 7. 6. 7. 8. 9. 10. 11. 12. b. 1 2 3 4 Acquisition unit Name and address of Manufacturer Manufacturer's type and designation No. of analogue channels No. of digital recording channels Built in feature of Main1/Main 2 distance relay is offered Pre-fault memory (milli seconds) Post fault memory (seconds) Total storage memory in seconds Sampling Frequency Resolution of the event channels (ms) Time display present? Data out put in COMTRADE is available Evaluation Unit Name and address of Manufacturer Manufacturer's type and designation No of acquisition unit that can be connected to One evaluation unit Technical Parameters of evaluation unit A Processor and speed B RAM and hard disk capacity C Additional facilities D Details of printer 5. Details of power supply arrangement for Acquisition unit (including printer) 1 2 3.... 4 A B C D 6. 1 2 3 4 5 6 7 8 9 10.. 11.. 12..
AUTO RECLOSE RELAY 1. 2. 3. 4. Name and address of Manufacturer Manufacturer's type and designation Electromechanical /static/numerical Auto reclose relay along with Dead line charging and check synchronisng relay (For 132 KV lines) offered as a part of distance relay 1 2. .. 3 4
Part-III (Vol. 1/2)
209
5. 6. 7. 8.
Suitable for single and three phase? Single phase dead time setting Range Three phase dead time setting range Reclaim time setting range
5 6 7 8
TRANSFORMER PROTECTION Differential relay 1. 2. 3. 4. 5. 6. 7. 8. 9. Name and address of Manufacturer Manufacturer's type and designation Second harmonic restraint provided Whether three instantaneous units provided Operating Current setting range Bias setting range Operating time at 5X setting current Resetting time 1.. 2.. 3.. 4.. 5.. 6.. 7.. 8.. 9..
How ratio / phase angle corrections are being done(inter posing transformer/internal feature in the relay) Restricted Earth Fault Protection 1. Name and address of Manufacturer 2. 3. Manufacturer's type and designation Operating time at 2 x setting
1.. 2.. 3..
Over Fluxing relays 1. 2. 3. 4. 5. 6. Name and address of Manufacturer Manufacturer's type and designation Whether inverse time operating characteristics Maximum operating time Accuracy of operating time Resetting time 1.. 2.. 5.. 6.. 7.. 8..
Directional O/C and E/F relays 1. 2. 3. 4. 5. Name and address of Manufacturer Manufacturer's type and designation Whether Characteristic will confirm to IEC: 255-3 Directional sensitivity Over current unit setting range a) b) 6. a) Inverse time High set Inverse time 1.. 2.. 4.. 5.. 6 a) . b) . 7 a) ..
Earth fault unit setting range
Part-III (Vol. 1/2)
210
b)
High set
b) ..
GENERAL PROTECTION /MONITORING EQUIPMENT Trip Circuit Supervision relay 1. Name and address of Manufacturer 2. Manufacturer's type and designation 3. 4. Whether pre-closing and post closing supervision provided? Time delay 1.. 2.. 3.. 4..
High Speed Trip Relays 1. 2. 3. Name and address of Manufacturer Manufacturer's type and designation Contact ratings a) b) c) Make and carry continuously Make and carry for 0.5 sec. Break i) ii) 4. Resistive load Inductive load (With L/R=40milli sec.) 1.. 2.. 3. a) . b) .. c) .. i) .. ii) .. 4.. 5.. 6.. 1.. 2.. 3.. 4.. 5 a) .. b) ..
Operating time at rated voltage (maximum)
5. Resetting time 6. Whether supervisory relays included Local breaker back-up protection 1. Name and address of Manufacturer 2. 3. 4. 5. Manufacturer's type and designation Operating time Resetting time Setting ranges a) b) Current Time
Bus bar Protection 1. 2. 3. 4. 5. 6. 7. Name and address of Manufacturer Manufacturer's type and designation Type of relay (Elecro mechanical/static/Numerical) Principle of operation (Biased/High impedance) Operating time Resetting time Setting ranges (i) Current 1.. 2.. 3.. 4.. 5.. 6.. 7. i) ..
Part-III (Vol. 1/2)
211
(ii) 8.
Time
ii) .. 8..
Whether will it cause tripping for the differential current below the load current of heavily loaded feeder (Bidder shall submit application check for the same)
CONTROL PANEL EQUIPMENT Recording Meter for voltage 1. 2. 3. 4. 5. 6. Name of Manufacturer Manufacturer's type and designation Accuracy class Full span response time Is it strip type recorder /digital type If it is digital type i) ii) iii) No of channels being used Whether time tagged information is available Whether EMC/EMI compatibility is tested 1.. 2.. 3.. 4.. 5.. 6. i) .. ii) .. iii) ..
Recording Meter for frequency 1. 2. 3. 4. 5. 6. Name of Manufacturer Manufacturer's type and designation Accuracy class Full span response time Is it strip type recorder /digital type If it is digital type i) ii) iii) No of channels being used Whether time tagged information is available Whether EMC/EMI compatibility is tested 1.. 2.. 3.. 4.. 5.. 6 (i) .. (ii) .. (iii) ..
Terminal Block 1. 2. 3. 4. 5 Name of Manufacturer Manufacturer's type and designation Rated current Rated voltage Minimum no. of conductors of area 2.5 mm2 suitable for connection. (i) All circuits except C.T. Circuits 1. .. 2.. 3.. 4.. 5.. (i) .. (ii) ..
(ii) C.T. Circuits Control Switches 1. 2. 3. Name of Manufacturer Manufacturer's type and designation Number of positions provided (Trip/Normal after trip, close, normal after close)
1. 2. 3.
Part-III (Vol. 1/2)
212
4. 5. 6.
No. of contacts Type of handle Rating of contacts a) b) c) d) Make and carry continuously Make and carry for 0.5 sec. Break resistive load, in Amps (d.c.) Break inductive load with L/R=40 m. sec in Amps. (d.c).
4.. 5.. 6. a) .. b) .. c) .. d) .. 7
7.
Life of switch in terms of million mechanical operations
Push Buttons 1. 2. 3. 4. Name of Manufacturer Manufacturer's type and designation Contact ratings No. of contacts 1 2 3 4
Annunciators 1. 2. 3. 4. 5. Make Type & Model No. Static/electromechanical No of lamps per window Lamps a) b) 6. 7. Voltage Wattage 1 2 3 4 5 (a) .. (b) .. 7. 8.
Minimum duration of impulse for initiating contact in millisecond Type of reset self/manual
Part-III (Vol. 1/2)
213
POWER LINE CARRIER COMMUNICATION (PLCC)

. (Bidders Name) A. COUPLING DEVICE (Phase to Phase Type) 1. 2. 3. 4. 5. 6. 7. Name of Manufacturer and Country Type, Model and Catalogue Number Nominal primary side impedance Nominal secondary side impedance Composite loss with in pass-band Return loss with in pass-band Available Bandwidth (with 4400/6600/8800 pF CVTS) Nominal Peak Envelope Power (with Distortion and Inter modulation Products 80 dB down) Maximum number of PLC terminals that can be connected in parallel: a) 20 W (PEP) PLC terminals b) 40 W (PEP)PLC terminals c) 100 W(PEP) PLC terminals 10 Power Frequency Impedance between primary terminal and Earth Terminals of Coupling Device. 11 No of H.F. terminals provided for carrier equipment connection HIGH FREQUENCY CABLE 1. 2. 3. 4. 5. Name of Manufacturer and country Type, Model and Catalogue no. Applicable standards Maximum attenuation per km of cable for carrier Frequency range 40 to 500 kHz Maximum loop resistance/km of cable 1... 2.. 3.. 4.. 5.. 1... 2... 3... 4... 5... 6... 7...
8.
8..
9.
9... a).. b).. c).. 10.
11.
Part-III (Vol. 1/2)
Section-GTP: PLCC
214
POWER LINE CARRIER TERMINAL FOR SPEECH AND DATA TRANSMISSION OR NETWORK PROTECTION 1. 2. 3. 4. 5. 6. 7. 8. Name of Manufacturer and country Type, Model and Catalogue no. Type of Modulation Mode of transmission Carrier Frequency Range Nominal carrier frequency band in either direction of transmission Return loss within the nominal carrier frequency band Effectively transmitted V.F. band a) For speech b) For telephone signaling 9. Return Loss within the effectively transmitted voice frequency band 9... 1... 2... 3... 4... 5... 6... 7.. 8...
10 Maximum H.F Amplifier output with single /Multiple 10. tone keying (Peak Envelope Power) 11 Nominal carrier frequency power (peak envelop power) at output terminals. 11.
VF TRANSMISSION TERMINAL FOR NETWORK PROTECTION SIGNALS (PROTECTION COUPLER) 1. 2. 3. 4. 5. Name of Manufacturer and country Type, Model and catalogue number Whether equipment works on frequency shift principle of coded signal principle Whether Equipment is suitable for independently protecting two circuits Frequencies used in the equipment for transmission of signal for un-coded signal transmission a) Guard frequency 1.. 2.. 3.. 4... 5.. a) .. b) .. c) .. d) .. 6.. 7.. a). b).
b) Working frequency (Trip system-I) c) Working frequency (Trip system-II) d) Working frequency (Trip system (I&II) 6. 7. Criteria used for command transmission Transmission time corresponding to telegraph speed for transmission on PLCC channel of coded signal a) 600 Bds. b) 400 Bds.
Part-III (Vol. 1/2)
Section-GTP: PLCC
215
c) 200 Bds. 8. 9. Mode of transmission of guard signal Whether equipment is suitable for Direct circuit breaker tripping.
c) 8.. 9.. 10. 11.
10 Whether loop test is possible 11 Whether the equipment is suitable for transmitting and receiving more than two independent commands (please furnish details) 12 Whether receiver design provides protection against false tripping from random noise LINE TRAPS 1. 2. 3. 4. 5. 6. 7. Name of Manufacturer and country Type & Model System Voltage Rating Continuous current rating at 50C ambient Continuous current rating at 65C Maximum Symmetrical short circuit current rating for 1 sec. duration Asymmetric peak value of first half wave of rated short time current Rated Inductance Blocking Range
12.
1... 2... 3... 4... 5... 6... 7...
8. 9.
8... 9... 10. 11. 12.
10 Minimum Guaranteed Resistive component in blocking frequency range 11 Details of protection of capacitors and coils against voltage surges. Indicate type of protective device. 12 Rated voltage of the arrestor (protective device)
ELECTRONIC PRIVATE AUTOMATIC EXCHANGE (EPAX) 1. 2. 3. 4. Name of manufacturer Type and model Capacity of exchange (Subscribers & trunk lines) Whether compatible to both i.e PLCC & DOT lines for communication 1.. 2.. 3.. 4..
Part-III (Vol. 1/2)
Section-GTP: PLCC
SPECTIFICATION NO: DoP/TED/132 KV/KHUPPI-TWG
216
(1) 132 KV TOWER
Sl. No. 1 1.1 1.2
Description
Particular
1.3 1.4 1.5
132 kV Tower Furnished? Bidders Experience Yes/No Stringing Procedure Yes/No The details of the stringing procedure proposed the details and all other necessary tools and plants the Bidder wishes to deploy for timely completion of the work. Standard of which fabrication, Galvanizing etc., will conform Quality of zinc used for galvanizing (Purity) % Cement consumption in for Different type of Concrete Mixture a) For M 15 concrete (1:2:4 nominal mix.) (kG/m3) b) For M 10 concrete (1:3:6 nominal mix.) (kG/m3) c) For M 1:5 random rubble stone masonry (kG/m3)
Da t e : Place:
(Signature) (Printed Name). (Designation) (Common Seal).
Part-III (1/2)
Section-GTP
217
(2) ACSR CONDUCTOR
(PANTHER)
Sl. No. 1 1.1 Parameters Particulars of Raw Materials Aluminium a) Minimum Purity of aluminium b) Maximum Copper Content Steel Wires/Rods a) Carbon b) Manganese c) Phosphorous d) Sulphur e) Silicon Zinc a) Minimum purity of zinc Aluminium Strands after stranding Diameter a) Nominal b) Maximum c) Minimum Minimum Breaking load of strand Maximum resistance of 1 m length of conductor Steel Strands after stranding Diameter a) Nominal b) Maximum c) Minimum Galvanizing a) Minimum weight of zinc coating per uncoated wire surface b) Minimum number of one minutes dips galvanized strand can withstand in the Preece Test c) Minimum number of twists to be withstood in torsion test Unit Values
% % % % % % % % % mm mm mm kN Ohm
1.2
1.3 2 2.1
2.2 2.3 3 3.1
mm mm mm gm No. No.
when tested on a gauge length of 100 times diameter of wire

5 5.1 5.2 ACSR Stranded Conductor UTS of Conductor Lay ratio of conductor a) Outer Steel layer b) 12 Wire aluminium layer c) 18 Wire aluminium layer d) 24 Wire aluminium layer D.C. resistance of conductor at 20 deg. C Standard length of conductor Maximum length of conductor that can be Tolerance on standard length of conductor Direction of lay for outside layer Linear mass of the conductor a) Standard b) Minimum c) Maximum No. of cold pressure butt welding available at works. kN Max.
5.3 5.4 5.5 5.6 6 6.1
Ohm/k M M Meter %
kG/kM kG/kM kG/kM No.
Part-III (1/2)
Section-GTP
218
(3) SUSPENSION HARDWARE FITTINGS

Sl. No. 1 2 3 4 5 6 7 8 a) b) c) d) e) f) Description Unit Value guaranteed by the Bidder
g) h) 9 a) b) c) d) e) 10 a) b) c) 11 12 13 Da t e : Place:
Name of Manufacturer Address of Manufacturer Dimensioned drawings of insulator strings (with disc insulators) enclosed Detailed dimensional drawings of all hardware components enclosed Material of all components indicated Material magnetic power loss of suspension assembly at Watts conductor current of 350 amperes. Slipping strength of suspension Assembly (clamp torque kN Vs slip curve shall be enclosed) Particulars of standard/AGS performed armour rod set for suspension assembly No. of rods per set No. Direction of lay Overall length after mm Actual length of each rod along its helix mm Diameter of each rod mm Tolerance in mm i) Diameter of each rod mm ii) Length of each rod mm iii) Difference of length between the longest and shortest mm rod in a set. Type of aluminium alloy used for manufacture of PA rod se t UTs of each rod kG/mm2 Particulars of Elastomer (For AGS Clamp only) Contractor of elastomer Type of elastomer Shore hardness of elastomer Temperature range for which elastomer is designed Moulded on insert Yes/No UTS of string hardware Single Suspension kN/kG Single tension kN/kG Double Tension kN/kG Purity of Zinc used for galvanizing % Min No. of dips in standard precee test the ferrous parts No can withstand Design calculations for yoke plates enclosed Yes/No
Yes/No Yes/No Yes/No
Standard AGS
(Signature)............... (Printed Name) (Designation).. (Common Seal)...
Part-III (1/2)
Section-GTP
219
(4) SINGLE TENSION TYPE HARDWARE FITTINGS

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Name of Manufacturer Address of Manufacturer Dimensioned drawings of insulator strings (with disc insulators) enclosed Detailed dimensional drawings of all hardware components enclosed Material of all components indicated in drawings Electrical resistance of dead end assembly Slip strength of dead end assembly Total weight of tension assembly UTS of string hardware Purity of Zinc used for galvanizing Min No. of dips in standard precee test the ferrous parts can withstand Design calculations for yoke plates enclosed Unit Value guaranteed by the Bidder
Yes/No Yes/No Yes/No Ohms kN kG kN/kG % No. Yes/No
Da t e : Place:
Part-III (1/2)
Section-GTP
220
(5) DOUBLE TENSION TYPE HARDWARE FITTINGS

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Name of Manufacturer Address of Manufacturer Dimensioned drawings of insulator strings (with disc insulators) enclosed Detailed dimensional drawings of all hardware components enclosed Material of all components indicated in drawings Electrical resistance of dead end assembly Slip strength of dead end assembly Total weight of tension assembly UTS of string hardware Purity of Zinc used for galvanizing Min No. of dips in standard precee test the ferrous parts can withstand Design calculations for yoke plates enclosed Unit Value guaranteed by the Bidder
Yes/No Yes/No Yes/No Ohms kN kG kN/kG % No. Yes/No
Da t e : Place:
Part-III (1/2)
Section-GTP
221
(6) MID SPAN COMPRESSION JOINT FOR CONDUCTOR

Sl. No. 1 Description Manufacturers Name and Address Unit Value guaranteed by the Bidder
2 3 a) b) 4 i) ii) iii) 5 a) b) c) 6 a)
b)
c) 7 a) b) 8 a) b) 9 a) b) c) 10 11
Drawing enclosed Material for joint Type of material with chemical composition Purity Inside diameter of sleeve before compression Steel Sleeve Aluminium sleeve Aluminium filler sleeve Outside diameter of sleeve before compression Steel sleeve Aluminium sleeve Aluminium filler sleeve Outside dimensions of sleeve after compression Steel sleeve i) Corner to corner ii) Surface to surface Aluminium cover i) Corner to corner ii) Surface to surface Aluminium sleeve Length of steel sleeve Before compression After compression Length of aluminium sleeve Before compression After compression Weight of sleeve Steel Aluminium Aluminium filler sleeve Slip strength Conductivity of the compressed unit expressed as a percentage of the conductivity of equivalent length of bare earth wire
Yes/No
mm mm mm mm mm mm mm
mm mm mm mm
mm mm Mm mm kG kG kG kN %
Da t e : Place:
Part-III (1/2)
Section-GTP
222
(7) REPAIR SLEEVE FOR ACSR PANTHER CONDUCTOR

Sl. No. 1 Description Manufacturers name and Address Unit Value guaranteed by the Bidder
2 3 a) b) 4 5 a) b) 6 a) b) 7 a) b) 8
Suitable for conductor size Material for aluminium sleeve Aluminium/Aluminium Alloy Purity of Aluminnium/Grade of Aluminium alloy Inside diameter of sleeve before compression Outside diameter of sleeve Before compression After compression Dimensions of sleeve after compression Corner to corner Face to face Length of sleeve Before compression After compression Weight of sleeve
mm
mm mm mm mm mm mm mm kG
Da t e : Place:
Part-III (1/2)
Section-GTP
223
(8) 11 KV DISC INSULATOR 90 KN

Sl. No.
1
Description 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
Particulars
2 3 4
5 6 7 8 9 10 11 12
13
14 15 16 17 18 19 20 21 22
Part-III (1/2)
Section-GTP
224
(9) GALVANISED STEEL EARTHWIRE/OPGW

Sl. No. 1 Description Manufacturers Name and Address Unit Particulars for 7/3.15 size
2 2.1 a) b) c) d) e) 2.2 a) 3 3.1 a) b) c) 3.2 3.3 a) b)
c)
4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 a) b) c) 5
PARTICULARS OF RAW MATERIALS Steel Wires/Rods Carbon Maganese Phosphorous Sulphur Silicon Zinc Minimum purity of Zinc STEEL STRANDS ATER STRANDING Diameter Nominal Maximum Minimum Minimum breaking load of strand Galvanizing Minimum weight of zinc coating per sq. m. Minimum number of one minute dips that the galvanized strand can withstand in the standard preece t es t Min. No. of twists in gauge length equal 100 times the dia. Of wire which the strand can withstand in the torsion test. STRANDED EARTWIRE UTS of earth wire Lay length of outer steel layer DC resistance of earth wire at 20oC Standard length of earth wire Tolerance on standard length Direction of lay of outer layer Linear mass of earth wire Standard Minimum Maximum Drum is as per specification
% % % % % %
mm Mm Mm kN Gm
kN Mm Ohm/kM M m
kG/kM kG/kM kG/kM
Da t e : Place:
Part-III (1/2)
Section-GTP
225
10) TENSION CLAMP FOR GALVANISED STEEL EARTHWIRE (7/3.15 MM) Sl. No. 1 Description Manufacturers name and Address Unit Value guaranteed by the Bidder
2 3 a) b) c) 4 5 a) b) 6 a) b) 7 a) b) 8 9 10 11
Drawing enclosed Material Shackle Compression Clamp Hardness of the material (BHN) Inside diameter of Clamp before compression Outside diameter of clamp Before compression After compression Dimensions of clamp after compression Corner to corner Face to face Length of clamp Before compression After compression Weight of clamp Slip strength (minimum) Compression Pressure Minimum breaking strength of assembly (excluding clamp)
mm Yes/No
Mm Mm Mm Mm Mm Mm Mm kG kN T kGf
Da t e : Place:
Part-III (1/2)
Section-GTP
226
(11) MID SPAN COMPRESSION JOINT FOR EARTH WIRE

2 3 a) b) 4 5 6 7 i) ii) 8 9 10 11
Suitable for size Material for joint Type of material with chemical composition Range of hardness of the steel sleeves Outside diameter of sleeve before compression Inside diameter of sleeve before compression Length of sleeve before compression Dimensions of sleeve after compression Corner to corner Face to Face Length of sleeve after compression Weight of sleeve Slip Strength Conductivity of the compressed unit expressed as percentage of the conductivity of equivalent length of bare conductor
mm
mm mm mm mm mm mm kG kN Ohm
Da t e : Place:
Part-III (1/2)
Section-GTP
227
(12) FLEXIBLE COPPER BOND

Drawing enclosed Stranding Cross sectional area Minimum copper equivalent area Length of copper cable Material of lugs Bolt size i) Diameter ii) Length 9 Resistance 10 Total weight of flexible copper bond
2 3 4 5 6 7 8
Yes/No Sq. mm. Sq. mm. mm
mm mm Ohm kG
Da t e : Place:
(Signature)............ (Printed Name) (Designation).. (Common Seal)
Note: Tolerances, wherever applicable, shall be specified
Part-III (1/2)
Section-GTP
228
(13) VIBRATION DAMPER FOR ACSR PANTHER CONDUCTOR

2 a) b) 3 4 5 6 7 8 9 10 11 12 13 14 15 a) b) 16 17 a) b) 18 19 20
Drawing enclosed Design drawing Placement chart Suitable for conductor size Total weight of one damper Diameter of each damper mass Length of each damper mass Weight of each damper mass Material of damper masses Material of clamp Material of the stranded messenger cable Number of stands in stranded messenger cable Lay ratio of stranded messenger cable Minimum ultimate tensile strength of stranded messenger cable Slip strength of stranded messenger cable (mass pull o f) Resonance frequencies First frequency Second frequency Designed clamping torque Slipping strength of damper clamp Before fatigue test After fatigue test Magnetic power loss per vibration Damper for 350 amps. 50 Hz Alternating Current Percentage variation in Reactance after fatigue test in comparison with that before fatigue test Percentage variation in power dissipation after fatigue test in comparison with that before fatigue test
Yes/No Yes/No mm kG mm mm kG
RIGHT
LEFT
kG/mm2 kN
Hz Hz kG-m kN kN watts % %
Da t e : Place:
Note: Tolerances, wherever applicable, shall be specified

Part-III (1/2) Section-GTP
229
(14) VIBRATION DAMPER FOR GALVANISED STEEL EARTHWIRE/OPGW (7/3.15 MM)

Sl. No. 1 Description Manufacturers name and Address Unit Guaranteed Value
2 3 4 5 6 7 8 9 10 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 mass Material of damper masses Material of Clamp Material of Stranded messenger cable Number of strands in stranded messenger cable Lay ratio of stranded messenger cable Minimum ultimate tensile strength of stranded messenger cable 13 Slip strength of standard messenger cable (mass pull o ff) 14 Resonance frequencies a) First frequency b) Second frequency
mm kG mm mm kG
kG/mm2 kN
Hz Hz
Da t e : Place:
Part-III (1/2)
Section-GTP
230
(15) G.I. PLATE (EARTH)

Sl. No. A. 1. 2. 3. 4. 5. Description G.I. Plate Size of Plate Thickness of Plate Weight of Plate Hydraulic Test Guarantee : : : : : : Particulars
B. G.I. Strip 1. 2. 3. 4. 5. 6. Size of Strip Length of Strip Thickness of Strip Weight of Strip Hydraulic Test Guarantee : : : : : :
Da t e : Place:
Part-III (1/2)
Section-GTP
231
SINGLE LINE DIAGRAM FOR 132 KV BUS AT KHUPPI (NEEPCO) EXTENSION FROM BALIPARA NEEPCO TO
132 KV TRANSFER BUS Our scope of Work.
132 KV MAIN BUS
LEGEND
1 2 3 4 5 Circuit Breaker Current Transformer Isolator Lightning Arrestor CVT 2 Nos 6 Nos 6 Nos 6 Nos 6 Nos
ISOLATOR CT CB EARTH SW LA
WAV E TRAP CVT
232 SINGLE LINE DIAGRAM FOR 132 KV SUB-STATION AT BOMDILA FROM KHUPPI (NEEPCO) TAWANG
FUTURE
132 KV TRANSFER BUS
132 KV MAIN BUS
STAND BY
4 X 5 MVA, 132/33 KV 1 ph. TRANSFORMER
33 KV BUS
33/0.433 KV, 250 KVA LT. TRANSFOREMR TO LT SWGR 33 KV OUT GOING FEEDERS 33 KV OUT GOING FEEDERS TO LT SWGR
EARTH SW
LEGEND
132 KV 33KV
ISOLATOR
WAVE TRAP CVT
1 2 3 3 4 5
Circuit Breaker Current Transformer Potential Transformer Isolator Lightning Arrestor CVT
7 Nos 12 Nos 2 Sets 16 Nos 12 Nos 9 Nos
6 Nos 21 Nos 21 Nos 14 Nos 21 Nos
LA CT CB PT
233
SINGLE LINE DIAGRAM FOR 132 KV SUB-STATION AT TAWANG FROM BOMDILA FUTURE FUTURE
132 KV TRANSFER BUS
132 KV MAIN BUS
STAND BY
4 X 5 MVA, 132/33 KV 1 ph. TRANSFORMER
33 KV BUS
33/0.433 KV, 250 KVA LT. TRANSFOREMR TO LT SWGR 33 KV OUT GOING FEEDERS 33 KV OUT GOING FEEDERS TO LT SWGR
LEGEND
132 KV 33KV
ISOLATOR EARTH SW LA CT CB PT CVT
WAVE TRAP
1 2 3 3 4 5
Circuit Breaker Current Transformer Potential Transformer Isolator Lightning Arrestor CVT
7 Nos 12 Nos 1 Set 16 Nos 12 Nos 9 Nos
6 Nos 21 Nos 21 Nos 14 Nos 21 Nos
DEPARTMENT OF POWER BID DOCUMENT PART-III

(Volume-2/2)
TECHNICAL SPECIFICATIONS FOR

UNDER
SPECIFICATION NO:- DoP/TED/ 132 KV/KHUPPI-TWG
SPECIFICATION NO:- DOP/TED/132 KV/KHUPPI-TWG
BID DOCUMENT PART-III

(Volume-2/2) TECHNICAL SPECIFICATIONS FOR
CONTENTS
Sr. No. Description Technical Specification for 132/33 KV S/S 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 11. 12. 13. 14. 15. 16. 17. 18. 19. General Technical Requirement 132/33 kV Transformer Circuit Breakers Isolators Instrument Transformers Surge Arresters Structures Civil Works Battery & Battery Charger LT Transformer Power & Control Cables LT Switch Gears Control & Relay Panels (Without Auto System) Control & Relay Panels (With Auto System) Switchyard Erection PLCC Lighting System Fire Protection System Air Conditioners Technical Specification for 132 KV Line 20. 21. 22. 23. 24. 25. Section I: General Technical Specifications Section II: Technical Description of Earth Wire Section III: Technical Description of Hardware Fittings Section IV: Technical Description of ACSR (PANTHER) Section V. Technical Description of Insulator Detail Drawings of Earthing 407-440 441-451 452-476 477-488 489-496 497-498 1-47 48-84 85-101 102-110 111-121 122-128 129-136 137-162 163-176 177-184 185-195 196-218 219-254 255-279 280-316 317-335 336-353 354-402 403-406 Page No.
Part-III (Vol. 2/2)
Section-Main Content
GENERAL TECHNICAL REQUIREMENT
(GTR)
Part-III (Vol. 2/2)
Section-Technical Specifications-GTR Transformer
CHAPTER-GENERAL TECHNICAL REQUIREMENT SEC-GTR (GENERAL TECHNICAL REQUIREMENT)

_____________________________________________________________ Clause No. Description Page No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 Annexure-A Annexure-B Foreword: General Requirement: Standards: 3 3 3
Services to be performed by the Equipment being furnished: 4 Engineering Data and Drawings 7 Material/Workmanship: Design Improvements/Coordination: Quality Assurance Programme: Type Testing, Inspection & Inspection Certificate: Tests: Packaging & Protection: Finishing of Metal Surfaces: Handling, Storing & Installation: Tools and Tackles: Auxiliary Supply: Support Structure: Clamps and Connectors including Terminal Connectors: Control Cabinets, Junction Boxes, Terminal Boxes & Marshalling Boxes for Outdoor Equipment: Auxiliary Switches: Terminal Blocks and Wiring: Lamps and Sockets: Bushings, Hollow Column Insulators, Support Insulators: Motors: Technical Requirement of Equipments: List of Specifications: List of the makes for which type test reports not required to be submitted: 9 11 12 12 14 15 15 17 18 18 18 18 20 21 21 22 23 23 25 29 47
Part-III (Vol. 2/2)
CHAPTER - GTR SECTION: GTR (GENERAL TECHNICAL REQUIREMENTS)

1.0 FOREWORD 1.1 The provisions under this section are intended to supplement general requirements for the materials, equipments and services covered under other sections of tender documents and are not exclusive. However in case of conflict between the requirements specified in this section and requirements specified under other sections, the requirements specified under respective sections shall prevail.
2.0
GENERAL REQUIREMENT 2.1 2.2 2.3 The bidders shall submit the technical requirements, data and information as per the technical data sheets provided in the Part-III (Vol-1/2) of bid documents. The bidders shall furnish catalogues, engineering data, technical information, design documents, drawings etc., fully in conformity with the technical specification. It is recognised that the Contractor may have standardised on the use of certain components, materials, processes or procedures different from those specified herein. Alternate proposals offering similar equipment based on the manufacturers standard practice will also be considered provided such proposals meet the specified designs, standard and performance requirements and are acceptable to the Purchasers. Unless brought out clearly, the Bidder shall be deemed to conform to this specification scrupulously. All deviations from the specification shall be clearly brought out in the respective schedule of deviations. Any discrepancy between the specification and the catalogues or the bid, if not clearly brought out in the specific requisite schedule, will not be considered as valid deviation. Except for lighting fixtures, wherever a material or article is specified or defined by the name of a particular brand, Manufacturer or Vendor, the specific name mentioned shall be understood as establishing type, function and quality and not as limiting competition. For lighting fixtures, makes shall be as defined in Section- Lighting System. Equipment furnished shall be complete in every respect with all mountings, fittings, fixtures and standard accessories normally provided with such equipment and/or needed for erection, completion and safe operation of the equipment as required by applicable codes though they may not have been specifically detailed in the Technical Specifications unless included in the list of exclusions. Materials and components not specifically stated in the specification but which are necessary for commissioning and satisfactory operation of the switchyard/sub-station unless specifically excluded shall be deemed to be included in the scope of the specification and shall be supplied without any extra cost. All similar standard components/parts of similar standard equipment provided, shall be inter-changeable with one another.
2.4
2.5
3.0
STANDARDS
3.1
The works covered by the specification shall be designed, engineered, manufactured, built, tested and commissioned in accordance with the Acts, Rules, Laws and Regulations of India including local statutory laws & rules. The equipment to be furnished under this specification shall conform to latest issue with all amendments (as on the date of bid opening) of standard specified under Annexure-A of this section, unless specifically mentioned in the specification. The Bidder shall note that standards mentioned in the specification are not mutually exclusive or complete in themselves, but intended to compliment each other. The Contractor shall also note that list of standards presented in this specification is not complete. Whenever necessary the list of standards shall be considered in conjunction with specific IS/IEC.
3.2
3.3 3.4
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3.5
When the specific requirements stipulated in the specifications exceed or differ than those required by the applicable standards, the stipulation of the specification shall take precedence. Other internationally accepted standards which ensure equivalent or better performance than that specified in the standards specified under Annexure-A or individual sections for various equipments shall also, be accepted, however the salient points of difference shall be clearly brought out in additional information schedule of Part-III (Vol-1/2) along with English language version of such standard. The equipment conforming to standards other than specified under Annexure-C or individual sections for various equipments shall be subject to Purchasers approval. The bidder shall clearly indicate in his bid the specific standards in accordance with which the works will be carried out.
3.6
3.7
4.0
SERVICES TO BE PERFORMED BY THE EQUIPMENT BEING FURNISHED 4.1 The equipment furnished under this specification shall perform all its functions and operate satisfactorily without showing undue strain, restrike etc. under such over voltage conditions. All equipments shall also perform satisfactorily under various other electrical, electromechanical and meteorological conditions of the site of installation. All equipment shall be able to withstand all external and internal mechanical, thermal and electromechanical forces due to various factors like wind load, temperature variation, ice & snow, (wherever applicable) short circuit etc for the equipment. The bidder shall design terminal connectors of the equipment taking into account various forces that are required to withstand. The equipment shall also comply to the following: a) b) c) All outdoor EHV equipments except marshalling kiosks shall be suitable for hot line washing. To facilitate erection of equipment, all items to be assembled at site shall be match marked. All piping, if any between equipment control cabinet/operating mechanism to marshalling box of the equipment, shall bear proper identification to facilitate the connection at site.
4.2 4.3
4.4 4.5
4.6
Operating times of circuit breakers, protective relays and PLCC equipment have been specified in respective sections. However, the bidder is allowed to have minor variations on the individual equipment timings subject to the condition that overall fault clearing time remains within 100 milli seconds at 132 kV and 160 milli seconds at 33 kV level under comparable conditions. EHV equipments and system shall be designed to meet the following major technical parameters as brought out hereunder.
4.7
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4.7.1
System Parameter
Sr. No. 1. 2. 3. 4. 5. i. ii. iii. 6. 7. Description of parameters 132 kV System 132 kV 145 kV 50 Hz 3 33 kV System 33 kV 36 kV 50 Hz 3 170 kVp 80 kV -
8. 9. i. ii. iii. 10. 11.
System operating voltage Maximum operating voltage of the system Rated frequency Number of phases Rated insulation level full wave impulse withstand voltage (1.2/50 micro 650 kVp second) Switching impulse withstand voltage (250/2500 micro second) dry and wet One minute power frequency dry and wet withstand 275 kV voltage (rms) Corona extinction voltage 105 kV Maximum radio interference voltage for frequency 500 microbetween 0.5 MHz and 2 MHz at 92 kV rms for 132 volt kV system Minimum creepage distance 25 mm/kV (3625 mm) Minimum clearance Phase to phase 1300 mm Phase to earth 1300 mm Sectional clearances 4000 mm Rated short circuit current for 1 second duration 31.5 kA System neutral earthing Effectively earthed
25 mm/kV (900 mm) 320 mm 320 mm 3000 mm 25 kA Effectively earthed
Note: The insulation and RIV levels of the equipments shall be as per values given in the respective chapter of the equipments.
4.7.2
Major Technical Parameters The major technical parameters of the equipments are given below. For other parameters and features respective technical sections should be referred. A. For 145 kV Circuit Breaker and Isolator Rated voltage kV (rms): Rated frequency (Hz): No. of Poles: Design ambient temperature: Rated insulation levels: 1. Full wave impulse withstand voltage (1.2/50 micro second) - between line terminals & ground for CT & CVT: 650 kVp - between terminals with circuit breaker open: - between terminals with isolators open: 650 kVp 750 kVp 145 50 3 50
2. One minute power frequency dry and wet withstand voltage - between line terminals & ground: - between terminals with isolator open: Maximum radio interference voltage (micro volts) for frequency between 0.5 MHz and 2 MHz in all positions of the equipment: Minimum creepage distance: Phase to ground (mm):
Part-III (Vol. 2/2)
275 kV (rms) 315 kV (rms)
500 at 92 kV rms
3625
Between CB terminals (mm): System neutral earthing: Seismic acceleration: Rating of auxiliary contacts: Breaking capacity of Auxiliary Contacts:
3265 Effectively earthed 0.3g Horizontal 10 A at 220 V DC 2 A DC with circuit time constant of not less than 20 ms 2700
Phase to phase spacing (mm):
Auxiliary Switch shall also comply with other clauses of this chapter. B. FOR 145 kV CT/CVT/SA Rated voltage kV (rms): Rated frequency (Hz): Number of poles: Design ambient temperature (C): Rated insulation levels: 1. Full wave impulse withstand voltage (1.2/50 micro second) - between line terminals & ground for CT & CVT: 650 kVp - for arrester housing: 650 kVp 2. One minute power frequency dry and wet withstand voltage - between line terminals & ground for CT & CVT: 275 kV rms - for arrester housing: Maximum radio interference voltage (micro volts) for frequency between 0.5 MHz and 2 MHz in all positions of the equipment: Minimum creepage distance: Phase to ground (mm): System neutral earthing: Seismic acceleration: Partial discharge for: - Surge arrester at 1.05 COV: - for CT/CVT: Not exceeding 50% Not exceeding 10% 3625 Effectively earthed 0.3g Horizontal 275kV rms 145 50 1 50
500 at 92 kV rms
C. Technical Parameters of Bushings/Hollow Column insulators/ support insulators for 132 kV System: a. Rated Voltage: 145 kV 650 kVp --
b. Impulse withstand voltage (Dry & Wet): c. Switching surge withstand voltage (Dry & Wet): e. Total creepage distance:
f.
d. Power frequency withstand voltage (Dry & Wet): 275 kV (rms)

3625 mm Pollution Class-III Heavy (as per IEC 71) and as specified in Section-2 for all class of equipment.
Part-III (Vol. 2/2)
5.0 ENGINEERING DATA AND DRAWINGS 5.1 5.2 The engineering data shall be furnished by the Contractor in accordance with the Schedule for each set of equipment as specified in the Technical Specifications. The list of drawings/documents which are to be submitted to the Purchaser shall be discussed and finalised by the Purchaser at the time of award. The Contractor shall necessarily submit all the drawings/documents unless anything is waived. The Contractor shall submit 4 (four) sets of drawings/design documents /data/test reports as may be required for the approval of the Purchaser. 5.3 Drawings 5.3.1 All drawings submitted by the Contractor including those submitted at the time of bid shall be in sufficient detail to indicate the type, size, arrangement, material description, Bill of Materials, weight of each component, break-up for packing and shipment, dimensions, internal & the external connections, fixing arrangement required and any other information specifically requested in the specifications. Each drawing submitted by the Contractor shall be clearly marked with the name of the Purchaser, the unit designation, the specifications title, the specification number and the name of the Project. If standard catalogue pages are submitted, the applicable items shall be indicated therein. All titles, noting, markings and writings on the drawing shall be in English. All the dimensions should be in metric units. Further work by the Contractor shall be in strict accordance with these drawings and no deviation shall be permitted without the written approval of the Purchaser, if so required. The review of these data by the Purchaser will cover only general conformance of the data to the specifications and documents, interfaces with the equipment provided under the specifications, external connections and of the dimensions which might affect substation layout. This review by the Purchaser may not indicate a thorough review of all dimensions, quantities and details of the equipment, materials, any devices or items indicated or the accuracy of the information submitted. This review and/or approval by the Purchaser shall not be considered by the Contractor, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these specifications and documents. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawings shall be at the Contractors risk. The Contractor may make any changes in the design which are necessary to make the equipment conform to the provisions and intent of the Contract and such changes will again be subject to approval by the Purchaser. Approval of Contractors drawing or work by the Purchaser shall not relieve the contractor of any of his responsibilities and liabilities under the Contract. All engineering data submitted by the Contractor after final process including review and approval by the Purchaser shall form part of the Contract Document and the entire works performed under these specifications shall be performed in strict conformity, unless otherwise expressly requested by the Purchaser in Writing.
5.3.2
5.3.3
5.4
5.5
5.6
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5.7
Approval Procedure The scheduled dates for the submission of the drawings as well as for, any data/information to be furnished by the Purchaser would be discussed and finalised at the time of award. The following schedule shall be followed generally for approval and for providing final documentation.
Sr. Item of subject No. i. Approval/comments by the Purchaser ii. Resubmission (whenever required) Time period As per agreed schedule. Within 3 (three) weeks from the date of comments including both ways postal time. Within 3 (three) weeks of receipt of resubmission. 2 weeks from the date of final approval.
iii. Approval or comments
iv. Furnishing of distribution copies in bound volume (5 copies for sub-station and one copy for Head Office of Chief Engineer) v. Furnishing of distribution copies of test reports a. Type test reports (one copy for sub-station plus one copy for Head Office of Chief Engineer) b. Routine Test Report (one copy for each substation) vi. Furnishing of instruction/operation manuals (four copies for sub-station and two copies for Head Office of Chief Engineer. vii. RTFs of drawing (one set for sub-station and one set for Head Office of Chief Engineer. viii. Video Cassette (VHS-PAL) highlighting installation & maintenance technique/requirements of circuit breaker & isolators (one for sub-station plus one for Head Office of Chief Engineer. ix. As built drawing & RTFs (two sets for sub-station plus one for Head Office of Chief Engineer. x. ROM optical discs for all built drawings (one for sub-station plus one for Head Office of chief Engineer. Note:
2 weeks from the date of final approval. 2 weeks from the date of final approval. As per agreed schedule.
As per agreed schedule. As per agreed schedule.
On completion of entire works. As per agreed schedule.
1. The contractor may please note that all resubmissions must incorporate all comments given in the earlier submission by the Purchaser or adequate justification for not incorporating the same must be submitted failing which the submission of documents is likely to be returned.
2. The drawings which are required to be referred frequently during execution

should be submitted on cloth lined paper. The list of such drawings shall be finalised with the Contractor at the time of Award.
3. All major drawings should be submitted in Auto Card Version 12 or better. 4. The instruction Manuals shall contain full details of drawings of all equipment
being supplied under this contract, their exploded diagrams with complete instructions for storage, handling, erection, commissioning, testing, operation, trouble shooting, servicing and overhauling procedures.
5. If after the commissioning and initial operation of the substation, the instruction
manuals require any modifications/additions/changes, the same shall be incorporated and the updated final instruction manuals shall be submitted by the Contractor to the Purchaser.
6. The Contractor shall furnish to the Purchaser catalogues of spare parts.

Part-III (Vol. 2/2) Section-Technical Specifications-GTR Transformer
6.0 MATERIAL/WORKMANSHIP 6.1 General Requirement 6.1.1 Where the specification does not contain references to workmanship, equipment, materials and components of the covered equipment, it is essential that the same must be new, of highest grade of the best quality of their kind, conforming to best engineering practice and suitable for the purpose for which they are intended. Incase where the equipment, materials or components are indicated in the specification as similar to any special standard, the Purchaser shall decide upon the question of similarity. When required by the specification or when required by the Purchaser the Contractor shall submit, for approval, all the information concerning the materials or components to be used in manufacture. Machinery, equipment, materials and components supplied, installed or used without such approval shall run the risk of subsequent rejection, it being understood that the cost as well as the time delay associated with the rejection shall be borne by the Contractor. The design of the Works shall be such that installation, future expansions, replacements and general maintenance may be undertaken with a minimum of time and expenses. Each component shall be designed to be consistent with its duty and suitable factors of safety, subject to mutual agreements. All joints and fastenings shall be devised, constructed and documented so that the component parts shall be accurately positioned and restrained to fulfill their required function. In general, screw threads shall be standard metric threads. The use of other thread forms will only be permitted when prior approval has been obtained from the Purchaser. Whenever possible, all similar part of the Works shall be made to gauge and shall also be made interchangeable with similar parts. All spare parts shall also be interchangeable and shall be made of the same materials and workmanship as the corresponding parts of the Equipment supplied under the Specification. Wherever feasible, common component units shall be employed in different pieces of equipment in order to minimize spare parts stocking requirements. All equipment of the same type and rating shall be physically and electrically interchangeable. All materials and equipment shall be installed in strict accordance with the manufacturers recommendation(s). Only first-class work in accordance with the best modern practices will be accepted. Installation shall be considered as being the erection of equipment at its permanent location. This, unless otherwise specified, shall include unpacking, cleaning and lifting into position, grouting, leveling aligning, coupling of or bolting down to previously installed equipment bases/foundations, performing the alignment check and final adjustment prior to initial operation, testing and commissioning in accordance with the manufacturers tolerances, instructions and the Specification. All factory assembled rotating machinery shall be checked for alignment and adjustments made as necessary to re-establish the manufacturers limits suitable guards shall be provided for the protection of personnel on all exposed rotating and/or moving machine parts and shall be designed for easy installation and removal for maintenance purposes. The spare equipment(s) shall be installed at designated locations and tested for healthiness. The Contractor shall apply oil and grease of the proper specification to suit the machinery, as is necessary for the installation of the equipment. Lubricants used for installation purposes shall be drained out and the system flushed through where necessary for applying the lubricant required for operation. The Contractor shall apply all operational lubricants to the equipment installed by him.
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
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6.1.7
All oil, grease and other consumables used in the Works/Equipment shall be purchased in India unless the Contractor has any special requirement for the specific application of a type of oil or grease not available in India. In such is the case he shall declare in the proposal, where such oil or grease is available. He shall help Purchaser in establishing equivalent Indian make and Indian Contractor. The same shall be applicable to other consumables too. A cast iron or welded steel base plate shall be provided for all rotating equipment which are to be installed on a concrete base unless otherwise agreed to by the Purchaser. Each base plate shall support the unit and its drive assembly, shall be of design with pads for anchoring the units, shall have a raised up all around and shall have threaded in air connections, if so required.
6.1.8
6.2 Provisions For Exposure to Hot and Humid climate Outdoor equipment supplied under the specification shall be suitable for service and storage under tropical conditions of high temperature, high humidity, heavy rainfall and environment favourable to the growth of fungi and mildew. The indoor equipments located in non-air-conditioned areas shall also be of same type. 6.2.1 Space Heaters 6.2.1.1 The heaters shall be suitable for continuous operation at 240 V as supply voltage. On-off switch and fuse shall be provided. 6.2.1.2 One or more adequately rated thermostatically connected heaters shall be supplied to prevent condensation in any compartment. The heaters shall be installed in the compartment and electrical connections shall be made sufficiently away from below the heaters to minimize deterioration of supply wire insulation. The heaters shall be suitable to maintain the compartment temperature to prevent condensation. 6.2.1.3 Suitable anti-condensation heaters with the provision of thermostat shall be provided. 6.2.2 Fungi static varnish Besides the space heaters, special moisture and fungus resistant varnish shall be applied on parts which may be subjected or predisposed to the formation of fungi due to the presence or deposit of nutrient substances. The varnish shall not be applied to any surface of part where the treatment will interfere with the operation or performance of the equipment. Such surfaces or parts shall be protected against the application of the varnish. 6.2.3 Ventilation opening Wherever ventilation is provided, the compartments shall have ventilation openings with fine wire mesh of brass to prevent the entry of insects and to reduce to a minimum the entry of dirt and dust. Outdoor compartment openings shall be provided with shutter type blinds and suitable provision shall be made so as to avoid any communication of air/dust with any part in the enclosures of the Control Cabinets, Junction boxes and Marshalling Boxes, panels etc.
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6.2.4 Degree of Protection The enclosures of the Control Cabinets, Junction boxes and Marshalling Boxes, panels etc. to be installed shall provide degree of protection as detailed here under: a) Installed out door: IP- 55 b) Installed indoor in air conditioned area: IP-31
c) Installed in covered area: IP-52 d) Installed indoor in non air conditioned area where possibility of entry of water is limited: IP-41. e) For LT Switchgear (AC & DC distribution Boards): IP-52 The degree of protection shall be in accordance with IS: 13947 (Part-I)/IEC-947 (Part-I)/IS: 12063/IEC 529. Type test report for degree of protection test, on each type of the box shall be submitted for approval. 6.3 Rating Plates, Name Plates and Labels 6.3.1 Each main and auxiliary item of substation is to have permanently attached to it in a conspicuous position a rating plate of non-corrosive material upon which is to be engraved manufacturers name, year of manufacture, equipment name, type or serial number together with details of the loading conditions under which the item of substation in question has been designed to operate, and such diagram plates as may be required by the Purchaser. The rating plate of each equipment shall be according to IEC requirement. All such nameplates, instruction plates, rating plates of transformers, reactors, CB, CT, CVT, SA, Isolators, C & R panels and PLCC equipments shall be bilingual with Hindi inscription first followed by English. Alternatively two separate plates one with Hindi and the other with English inscriptions may be provided.
6.3.2
6.4 First fill consumables, oil and lubricants All the first fill of consumables such as oils, lubricants, filling compounds, touch up paints, soldering/brazing material for all copper piping of circuit breakers and essential chemicals etc. which will be required to put the equipment covered under the scope of the specifications, into successful Operation, shall be furnished by the Contractor unless specifically excluded under the exclusions in these specifications and documents. 7.0 DESIGN IMPROVEMENTS/COORDINATION 7.1 The bidder shall note that the equipment offered by him in the bid only shall be accepted for supply. However, the Purchaser or the Contractor may propose changes in the specification of the equipment or quality thereof and if the Purchaser & contractor agree upon any such changes, the specification shall be modified accordingly. If any such agreed upon change is such that it affects the price and schedule of completion, the parties shall agree in writing as to the extent of any change in the price and/or schedule of completion before the Contractor proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amended accordingly. The Contractor shall be responsible for the selection and design of appropriate equipments to provide the best co-ordinated performance of the entire system. The basic design requirements are detailed out in this Specification. The design of various components, sub-assemblies and assemblies shall be so done that it facilitates easy field assembly and maintenance.
7.2
7.3
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7.4
The Contractor has to coordinate designs and terminations with the agencies (if any) who are Consultants/Contractor for the Purchaser. The names of agencies shall be intimated to the successful bidders. The Contractor will be called upon to attend design co-ordination meetings with the Engineer, other Contractors and the Consultants of the Purchaser (if any) during the period of Contract. The Contractor shall attend such meetings at his own cost at New Delhi or at mutually agreed venue as and when required and fully cooperate with such persons and agencies involved during those discussions.
7.5
8.0 QUALITY ASSURANCE PROGRAMME 8.1 To ensure that the equipment and services under the scope of this Contract whether manufactured or performed within the Contractors Works or at his Sub-contractors premises or at the Purchasers site or at any other place of Work are in accordance with the specifications, the Contractor shall adopt suitable quality assurance programme to control such activities at all points necessary. Such programme shall be broadly outlined by the contractor and finalised after discussions before the award of contract. The detailed programme shall be submitted by the contractor after the award of contract and finally accepted by department of Power after discussion. However, in case detailed valid programme approved by department of Power for the equipment already exist, same would be followed till its validity. A quality assurance programme of the contractor shall generally cover the following: (a) His organisation structure for the management and implementation of the proposed quality assurance programme. (b) Documentation control system; (c) Qualification data for bidders key personnel; (d) The procedure for purchases of materials, parts components and selection of subContractors services including vendor analysis, source inspection, incoming raw material inspection, verification of material purchases etc. (e) System for shop manufacturing and site erection controls including process controls and fabrication and assembly control; (f) Control of non-conforming items and system for corrective actions; (g) Inspection and test procedure both for manufacture and field activities. (h) Control of calibration and testing of measuring instruments and field activities; (i) System for indication and appraisal of inspection status; (j) System for quality audits; (k) System for authorising release of manufactured product to the Purcahser. (l) System for maintenance of records; (m) System for handling storage and delivery; and (n) A quality plan detailing out the specific quality control measures and procedures adopted for controlling the quality characteristics relevant to each item of equipment furnished and/or services rendered. The Purchaser or his duly authorised representative reserves the right to carry out quality audit and quality surveillance of the system and procedure of the Contractor/his vendors quality management and control activities.
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8.2 Quality Assurance Documents The contractor would be required to submit all the Quality Assurance Documents as stipulated in the Quality Plan at the time of purchasers inspection of equipment/material. 9.0 TYPE TESTING, INSPECTION, TESTING & INSPECTION CERTIFICATE 9.1 All equipment being supplied shall conform to type tests including additional type tests as per technical specification and shall be subject to routine tests in accordance with requirements stipulated under respective sections. Purchaser reserves the right to witness any or all the type tests. The Contractor shall intimate the Purchaser the detailed program about the tests atleast three (3) weeks in advance in case of domestic supplies & six (6) weeks in advance in case of foreign supplies.
9.2
The reports for all type tests and additional type tests as per technical specification shall be furnished by the Contractor alongwith equipment/material drawings. The type tests conducted earlier should have either been conducted in accredited laboratory (accredited based on ISO/IEC Guide 25/17025 or EN 45001 by the national accredition body of the country where laboratory is located) or witnessed by the representative(s) of Department of Power or Utility. The test reports submitted shall be of the tests conducted within last 5 (five) years prior to the date of bid opening. In case the test reports are of the test conducted earlier than 5 (five) years prior to the date of bid opening, the contractor shall repeat these test(s) at no extra cost to the purchaser. In the event of any discrepancy in the test reports i.e. any test report not acceptable due to any design/manufacturing changes (including substitution of components) or due to non-compliance with the requirement stipulated in the Technical Specification or any/all additional type tests not carried out, same shall be carried out without any additional cost implication to the Purchaser.
9.3
The Purchaser intends to repeat the type tests and additional type tests on transformers, reactors, cables and battery chargers for which test charges shall be payable as per provision of contract. The price of conducting type tests and additional type tests shall be included in Bid price and break up of these shall be given in the relevant schedule of Bid Proposal Sheets. These Type test charges would be considered in bid evaluation. In case Bidder does not indicate charges for any of the type tests or does not mention the name of any test in the price schedules, it will be presumed that the particular test has been offered free of charge. Further, in case any Bidder indicates that he shall not carry out a particular test, his offer shall be considered incomplete and shall be liable to be rejected. For outdoor receptacles, trefoil clamps, diesel engine, alternator, motors, cable glands and junction boxes, type testing and type test reports are not required to be submitted for the makes indicated at Annexure-B/Department of power approved list of subvendors. For the new makes (other than those indicated at Annexure-B/Department of Power approved list of sub-vendors), type test reports as per relevant standard shall be submitted for purchasers approval.
9.4
The Purchaser, his duly authorised representative and/or outside inspection agency acting on behalf of the Purchaser shall have at all reasonable times free access to the Contractors/sub-vendors premises or Works and shall have the power at all reasonable times to inspect and examine the materials and workmanship of the Works during its manufacture or erection if part of the Works is being manufactured or assembled at other premises or works, the Contractor shall obtain for the Engineer and for his duly authorized representative permission to inspect as if the works were manufactured or assembled on the Contractors own premises or works. Inspection may be made at any stage of manufacture, despatch or at site at the option of the Purchaser and the equipment if found unsatisfactory due to bad workmanship or quality, material is liable to be rejected.
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9.5
The Contractor shall give the Purchaser/Inspector thirty (30) days written notice of any material being ready for joint testing including contractor and department of Power. Such tests shall be to the Contractors account except for the expenses of the Inspector. The Purchaser/inspector, unless witnessing of the tests is virtually waived, will attend such tests within thirty (30) days of the date of which the equipment is notified as being ready for test/inspection, failing which the Contractor may proceed alone with the test which shall be deemed to have been made in the Inspectors presence and he shall forthwith forward to the Inspector duly certified copies of tests in triplicate. The Purchaser or Inspector shall, within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Contractor, of any objection to any drawings and all or any equipment and workmanship which in his opinion is not in accordance with the Contract. The Contractor shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the Purchaser/Inspector giving reasons therein, that no modifications are necessary to comply with the Contract. When the factory tests have been completed at the Contractors or Sub-Contractors works, the Purchaser/inspector shall issue a certificate to this effect within fifteen (15) days after completion of tests but if the tests are not witnessed by the Purchaser/Inspector, the certificate shall be issued within fifteen (15) days of receipt of the Contractors Test certificate by the Engineer/Inspector. Failure of the Purchaser/Inspector to issue such a certificate shall not prevent the Contractor from proceeding with the Works. The completion of these tests or the issue of the certificate shall not bind the Purchaser to accept the equipment, should it on further tests after erection, be found not to comply with the Contract. The equipment shall be dispatched to site only after approval of test reports and issuance of CIP by the Purchaser. In all cases where the Contract provides for tests whether at the premises or at the works of the Contractor or of any Sub-Contractor, the Contractor except where otherwise specified shall provide free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Purchaser/Inspector or his authorised representative to carry out effectively such tests of the equipment in accordance with the Contract and shall give facilities to the Purchaser/Inspector or to his authorised representative to accomplish testing. The inspection by Purchaser and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the agreed quality assurance programme forming a part of the Contract.
9.6
9.7
9.8
9.9
9.10 The Purchaser will have the right of having at his own expenses any other test(s) of reasonable nature carried out at Contractors premises or at site or in any other place in addition of aforesaid type and routine tests, to satisfy that the material comply with the specification. 9.11 The Purchaser reserves the right for getting any field tests not specified in respective sections of the technical specification conducted on the completely assembled equipment at site. The testing equipments for these tests shall be provided by the Purchaser. 10. TESTS 10.1 Pre-commissioning Tests On completion of erection of the equipment and before charging, each item of the equipment shall be thoroughly cleaned and then inspected jointly by the Purchaser and the Contractor for correctness and completeness of installation and acceptability for charging, leading to initial pre-commissioning tests at Site. The list of pre-commissioning tests to be performed are given in respective chapters and shall be included in the Contractors quality assurance programme.
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10.2 Commissioning Tests 10.2.1 The testing equipments required for testing and commissioning shall be arranged by the Contractor. 10.2.2 The specific tests requirement on equipment have been brought out in the respective chapters of the technical specification. 10.3 The Contractor shall be responsible for obtaining statutory clearances from the concerned authorities for commissioning the equipment and the switchyard. However necessary fee shall be reimbursed by Department of Power on production of requisite documents.
11.0 PACKAGING & PROTECTION 11.1 All the equipments shall be suitably protected, coated, covered or boxed and crated to prevent damage or deterioration during transit, handling and storage at Site till the time of erection. On request of the Purchaser, the Contractor shall also submit packing details/associated drawing for any equipment/material under his scope of supply, to facilitate the Purchaser to repack any equipment/material at a later date, in case the need arises. While packing all the materials, the limitation from the point of view of availability of Railway wagon sizes in India should be taken into account. The Contractor shall be responsible for any loss or damage during transportation, handling and storage due to improper packing. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor. Purchaser takes no responsibility of the availability of the wagons. 11.2 All coated surfaces shall be protected against abrasion, impact, discolouration and any other damages. All exposed threaded portions shall be suitably protected with either a metallic or a non-metallic protecting device. All ends of all valves and pipings and conduit equipment connections shall be properly sealed with suitable devices to protect them from damage. 12.0 FINISHING OF METAL SURFACES 12.1 All metal surfaces shall be subjected to treatment for anti-corrosion protection. All ferrous surfaces for external use unless otherwise stated elsewhere in the specification or specifically agreed, shall be hot-dip galvanized after fabrication. High tensile steel nuts & bolts and spring washers shall be electro galvanized to service condition 4. All steel conductors including those used for earthing/grounding (above ground level) shall also be galvanized according to IS: 2629. 12.2 Hot Dip Galvanising 12.2.1 The minimum weight of the zinc coating shall be 610 gm/sq. m and minimum thickness of coating shall be 85 microns for all items thicker than 6mm. For items lower than 6 mm thickness requirement of coating thickness shall be as per relevant ASTM. For surface which shall be embedded in concrete, the zinc coating shall be 610 gm/sq. m minimum. 12.2.2 The galvanized surfaces shall consist of a continuous and uniform thick coating of zinc, firmly adhering to the surface of steel. The finished surface shall be clean and smooth and shall be free from defects like discoloured patches, bare spots, unevenness of coating, spelter which is loosely attached to the steel globules, spiky deposits, blistered surface, flaking or peeling off, etc. The presence of any of these defects noticed on visual or microscopic inspection shall render the material liable to rejection.
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12.2.3 After galvanizing. no drilling or welding shall be performed on the galvanized parts of the equipment excepting that nuts may be threaded after galvanizing. Sodium dichromate treatment shall be provided to avoid formation of white rust after hot dip galvanization. 12.2.4 The galvanized steel shall be subjected to six one minute dips in copper sulphate solution as per IS-2633. 12.2.5 Sharp edges with radii less than 2.5 mm shall be able to withstand four immersions of the Standard Preece test. All other coatings shall withstand six immersions. The following galvanizing tests should essentially be performed as per relevant Indian Standards. - Coating thickness - Uniformity of zinc - Adhesion test - Mass of zinc coating 12.2.6 Galvanised material must be transported properly to ensure that galvanised surfaces are not damaged during transit. Application of zinc rich paint at site shall not be allowed. 12.3 Painting 12.3.1 All sheet steel work shall be degreased, pickled, phosphated in accordance with the IS-6005 Code of practice for phosphating iron and sheet. All surfaces, which will not be easily accessible after shop assembly shall beforehand be treated and protected for the life of the equipment. The surfaces, which are to be finished painted after installation or require corrosion protection until installation, shall be shop painted with at least two coats of primer. Oil, grease, dirt and swaf shall be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with dilute acid followed by washing with running water, rinsing with slightly alkaline hot water and drying. 12.3.2 After phosphating, thorough rinsing shall be carried out with clean 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, stoving type zinc chromate primer. The first coat may be flash dried while the second coat shall be stoved. 12.3.3 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 inspection of first coat of painting. 12.3.4 The exterior colour of the paint shall be as per shade no: 697 (for outdoor) & 692 (for indoor) of IS-5 and inside shall be glossy white for all equipment, marshalling boxes, junction boxes, control cabinets, panels etc. unless specifically mentioned under respective sections of the equipments. Each coat of primer and finishing paint shall be of slightly different shade to enable inspection of the painting. A small quantity of finishing paint shall be supplied for minor touching up required at site after installation of the equipments. 12.3.5 In case the Bidder proposes to follow his own standard surface finish and protection procedures or any other established painting procedures, like electrostatic painting etc., the procedure shall be submitted alongwith the Bids for Purchasers review & approval.
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12.3.6 The colour scheme as given below shall be followed for Fire Protection and Air Conditioning systems:
Sr. Pipe line No. Fire Protection System 1 Hydrant and Emulsifier System pipeline 2 Emulsifier system detection line - water 3 Emulsifier system detection line - air 4 Pylon support pipes Air Conditioning System 5 Refrigerant gas pipeline- at compression suction 6 Refrigerant gas pipeline- at compression discharge 7 Refrigerant liquid pipeline 8 Chilled water pipe 9 Condensed water pipeline Base Colour FIRE RED FIRE RED FIRE RED FIRE RED Canary Yellow Canary Yellow Dark Admiralty Green Sea green Sea green Band Colour Sea Green Sky Blue Red Dark Blue
The direction of flow shall be marked by (arrow) in black colour. Base Colour Direction of flow Band Colour shall be as per convention. 13.0 HANDLING, STORING AND INSTALLATION 13.1 In accordance with the specific installation instructions as shown on manufacturers drawings or as directed by the Purchaser or his representative, the Contractor shall unload, store, erect, install, wire, test and place into commercial use all the equipment included in the contract. Equipment shall be installed in a neat, workmanlike manner so that it is level, plumb, square and properly aligned and oriented. Commercial use of switchyard equipment means completion of all site tests specified and energisation at rated voltage. Contractor may engage manufacturers Engineers to supervise the unloading, transportation to site, storing, testing and commissioning of the various equipment being procured by them separately. Contractor shall unload, transport, store, erect, test and commission the equipment as per instructions of the manufacturers supervisory Engineer(s) and shall extend full cooperation to them. In case of any doubt/misunderstanding as to the correct interpretation of manufacturers drawings or instructions, necessary clarifications shall be obtained from the Purchaser. Contractor shall be held responsible for any damage to the equipment consequent to not following manufacturers drawings/instructions correctly. Where assemblies are supplied in more than one section, Contractor shall make all necessary mechanical and electrical connections between sections including the connection between buses. Contractor shall also do necessary adjustments/alignments necessary for proper operation of circuit breakers, isolators and their operating mechanisms. All components shall be protected against damage during unloading, transportation, storage, installation, testing and commissioning. Any equipment damaged due to negligence or carelessness or otherwise shall be replaced by the Contractor at his own expense. Contractor shall be responsible for examining all the shipment and notify the Purchaser immediately of any damage, shortage, discrepancy etc. for the purpose of Purchasers information only. The Contractor shall submit to the Purchaser every week a report detailing all the receipts during the weeks. However, the Contractor shall be solely responsible for any shortages or damages in transit, handling and/or in storage and erection of the equipment at Site. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor.
13.2
13.3
13.4
13.5
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13.6
The Contractor shall be fully responsible for the equipment/material until the same is handed over to the Purchaser in an operating condition after commissioning. Contractor shall be responsible for the maintenance of the equipment/material while in storage as well as after erection until taken over by Purchaser, as well as protection of the same against theft, element of nature, corrosion, damages etc. Where material/equipment is unloaded by Purchaser before the Contractor arrives at site or even when he is at site, Purchaser by right can hand over the same to Contractor and there upon it will be the responsibility of Contractor to store the material in an orderly and proper manner. The Contractor shall be responsible for making suitable indoor storage facilities, to store all equipment which require indoor storage. The words erection and installation used in the specification are synonymous.
13.7
13.8 13.9
13.10 Exposed live parts shall be placed high enough above ground to meet the requirements of electrical and other statutory safety codes. 13.11 The design and workmanship shall be in accordance with the best engineering practices to ensure satisfactory performance throughout the service life. If at any stage during the execution of the Contract, it is observed that the erected equipment(s) do not meet the above minimum clearances as given in clause 4.7.1 the Contractor shall immediately proceed to correct the discrepancy at his risks and cost. 13.12 Equipment Bases A cast iron or welded steel base plate shall be provided for all rotating equipment which is to be installed on a concrete base unless otherwise agreed to by the Purchaser. Each base plate shall support the unit and its drive assembly, shall be of a neat design with pads for anchoring the units, shall have a raised lip all around, and shall have threaded drain connections. 14.0 TOOLS AND TACKLES The Contractor shall supply with the equipment one complete set of all special tools and tackles for the erection, assembly, dis-assembly and maintenance of the equipment. However, these tools and tackles shall be separately, packed and brought on to Site. 15.0 AUXILIARY SUPPLY 15.1 The sub-station auxiliary supply is normally met through a system indicated under section Electrical & Mechanical Auxiliaries having the following parameters. The auxiliary power for station supply, including the equipment drive, cooling system of any equipment, air-conditioning, lighting etc shall be designed for the specified Parameters as under. The DC supply for the instrumentation and PLCC system shall also conform the parameters as indicated in the following.
Normal voltage connection 415 V 240 V 220 V 50 V Variation (Voltage) + 10% + 10% 190 V to 240 V Frequency (Hz) 50 + 5% 50 + 5% DC DC Phase/ Wire 3P-4W 1P-2W Neutral Solidly earthed Solidly earthed Isolated 2-wire system 2-wire system (+) earthed
Combined variation of voltage and frequency shall be limited to +/- 10%.
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16.0 SUPPORT STRUCTURE 16.1 The bidder has to bid for standard design of support structure and other control dimensions as relevant standard specifications followed in the country and the drawings of which will be supplied by them for approval. The Bidder shall strictly adhere to the dimensions of the drawings of such specifications. The Contractor is required to supply standard structures of various equipments. Bidder may also refer relevant Clauses of Section (Structure) in this regard. Any substructure or adopter plate required to meet the bus termination height other than the standard structure will be supplied by the Contractor as part of the equipment. All brackets, angels, stool or other members necessary for attaching the operating mechanism to the supporting structure shall be engineered and supplied by the Contractor. The Support structures for all equipments shall be supplied by the Contractor. The support structures should be hot dip galvanised with minimum 610 gram/sq.m net of zinc. In case of any deviation in this regard the bid is liable to be considered technically non responsive and shall be liable to be rejected. Support structure shall meet the following mandatory requirements:
16.2 16.3 16.4
16.4.1 The minimum vertical distance from the bottom of the lowest porcelain part of the bushing, porcelain enclosures or supporting insulators to the bottom of the equipment base, where it rests on the foundation pad shall be 2.55 metres. 17.0 CLAMPS AND CONNECTORS INCLUDING TERMINAL CONNECTORS 17.1 All power clamps and connectors shall conform to IS:5561 & NEMA CC1 and shall be made of materials listed below:
Sr. No. a. Items of connectors For connecting ACSR conductors Materials Aluminum alloy casting, conforming to designation A6 of IS: 617 and all test shall conform to IS: 617.
b.
c.
For connecting equipment Bimetallic connectors made from aluminum alloy terminals made of copper casting, conforming to designation A6 of IS: 617 with 2 mm thick bimetallic liner and all test shall conform to IS: with ACSR conductors 617. For connecting GI wire Galvanized mild steel shield. Electro-galvanized for sizes below M12, for others hot dip galvanized. Electro-galvanized mild steel suitable for at least service condition-3 as per IS: 1573.
d. i. Bolts, nuts & plain washers ii. Spring washers for items 'a' to 'c'
17.2
Each equipment shall be supplied with the necessary terminals and connectors, as required by the ultimate design for the particular installation. The conductor terminations of equipment shall be either expansion, sliding or rigid type suitable for aluminum tube or Quad/Twin ACSR/AAAC Conductor of respective sizes and specifications. The requirement regarding external corona and RIV as specified for any equipment shall include its terminal fittings and the equipment shall be factory tested with the connectors in position. If corona rings are required to meet these requirements, they shall be considered as part of that equipment and included in the scope of work. Where copper to aluminum connections are required, bi-metallic clamps shall be used, which shall be properly designed to ensure that any deterioration of the connection is kept to a minimum and restricted to parts which are not current carrying or subjected to stress. The design details of the joint shall be furnished to the Purchaser by the Contractor.
17.3
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17.4 17.5
Low voltage connectors, grounding connectors and accessories for grounding all equipment as specified in each particular case, are also included in the scope of Work. No current carrying part of any clamp shall be less than 10 mm thick. All ferrous parts shall be hot dip galvanised. Copper alloy liner of minimum 2 mm thickness shall be cast integral with aluminum body for Bi-metallic clamps. All casting shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be blurred and rounded off. Flexible connectors, braids or laminated straps made for the terminal clamps for bus posts shall be suitable for both expansion or through (fixed/sliding) type connection of 4" IPS aluminum tube as required. In both the cases the clamp height (top of the mounting pad to centre line of the tube) should be same. Clamp shall be designed to carry the same current as the conductor and the temperature rise shall be equal or less than that of the conductor at the specified ambient temperature. The rated current for which the clamp/connector is designed with respect to the specified reference ambient temperature, shall also be indelibly marked on each component of the clamp/connector, except on the hardware. All current carrying parts shall be designed and manufactured to have minimum contact resistance.
17.6 17.7
17.8
17.9
17.10 Clamps and connectors shall be designed to be corona controlled. Corona extinction voltages shall not be less than standard specifications and R.I.V. level shall not be more than the specification requirement at the test voltage specified in respective sections. 17.11 Tests 17.11.1 Clamps and connectors should be type tested as per IS: 5561 and shall also be subjected to routine tests as per IS: 5561. Following type test reports on three samples of similar type shall be submitted for approval as per clause 9.2 above except for serial (ii), for which type test once conducted shall be applicable (i.e. the requirement of test conducted within last five years shall not be applicable). i) ii) iii) Temperature rise test (maximum temperature rise allowed is 35C over 50C ambient). Short time current test. Resistance test and tensile test.
18.0 CONTROL CABINETS, JUNCTION BOXES, TERMINAL BOXES & MARSHALLING BOXES FOR OUTDOOR EQUIPMENT 18.1 18.2 All types of boxes, cabinets etc. shall generally conform to & be tested in accordance with IS-5039/IS-8623, IEC-439, as applicable, and the clauses given below: Control cabinets, junction boxes, Marshalling boxes & terminal boxes shall be made of sheet steel or aluminum enclosure and shall be dust, water and vermin proof. Sheet steel used shall be at least 2.0 mm thick cold rolled or 2.5 mm hot rolled. The box shall be properly braced to prevent wobbling. There shall be sufficient reinforcement to provide level surfaces, resistance to vibrations and rigidity during transportation and installation. In case of aluminum enclosed box the thickness of aluminum shall be such that it provides adequate rigidity and long life as comparable with sheet steel of specified thickness. Cabinet/boxes shall be free standing floor mounting type, wall mounting type or pedestal mounting type as per requirements. A canopy and sealing arrangements for operating rods shall be provided in marshalling boxes/Control cabinets to prevent ingress of rain water.
18.3
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18.4
Cabinet/boxes shall be provided with double hinged doors with padlocking arrangements. The distance between two hinges shall be adequate to ensure uniform sealing pressure against atmosphere. The quality of the gasket shall be such that it does not get damaged/cracked during the operation of the equipment. All doors, removable covers and plates shall be gasketed all around with suitably profiled EPDM gaskets. The gasket shall be tested in accordance with approved quality plan. The quality of gasket shall be such that it does not get damaged/cracked during the ten years of operation of the equipment or its major overhaul whichever is earlier. All gasketed surfaces shall be smooth straight and reinforced if necessary to minimize distortion and to make a tight seal. Ventilating Louvers, if provided, shall have screen and filters. The screen shall be fine wire mesh made of brass. All boxes/cabinets shall be designed for the entry of cables from bottom by means of weather proof and dust-proof connections. Boxes and cabinets shall be designed with generous clearances to avoid interference between the wiring entering from below and any terminal blocks or accessories mounted within the box or cabinet. Suitable cable gland plate projecting at least 150 mm above the base of the marshalling kiosk/box shall be provided for this purpose along with the proper blanking plates. Necessary number of cable glands shall be supplied and fitted on this gland plate. The gland shall project at least 25 mm above gland plate to prevent entry of moisture in cable crutch. Gland plate shall have provision for some future glands to be provided later, if required. The Nickel plated glands shall be dust proof, screw on & double compression type and made of brass. The gland shall have provision for securing armour of the cable separately and shall be provided with earthing tag. The glands shall conform to BS: 6121. A 240V, single phase, 50 Hz, 15 amp AC plug and socket shall be provided in the cabinet with ON-OFF switch for connection of hand lamps. Plug and socket shall be of industrial grade. For illumination of a 20 Watts flourscent tube or 15 watts CFL shall be provided. The switching of the fittings shall be controlled by the door switch. All control switches shall be of rotary switch type and Toggle/piano switches shall not be accepted. Positive earthing of the cabinet shall be ensured by providing two separate earthing pads. The earth wire shall be terminated on to the earthing pad and secured by the use of self etching washer. Earthing of hinged door shall be done by using a separate earth wire. The bay marshalling kiosks, if required, shall be provided with danger plate and a diagram showing the numbering/connection/feruling by pasting the same on the inside of the door. The bus bars in the bay marshalling kiosks shall be suitably covered to guard against unintentional contact. a. The following routine tests along with the routine tests as per IS: 5039 shall also be conducted: i. Check for wiring ii. Visual and dimension check b. The enclosure of bay marshalling kiosk, junction box, terminal box shall conform to IP-55 as per IS: 13947 including application of 2.5 kV rms for 1 (one) minute, insulation resistance and functional test after IP-55 test.
18.5
18.6
18.7
18.8 18.9 18.10
18.11
18.12
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19.0 AUXILIARY SWITCHES (APPLICABLE FOR ISOLATORS AND CIRCUIT BREAKERS)
The following type test reports on auxiliary switches shall be submitted for approval: a. Electrical endurance test - A minimum of 2000 operation for 2A DC with a time constant greater than or equal to 20 millisecond with a subsequent examination of mV drop/visual defects/temperature rise test. b. Mechanical endurance test. A minimum of 1,00,000 operations with a subsequent checking of contact pressure test/visual examination. c. Heat run test on contacts. d. IR/HV test etc. 20.0 TERMINAL BLOCKS AND WIRING 20.1 Control and instrument leads from the switchboards or from other equipment will be brought to terminal boxes or control cabinets in conduits. All inter-phase and external connections to equipment or to control cubicles will be made through terminal blocks. Terminal blocks shall be 650 V grade and have continuous rating to carry the maximum expected current on the terminals. These shall be of moulded piece, complete with insulated barriers, stud type terminals, washers, nuts and lock nuts. Screw clamp, overall insulated, insertion type, rail mounted terminals can be used in place of stud type terminals. But preferably the terminal blocks shall be nondisconnecting stud type equivalent to Elmex type CATM4, Phoenix cage clamp type of Wago or equivalent. Terminal blocks for current transformer and voltage transformer secondary leads shall be provided with test links and isolating facilities. The current transformer secondary leads shall also be provided with short circuiting and earthing facilities. The terminal shall be such that maximum contact area is achieved when a cable is terminated. The terminal shall have a locking characteristic to prevent cable from escaping from the terminal clamp unless it is done intentionally. The conducting part in contact with cable shall preferably be tinned or silver plated however Nickel plated copper or zinc plated steel shall also be acceptable. The terminal blocks shall be of extensible design. The terminal blocks shall have locking arrangement to prevent its escape from the mounting rails. The terminal blocks shall be fully enclosed with removable covers of transparent, nondeteriorating type plastic material. Insulating barriers shall be provided between the terminal blocks. These barriers shall not hinder the operator from carrying out the wiring without removing the barriers. Unless otherwise specified terminal blocks shall be suitable for connecting the following conductors on each side. a) All circuits except CT circuits: b) All CT circuits: Minimum 2x2.5 sq. mm flexible copper. Minimum 4x2.5 sq. mm flexible copper.
20.2
20.3
20.4
20.5 20.6 20.7 20.8
20.9
20.10 The arrangements shall be in such a manner so that it is possible to safely connect or disconnect terminals on live circuits and replace fuse links when the cabinet is live. 20.11 At least 20% spare terminals shall be provided on each panel/cubicle/box and these spare terminals shall be uniformly distributed on all terminals rows. 20.12 There shall be a minimum clearance of 250 mm between the First/bottom row of terminal block and the associated cable gland plate. Also the clearance between two rows of terminal blocks shall be a minimum of 150 mm.
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20.13 The Contractor shall furnish all wire, conduits and terminals for the necessary interphase electrical connections (where applicable) as well as between phases and common terminal boxes or control cabinets. In order to avoid surge over-voltages either transferred through the equipment or due to transients induced from the EHV circuits, the wiring required in these items shall be run in metallic ducts or shielded cables. 20.14 All input and output terminals of each control cubicle shall be tested for surge withstand capability in accordance with the relevant IEC Publications, in both longitudinal and transverse modes. The Contractor shall also provide all necessary filtering, surge protection, interface relays and any other measures necessary to achieve an impulse withstand level at the cable interfaces of the equipment 21.0 LAMPS AND SOCKETS 21.1 Lamps All incandescent lamps shall use a socket base as per IS-1258, except in the case of signal lamps. 21.2 Sockets All sockets (convenience outlets) shall be suitable to accept both 5 Amp & 15 Amp pin round Standard Indian plugs. They shall be switched sockets with shutters. 21.3 Hand Lamp: A 240 Volts, single Phase, 50 Hz AC plug point shall be provided in the interior of each cubicle with ON-OFF Switch for connection of hand lamps. 21.4 Switches and Fuses: 21.4.1 Each panel shall be provided with necessary arrangements for receiving, distributing, isolating and fusing of DC and AC supplies for various control, signalling, lighting and space heater circuits. The incoming and sub-circuits shall be separately provided with switch fuse units. Selection of the main and Sub-circuit fuse ratings shall be such as to ensure selective clearance of subcircuit faults. Potential circuits for relaying and metering shall be protected by HRC fuses. 21.4.2 All fuses shall be of HRC cartridge type conforming to IS: 9228 mounted on plug-in type fuse bases. Miniature circuit breakers with thermal protection and alarm contacts will also be accepted. 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. 22.0 BUSHINGS, HOLLOW COLUMN INSULATORS, SUPPORT INSULATORS: 22.1 Bushings shall be manufactured and tested in accordance with IS: 2099 & IEC: 137 while hollow column insulators shall be manufactured and tested in accordance with IEC 233/IS 5621. The support insulators shall be manufactured and tested as per IS 2544/IEC 168 and IEC 273. The insulators shall also conform to IEC 815 as applicable. The bidder may also offer composite silicon insulator, conforming to IEC-1109. 22.2 Support insulators, bushings and hollow column insulators shall be manufactured from high quality porcelain. Porcelain used shall be homogeneous, free from laminations, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified tough and impervious to moisture. Glazing of the porcelain shall be uniform brown in colour, free from blisters, burrs and similar other defects.
22.3
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22.4
Support insulators/bushings/hollow column insulators shall be designed to have ample insulation, mechanical strength and rigidity for the conditions under which they will be used. When operating at normal rated voltage there shall be no electric discharge between the conductors and bushing which would cause corrosion or injury to conductors, insulators or supports by the formation of substances produced by chemical action. No radio interference shall be caused by the insulators/bushings when operating at the normal rated voltage. Bushing porcelain shall be robust and capable of withstanding the internal pressures likely to occur in service. The design and location of clamps and the shape and the strength of the porcelain flange securing the bushing to the tank shall be such that there is no risk of fracture. All portions of the assembled porcelain enclosures and supports other than gaskets, which may in any way be exposed to the atmosphere shall be composed of completely non hygroscopic material such as metal or glazed porcelain. All iron parts shall be hot dip galvanised and all joints shall be air tight. Surface of joints shall be trued up porcelain parts by grinding and metal parts by machining. Insulator/bushing design shall be such as to ensure a uniform compressive pressure on the joints. Tests In bushing, hollow column insulators and support insulators shall conform to type tests and shall be subjected to routine tests in accordance with IS: 2099 & IS: 2544 & IS: 5621. The type test reports shall be submitted for approval.
22.5
22.6
22.7
22.8
23.0 MOTORS Motors shall be Squirrel Cage three phase induction motors of sufficient size capable of satisfactory operation for the application and duty as required for the driven equipment and shall be subjected to routine tests as per applicable standards. The motors shall be of approved make. 23.1 Enclosures a. Motors to be installed outdoor without enclosure shall have hose proof enclosure equivalent to IP 55 as per IS: 4691. For motors to be installed indoor i.e. inside a box, the motor enclosure, shall be dust proof equivalent to IP 44 as per IS: 4691. b. Two independent earthing points shall be provided on opposite sides of the motor for bolted connection of earthing conductor. c. Motors shall have drain plugs so located that they will drain water resulting from condensation or other causes from all pockets in the motor casing. d. Motors weighing more than 25 Kg. shall be provided with eyebolts, lugs or other means to facilitate lifting. 23.2 Operational Features a. Continuous motor rating (name plate rating) shall be at least ten (10) percent above the maximum load demand of the driven equipment at design duty point and the motor shall not be over loaded at any operating point of driven equipment that will rise in service. b. Motor shall be capable at giving rated output without reduction in the expected life span when operated continuously in the system having the particulars as given in Clause 15.0 of this Section.
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23.3
Starting Requirements: a. All induction motors shall be suitable for full voltage direct-on-line starting. These shall be capable of starting and accelerating to the rated speed along with the driven equipment without exceeding the acceptable winding temperature even when the supply voltage drops down to 80% of the rated voltage. b. Motors shall be capable of withstanding the electro-dynamic stresses and heating imposed if it is started at a voltage of 110% of the rated value. c. The locked rotor current shall not exceed six (6) times the rated full load current for all motors, subject to tolerance as given in IS: 325. d. Motors when started with the driven equipment imposing full starting torque under the supply voltage conditions specified under Clause 15.0 shall be capable of withstanding at least two successive starts from cold condition at room temperature and one start from hot condition without injurious heating of winding. The motors shall also be suitable for three equally spread starts per hour under the above referred supply condition. e. The locked rotor withstand time under hot condition at 110% of rated voltage shall be more than starting time with the driven equipment of minimum permissible voltage by at least two seconds or 15% of the accelerating time whichever is greater. In case it is not possible to meet the above requirement, the Bidder shall offer centrifugal type speed switch mounted on the motor shaft which shall remain closed for speed lower than 20% and open for speeds above 20% of the rated speed. The speed switch shall be capable of withstanding 120% of the rated speed in either direction of rotation.
23.4
Running Requirements: a. The maximum permissible temperature rise over the ambient temperature of 50 degree C shall be within the limits specified in IS:325 (for 3 - phase induction motors) after adjustment due to increased ambient temperature specified. b. The double amplitude of motor vibration shall be within the limits specified in IS: 4729. Vibration shall also be within the limits specified by the relevant standard for the driven equipment when measured at the motor bearings. c. All the induction motors shall be capable of running at 80% of rated voltage for a period of 5 minutes with rated load commencing from hot condition.
23.5
Testing and Commissioning An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the field Q.P./Instructions of the equipment Contractor or Purchaser without any extra cost to the Purchaser. The Contractor shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the Purchaser for approval. a. Insulation resistance. b. Phase sequence and proper direction of rotation. c. Any motor operating incorrectly shall be checked to determine the cause and the conditions corrected.
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24.0 TECHNICAL REQUIREMENT OF EQUIPMENTS 24.1 Circuit Breakers a. The manufacturer(s) whose SF6 Circuit Breaker are offered should have designed, manufactured tested as per IEC/IS or equivalent standard supplied the same for the specified system voltage and which are in satisfactory operation for at least 2 (two) years as on the date of bid opening. Or b. The manufacturer(s) whose SF6 Circuit Breaker are offered who have recently established production line in India for the specified system voltage or above class, based on technological support of a parent company or collaborator for the respective equipment(s) can also be considered provided the parent company (Principal) or collaborator meets qualifying requirements stipulated under clause no 24.1.a. given above. And Furnishes (jointly with parent company or collaborator) a legally enforceable undertaking to guarantee quality, timely supply, performance and warranty obligations as specified for the equipment(s) And Furnishes a confirmation letter from the parent company or collaborator along with the bid stating that parent company or collaborator shall furnish performance guarantee for an amount of 10% of the cost of such equipment(s). This performance guarantee shall be in addition to contract performance guarantee to be submitted by the Bidder. 24.2 Isolators The manufacturer whose isolators are offered, should have designed, manufactured, tested as per IEC/IS or equivalent standard and supplied the isolator for the specified system voltage and fault level and should be in satisfactory operation for at least 2 (two) years as on the date of bid opening. 24.3 Instrument Transformers The manufacturer whose instrument transformers are offered, should have designed, manufactured & tested as per IS/IEC or equivalent standard and supplied the same for the specified system voltage for CT & CVT and fault level in case of CT. These equipment should be in satisfactory operation for at least 2 (two) years as on the date of bid opening. 24.4 Surge Arresters The manufacturer whose Surge Arresters are offered should have designed, manufactured and tested as per IEC/IS or equivalent standard and supplied the Surge Arrester for the specified energy capability with rated system voltage and which are in satisfactory operation for at least 2 (two) years as on the date of bid opening. 24.5 1.1 kV Grade Power & Control Cables 24.5.1 Applicable for PVC Control Cable The manufacturers, whose PVC control cables are offered, should have designed, manufactured, tested and supplied in a single contract at least 100 kilometers of 1.1 kV grade PVC insulated control cables as on the date of bid opening. Further the manufacturer should also have designed, manufactured, tested and supplied at least 1 kilometers of 27Cx2.5 Sq. mm or higher size as on the date of bidding.
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24.5.2 Applicable for PVC Power Cable The manufacturer, whose PVC Power Cables are offered, should have designed, manufactured, tested and supplied in a single contract at least 100 kilometers of 1.1 kV or higher grade PVC insulated power cables as on the date of bid opening. Further the manufacturer should also have designed, manufactured, tested and supplied at least 1 kilometers of 1Cx150 Sq. mm or higher size as on the date of bid opening. 24.5.3 Applicable for XLPE Power Cables The Manufacturer, whose XLPE Power cables are offered, should have designed, manufactured, tested and supplied in a single contract at least 25 kilometers of 1.1 kV or higher grade XLPE insulated power cables as on the date of bid opening. Further the manufacturer should also have designed, manufactured, tested and supplied at least 1 kilometer of 1Cx630 Sq. mm or higher size as on the date of bid opening. 24.6 LT Switchgear 24.6.1 The Manufacturer whose LT Switchgear are offered, should be a manufacturer of LT Switchboards of the type and rating being offered. He should have designed, manufactured, tested and supplied at least 50 nos. draw out circuit breaker panels, out of which at least 5 numbers should have been with relay and protection schemes with current transformer. He should have also manufactured at least 50 numbers motor control center panels of the type and rating being offered which should be in successful operation as on date of bid opening. 24.6.2 The Switchgear items (such as circuit breakers, fuse switch units, contactors etc.), may be of his own make or shall be procured from reputed manufacturers and of proven design. At least one hundred circuit breakers of the make and type being offered shall be operating satisfactory as on date of bid opening. 24.7 Battery and Battery Charger 24.7.1 Requirements for Battery Manufacturers The manufacturer whose Batteries are offered should have designed, manufactured and supplied DC Batteries of the type specified and being offered, having a capacity of at least 600 AH and these shall be operating satisfactorily for two years in power sector and/or industrial installations as on date of bid opening. 24.7.2 Requirements for Battery Charger Manufacturers The manufacturer, whose Battery Chargers are offered, should have designed, manufactured and supplied Battery Chargers generally of the type offered, with static automatic voltage regulators and having a continuous output of at least ten (10) kW and these should be in successful as on the date of bid opening. 24.8 LT Transformers The manufacturer, whose transformers are offered should have designed, manufactured, type tested including short circuit test as per IEC/IS or equivalent standards and supplied transformers of at least 33 kV class of 800 kVA or higher. The transformer should have been in successful operation for at least 2 years as on the date of bid opening.
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24.9
Fire Fighting System The bidder or his sub-vendor should have designed, supplied, tested, erected and commissioned at least one number fire protection system of the each type described in (i), (ii) and (iii) below in installations such as power plants, substations, refineries, fertilizer plants or other industrial or commercial installations. Such systems must have been designed to the recommendations of Tariff Advisory Committee of India or any other international reputed authority like (FOC, London or NFPA, USA etc.) executed during last ten (10) years and should have been in successful operation for at least 2 years as on the date of bid opening. (i) (ii) (iii) Automatic hydrant type fire protection system. Automatic high velocity or automatic medium velocity water spray type fire protection system. Smoke detection system.
In case bidder himself do not meet the requirement of design, he can engage a consultant(s) who must have designed i) Automatic hydrant type fire protection system, ii) Automatic high velocity or automatic medium velocity water spray type fire protection system and iii) Smoke detection system, which must be in successful operation for at least two years as on the date of bid opening. 24.10 Control and Relay Panels 24.10.1 The manufacturer whose C&R panels and protective relay are offered should have designed, manufactured, tested, installed and commissioned C&R panels including protection relays which must be in satisfactory operation on 132 kV system for at least 2 (two) years on the date of bid opening. 24.10.2 The C&R Panel from a manufacturer whose have designed, manufactured, tested, installed and commissioned C&R panels which are in satisfactory operation on 132 kV system for at least 2 (two) years on the date of bid opening can also be offered, provided the protective relay schemes should be offered from a Contractor who fully meets the requirements stipulated under clause 24.10.1 above. Further, in such an event the manufacturer shall furnish an undertaking jointly executed by him and his protective relay schemes Supplier, as per the format enclosed in the bid documents for successful performance of the protection system offered. 24.11 PLCC 24.11.1 The manufacturer whose PLCC panels are offered should have designed, manufactured, tested, supplied and commissioned PLCC panels for the specified voltage level and the same should be in successful operation for at least 2 (two) years as on the date of bid opening. 24.11.2 The manufacturer whose line traps are offered should have designed, manufactured tested, supplied and commissioned similar line traps for the specified voltage and fault level and should be successful operation for at least 2 (two) years as on the date of bid opening. 24.11.3 PLCC Panels/line traps manufactured by the manufacturer meeting the requirements at Clause No. 24.11.1 & 24.11.2 except that the PLCC Panels/line traps manufactured, tested and supplied by them is not in operation for the stipulated period can also be offered provided the manufacturer furnishes an undertaking jointly executed by him and his collaborator, who in turn fully meets the requirement specified at 24.11.1/24.11.2 above as per the format enclosed in the bid document for successful performance of the equipment offered.
Part-III (Vol. 2/2)
29
Annexure-A LIST OF SPECIFICATIONS GENERAL STANDARDS AND CODES India Electricity Rules Indian Electricity Act Indian Electricity (Supply) Act Indian Factories Act IS-5 IS-335 IS-617 Colors for Ready Mixed Paints and Enamels. New Insulating Oils. Aluminum and Aluminum Alloy Ingots and Castings for General Engineering Purposes. Methods of Test for Petroleum and its Products. Methods of High Voltage Testing. Classification of degrees of protection provided by enclosures of electrical equipment.
IS-1448 (P1 to P 145) IS-2071 (P1 to P3) IS-12063 IS-2165 P1:1997 P2:1983 IS-3043 IS-6103 IS-6104 IS-6262 IS-6792 IS-5578 IS-11353 IS-8263 -
Insulation Coordination.
Code of Practice for Earthing. Method of Test for Specific Resistance (Resistivity) of Electrical Insulating Liquids. Method of Test for Interfacial Tension of Oil against Water by the Ring Method. Method of test for Power factor & Dielectric Constant of Electrical Insulating Liquids. Method for determination of electric strength of insulating oils. Guide for marking of insulated conductors. Guide for uniform system of marking & identification of conductors & apparatus terminals. Methods for Radio Interference Test on High voltage Insulators. Low Voltage Fuses
IS-9224 (Part-1, 2 & 4) -
IEC-60060 (Part 1 to P4) - High Voltage Test Techniques IEC 60068 IEC-60117 IEC-60156 IEC-60270 IEC-60376 IEC-60437 IEC-60507
Part-III (Vol. 2/2)
Environmental Test Graphical Symbols Method for the Determination of the Electrical Strength of Insulation Oils. Partial Discharge Measurements. Specification and Acceptance of New Sulphur Hexafloride Radio Interference Test on High Voltage Insulators. Artificial Pollution Tests on High Voltage Insulators to be used on AC Systems.
30
IEC-6094 IEC-60815 IEC-60865 (P1 & P2) ANSI-C.1/NFPA.70 ANSI-C37.90A ANSI-C63.21 C63.3 C36.4ANSI-C68.1 ANSI-C76.1/EEE21 ANSI-SI-4 ANSI-Y32-2/C337.2 ANSI-Z55.11 NEMA-107T NEMA-ICS-II CISPR-1 CSA-Z299.1-1978h CSA-Z299.2-1979h CSA-Z299.3-1979h CSA-Z299.4-1979h
Common Specification for High Voltage Switchgear & Control gear Standards. Guide for the Selection of Insulators in respect of Polluted Conditions. Short Circuit Current - Calculation of effects. National Electrical Code. Guide for Surge Withstand Capability (SWC) Tests. Specification for Electromagnetic Noise and. Field Strength Instrumentation 10 KHz to 1 GHZ. Techniques for Dielectric Tests. Standard General Requirements and Test Procedure for Outdoor Apparatus Bushings. Specification for Sound Level Meters. Drawing Symbols. Gray Finishes for Industrial Apparatus and Equipment No. 61 Light Gray. Methods of Measurements of RIV of High Voltage Apparatus. General Standards for Industrial Control and Systems Part ICSI-109. Specification for CISPR Radio Interference Measuring Apparatus for the frequency range 0.15 MHz to 30 MHz. Quality Assurance Program Requirements. Quality Control Program Requirements. Quality Verification Program Requirements. Inspection Program Requirements.
TRANSFORMERS AND REACTORS IS:10028 (Part 2 & 3) IS-2026 (P1 to P4) Code of practice for selection, installation & maintenance of Transformers (P1:1993), (P2:1991), (P3:1991). Power Transformers.
IS-3347 (part 1 to Part 8)- Dimensions for Porcelain transformer Bushings for use in lightly polluted atmospheres. IS-3639 IS-6600 Fittings and Accessories for Power Transformers. Guide for Loading of Oil immersed Transformers.
IEC-60076 (Part 1 to Part 5) - Power Transformers. IEC-60214 IEC-60289 IEC- 60354 IEC-60076-10 ANSI-C571280 ANSI-C571290 ANSI-C5716
Part-III (Vol. 2/2)
On-Load Tap-Changers. Reactors. Loading Guide for Oil - Immersed power transformers. Determination of Transformer and Reactor Sound Levels. General requirements for Distribution, Power and Regulating Transformers. Test Code for Distribution, Power and Regulation Transformers. Terminology & Test Code for Current Limiting Reactors.
31
ANSI-C5721 ANSI-C5792 ANSI-CG,1EEE-4 CIRCUIT BREAKERS IEC-62271-100 IEC-60427 IEC-61264
Requirements, Terminology and Test Code for Shunt Reactors Rated over 500 kVA. Guide for Loading Oil-Immersed Power Transformers up to and including 100 MVA with 55 deg C or 65 deg C Winding Rise. Standard Techniques for High Voltage Testing.
High Voltage Alternating Current Circuit Breakers. Synthetic Testing of High Voltage alternating current circuit Breakers. Pressurised Hollow Column Insulators.
CURRENT TRANSFORMERS, VOLTAGE TRANSFORMERS AND COUPLING CAPACITOR VOLTAGE TRANSFORMERS IS-2705- (P1 to P4) IS:3156- (P1 to P4) IS-4379 IEC-60044-1 IEC-60044-2 IEC-60358 IEC-60044-4 IEC-60481 ANSI-C5713 ANSIC92.2 ANSI-C93.1 IS-2099 IEC-60137 SURGE ARRESTERS IS-3070 (PART2) IEC-60099-4 IEC-60099-5 ANSI-C62.1 NEMA-LA 1 Lightning arresters for alternating current systems: Metal oxide lightning arrestors without gaps. Metal oxide surge arrestors without gaps. Selection and application recommendation. IEE Standards for S A for AC Power Circuits. Surge Arresters. Current Transformers. Voltage Transformers. Identification of the Contents of Industrial Gas Cylinders. Current transformers. Voltage Transformers. Coupling capacitors and capacitor dividers. Instrument Transformers: Measurement of Partial Discharges. Coupling Devices for Power Line Carrier Systems. Requirements for Instrument transformers. Power Line Coupling voltage Transformers. Requirements for Power Line Carrier Coupling Capacitors Bushing. Bushings for Alternating Voltages above 1000V. Insulated Bushings for Alternating Voltages above 1000V.
CUBICLES AND PANELS & OTHER RELATED EQUIPMENTS IS-722, IS-1248, IS-3231, 3231 (P-3) - Electrical relays for power system protection. IS:5039 IEC-60068.2.2 IEC-60529 IEC-60947-4-1 IEC-61095 IEC-60439 (P1 & 2) ANSI-C37.20
Part-III (Vol. 2/2)
Distributed pillars for Voltages not Exceeding 1000 Volts. Basic environmental testing procedures Part-2: Test B: Dry heat. Degree of Protection provided by enclosures. Low voltage switchgear and control gear. Electromechanical Contactors for household and similar purposes. Low Voltage Switchgear and control gear assemblies. Switchgear Assemblies, including metal enclosed bus.
32
ANSI-C37.50 ANSI-C39 ANSI-C83
Test Procedures for Low Voltage Alternating Current Power Circuit Breakers. Electric Measuring instrument. Components for Electric Equipment. Specification for Switchgear & Control Assemblies. Moulded Case Circuit and Systems. Industrial Controls and Systems. Panel Boards. Low voltage Power Circuit breakers. Power Switchgear Assemblies. Power switching Equipment. Motor Control Centers. Direct acting indicating analogue electrical measuring instruments & their accessories.
IS: 8623: (Part I to 3) NEMA-AB NEMA-CS NEMA-PB-1 NEMA-SG-5 NEMA-SG-3 NEMA-SG-6 NEMA-5E-3 1248 (P1 to P9) -
Disconnecting switches IEC-60129 IEC-1129 Alternating Current Disconnectors (Isolators) and Earthing switches. Alternating Current Earthing Switches Induced Current switching.
IEC-60265 (Part 1 & Part 2) - High Voltage switches. ANSI-C37.32 Schedule of preferred Ratings, Manufacturing Specifications and Application Guide for high voltage Air Switches, Bus supports and switch accessories. Test Code for high voltage air switches. Power switching equipment.
ANSI-C37.34 NEMA-SG6 PLCC and line traps IS-8792 IS-8793 IS-8997 IS-8998 IEC-60353 IEC-60481 IEC-60495 IEC-60683 CIGRE CIGRE CCIR CCITT EIA
Line traps for AC power system. Methods of tests for line traps. Coupling devices for PLC systems. Methods of test for coupling devices for PLC systems. Line traps for A.C. power systems. Coupling Devices for Power Line Carrier systems. Single Side Board Power Line Carrier terminals. Planning of (Single Side-Band) Power Line Carrier systems. Tele-protection report by Committee 34 & 35. Guide on power line carrier 1979. International Radio Consultative Committee. International Telegraph & Telephone Consultative Committee. Electric Industries Association.
Protection and control equipment IEC-60051 : (P1 to P9) Recommendations for Direct Acting indicating analogue electrical measuring instruments and their accessories.
Part-III (Vol. 2/2)
33
IEC-60255 (Part 1 to part 23) - Electrical relays. IEC-60297 (P1 to P4) IEC-60359 IEC-60387 IEC-60447 IEC-60521 IEC-60547 ANSI-81 ANSI-B18 ANSI-C37.1 ANSI-C37.2 ANSI-C37.2 ANSI-C39.1 MOTORS IS-325 IS-4691 Three phase induction motors. Degree of protection provided by enclosure for rotating electrical machinery. Rotating electrical machines. Three phase induction motors (Central Office) NEMA-MGI Motors and Generators. Dimensions of mechanical structures of the 482.6mm (19 inches) series. Expression of the performance of electrical & electronic measuring equipment. Symbols for Alternating-Current Electricity meters. Man machine interface (MMI) Actuating principles. Class 0.5, 1 and 2 alternating current watt hour meters. Modular plug-in Unit and standard 19-inch rack mounting unit based on NIM Standard (for electronic nuclear instruments). Screw threads. Bolts and Nuts. Relays, Station Controls etc. Manual and automatic station control, supervisory and associated tele-metering equipment. Relays and relay systems associated with electric power apparatus. Requirements for electrical analog indicating instruments.
IEC-60034 (P1 to P19:) IEC-Document 2 -
Electronic equipment and components MIL-21B, MIL-833 & MIL-2750. IEC-60068 (P1 to P5) Environmental testing. IEC-60326 (P1 to P2): Printed boards. Material and workmanship standards. IS-1363 (P1 to P3) IS-1364 (P1 to P5) IS-3138 ISO-898 ASTM Hexagon head bolts, screws and nuts of product grade C. Hexagon head bolts, screws and nuts of products grades A and B. Hexagonal Bolts and Nuts (M42 to M150). Fasteners: Bolts, screws and studs. Specification and tests for materials.
Clamps & connectors IS-5561 NEMA-CC1 NEMA-CC 3 Electric power connectors. Electric Power connectors for sub station. Connectors for Use between aluminum or aluminum-Copper Overhead Conductors.
Bus hardware and insulators

34
IS: 2121 IS-731 IS-2486 (P1 to P4) IEC-60120 IEC-60137 IEC-60168 IEC-60233 IEC-60273 IEC-60305
Fittings for Aluminum and steel cored aluminum conductors for overhead power lines. Porcelain insulators for overhead power lines with a nominal voltage greater than 1000 V. Insulator fittings for overhead power lines with a nominal voltage greater than 1000 V. Dimensions of Ball and Socket Couplings of string insulator units. Insulated bushings for alternating voltages above 1000 V. Tests on indoor and outdoor post insulators of ceramic material or glass for Systems with Nominal Voltages Greater than 1000 V. Tests on Hollow Insulators for use in electrical equipment. Characteristics of indoor and outdoor post insulators for systems with nominal voltages greater than 1000 V. Insulators for overhead lines with nominal voltage above 1000Vceramic or glass insulator units for a.c. systems characteristics of String Insulator Units of the cap and pin type. Locking devices for ball and socket couplings of string insulator units: dimensions and tests. Insulators for overhead lines with a nominal voltage above 1000 V. Characteristics of string insulator units of the long rod type. Dimensions of Clevis and tongue couplings of string insulator units. Wet process porcelain insulators. Test methods for electrical power insulators. For insulators, wet-process porcelain and toughened glass suspension type. For wet-process porcelain insulators apparatus, post-type. Iron and steel hardware. Recommendations of the CISPR, tolerances of form and of Position, Part I. Zinc Coating (Hot-Dip) on iron and steel hardware.
IEC-60372 (1984)
IEC-60383 (P1 and P2) IEC-60433 IEC-60471 ANSI-C29 ANSI-C29.1 ANSI-C92.2 ANSI-C29.8 ANSI-G.8 CISPR-7B ASTM A-153 -
Strain and rigid bus-conductor IS-2678 IS-5082 ASTM-B 230-82 ASTM-B 231-81 ASTM-B 221 ASTM-B 236-83 ASTM-B 317-83 Dimensions & tolerances for Wrought Aluminum and Aluminum Alloys drawn round tube. Wrought Aluminum and Aluminum Alloy Bars. Rods, Tubes and Sections for Electrical purposes. Aluminum 1350 H19 Wire for electrical purposes. Concentric - lay - stranded, aluminum 1350 conductors. Aluminum - Alloy extruded bar, road, wire, shape. Aluminum bars for electrical purpose (Bus-bars). Aluminum-Alloy extruded bar, rod, pipe and structural shapes for electrical purposes (Bus Conductors).
BATTERIES AND BATTERIES CHARGER

35
Battery IS: 1651 IS: 1652 IS: 1146 IS: 6071 IS: 266 IS: 1069 IS: 3116 IS: 1248 Battery Charger IS: 3895 IS: 4540 IS: 6619 IS: 2026 IS: 2959 IS: 1248 IS: 2208 IS: 13947 (Part-3) IS: 2147 IS: 6005 IS: 3231 IS: 3842 IS: 5 IEEE-484 IEEE-485 Mono-crystalline Semiconductor Rectifier Cells and Stacks. Mono-crystalline Semiconductor Rectifier Assemblies and Equipment. Safety Code for Semiconductor Rectifier Equipment. Power Transformers. AC Contactors for Voltages not Exceeding 1000 Volts. Indicating Instruments. HRC Fuses. Air break switches, air break disconnectors & fuse combination units for voltage not exceeding 1000V AC or 1200V DC. Degree of protection provided by enclosures for low voltage switchgear and control gear. Code of practice for phosphating of Iron and Steel. Electrical relays for power system protection. Electrical relay for AC Systems. Colours for ready mix paint. Recommended Design for installation design and installation of large lead storage batteries for generating stations and substations. Sizing large lead storage batteries for generating stations and substations. Stationary Cells and Batteries, Lead-Acid Type (with Tubular Positive Plates). Stationary Cells and Batteries, Lead-Acid Type (with Plane Positive Plates). Rubber and Plastic Containers for Lead-Acid Storage Batteries. Synthetic Separators for Lead-Acid Batteries. Specification for Sulphuric Acid. Specification for Water for Storage Batteries. Specification for Sealing Compound for Lead-Acid Batteries. Indicating Instruments.
Wires and cables ASTMD-2863 IS-694 IS-1255 IS-1554 (P1 and P2) IS: 1753
Part-III (Vol. 2/2)
Measuring the minimum oxygen concentration to support candle like combustion of plastics (oxygen index). PVC insulated cables for working voltages up to and including 1100 Volts. Code of practice for installation and maintenance of power cables, up to and including 33 kV rating. PVC insulated (heavy duty) electric cables, Part-1 for working voltage upto and including 1100 V. Part-2 for working voltage from 3.3 kV upto and including 11 kV. Aluminum conductor for insulated cables.
36
IS:2982 IS: 3961 (P1 to P5) IS: 3975 IS: 5831 IS: 6380 IS: 7098 IS: 7098 IS: 8130 IS: 1753 IS: 10418
Copper Conductor in insulated cables. Recommended current ratings for cables. Mild steel wires, formed wires and tapes for armouring of cables. PVC insulating and sheath of electric cables. Electro-metric insulating and sheath of electric cables. Cross linked polyethylene insulated PVC sheathed cables for working voltage upto and including 1100 volts. Cross-linked polyethyle insulated PVC sheathed cables for working voltage from 3.3 kV upto and including 33 kV. Conductors for insulated electrical cables and flexible cord. Aluminum Conductors for insulated cables. Specification for drums for electric cables. Radio Frequency cables. Guide to the Selection of High Voltage Cables. Low frequency cables and wires with PVC insulation and PVC sheath. Polyvinyl Chloride insulated cables of rated voltages up to and including 450/750V. Conductors of insulated cables. Impulse tests on cables and their accessories. Calculation of the continuous current rating of cables (100% load factor). Standard colours for insulation for low-frequency cables and wires. Fire resisting characteristics of Electric cables. Tests on electric cables under fire conditions. Extruded solid dielectric insulated power cables for rated voltages from 1 kV upto to 30 kV. Tests on gases evolved during combustion of electric cables.
IEC: 60096 (P 0 to P4) IEC: 60183 -
IEC: 60189 (P1 to P7) IEC: 60227 (P1 to P7) IEC: 60228 IEC: 60230 -
IEC: 60287 (P1 to P3) IEC: 60304 IEC: 60331 -
IEC: 60332 (P1 to P3) IEC: 60502 -
IEC: 754 (P1 and P2) -
Air Conditioning and Ventilation IS: 659 IS: 660 ARI: 520 IS: 4503 ASHRAE-24 ANSI-B-31.5 IS: 2062 IS: 655 IS: 277 IS: 737 IS: 1079 IS: 3588
Part-III (Vol. 2/2)
Safety code for air conditioning. Safety code for Mechanical Refrigeration. Standard for Positive Displacement Refrigeration Compressor and Condensing Units. Shell and tube type heat exchanger. Method of testing for rating of liquid coolers. Refrigeration Piping. Steel for general structural purposes. Specification for Metal Air Dust. Specification for Galvanised Steel Sheets. Specification for Wrought Aluminium and Aluminium Sheet & Strip. Hot rolled cast steel sheet & strip. Specification for Electrical Axial Flow Fans.
37
IS: 2312 BS-848 BS-6540 Part-I BS-3928 US-PED-2098 MIL-STD-282 ASHRAE-52 IS: 3069 IS: 4671 IS: 8183 IS: 3346 ASTM-C-591-69 IS: 4894 BS: 848 IS: 325 IS: 4722 IS: 1231 IS: 2233 IS: 2254 IS: 7816 IS: 4029 IS: 4729 IS: 4691 IS: 7572 IS: 2148 BS: 4999 (Part-51) Galvanizing IS: 209 IS-2629 IS-2633 ASTM-A-123
Propeller Type AC Ventilation Fans. Methods of Performance Test for Fans. Air Filters used in Air Conditioning and General Ventilation. Sodium Flame Test for Air Filters (Other than for Air Supply to I.C. Engines and Compressors). Method of cold DOP & hot DOP test. DOP smoke penetration method. Air cleaning device used in general ventilation for removing particle matter. Glossary of Terms, Symbols and Units Relating to Thermal Insulation Materials. Expanded Polystyrene for Thermal Insulation Purposes. Bonded Mineral Wool. Evaluation of Thermal Conductivity properties by means of guarded hot plate method. Standard specification for rigid preformed cellular urethane thermal insulation. Centrifugal Fans. Method of Performance Test for Centrifugal Fans. Induction motors, three-phase. Rotating electrical machines. Three phase foot mounted Induction motors- dimensions. Designations of types of construction and mounting arrangements of rotating electrical machines. Vertical shaft motors for pumps- dimensions Guide for testing insulation resistance of rotating machines. Guide for testing three phase induction motors. Rotating electrical machines, vibration, measurement and evaluation. Degree of protection provided by enclosures for rotating electrical machinery. Guide for testing single-phase a.c. motors. Flame proof enclosure for electrical apparatus. Noise levels.
Zinc Ingot. Recommended Practice for Hot-Dip galvanizing on iron and steel. Methods for testing uniformity of coating of zinc coated articles. Specification for zinc (Hot Galavanizing) Coatings, on products Fabricated from rolled, pressed and forged steel shapes, plates, bars and strips. Zinc-coated (Galvanized) steel barbed wire.
ASTM-A-121-77
Part-III (Vol. 2/2)
38
Painting IS-6005 ANSI-Z551 SSPEC Code of practice for phosphating of iron and steel. Gray finishes for industrial apparatus and equipment. Steel structure painting council.
Fire protection system Fire protection manul issued by tariff advisory committee (TAC) of India HORIZONTAL CENTRIFUGAL PUMPS IS: 1520 IS: 9137 IS: 5120 API-610 BS: 599 PTC-8.2 DIESEL ENGINES IS: 10000 IS: 10002 BS: 5514 ISO: 3046 IS: 554 Methods of tests for internal combustion engines. Specification for performance requirements for constant speed compression ignition engines for general purposes (above 20 kW). The performance of reciprocating compression ignition (Diesel) engines, utilising liquid fuel only, for general purposes. Reciprocating internal combustion engines performance. Dimensions for pipe threads where pressure tight joints are required on threads. Internal combustion engine. Codes of Diesel Engine Manufacturers Association, USA. Horizontal centrifugal pumps for clear, cold and fresh water. Code for acceptance test for centrifugal & axial pumps. Technical requirement - Rotodynamic special purpose pumps. Centrifugal pumps for general services. Hydraulic Institutes Standards. Methods of testing pumps. Power Test Codes - Centrifugal pumps.
ASME Power Test Code PTC-17 -
PIPING VALVES & SPECIALITIES IS: 636 IS: 638 IS: 778 IS: 780 IS: 901 IS: 902 IS: 903 IS: 1538 IS: 1903 IS: 2062 IS: 2379 IS: 2643
Part-III (Vol. 2/2)
Non percolating flexible fire fighting delivery hose. Sheet rubber jointing and rubber inserting jointing. Gun metal gate, globe and check valves for general purpose. Sluice valves for water works purposes (50 to 300 mm). Couplings, double male and double female instantaneous pattern for fire fighting. Suction hose couplings for fire fighting purposes. Fire hose delivery couplings branch pipe nozzles and nozzle spanner. Cast iron fittings for pressure pipes for water, gas and sewage. Ball valve (horizontal plunger type) including floats for water supply purposes. SP for weldable structural steel. Colour Code for the identification of pipelines. Dimensions of pipe threads for fastening purposes.
39
IS: 2685 IS: 2906 IS: 3582 IS: 3589 IS: 4038 IS: 4927 IS: 5290 IS: 5312 (Part-I) IS: 5306 Part-I Part-II BS: 5150
Code of Practice for selection, installation and maintenance of sluice valves. Sluice valves for water-works purposes (350 to 1200 mm size). Basket strainers for fire fighting purposes (cylindrical type). Electrically welded steel pipes for water, gas and sewage (150 to 2000 mm nominal diameter). Foot valves for water works purposes. Unlined flax canvas hose for fire fighting. Landing valves (internal hydrant). Swing check type reflex (non-return) valves. Code of practice for fire extinguishing installations and equipment on premises. Hydrant systems, hose reels and foam inlets. Sprinkler systems. Specification for cast iron gate valves.
MOTORS & ANNUNCIATION PANELS IS: 325 IS: 900 IS: 996 IS: 1231 IS: 2148 IS: 2223 IS: 2253 IS: 2254 IS: 3202 IS: 4029 IS: 4691 IS: 4722 IS: 4729 IS: 5572 IS: 6362 IS: 6381 IS: 7816 IS: 4064 IEC DOCUMENT 2 (Control Office) 432
Three phase induction motors. Code of practice for installation & maintenance of induction motors. Single phase small AC and universal electric motors. Dimensions of three phase foot mounted induction motors. Flame proof enclosure of electrical apparatus. Dimensions of flange mounted AC induction motors. Designations for types of construction and mounting arrangements of rotating electrical machines. Dimensions of vertical shaft motors for pumps. Code of practice for climate proofing of electrical equipment. Guide for testing three phase induction motors. Degree of protection provided by enclosure for rotating electrical machinery. Rotating electrical machines. Measurement and evaluation of vibration of rotating electrical machines. Classification of hazardous areas for electrical (Part-I) installations (Areas having gases and vapours). Designation of methods of cooling for rotating electrical machines. Construction and testing of electrical apparatus with type of protection e. Guide for testing insulation for rotating machine. Air break switches. Three Phase Induction Motor.
40
VDE 0530 Part I/66 IS: 9224 (Part-II) IS: 6875 IS: 694 IS: 1248 IS: 375 IS: 2147 IS: 5 IS: 2959 PG Test Procedures NFPA-13 NFPA-15 NFPA-12A NFPA-72E
Three Phase Induction Motor. HRC Fuses Push Button and Control Switches. PVC Insulated cables. Indicating instruments. Auxiliary wiring & busbar markings. Degree of protection. Colour Relay and timers. Contactors.
Standard for the installation of sprinkler system. Standard for water spray fixed system for the fire protection. Standard for Halong 1301 Fire Extinguishing System. Standard on Automatic Fire Detectors.
Fire Protection Manual by TAC (Latest Edition) NFPA-12 IS: 3034 Standard on Carbon dioxide extinguisher systems. Fire of industrial building:
Electrical generating and distributing stations code of practice IS: 2878 IS: 2171 IS: 940 D.G. SET IS: 10002 IS: 10000 IS: 4722 IS: 12063 IS: 12065 STEEL STRUCTURES IS: 228 (1992) IS: 802 (P1 to P3) IS: 806 IS: 808 Method of Chemical Analysis of pig iron, cast iron and plain carbon and low alloy steels. Code of practice for use of structural steel in overhead transmission line towers. Code of practice for use of steel tubes in general building construction. Dimensions for hot rolled steel beam, column channel and angle sections. Specification for performance requirements for constant speed compression ignition (diesel engine) for general purposes. Method of tests for internal combustion engines. Rotating electrical machines-specification. Degree of protection provided by enclosures. Permissible limit of noise levels for rotating electrical machines. Indian Explosive Act 1932. CO2 (Carbon dioxide) Type Extinguisher. DC (Dry Chemical Powder) type. Pressurised Water Type.
Part-III (Vol. 2/2)
41
IS: 814 manganese steel. IS: 816 IS: 817 IS-875 (P1 to P4) IS: 1161 IS: 1182 IS: 1363 (P1 to P3) IS: 1364 IS: 1367 (P1 to P18) IS: 1599 IS: 1608 IS: 1893 IS: 1978 IS: 2062 IS: 2595 IS: 3063 IS: 3664 IS: 7205 IS: 9595 ANSI-B18.2.1 ANSI-B18.2.2 ANSI-G8.14 ASTM-A6 ASTM-A36 ASTM-A47 ASTM-A143 ASTM-A242 ASTM-A283 ASTM-A394 ASTM-441 ASTM-A572 AWS D1-0
Part-III (Vol. 2/2)
Covered electrodes for manual arc welding of carbon of carbon Code of Practice for use of metal arc welding for general construction in mild steel. Code of practice for training and testing of metal arc welders. Part-1: Manual Metal arc welding. Code of practice for design loads (other than earthquake) for buildings and structures. Steel tubes for structural purposes. Recommended practice for radiographic examination of fusion welded butt joints in steel plates. Hexagonal head bolts, screws & nuts of products grade C. Hexagon headbolts, screws and nuts of product grades A and B. Technical supply condition for threaded steel fasteners. Methods for bend test. Method for tensile testing of steel products. Criteria for earthquake resistant design of structures. Line Pipe. Steel for general structural purposes. Code of practice for Radiographic testing. Single coil rectagular section spring washers for bolts, nuts and screws. Code of practice for ultrasonic pulse echo testing by contact and immersion methods. Safety code for erection of structural steel work. Recommendations for metal arc welding of carbon and carbon manganese steels. Inch series square and Hexagonal bolts and screws. Square and hexagonal nuts. Round head bolts. Specification for General Requirements for rolled steel plates, shapes, sheet piling and bars of structural use. Specifications of structural steel. Specification for malleable iron castings. Practice for safeguarding against embrilement of Hot Galvanized structural steel products and procedure for detaching embrilement. Specification for high strength low alloy structural steel. Specification for low and intermediate tensile strength carbon steel plates of structural quality. Specification for Galvanized steel transmission tower bolts and nuts. Specification for High strength low alloy structural manganese vanadium steel. Specification for High strength low alloy colombium- Vanadium steel of structural quality. Code for welding in building construction welding inspection.
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AWS D1-1 AISC NEMA-CG1
Structural welding code. American institute of steel construction. Manufactured graphite electrodes.
Piping and pressure vessels IS: 1239 (Part 1 and 2) IS: 3589 IS: 6392 ASME ASTM-A120 ASTM-A53 ASTM-A106 ASTM-A284 ASTM-A234 ASTM-S181 ASTM-A105 ASTM-A307 ASTM-A193 ASTM-A345 ASTM-A197 ANSI-B2.1 ANSI-B16.1 ANSI-B16.1 ANSI-B16.5 ANSI-B16.9 ANSI-B16.11 ANSI-B16.14 ANSI-B16.25 ANSI-B18.1.1 ANSI-B18.2.1 ANSI-B18.2.2 NSI-B18.21.1 ANSI-B18.21.2 ANSI-B31.1 ANSI-B36.10 ANSI-B36.9 Mild steel tubes, tubulars and other wrought steel fittings. Seamless electrically welded steel pipes for water, gas and sewage. Steel pipe flanges. Boiler and pressure vessel code. Specification for pipe steel, black and hot dipped, zinc-coated (Galvanized) welded and seamless steel pipe for ordinary use. Specification for pipe, steel, black, and hot-dipped, zinc coated welded and seamless. Seamless carbon steel pipe for high temperature service. Low and intermediate tensile strength carbon-silicon steel plates for machine parts and general construction. Pipe fittings of wrought carbon steel and alloy steel for moderate and elevated temperatures. Specification for forgings, carbon steel for general purpose piping. Forgings, carbon steel for piping components. Carbon steel externally treated standard fasteners. Alloy steel and stainless steel bolting materials for high temperature service. Flat rolled electrical steel for magnetic applications. Cupola malleable iron. Pipe threads (Except dry seal). Cast iron pipe flanges and flanged fitting. 800. Class 25, 125, 250 and
Malleable iron threaded fittings, class 150 and 300. Pipe flanges and flanged fittings, steel nickel alloy and other special alloys. Factory-made wrought steel butt welding fittings. Forged steel fittings, socket-welding and threaded. Ferrous pipe plug, bushings and locknuts with pile threads. Butt welding ends. Fire hose couplings screw thread. Inch series square and hexagonal bolts and screws. Square and hexagonal nuts. Lock washers. Plain washers. Power piping. Welded and seamless wrought steel pipe. Stainless steel pipe.
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Other civil works standards IS: 269 IS: 2721 IS: 278 IS: 383 IS: 432 (P1 and P2) IS: 456 IS: 516 IS: 800 IS: 806 IS: 1172 IS: 1199 IS: 1566 IS: 1742 IS: 1785 IS: 1786 IS: 1811 IS: 1893 IS: 2062 IS: 2064 IS: 2065 IS: 2090 IS: 2140 IS: 2470 (P1 & P2) IS: 2514 IS: 2645 33 grade ordinary portland cement. Galvanized steel chain link fence fabric. Galvanized steel barbed wire for fencing. Coarse and fine aggregates from natural sources for concrete. Mild steel and medium tensile steel bars and hard-dawn steel wire for concrete reinforcement. Code of practice for plain and reinforced concrete. Method of test for strength of concrete. Code of practice for general construction in steel. Steel tubes for structural purposes. Basic requirements for water supply, drainage and sanitation. Methods of sampling and analysis of concrete. Hard-dawn steel wire fabric for concrete reinforcement. Code of Practice for Building drainage. Plain hard-drawn steel wire for pre-stressed concrete. High strength deformed Steel Bars and wires for concrete reinforcement. Methods of sampling Foundry sands. Criteria for earthquake resistant design of structures. Steel for general structural purposes. Selection, installation and maintenance of sanitary appliances-code of practices. Code of practice for water supply in buildings. High tension steel bars used in pre-stressed concrete. Standard Galvanized steel wire for fencing. Code of practice for installation of septic tanks. Concrete vibrating tables. Integral cement waterproofing compounds. Methods of sampling and test (Physical and chemical) for water and waste water.
IS-3025 (Part 1 to Part 48)IS: 4091 -
Code of practice for design and construction of foundations for transmission line towers and poles. Code of practice for ancillary structures in sewerage system. Plywood for concrete shuttering work. Sewage and drainage pumps.
IS: 4111 (Part 1 to P5) IS: 4990 IS: 5600 -
National Building Code of India 1970 USBR E12 ASTM-A392-81 ASTM-D1557-80 ASTM-D1586 (1967)
Part-III (Vol. 2/2)
Earth Manual by United States Department of the interior Bureau of Reclamation. Zinc/Coated steel chain link fence fabric. test for moisture-density relation of soils using 10-lb (4.5 kg) rame land 18-in. (457 mm) Drop. Penetration Test and Split-Barrel Sampling of Soils.
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ASTM-D2049-69 ASTM-D2435
Test Method for Relative Density of Cohesionless Soils. Test method for Unconsolidated, (1982). Undrained Strengths of Cohesive Soils in Triaxial Compression. Specification for accelerating Part-I Admixtures, Retarding Admixtures and Water Reducing Admixtures. Latest CPWD specifications.
BS-5075 CPWD
ACSR MOOSE CONDUCTOR IS: 6745 IS: 8263 IS: 209 IS: 398 Part-V BS: 215 (Part-II) IS: 1778 IS: 1521 IS: 2629 IS: 2633 IS: 4826 Methods for Determination of BS:443-1969 Mass of zinc coating on zinc coated Iron and Steel Articles. Methods for Radio Interference IEC:437-1973 Test on High Voltage Insulators NEMA:107-1964 CISPR. Zinc Ingot BS: 3436-1961. Aluminum Conductors for IEC:209-1966. Overhead Transmission Purposes. Aluminium Conductors galvanized IEC:209-1966 steel reinforced extra high voltage (400 kV and above). Reels and Drums for BS: 1559-1949 Bare Conductors. Method for Tensile Testing ISO/R89-1959 of steel wire. Recommended practice for Hot dip Galvanising on Iron and Steel. Method for Testing Uniformity of coating of zinc Coated Articles. Hot dip galvanized coatings on round steel wires ASTMA-472-729.
GALVANISED STEEL EARTHWIRE IS: 1521 IS: 1778 IS: 2629 IS: 2633 IS: 4826 IS: 6745 IS: 209 Method for Tensile Testing ISO/R: 89-1959 of Steel Wire. Reels and Drums for Bare Conductors. Recommended practice for Hot Dip galvanising on iron and Steel. Methods for testing uniformity of coating of zinc coated Articles. Hot dip galvanised coatings ASTM: A 475-72a on Round Steel Wires BS: 443-1969. Method for Determination BS: 443-1969 of mass of Zinc Coating on Zinc coated Iron and Steel Articles. Zinc ingot BS: 3463-1961.
IS: 398 (Pt. I to P5:1992)- Aluminum Conductors for BS: 215 (Part-II) overhead transmission purposes. Lighting Fixtures and Accessories (i) (ii) (iii) (iv) (v) (vi) (vii) IS: 1913 IS: 3528 IS: 4012 IS: 4013 IS: 10322 IS: 10322 IS: 2206 General and safety requirements for electric lighting fittings. Water proof electric lighting fittings. Dust proof electric lighting fittings. Dust tight proof electric lighting fittings. Industrial lighting fittings with metal reflectors. Industrial lighting fittings with plastic reflectors. Well glass lighting fittings for use under ground in mines (non-flameproof type).
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(viii) (ix) (x) (xi) (xii) (xiii) (xiv) (xv) (xvi) (xvii) (xix) (xx) (xxi) (xxii)
IS: 10322 IS: 10322 IS: 10322 IS: 2418 IS: 9900 IS: 1258 IS: 3323 IS: 1534 (Part-I) IS: 1569 IS: 2215 IS: 418 IS: 3553 IS: 2713 IS: 280
Specification for flood light. Specification for decorative lighting outfits. Luminaries for street lighting. Tubular fluorescent lamps. High pressure mercury vapour lamps. Specification for Bayonet lamp fluorescent lamp. Bi-pin lamp holder tubular fluorescent lamps. Ballasts for use in fluorescent lighting fittings. Capacitors for use in fluorescent lighting fittings. Starters for fluorescent lamps. Holders for starters for tubular fluorescent lamps. GLS lamps. Water tight electric fittings. Tubular steel poles. MS wire for general engineering purposes.
(xviii) IS: 3324
Conduits, Accessories and Junction Boxes (1) (2) (3) (4) (5) (6) (7) IS: 9537 IS: 3480 IS: 2667 IS: 3837 IS: 4649 IS: 5133 IS: 2629 Rigid steel conduits for electrical wiring. Flexible steel conduits for electrical wiring. Fittings for rigid steel conduits for electrical wiring. Accessories for rigid steel conduits for electrical wiring. Adaptors for flexible steel conduits. Steel and Cast Iron Boxes. Hot dip galvanising of Iron & Steel.
Lighting Panels (1) (2) (3) (4) (5) (6) (7) (8) (9) IS: 13947 IS: 8828 IS: 5 IS: 2551 IS: 2705 IS: 9224 IS: 5082 IS: 8623 IS: 1248 LV Switchgear and Control gear(Part 1 to 5). Circuit breakers for over current protection for house hold and similar installations. Ready mix paints. Danger notice plates. Current transformers.
HRC Cartridge fuse links for voltage above 650 V (Part-2).
Wrought aluminum and Al. alloys, bars, rods, tubes and sections for electrical purposes. Factory built Assemblies of Switchgear and Control Gear for voltages up to and including 1000V AC and 1200 V DC. Direct Acting electrical indicating instruments.
Electrical Installation (1) (2) (3) IS: 1293 IS: 371 IS: 3854 3 pin plug. Two to three ceiling roses. Switches for domestic and similar purposes.
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(4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
IS: 5216 IS: 732 IS: 3043 IS: 3646 IS: 1944 IS: 5571 IS: 800 IS: 2633 IS: 6005
Guide for safety procedures and practices in electrical work. Code of practice for electrical wiring installation (system voltage not exceeding 650 Volts.) Code of practice for earthing. Code of practice of interior illumination part II & III. Code of practice for lighting of public through fares. Guide for selection of electrical equipment for hazardous areas. Code of practice for use of structural steel in general building construction. Methods of Testing uniformity of coating on zinc coated articles. Code of practice for phosphating iron and steel.
INDIAN ELECTRICITY ACT. INDIAN ELECTRICITY RULES.
LT SWITCHGEAR IS: 8623 (Part-I) IS: 13947 (Part-I) IS: 13947 (part-2) IS: 13947 (part-3) IS: 13947 (part-4) IS: 13947 (part-5) IS: 13947 (part-6) IS: 13947 (part-7) IS: 12063 IS: 2705 IS: 3156 IS: 3231 IS: 1248 IS: 722 IS: 5578 IS: 13703 (Part-1) IS: 13703 (Part-2) IS: 6005 IS: 5082 IS: 2633 Specification for low voltage switchgear and control gear assemblies. Specification for low voltage switchgear and control gear, Part 1 General Rules. Specification for low voltage switchgear and control gear, Part 2 circuit breakers. Specification for low voltage switchgear and control gear. Part 3 Switches, Disconnectors, Switch-disconnectors and fuse combination units. Specification for low voltage switchgear and control gear. Part 4 Contactors and motors starters. Specification for low voltage switchgear and control gear. Part 5 Controlcircuit devices and switching elements. Specification for low voltage switchgear and control gear. Part 6 Multiple function switching devices. Specification for low voltage switchgear and control gear. Part 7 Ancillary equipments. Degree of protection provided by enclosures. Current Transformers. Voltage Transformers. Electrical relays for power system protection. Electrical indicating instruments. AC Electricity meters. Guide for Marking of insulated conductors of apparatus terminals. Low voltage fuses for voltage not exceeding 1000 V AC or 1500V DC Part-1 General Requirements. Low voltage fuses for voltage not exceeding 1000 V AC or 1500V DC Part-2 fuses for use of authorized persons. Code of practice of phosphating iron and steel. Wrought Aluminum and Aluminum alloys for electrical purposes. Hot dip galvanizing.
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SPECIFICATION NO:- DoP/TED/PACKAGE-B/132 KV/SS/BDL-TWG
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Annexure- B LIST OF THE MAKES FOR WHICH TYPE TEST REPORTS NOT REQUIRED TO BE SUBMITTED
Sr. No. 1.
Item description
Make
Out door receptacles Tre foil clamps Diesel Engine Alternator Motors Cable Glands Junction Box
2. 3. 4. 5. 6. 7.
CGL/B&C/BCH/Sakti, Chennai/Indo Asian Moulded Fibre Glass Products, Calcutta K. Cummins/Ruston & Hornsby AVK/KIRLOSKAR/STAMFORD KEC/Siemens/NGEF/Crompton/ABB Sunil & Co./Arup/Comet/QPIE Sarvana/ECS/C&S/Vikas
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132/33 KV TRANSFORMERS
(TF)
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Section-Technical Specifications-132/33 kV Transformer
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Sl.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Cl.No. 1.0 2.0 3.0 3.1 3.2 3.3 3.4 3.5 3.9 4 4.2
DESCRIPTION General Performance Construction Details Tank and tank accessories Core Windings
Page No. 50 50 52 52 58 58 59 61 63 70
Unused inhibited Insulating Oil Terminal Arrangements Tap Changing equipment Fittings Nitrogen Injection Type Fire Prevention & Extinguishing System Inspection and Testing Factory Tests Inspection and testing at site Technical parameters Bushing Current Transformer Oil Storage Tank Oil Sampling Bottle Annexure -A
71 73 76 77 79 80 81 81 83
12. 13. 14. 15. 16. 17. 18. 19.
5 5.2 5.3 6.0 7.0 8.0 9.0 -
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1.0 1.1
General This specification covers design, engineering, manufacture, testing at manufacturer's works, delivery at site including all materials, accessories, spares, unloading, handling, proper storage at site, erection, testing and commissioning of the equipment specified. The transformers in new substation shall be as per the parameters specified in this technical specification. In existing substation, where transformers are already available, the offered transformer shall be suitable for parallel operation with existing transformer, i) The impedance, vector group, OLTC connection & range etc. of the transformer is to be matched with that of the existing transformer. The rating plate details of the existing transformer shall be furnished by the Owner. ii) Necessary provision is to be kept in the transformer control scheme for parallel operation with the existing OLTC control scheme having provision of Master/Follower/Independent /off operation. iii) Matching of physical dimension, orientation etc. to facilitate inter changeability with the existing spare single phase transformer, if necessary Reference Drawings The drawing indicated below form a part of this specification. Standard dimensions for OIP 0000-T-E-A-001 R-02 Condenser bushings (Lower portion) Arrangement of CTs on Transformer up to Drawing no: 0000-000-T-E-J-000, Rev-0 132 kV class
1.2
1.3
1.4
Transportation The Contractor shall despatch the transformer filled with oil or in an atmosphere of nitrogen or dry air. In the former case the contractor shall take care of the weight limitation on transport and handling facility at site. In the latter case, necessary arrangement shall be ensured by the contractor to take care of pressure drop of nitrogen or dry air during transit and storage till completion of oil filling during erection. A gas pressure testing valve with necessary pressure gauge and adaptor valve shall be provided. Transformer shall also be fitted with at least one Electronic impact recorder (on returnable basis) during transportation to measure the magnitude and duration of the impact in all three directions. The acceptance criteria and limits of impact in all three directions which can be withstood by the equipment during transportation and handling shall be submitted by the contractor during detailed engineering. The recording shall commence in the factory before despatch and must continue till the unit is installed on its foundation. The data of electronic impact recorder(s) shall be down loaded at site and a soft copy of it shall be handed over to Engineer-in-charge. Further, within three weeks the contractor shall communicate the interpretation of the data. In the unlikely event of impact recorder output not available at site, the equipment shall be thoroughly internally inspected by the manufacturers representative before erection at site to ensure healthiness of the equipment. Contractor shall mount Vehicle tracking system (GPRS/ GPS/ GSM based) to track the exact position of the vehicle on which the equipment is being loaded for transportation in order to ensure traceability and safety during transportation.
2.0 2.1 2.2
Performance The transformers shall be used for bi-directional flow of rated power. Transformers shall be capable of operating under natural cooled condition up to the full load. Transformers shall be fitted with coolers, capable of dissipating total losses at continuous maximum rating.
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2.3
The transformers shall be capable of being operated, without danger, on any tapping at the rated MVA with voltage variation of 10% corresponding to the voltage of the tapping. The maximum flux density in any part of the core and yoke at the rated MVA, voltage and frequency shall be such that under 10 per cent continuous over voltage condition it does not exceed 1.9 Tesla at the lowest tap position. That is, the transformer with minimum tap and operating at 1.1 Un system voltage, the maximum flux density shall be within 1.9 tesla. DGA of oil shall be periodically monitored by the Employer and the interpretation of DGA results will be as per IEC - 60599.
2.4
2.5
2.6 Radio Interference and Noise Level 2.6.1 The transformers shall be designed with particular attention to the suppression of maximum harmonic voltage, especially the third and fifth so as to minimize interference with communication circuit. 2.6.2 The noise level of transformer, when energised at normal voltage and frequency with cooler equipments in operation shall not exceed, when measured under standard conditions, the values specified at relevant clause. The transformers shall be capable of being loaded in accordance with IEC-60076-7. There shall be no limitation imposed by bushings, tap changers etc. or any other associated equipment. The transformer and all its accessories including CTs etc. shall be designed to withstand without injury, the thermal and mechanical effects of any external short circuit to earth and of short circuits at the terminals of any winding for a period of 3 secs. The short circuit level of the HV & LV System to which the subject transformers will be connected is 31.5 kA ( sym, rms,3 phase fault on 132 kV ) & 25kA (sym rms 3 phase fault on 33kV). Transformer shall be capable of withstanding thermal and mechanical stresses caused by symmetrical or asymmetrical faults on any winding. Transformers shall withstand, without injurious heating, combined voltage and frequency fluctuations which produce the following over fluxing conditions: 125% for 1 - minute 140% for 5 - seconds 2.11 Design review The transformers shall be designed, manufactured and tested in accordance with the best international engineering practices under strict quality control to meet the requirement stipulated in the technical specification. Adequate safety margin with respect to thermal, mechanical, dielectric and electrical stress etc. shall be maintained during design, selection of raw material, manufacturing process etc so that the transformer provide long life with least maintenance. Design reviews shall be conducted by Owner or an appointed Consultant at different stages of the procurement process for transformer; however the entire responsibility of design shall be with the manufacturer. Owner may visit to the manufacturers works to inspect design, manufacturing and test facilities. The design review will commence after placement of award with successful bidder and shall be finalized before commencement of manufacturing activity. These design reviews
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2.7
2.8
2.9
2.10
52
shall be carried out in detail to the specific design with reference of the transformer under scope of this specification. The design review shall be conducted generally following the Guidelines for conducting design reviews for transformers 100 MVA and 123kV and above prepared by Cigre SC 12 Working Group 12.22. The manufacturer shall provide all necessary information and calculations during design review to demonstrate that the transformer meets the requirements for short circuit strength and durability. The latest recommendations of IEC and Cigre SC 12 shall be applied for short circuit withstand evaluation. The manufacturer will be required to demonstrate the use of adequate safety margin for thermal, mechanical, dielectric and vibration etc. design to take into the account the uncertainties of his design and manufacturing processes. The scope of such a design review shall at least include the following: 1. Core and magnetic design 2. Winding and tapping design 3. Short-circuit withstand capability 4. Thermal design including review of localized potentially hot area. 5. Cooling design 6. Overload capability 7. Eddy current losses 8. Seismic design, as applicable 9. Insulation co-ordination 10. Tank and accessories 10.1 Bushings and barrier design 10.2 Tap changers 10.3 Protective devices 10.4 Radiators 10.5 Oil and oil preservation system 11. Corrosion protection 12. Electrical and physical Interfaces with substation 13. Earthing 14. Processing and assembly 15. Testing capabilities 16. Inspection and test plan 17. Transport and storage 18. Sensitivity of design to specified parameters 19. Acoustic Noise 20. Spares, inter-changeability and standardization 21. Maintainability 3.0 Construction Details The features and construction details of each power transformer shall be in accordance with the requirement stated hereunder. Tank and Tank Accessories
3.1
3.1.1 Tank 3.1.1.1 Tank shall preferably be of welded construction and fabricated from tested quality low carbon steel of adequate thickness. 3.1.1.2 All seams and those joints not required to be opened at site shall be factory welded, and wherever possible they shall be double welded. After completion of tank and before
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painting, dye penetration test shall be carried out on welded parts of jacking bosses, lifting lugs and all load bearing members. The requirement of post weld heat treatment of tank/stress relieving shall be based on recommendation of BS- 5500 table 4.4.3.1. 3.1.1.3 Tank stiffeners shall be provided for general rigidity and these shall be designed to prevent retention of water. 3.1.1.4 The transformer shall have conventional type tank. In case the joint is welded it shall be provided with flanges suitable for repeated welding. The joint shall be provided with a suitable gasket to prevent weld splatter inside the tank. Proper tank shielding shall be done to prevent excessive temperature rise of the joint. 3.1.1.5 Each tank shall be provided with: (a) Lifting lugs suitable for lifting the equipment complete with oil. (b) A minimum of four jacking pads in accessible position to enable the transformer complete with oil to be raised or lowered using hydraulic jacks. Each jacking pad shall be designed to support with an adequate factor of safety for at least half of the total mass of the transformer filled with oil allowing in addition for maximum possible misalignment of the jacking force to the centre of the working surface. (c) Suitable haulage holes shall be provided. 3.1.1.6 The tank shall be designed in such a way that it can be mounted either on the plinth directly or on rollers, as per manufacturer's standard practice. 3.1.1.7 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 plates or rails. 3.1.1.8 Paint system and procedures The painting details for transformer main tank, pipes, conservator tank, radiator, control cabinet/ marshalling box / oil storage tank etc. shall be as given below. The paint should not fade during drying process. The paint should be able to withstand temperature up to 120 deg. C .The detailed painting procedure shall also be submitted along with the bid which shall be finalized before award of the contract. Surface preparation Primer coat Intermediate undercoat Finish coat Total dry film thickness (DFT) Minimum 155m Colour shade
Main tank, pipes, conservator tank, oil storage tank etc. (external surfaces) Main tank, pipes (above 80 NB), conservator tank, oil storage tank etc. (Internal surfaces)
Shot Blast cleaning Sa 2 *
Epoxy base Zinc primer (30-40m)
Epoxy high build Micaceou s iron oxide (HB MIO) (75m)
Aliphatic polyureth ane (PU) (Minimu m 50m)
RAL 7035
Shot Blast cleaning Sa 2 *
Hot oil resistant, noncorrosive varnish or paint or epoxy
--
--
Minimum 30m
Glossy white for paint
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Radiator (external surfaces)
Chemical / Shot Blast cleaning Sa 2 *
PU paint (Minimum m 50m)
Minimum 100m
Radiator and pipes up to 80 NB (Internal surfaces) Control cabinet / marshalling box
Chemical cleaning, if required
Hot oil proof, low viscosity varnish Zinc chromate primer (two coats)
--
--
--
Matching shade of tank/ different shade aesthetically matching to tank --
Seven tank process as per IS:3618 & IS:6005
--
EPOXY paint with PU top coat
Minimum 80m
RAL 7035 shade for exterior and interior
Note: * Indicates Sa 2 as per Swedish Standard SIS 055900 of ISO 8501 Part-1. 3.1.2 Tank Cover 3.1.2.1 The tank cover shall be designed to prevent retention of rain water and shall not distort when lifted. The internal surface of the top cover shall be shaped to ensure efficient collection and direction of free gas to the buchholz relay. 3.1.2.2 At least one adequately sized inspection openings shall be provided in the transformers for easy access to bushings and earth connections. The inspection covers shall not weigh more than 25 kg. Handles shall be provided on the inspection cover to facilitate lifting. 3.1.2.3 The tank covers shall be fitted with pockets at the position of maximum oil temperature at maximum continuous rating for bulbs of oil and winding temperature indicators. It shall be possible to remove these bulbs without lowering the oil in the tank. The thermometer shall be fitted with a captive screw to prevent the ingress of water. 3.1.2.4 Bushing turrets, covers of inspection openings, thermometer pockets etc. shall be designed to prevent ingress of water into or leakage of oil from the tank. 3.1.2.5 All bolted connections shall be fitted with weather proof, hot oil resistant, resilient gasket in between for complete oil tightness. If gasket is compressible, metallic stops/other suitable means shall be provided to prevent over-compression. All gasketed joints shall be designed, manufactured and assembled to ensure long-term leak and maintenance free operation. Groove provided to accommodate round nitrile rubber cord for rectangular openings shall be milled. Details of all gasketed joints shall be submitted for approval. 3.1.2.6 Tank hotspot The maximum temperature on any metal part shall not exceed 130 deg. Celsius.
3.1.2.7 Currents flowing in tank cover and bushing turrets To allow for the effect of possible induced and capacitive surge current, good electrical connection shall be maintained between the tank and turrets. 3.1.2.8 The transformer shall be provided with pipe flange of suitable diameter with bolted blanking plate, gasket and shall be fitted at the highest point of the transformer tank for maintaining vacuum in the tank.
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3.1.3 Axles and Wheels 3.1.3.1 The transformer shall be mounted either on rollers or on concrete plinth foundation directly, as per manufacturer's standard practice. 3.1.3.2 The roller mounted transformers are to be provided with flanged bi-directional wheels and axles. This set of wheels and axles shall be suitable for fixing to the under carriage of transformer to facilitate its movement on rail track. Suitable locking arrangement along with foundation bolts shall be provided for the wheels to prevent accidental movement of transformer. 3.1.3.3 The rail track gauge shall be 1676 mm.
3.1.4 Foundation and Anti Earthquake Clamping Device To prevent transformer movement during earthquake, suitable clamping devices shall be provided for fixing the transformer to the foundation. 3.1.5 Conservator & Oil Preservation System Main conservator shall have air cell type constant oil pressure system to prevent oxidation and contamination of oil due to contact with moisture, and shall be fitted with magnetic oil level gauge with low oil level potential free contacts. 3.1.5.2 3.1.5.3 OLTC shall have conventional type conservator with prismatic oil level gauge. Conservator tank and pipe work
3.1.5.3.1 Conservator tank shall have adequate capacity with highest and lowest visible-levels to meet the requirements of expansion of total cold oil volume in the transformer and cooling equipment from minimum ambient temperature to 100degC. The capacity of the conservator tank shall be such that the transformer shall be able to carry the specified overload without overflowing of oil. 3.1.5.3.2 The conservator shall be fitted with integral lifting lugs in such a position so that it can be removed for cleaning purposes. Suitable provision shall be kept to replace air cell and cleaning of the conservator wherever applicable. 3.1.5.3.3 Conservator shall be positioned so as not to obstruct any electrical connection to transformer. Pipe work shall neither obstruct the removal of tap changers for maintenance or the opening of inspection or manhole covers. 3.1.5.3.4 Pipe work connections shall be of adequate size for their duty and as short and direct as possible. Only radiuses elbows shall be used. 3.1.5.3.5 The feed pipe to the transformer tank shall enter the transformer cover plate at its highest point and shall be straight for a distance not les than five times its internal diameter on the transformer side of the Buchholz relay, and straight for not less than three times that diameter on the conservator side of the relay. 3.1.5.3.6 This pipe shall rise towards the oil conservator, through the Buchholz relay, at an angle of not less than 5 degree. 3.1.5.4 Oil Preservation Equipment The requirements of air cell type oil sealing system are given below.
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3.1.5.4.1 Contact of the oil with atmosphere is prohibited by using a flexible air cell of nitrile rubber reinforced with nylon cloth. 3.1.5.4.2 The temperature of oil is likely to rise upto 100deg C during operation. As such air cell used shall be suitable for operating continuously at 100deg C. 3.1.5.4.3 Air cell of conservator shall be able to withstand the vacuum during installation /maintenance periods. Otherwise provision shall be kept to isolate the conservator from the main tank when the latter is under vacuum by providing a vacuum sealing valve or other suitable means in the pipe connecting main tank with the conservator. The transformer manual shall give full and clear instructions on the operation, maintenance, testing and replacement of the air cell. It shall also indicate shelf life, life expectancy in operation, the recommended replacement intervals and the supplier. 3.1.5.4.4 The connection of air cell to the top of the conservator is by air proof seal preventing entrance of air into the conservator. 3.1.5.5 that: a) Passage of air is through silicagel. b) Silicagel is isolated from atmosphere by an oil seal. c) Moisture absorption indicated by a change in colour of the tinted crystals can be easily observed from a distance. d) Breather is mounted not more than 1200 mm above rail top level. e) To minimize the ingress of moisture two breathers (of identical size) shall be connected in series for main tank conservator and two breathers (of identical size) shall be connected in series for OLTC tank conservator. 3.1.5.6 Pressure Relief Device Adequate number of pressure relief devices shall be provided at suitable locations. These shall be of sufficient size for rapid release of any pressure that may be generated in the tank and which may result in damage to equipment. The device shall operate at a static pressure less than the hydraulic test pressure of the transformer tank. It shall be mounted directly on the tank. One set of electrically insulated contacts shall be provided for alarm/tripping.. Discharge of pressure relief device shall be properly taken through pipes and directed away from the transformer/other equipment and this shall be prevented from spraying on the tank. Following routine tests shall be conducted on PRD a. Air pressure test b. Liquid pressure test c. Leakage test d. Contact test e. Dielectric test. 3.1.5.7 Buchholz Relay A double float/reed type Buchholz relay shall be provided. Any gas evolved in the transformer shall collect in this relay. The relay shall be provided with a test cock suitable for a flexible pipe connection for checking its operation and taking gas sample. A copper/stainless steel tube shall be connected from the gas collector to a valve located about 1200 mm above ground level to facilitate sampling with the transformer in service. The device shall be provided with two electrically independent ungrounded contacts, one for alarm on gas accumulation and the other for tripping on sudden rise of pressure. Buchholz relay shall be type tested as per IS : 3637. Buchholz relay and its terminal box shall conform to IP 55 degree of protection.
Dehydrating Filter Breather Conservator shall be fitted with a dehydrating filter breather. It shall be so designed
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3.1.5.8 Temperature Indicators 3.1.5.8.1 Oil Temperature Indicator (OTI) All transformers shall be provided with a 150 mm (approx.) dial type thermometer for top oil temperature indication. The thermometer shall have adjustable, electrically independent ungrounded alarm and trip contacts, maximum reading pointer and resetting device shall be provided in the OTI. A temperature sensing element suitably located in a pocket on top oil shall be furnished. This shall be connected to the OTI by means of capillary tubing. Temperature indicator dials shall have linear gradations to clearly read at least every 2C. Accuracy class of OTI shall be 1.5% or better. The setting of alarm and tripping contacts shall be adjustable at site and typical values are as given below which will be reviewed during detailed engineering based on manufacturers recommendation. Alarm 95 degC Trip 105 degC 3.1.5.8.2 Winding Temperature Indicator (WTI) A device for measuring the hot spot temperature of each winding shall be provided (HV and LV). It shall comprise the following: i) Temperature sensing element. ii) Image coil. iii) Auxiliary CTs, if required to match the image coil, shall be furnished and mounted in the cooler control cabinet. iv) 150 mm (approx) dia local indicating instrument with maximum reading pointer and two adjustable electrically independent, ungrounded contacts; besides that required for control of cooling equipment if any, one for high winding temperature alarm and one for trip. Temperature indicator dials shall have linear gradations to clearly read at least every 2C. v) Calibration device. vi) Accuracy class of WTI shall be 1.5% or better. The setting of alarm and tripping contacts shall be adjustable at site and typical values are as given below which will be reviewed during detailed engineering based on manufacturers recommendation. Alarm 110degC Trip - 120degC vii) In addition to the above, the following equipment shall be provided for remote indication of winding temperature for each of the winding: a) Signal transmitter for each winding Signal transmitter shall have additional facility to transmit signal for recording winding temperature at Employer's data acquisition system, for which duplex platinum RTD with nominal resistance of 100 ohms at zero degree centigrade shall be supplied. The RTD shall be three wire ungrounded system. The calibration shall be as per SAMA (USA) standard or equivalent. The RTD may be placed in the pocket containing temperature sensing element and image coil for WTI system which will be used for both remote WTI and DAS. Necessary equipment for sending the signal to remote WTI and DAS shall be provided. In lieu, separate RTD for each of the functions shall be provided. b) Remote winding temperature indicator It shall be suitable for flush mounting on Employer's panel. This shall not be repeater dial of local WTI and will operate by signal transmitter. Any special cable required for shielding purpose, for connection between cooler control cabinet and remote WTI control circuit, shall be in the scope of
58
Contractor. Only one RWTI with a selector switch shall be provided for all the windings (HV and LV). 3.1.9 Earthing Terminals 3.1.9.1 Two (2) earthing pads (each complete with two (2) nos. holes, M 10 bolts, plain and spring washers) suitable for connection to 75 x 6 mm galvanised steel grounding flat shall be provided each at position close to earth of the two (2) diagonally opposite bottom corners of the tank. 3.1.9.2 Two earthing terminals suitable for connection to 75 x 6 mm galvanised steel flat shall also be provided on cooler, marshalling box and any other equipment mounted separately. 3.2 3.2.1 Core The core shall be constructed from prime quality, non-ageing, cold rolled, super grain oriented, and 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 production of flux component at right angles to the plane of laminations which may cause local heating. The temperature of any part of the core or its support structure in contact with oil shall not exceed 120 deg C under normal operating condition and 130 deg C under most extreme operating condition. Adequate temperature margin shall be provided to maintain longer life expectancy for this material. The insulation of core to bolts and core to clamp plates shall be able to withstand a voltage of 2 KV (rms) for 1 minute. Core and winding shall be capable of withstanding the shock during transport, installation and service. Adequate provision shall be made to prevent movement of core and winding relative to tank during these conditions. All steel sections used for supporting the core shall be thoroughly sand blasted after cutting, drilling and welding. Each core lamination shall be insulated with a material that will not deteriorate due to pressure and hot oil. The supporting frame work of the core shall be so designed as to avoid presence of pockets which would prevent complete emptying of tank through drain valve or cause trapping of air during oil filling.
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8 Adequate lifting lugs will be provided to enable the core and windings to be lifted. 3.2.9 The core shall be earthed to the core clamping structure at one point only, through a removable external link suitably located and protected to facilitate testing after installation of the transformer. In case core laminations are divided into sections by insulating barriers or cooling ducts parallel to the plane of the lamination, tinned copper bridging strips shall be inserted to maintain electrical continuity between sections. A drawing furnishing the details of the internal earthing design shall be included in the manual. 3.3 Windings 3.3.1 The Contractor shall ensure that windings of all transformers are made in dust proof and conditioned atmosphere. 3.3.2 The conductors shall be of electrolytic grade copper free from scales and burrs.
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3.3.3
The insulation of transformer windings and connections shall be free from insulating compounds which are liable to soften, ooze out, shrink or collapse and be noncatalytic and chemically inactive in transformer oil during service. Coil assembly and insulating spacers shall be so arranged as to ensure free circulation of oil and to reduce the hot spot of the winding. The coils would be made up, shaped and braced to provide for expansion and contraction due to temperature changes. The conductor shall be transposed at sufficient intervals in order to minimize eddy currents and to equalize the distribution of currents and temperature along the winding. Unused inhibited Insulating Oil The insulating oil shall be virgin high grade inhibited, conforming to IEC-60296 & all parameters specified below, while tested at supplier's premises. The contractor shall furnish test certificates from the supplier against the acceptance norms as mentioned below, prior to despatch of oil from refinery to site. Under no circumstances, poor quality oil shall be filled into the transformer and only thereafter be brought up to the specified parameter by circulation within the transformer. Property Function Viscosity at 100degC Viscosity at 40degC Viscosity at -30degC Appearance Test Method ISO 3104 or ASTM D445 ISO 3104 or ASTM D445 ISO 3104 or ASTM D445 A representative sample of the oil shall be examined in a 100 mm thick layer, at ambient temperature ISO 3016 or ASTM D97 IEC 60814 or ASTM D1533 Limits (Max.) 3 mm2/s (Max.)12 mm2/s (Max.)1800 mm2/s The oil shall be clear and bright, transparent and free from suspended matter or sediment (Max.)- 40degC (Max.) 30 mg/kg 40 mg/kg (Min.) 50 kV(new unfiltered oil) / 70 kV (after treatment) 0.820 - 0.895 g/ml (Max) 0.0025
3.3.4
3.3.5
3.3.6
3.4 3.4.1
Sl. No. A1. 1a. 1b. 1c. 2.
3. 4.
5.
Pour point Water content a) for bulk supply b) for delivery in drums Electric strength (breakdown voltage) Density at 20 deg C Dielectric dissipation factor (tan delta) at 90 deg C Resistivity at 90 deg C Negative impulse testing KVp @ 25 deg C Carbon type composition (% of Aromatic, Paraffins and Naphthalene ) Refining / Stability Acidity Interfacial tension at 27degC Total sulfur content Corrosive sulphur
IEC 60156 or ASTM D1298
6. 7.
ISO 3675 or ISO 12185 IEC 60247 or IEC 61620 Or ASTM D924 IEC 60247 ASTM D-3300 IEC 60590 or ASTM D 2140
8. 9. 10.
150 X 10^12 Ohm cm, (Min.) 145 (Min.) Max.Aromatic : 4 to12 % Paraffins : <50% & balance shall be Naphthalene. (Max) 0.01 mg KOH/g (Min) 0.04 N/m 0.15 % (Max.) Non-Corrosive on copper and Paper
B1 1. 2. 3. 4.
IEC 62021-1 or ASTM D974 ISO 6295 or ASTM D971 BS 2000 part 373 or ISO 14596 IEC 62535
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5.
Presence of oxidation Inhibitor
IEC 60666 or ASTM D2668 or D4768
6. C1. 1
2. 3. D1 1. 2. 3.
2-Furfural content Performance Oxidation stability -Total acidity -Sludge - Dielectric dissipation factor (tan delta) at 90degC Gassing
IEC 61198 or ASTM D5837 IEC 61125 (method c) Test duration 500 hour IEC 60247
0.08% (Min.) to 0.4% (Max.) Oil should contain no other additives. Supplier should declare presence of additives, if any. 25 Microgram/litre (Max.) Max 0.3 mg KOH/g Max 0.05 % Max 0.05
IEC 60628A or ASTM D2300 Oxidation stability IEC : 61125(Method B) / (Rotating Bomb test ) ASTM D2112 (e) Health, safety and environment (HSE) Flash point ISO 2719 PCA content BS 2000 Part 346 PCB content IEC 61619 or ASTM D4059
No general requirement 220 Minutes (Min.)
(Min.)135degC Max 3% Not detectable (Less than 2 mg/kg)
3.4.2 i)
Prior to filling in main tank at site and shall be tested for 1. Break Down voltage (BDV) : 70kV (min.) 2. Moisture content : 30 ppm (max.) 3. Tan-delta at 90 C : Less than 0.01 4. Interfacial tension : More than 0.035 N/m ii) Prior to energisation at site oil shall be tested for following properties &acceptance norms as per below generally in line with IS: 1866 / IEC 60422: 1. Break Down voltage (BDV) : 70 kV (min.) 2. Moisture content : 10 ppm (max.) 3. Tan-delta at 90 C : 0.01 (max.) 4. Resistivity at 90 C : 6 X 10 ^12 ohm-cm (min.) 5. Interfacial tension : 0.035 N/m (min.) 6. *Oxidation Stability (Test method as per IEC 61125 method C,Test duration: 500hour for inhibited oil) a) Acidity : 0.3 (mg KOH /g) (max.) b) Sludge : 0.05 % (max.) c) Tan delta at 90 C : 0.05 (max.) 7. * Total PCB content : Not detectable (2 mg/kg total)
* For Sr. No. 6 & 7 separate oil sample shall be taken and test results shall be submitted within 45 days after commissioning for approval of DOP. 3.4.3 At manufacturer's works the quality of oil used for first filling, testing and impregnation of active parts shall meet at least parameters as mentioned in serial no. 1to 5 of clause 3.3.4.2 ii) above. The oil test results shall form part of equipment test report. Oil sample shall be drawn before and after heat run test and shall be tested for dissolved gas analysis. Oil sampling to be done 2 hours prior to commencement of temperature rise test. For ONAN/ONAF cooled transformers, sample shall not be taken earlier than 2 hours after shutdown. The acceptance norms with reference to various gas generation rates shall be as per IEC 61181.
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3.4.4
Sufficient quantity of oil shall be supplied for maintaining adequate oil level in tank, radiators, conservator etc till the completion of warranty period shall be supplied.
3.4.5 Storage of spare units (if applicable). The spare transformer shall be completely erected, oil filled and commissioned similar to the other transformers and kept on the foundation after completing all necessary activities for long term storage. Any special maintenance procedure required during long term storage shall be clearly brought out in the instruction manual. All pre commissioning tests on the spare transformer similar to the unit kept in service shall be carried out by the contractor. 3.5 Terminal Arrangements
3.5.1 Bushings 3.5.1.1 The electrical and mechanical characteristics of bushings shall be in accordance with IEC 60137/ DIN 42530. 3.5.1.2 Bushing for various voltage rating shall be as follows 52 kV and above Hermetically sealed Oil filled condenser type/ RIP bushing with porcelain or composite insulator. Mounting dimensions of bushing shall be as per drawing No.0000T-E-A-001 R02. Solid porcelain or oil communicating type. Dimensions of 36 kV bushing shall conform to IS: 3347 Part-V.
36 kV and below
3.5.1.3 fittings:
Oil Filled condenser type bushing shall be provided with at least the following
(a) Oil level gauge. (b) Tap for capacitance and tan delta test. Test taps relying on pressure contacts against the outer earth layer of the bushing is not acceptable. 3.5.1.4 Where current transformers are specified, the bushings shall be removable without disturbing the current transformers. 3.5.1.5 Bushings of identical rating shall be interchangeable.
3.5.1.6 Porcelain used in bushing manufacture shall be homogenous, free from lamination, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. 3.5.1.7 Clamps and fittings shall be of hot dip galvanised steel. 3.5.1.8 Bushing turrets shall be provided with vent pipes, to route any gas collection through the Buchholz relay. 3.5.1.9 No arcing horns shall be provided on the bushings. 3.5.1.10 Spare Bushing shall be specially packed suitable for long storage. 3.3.6 Terminal Marking The terminal marking and their physical position shall be as per IEC: 60076. 3.3.7 Neutral Earthing Arrangement
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3.3.7.1 The neutral terminals of transformer shall be brought to the ground level by a brass/tinned copper grounding bar, supported from the tank by using porcelain insulators. The end of the brass/tinned copper bar shall be brought to the bottom of the tank, at a convenient point, for making bolted connection to two (2) 75 x 6 mm galvanised steel flats connected to Employer's grounding mat. 3.3.7.2 The neutral terminals of winding of the three (3) single phase transformers shall be connected to an overhead common brass/tinned copper/Aluminium pipe /ACSR conductor grounding bus, supported from the tank and fire walls by using porcelain insulators or by using 1C x 95 sq.mm, 33kV XLPE cables. The neutral formation shall be such that neutral winding of single phase spare transformer can be disconnected or connected to either of the three phase banks unless approved otherwise. 3.8 Cooling Equipment and its Control
3.8.1 Cooling Equipment 3.8.1.1 The cooler shall be designed using sufficient number of tank mounted radiators. Design of cooling system shall satisfy the performance requirements. 3.8.1.2 Tank mounted radiators shall have its cooling fans ( For ONAF Cooling only ) , shut off valves at the top and bottom of suitable size, lifting lugs, top and bottom oil filling valves, air release plug at the top, a drain and sampling valve and thermometer pocket fitted with captive screw cap on the inlet and outlet. 3.8.1.3 Required number of standby fans of approximately 20% capacity shall also be provided with radiators. 3.8.1.4 Cooling fans shall be directly mounted on radiator. Each fan shall be suitably protected by galvanised wire guard. The exhaust air flow from cooling fan shall not be directed towards the main tank in any case. 3.8.1.5 Cooling fans motors shall be suitable for operation from 415 volts, three phase 50 Hz power supply and shall conform to IS: 325. Each cooling fan motors shall be provided with starter thermal overload and short circuit protection. The motor winding insulation shall be conventional class 'B' type. Motors shall have hose proof enclosure equivalent to IP: 55 as per IS: 4691. 3.8.1.6 The cooler and its accessories shall preferably be hot dip galvanised or corrosion resistant paint (as per clause 3.1.1.8) should be applied to it. 3.8.1.7 Air release device and oil plug shall be provided on oil pipe connections. Drain valves shall be provided in order that each section can be drained independently. 3.8.2 Cooling Equipment Control (ONAN/ONAF COOLING) 3.8.2.1 Automatic operation control of fans shall be provided (with temperature change) from contacts of winding temperature indicator. The Contractor shall recommend the setting of WTI for automatic change over of cooler control from ONAN to ONAF. The setting shall be such that hunting i.e. frequent start-up operations for small temperature differential do not occur. 3.8.2.2 Suitable manual control facility for cooler fans shall be provided.
3.8.2.3 Selector switches and push buttons shall also be provided in the cooler control cabinet to disconnect the automatic control and start/stop the fans manually.
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3.8.2.4 Indicating Devices Following lamp indications shall be provided in cooler control cabinet: a) Control Supply failure. b) Cooling fan failure. c) Common thermal overload trip One potential free initiating contact for all the above conditions shall be wired independently to the terminal blocks of cooler control cabinet. 3.8.3 Valves 3.8.3.1 All valves shall be of gun metal or of cast steel/cast iron. They shall be of full way type with internal screw and shall open when turned counter clock wise when facing the hand wheel. 3.8.3.2 Suitable means shall be provided for locking the valves in the open and close positions. Provision is not required for locking individual radiator valves. 3.8.3.3 Each valve shall be provided with the indicator to show clearly the position of the valve. 3.8.3.4 All valves flanges shall have machined faces. 3.8.3.5 All valves in oil line shall be suitable for continuous operation with transformer oil at 115C. 3.8.3.6 The oil sampling point for main tank shall have two identical valves to be put in series .Oil sampling valve shall have provision to fix rubber hose of 10 mm size to facilitate oil sampling. 3.8.3.7 A valve or other suitable means shall be provided to fix the on line dissolved gas monitoring system to facilitate continuous dissolved gas analysis. The location & size of the same shall be finalised during detail engineering stage 3.8.3.8 After testing, inside surface of all cast iron valves coming in contact with oil shall be applied with one coat of oil resisting paint/varnish with two coats of red oxide zinc chromate primer followed by two coats of fully glossy finishing paint conforming to IS: 2932. Outside surface except gasket setting surface of butterfly valves shall be painted with two coats of red oxide zinc chromate conforming to IS:2074 followed by two coats of fully glossy finishing paint. 3.8.3.9 All hardware used shall be cadmium plated/electro galvanised steel. 3.8.3.10 For estimation purpose of spares one set of valves would mean one valve of each type used in Transformer.
3.9
Tap Changing Equipment Each transformer shall be provided with Off load tap / On Load Tap changing equipment
3.9.1 Off load tap Change switch general requirement a) The off load switch handle will be provided with a locking arrangement along with tap position indicator thus enabling the switch to be locked in position. A warning plate indicating that switch shall be operated only when the transformer is deenergised shall be fitted. For three phase transformer the tap change switch shall simultaneous switch the similar taps on the three phases.
b)
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3.9.2
On Load Tap Changing Gear (OLTC) OLTC shall be motor operated for local as well as remote operation. An external handle shall be provided for local manual operation. This handle shall be suitable for operation by a man standing at ground level
3.9.2.1 Each single/ three phase transformer shall be provided with voltage control equipment of the tap changing type for varying its effective transformation ratio whilst the transformers are on load and without producing phase displacement. 3.9.2.2 a) The requirements of on load tap changing equipment are given here below : The current diverting contacts shall be housed in a separate oil chamber not communicating with the oil in main tank of the transformer. b) The contacts shall be accessible for inspection without lowering oil level in the main tank and the contact tips shall be replaceable. c) The Bidder shall indicate the safeguards in order to avoid harmful arcing at the current diverting contacts in the event of operation of the OLTC gear under overload conditions of the transformer. Necessary tools and tackles shall be furnished for maintenance of OLTC gear. d) The diverter switch or arcing switch oil chamber shall have oil filling and drain plug, oil sampling valve, relief vent and level glass. It shall also be fitted with a oil surge relay the outlet of which shall be connected to a separate conservator tank. e) The diverter switch or arcing switch shall be designed so as to ensure that its operation once commenced shall be completed independently of the control relays or switches, failure of ancillary supplies etc. To meet any contingency which may result in incomplete operation of the diverter switch, adequate means shall be provided to safeguard the transformer and its ancillary equipment. f) Tap changer shall be so mounted that bell cover of transformer can be lifted without removing connections between windings and tap changer. g) Local OLTC control cabinet shall be mounted on the tank in accessible position. It should be adequately ventilated and provided with anti-condensation metal clad heaters. All contactors relay coils and other parts shall be protected against corrosion, deterioration due to condensation, fungi etc. h) Operating mechanism for on load tap changer shall be designed to go through one step of tap change per command. Subsequent tap changes shall be initiated only by a new or repeat command. i) On load tap changer shall be equipped with a time delayed INCOMPLETE STEP alarm consisting of a normally open contact which closes, if the tap changer fails to make a complete tap change. The alarm shall not operate for momentary loss of auxiliary power. j) The selsyn units or approved equivalents shall be installed in the local OLTC control cabinet to provide tap position indication for the transformer .The Bidder shall also provide a set of instruments for tap position indication in the control room. Complete mounting details shall be included in the approved diagram. k) Transformer on load tap shall be equipped with a fixed resistor network capable of providing discrete voltage steps for input to the supervisory system. l) Limit switches shall be provided to prevent overrunning of the mechanism and shall be directly connected in the circuit of the operating motor. In addition, a mechanical stop shall be provided to prevent over-running of the mechanism under any condition. m) Limit switches may be connected in the control circuit of the operating motor provided that a mechanical de-clutching mechanism is incorporated. n) Thermal device or other means shall be provided to protect the motor and control circuit. All relays, switches, fuses etc. shall be mounted in the local OLTC control cabinet and shall be clearly marked for the purpose of identification.
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o)
A permanently legible lubrication chart if required, shall be fitted within the local OLTC control cabinet. p) Any 'DROP DOWN' tanks associated with the tap changing apparatus shall be fitted with guide rod to control the movements during lifting or lowering. q) A counter of at least five digits shall be fitted to the tap changing equipment to indicate the number of operations completed and shall have no provision for resetting. r) All relays and operating devices shall operate correctly at any voltage between the limits specified. s) It shall not be possible to operate the electric drive when the manual operating gear is in use. t) It shall not be possible for any two controls to be in operation at the same time. u) The equipment shall be suitable for supervisory control and indication with make before break multi-way switch, having one potential free contact for each tap position. This switch shall be provided in addition to any other switch/switches which may be required for remote tap position indication. v) Operation from the local or remote control switch shall cause one tap movement only until the control switch is returned to the off position between successive operations. w) All electrical control switches and the local operating gear shall be clearly labelled in a suitable manner to indicate the direction of tap changing. x) Transfer of source in the event of failure of one AC supply shall not affect the tap changer. 3.9.2.3 OLTC Control of Three Phase Transformers Each three phase transformer shall be suitable for local and remote control. The control feature shall provide the following:
3.9.2.3.1 Local Electrical Control (a) 'Local-remote' selector switch mounted in the local OLTC control cabinet shall switch control of all load tap changers as followings: When the selector switch is in 'local' position, it shall be possible to operate the 'raise-lower' control switches specified in clause 3.9.3.1(b) below. Remote control of the raise-lower functions shall be prevented. ii) When the selector switch is in 'remote' position the local OLTC control cabinet mounted 'raise-lower' switch specified in clause 3.9.3.1(b) below shall be inoperative. Remote control of the raise/lower function shall be possible from the remote control panel. The 'local-remote' selector switch shall have at least two spare contacts per position which are closed in that position but open in the other position. A 'raise-lower' control switch/push button shall be provided in the local OLTC control cabinet. This switch shall be operative only when 'local remote' selector switch is in 'local' position. An OFF-ON tap changer control switch shall be provided in the local OLTC control cabinet of the transformer. The tap changer shall be in-operative in the OFF position. Also the OFF-ON switch shall have atleast one spare contact per position which is closed in that position but open in the other position. Manual Control i)
(b)
(c)
3.9.2.3.2
The cranking device for manual operation of the OLTC gear shall be removable and suitable for operation by a man standing at ground level. The mechanism shall be complete with the following: a) Mechanical tap position indicator which shall be clearly visible from near the transformer. b) A mechanical operation counter.
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c) d)
3.9.2.3.3
Mechanical stops to prevent over-cranking of the mechanism beyond the extreme tap positions. The manual control considered as back up to the motor operated load tap changer control shall be interlocked with the motor to block motor start-up during manual operation. The manual operating mechanism shall be labelled to show the direction of operation for raising the HV terminal voltage and viceversa. Remote Electrical Group Control The OLTC control scheme offered shall have provision of remote electrical group control during the parallel operation of transformer. This is in addition to independent control of OLTC: i) A four position selector switch having Master, Follower, Independent and Off position shall be provided in the remote OLTC control panel for each transformer. This shall be wired to enable operator to select operation of OLTC in either Master, Follower or Independent mode. Out of step relays with timer contacts shall also be provided to give alarm and indication in case tap position in all the transformers under group control are not in same position. Master Position If the selector switch is in Master position, it shall be possible to control the OLTC units in the follower mode by operating the controls of the master unit. Independent operation of the units under Follower mode shall have to be prevented. However the units under independent mode will be controlled independently. Follower Position If the selector switch is in Follower mode, control of OLTC shall be possible only from panel of the Master unit.
ii)
iii)
iv)
v) Independent Position In this position of Selector Switch, Control of OLTC of individual unit shall only be possible. 3.9.2.4 OLTC Control of single phase Transformer For three single phase units operating as three phase bank, including the operation of spare single phase unit in place of any one of the operating unit the OLTC gear shall be suitable for local and remote control. The control features shall provide the following: i) Local Electrical Control a) 'Local-remote' selector switch mounted in the local OLTC control cabinet shall switch control of all on load tap changers as under: When the selector switch is in 'local' position, it shall be possible to operate any of the 'raise-lower' control switches specified in Sub clause 3.9.4 b and c below. Control of the raise-lower function from the control panel shall be prevented. When the selector switch is in 'remote' position the raise-lower functions form switches in local OLTC control cabinets as well as cooler control cabinet specified in Sub clause 3.9.4 c and d shall be inoperative. Remote control of the raise-lower function of the three phase transformer banks shall be possible from the control panel. The remote-local selector switch shall be have atleast two spare contacts per position.
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b)
'Independent-combined selector switch shall be provided for single phase transformer only and shall be mounted in the cooler control cabinet. This switch shall control the on load tap changers as follows. When the selector switch is in combined position, it shall be possible to raiselower taps by operating the combined 'raise-lower' switch in cooler control cabinet or the remote raise-lower switch. Independent operation of each single phase transformer will be prevented. When the selector switch is in independent position it shall be possible to raise-lower taps by operating individually each single phase transformer through their individual 'raise-lower' control switch mounted in Local OLTC Control Cabinet. Combined operation of all the three (3) single phase transformers will be prevented.
c)
A combined raise-lower control switch shall be provided in the cooler control cabinet for a bank of three single phase transformers only. This switch shall be functional only when 'local-remote' selector switch is in local position and 'Independent combined' selector switch is in combined position. An individual 'raise-lower' control cabinet for each single phase transformer. This switch shall be functional only when 'local-remote' selector switch is in local position and 'individual-combined' selector switch is in individual position.
d)
ii)
Local Manual control The cranking device for manual operation for OLTC gear shall be removable and suitable for operation by a man standing at ground level. The mechanism shall be complete with the following. a) Mechanical tap position indicator which shall be clearly visible from near the transformer. b) A mechanical operation counter. c) Mechanical stops to prevent over-cranking of the mechanism beyond the extreme tap positions. d) The manual control considered as back up to the motor operated on load tap charger control shall be interlocked with the motor to block motor startup during manual operation. The manual operating mechanism shall be labeled to show the direction of operation for raising the voltage and viceversa.
iii) Remote Electrical Group Control The remote OLTC scheme offered shall have provision to raise or lower taps only for the complete bank of three single phase transformers. Individual single phase OLTC operation shall not be possible from the remote control panel. The OLTC control scheme shall have provision of remote electrical group control when the three phase bank is in parallel operation with three phase transformers/three phase banks of single phase transformers. a) A four position selector switch having Master, Follower, Independent and Off position shall be provided in the remote OLTC control panel for three (3) phase bank of single phase transformers. This shall be wired to enable the operator to select operation of OLTC in either Master, Follower or Independent mode. Out of step relays with timer contacts shall also be provided to give alarm and indication in case taps of al the transformers under control are not in same position.
b)
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c) Master Position If the selector switch is in master position, it shall be possible to control the OLTC units of other transformer banks/three phase transformer in the follower made by operation the master unit. d) Follower Position If the selector switch is in Follower position control of OLTC shall be possible only from panel where master mode is selected. Independent Position In independent position of selector switch, control of OLTC shall be possible only from the panel where independent mode is selected. 3.9.2.5 3.9.2.5.1 The control circuits shall comply with following conditions: An interlock to cut off electrical control automatically upon recourse being taken to the manual control in emergency. Reinforcement of the initiating impulse for a tap change, ensuring a positive completion once initiated to the next (higher or lower) tap. "Step-by-Step" operation ensuring only one tap change from each tap changing impulse and a lock-out of the mechanism if the control switch (or push button) remains in the "operate" position. An interlock to cut-out electrical control when it tends to operate the gear beyond either of the extreme tap positions. An electrical interlock to cut-off a counter impulse for reverse step change being initiated during a progressing tap change and until the mechanism comes to rest and resets circuits for a fresh position. Tap change in progress indication shall be provided by means of an indicating lamp at the Employer's control panel. Necessary contacts for this and for remote tap position indicator at Employer's control panel shall be provided by the Bidder. Protective apparatus, considered essential by the Bidder according to specialities of the gear. Local OLTC Control Cabinet, Cooler Control Cabinet and Remote Tap Changer Control Panel Each three phase transformer / single phase transformer unit shall be provided with local OLTC control cabinet, cooler control cabinet and RTCC panel. Cabinets and Panels shall be tank mounted, provided with suitable lifting arrangement and have sloping roof. A space heater, and cubicle lighting with ON-OFF switch shall be provided in each panel. Necessary shorting of terminals shall be done at the cooler control cabinet, local OLTC cabinet and remote OLTC panel. All the CT secondary terminals in the cooler control cabinet shall have provision for short circuiting to avoid CT open circuit while it is not in use.
3.9.2.5.2
3.9.2.5.2.3
3.9.2.5.2.4
3.9.2.5.2.5
3.9.5.2.6
3.9.2.5.2.7
3.9.3
3.9.3.1
3.9.3.2
3.9.3.3
3.9.4
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3.9.5 Cooler Control Cabinet 3.9.5.1 The cooler control cabinet shall have all necessary devices meant for cooler control and local temp indicators. All the contacts of various protective devices mounted on the transformer and all the secondary terminals of the bushing CTs shall also be wired upto the terminal board in the cooler control cabinet. All the necessary terminals for remote connection to Employer's panel shall be wired upto the cooler control cabinet. 3.9.5.2 The cooler control cabinet shall have two (2) sections. One section shall have the control equipment exclusively meant for cooler control. The other section shall house the temperature indicators, aux. CTs and the terminal boards meant for termination of various alarm and trip contacts as well as various bushing CT secondary. Alternatively the two sections may be provided as two separate panels depending on the standard practice of the Bidder. 3.9.5.3 The temperature indicators shall be so mounted that the dials are about 1200 mm from ground level. Glazed door of suitable size shall be provided for convenience of reading. 3.9.6 Local OLTC Control Cabinet The Local OLTC control cabinet shall house all necessary devices meant for OLTC control and indication. It shall be complete with the following: A circuit breaker/contactor with thermal overload devices for controlling the AC Auxiliary supply to the OLTC motor. ii) Cubicle light with door switch. iii) Space heaters to prevent condensation of moisture. iv) Locking arrangement for hinged door of cabinet. v) Cable terminal glands for power and control cables to the OLTC gear. 3.9.7 Remote Tap Changer Control Panel. 3.9.7.1 The Contractor shall supply a Remote Tap Changer Control (RTCC) panel suitable for remote operation of On load tap changing gear. 3.9.7.2 The RTCC panel shall house actuating switch for electrical raise/lower control, tap position indicator, signal lamps for "Tap change in progress" and "Tap changer out of step", and all other auxiliary devices for remote electrical control of the OLTC. For tap position indicator, the dual output type OLTC transducer shall be provided in the RTCC panel. One of the outputs of this transducer shall be used for local indication of tap position in RTCC panel and other output (0-10 mA or 4-20 mA) shall be used for RTUs. 3.9.7.3 The RTCC panel shall be located in Employer's control room/Air conditioned Bay controller Kiosk. The size & colour of the RTCC panel shall match with Employer's control panel. The matching details shall be furnished at the time of award. 3.9.7.4 RTCC panel for Single phase unit shall have provision for connecting/operating the spare single phase unit. 3.10 Auxiliary Power Supply of OLTC, Cooler Control and Power Circuit 3.10.1 Two auxiliary power supplies, 415 volt, three phase four (4) wire shall be provided by the Employer at cooler control cabinet for OLTC and cooler control and power circuit. 3.10.2 All loads shall be fed by one of the two feeders through an electrically interlocked automatic transfer switch housed in the cooler control cabinet for on load tap changer control and cooler circuits. Design features of the transfer switch shall include the following:
i)
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a) b) c) d) e)
Provision for the selection of one of the feeder as normal source and other as standby. Upon failure of the normal source, the loads shall be automatically transferred after an adjustable time delay to standby sources. Indication to be provided at cooler control cabinet for failure of normal source and for transfer to standby source and also for failure to transfer. Automatic re-transfer to normal source without any intentional time delay following re-energization of the normal source. Both the transfer and the re-transfers shall be dead transfers and AC feeders shall not be paralleled at any time. Power Supply for OLTC Circuits AC feeder shall be brought to the local OLTC control cabinet by the Contractor after suitable selection at cooler control cabinet for which description is given in 3.10.2 above, for control power circuit of OLTC. The Contractor shall derive AC power for OLTC control circuitry from the AC feeder as mentioned above by using appropriately rated dry type transformers. If the control circuit is operated by DC supply, then suitable main and standby converters shall be provided by the Contractor to be operated from AC power source. Power Supply for Cooler Circuits Control and power supplies are to be given for Cooler circuits after the selection as mentioned above. The Contractor shall derive AC power for Cooler Control Circuitry by using appropriately rated dry type transformer in case of using supply voltage different from the Employers auxiliary supply. If the control circuit is operated by DC supply then suitable main and standby convertors shall be provided by the Contractor, to be operated from AC power source. Necessary isolating switches and MCBs/MCCBs shall be provided at suitable points as per Employer's approved scheme.
3.10.3 a)
b)
3.10.4 3.10.4.1
3.10.4.2
3.10.5
4 4.1
Fittings The following fittings shall be provided with each three/single phase transformer covered in this specification. Conservator for main tank with oil filling hole and cap, air cell, isolating valves, drain valve, magnetic oil level gauge with low level alarm contacts and dehydrating silicagel breather.
4.1.1
4.1.2 Oil preservation equipment. 4.1.3 Pressure relief devices with alarm/trip contacts. 4.1.5 Buchholz relay double float/reed type with isolating valves on both sides, bleeding pipe with pet cock at the end to collect gases and alarm and trip contacts.
4.1.6 Air release plug. 4.1.7 Inspection openings and covers. 4.1.8 Bushing with metal parts and gaskets to suit the termination arrangement.
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4.1.9
Winding temperature indicators for local and remote mounting. One remote winding temperature indicator with a four point selector switch shall be provided for the three windings for three phase unit to have selection of any of the three windings.
4.1.10 Cover lifting eyes, transformer lifting lugs, jacking pads, towing holes and core and winding lifting lugs. 4.1.11 Protected type mercury or alcohol in glass thermometer.
4.1.12 Bottom and top filter valves with threaded male adaptors, bottom sampling valve and drain valve. 4.1.13 4.1.14 4.1.15 4.1.16 4.1.17 4.1.18 Rating and diagram plates on transformers and auxiliary apparatus. Flanged bi-directional wheels/Trolley for movement Cooler cabinet. Off load / On load tap changing gear. Cooling equipment Bushing current transformers.
4.1.19 Drain valves/plugs shall be provided in order that each section of pipe work can be drained independently. 4.1.20 4.1.21 4.1.22 4.1.23 4.1.24 Terminal marking plates. Valves schedule plates. Oil temperature indicator Marshalling box/Common Marshalling box Suitable galvanized iron or stainless steel tray for cabling on main tank for better aesthetics.
4.1.25 The fittings listed above are only indicative and other fittings which generally are required for satisfactory operation of the transformer are deemed to be included. 4.1.26 One set of hand tools of reputed make packed in a carry bag/box broadly comprising of double ended spanners (open jaws, cranked ring, tubular with Tommy bar each of sizes 9mm to 24mm, one set each), adjustable wrenches (8 &12 inch one set), gasket punches (of different sizes as used in the reactor one set ), pliers (flat nose, round nose & side cutting one of each type), hammer with handle (one ), files with handle (two), knife with handle (one), adjustable hacksaw (one), and cold chisel (one) shall be supplied per Substation. 4.2 Nitrogen Injection Type Fire Prevention & Extinguishing System Nitrogen Injection Fire Protection System shall be designed to prevent explosion of transformer tank and the fire during internal faults resulting from arc and also to extinguish the external oil fires on transformer/ reactor due to tank explosion and/or external failures like bushing fires, OLTC fires and fire from surrounding equipments, etc. The system shall work on the principle of Drain & stir. On activation, it shall drain a predetermined quantity of oil from the tank top through drain valve to reduce the tank pressure, isolate conservator tank oil and inject nitrogen gas at high pressure from the bottom side of the tank through inlet valves to create stirring action and reduce the temperature of oil below flash point to extinguish the fire. The quantity of oil removed from the tank shall be such that adequate amount of oil shall remain to cover active part, i.e. core coil assembly even after stoppage of oil drain. Electrical isolation of transformer shall be an essential pre-condition for activating the system.
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4.2.1 Operational Controls The system operation shall be fully automatic and activate from the required fire and other trip signals. In addition to automatic operation, remote operation from control room/ remote centre and local manual control in the fire extinguishing cubicle shall also be provided. System shall operate on following situations. 4.2.2 Prevention of transformer explosion and Fire To prevent transformer explosion and fire in case of an internal fault, signals given by operation of Electrical protection relays and tripping of circuit breaker of transformer and operation of either Buchholtz relay, or pressure relief valve (PRV) shall be used to activate the system. The exact logic for system activation shall be finalized during detailed engineering. 4.2.3 Fire protection In case of fire, sensed by fire detectors, the system shall be activated only after electrical isolation of the transformer, confirmed by breaker trip. If the fire detection is not associated with any other fault, the system activation shall be only manual. Manual operation switch shall be provided in the control room/ remote control centre with a cover to avoid accidental operation of it. 4.2.4 Operation of System On receiving activation signal, the following shall take place: i. Open the quick opening drain valve to drain the top layer oil ii. Shut off the conservator isolation valve to prevent flow of oil from the Conservator tank to the main tank. iii. Open the Nitrogen regulator valve to inject Nitrogen into the transformer tank to create stirring of oil. There shall be interlock to prevent activation of the system if the transformer is not electrically isolated. There shall also be provision for isolating the system during maintenance and/or testing of the transformer. 4.2.5 Technical Particulars The contractor shall be responsible for the design of the complete system and shall submit the drawings and design calculations for the number of fire detectors, pipe sizing of drain pipe and Nitrogen injection pipe, Nitrogen cylinder capacity, number of injection points, etc. and get approval from POWERGRID. Facility shall be provided to test the system when the transformer is in service, without actually draining the oil and injecting Nitrogen. The Nitrogen regulator valve shall be designed in such a way that the Nitrogen shall not enter the transformer tank even in case of passing/ leakage of valve. The system shall work on station DC supply. POWERGRID shall give two distinct DC feeders in control. The control box of fire protection system shall have facility to receive these feeders for auto change over of supply. It shall be the contractors responsibility to further distribute power to the required locations. Individual system component / equipment should not have working voltage other than station DC voltage. AC-DC / DC-DC converter shall not be used for reliable operation. Following minimum indications and alarms shall be provided in the cubicle as well as the control box:Part-III (Vol. 2/2) Section-Technical Specifications-132/33 kV Transformer
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Nitrogen cylinder pressure indication. Nitrogen cylinder pressure low. Fire in Transformer/ Reactor. Oil drain started. Conservator oil isolation valve closed. Nitrogen injection started. DC supply fail Oil drain valve closed Gas inlet valve closed
4.2.6 Details of Supply of System Equipments and Other Related Activities: The scope of supply shall include the following items and any other items required for safe and trouble free operation of the system. (i) Fire extinguishing cubicle with base frame and containing at least the following: Nitrogen gas cylinder of sufficient capacity with pressure regulator and manometer with sufficient number of adjustable NO contacts. Oil Drain Assembly including oil drain pipe extension of suitable size for connecting pipes to oil pit. Mechanical release device for oil drain and nitrogen release. Limit switches for monitoring of the systems. Panel lighting. Flanges on top of the panel for connecting oil drain and nitrogen injection pipes for transformer. Back up pressure switch to operate nitrogen gas valve. Pressure indicators for Nitrogen pressure of the cylinder and actual injection through Nitrogen regulator. Control box to be installed in the control room of the station for monitoring system operation, automatic control and remote operation, with alarms, indication light, switches, push buttons, audio signal, suitable for tripping and signaling. Conservator isolation valve which shall be flow sensitive and shut off when the flow in the pipe is more than the flow expected in the permissible normal operating conditions. It shall be provided with physical position indicator along with remote alarm indication on control box. This valve shall be provided with locking arrangement for normal position and oil filling / filtration position. Conservator Isolation valve should not obstruct oil surge from transformer tank towards conservator and in normal working of transformer should allow flow of oil in both directions.
(ii)
(iii)
(iv)
Required number of fire detectors to be located in strategic locations to be finalized during detailed engineering. (v) All controls, alarms, panels, cables, cable trays (if required), junction boxes etc. 4.2.7 Installation and pre-commissioning test After installation the system pre-commissioning tests shall be carried out jointly with the POWERGRID representative before the system is put in service. 5 Inspection and Testing The Contractor shall carry out a comprehensive inspection and testing programme during manufacture of the equipment. An indication of inspection envisaged by the Employer is given under Clause 5.1. This is however not intended to form a comprehensive programme as it is Contractor's responsibility to draw up and carry out such a programme in the form of detailed quality plan duly approved by Employer for necessary implementation.
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5.1 Inspection 5.1.1 Tank and Conservator 5.1.1.1 Certification of chemical analysis and material tests of plates. 5.1.1.2 Check for flatness. 5.1.1.3 Electrical interconnection of top and bottom by braided tinned copper flexibles. 5.1.1.4 Welder's qualification and weld procedure. 5.1.1.5 Testing of electrodes for quality of base materials and coatings. 5.1.1.6 Inspection of major weld preparation. 5.1.1.7 Crack detection of major strength weld seams by dye penetration test. 5.1.1.8 Measurement of film thickness of : i) Oil insoluble varnish. ii) Zinc chromate paint. iii) Finished coat. 5.1.1.9 Check correct dimensions between wheels, demonstrate turning of wheels through 90C and further dimensional check. 5.1.1.10 Check for physical properties of materials for lifting lugs, jacking pads, etc. All load bearing welds including lifting lug welds shall be subjected to NDT. 5.1.1.11 Leakage test of the conservator. 5.1.1.12 Certification of all test results. 5.1.2 Core 5.1.2.1 Sample testing of core materials for checking specific loss, bend properties, magnetisation characteristics and thickness. 5.1.2.2 Check on the quality of varnish if used on the stampings : i) Measurement of thickness and hardness of varnish on stampings. ii) Solvent resistance test to check that varnish does not react in hot oil. iii) Check over all quality of varnish by sampling to ensure uniform shining colour, no bare spots, no over burnt varnish layer and no bubbles on varnished surface. 5.1.2.3 Check on the amount of burrs. 5.1.2.4 Bow check on stampings. 5.1.2.5 Check for the overlapping of stampings. Corners of the sheet are to be part. 5.1.2.6 Visual and dimensional check during assembly stage. 5.1.2.7 Check for interlaminar insulation between core sectors before and after pressing. 3.5.1.2.9 Visual and dimensional checks for straightness and roundness of core, thickness of limbs and suitability of clamps. 5.1.2.10 High voltage test (2 kV for one minute) between core and clamps. 5.1.2.11 Certification of all test results. 5.1.3 5.1.3.1. 5.1.3.2 5.1.3.3 5.1.3.4 5.1.3.5 5.1.3.6 5.1.3.7 5.1.4 5.1.4.1 5.1.4.2 5.1.4.3 5.1.4.4 5.1.4.5 Insulation Material Sample check for physical properties of materials. Check for dielectric strength. Visual and dimensional checks. Check for the reaction of hot oil on insulating materials. Dimension stability test at high temperature for insulating material. Tracking resistance test on insulating material Certification of all test results. Winding Sample check on winding conductor for mechanical properties and electrical conductivity. Visual and dimensional checks on conductor for scratches, dent marks etc. Sample check on insulating paper for pH value, bursting strength and electric strength. Check for the reaction of hot oil on insulating paper. Check for the bonding of the insulating paper with conductor.
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5.1.4.6 5.1.4.7 5.1.4.8 5.1.4.9 5.1.4.10 5.1.4.11 5.1.4.12 5.1.4.13
Check and ensure that physical condition of all materials taken for windings is satisfactory and free of dust. Check for absence of short circuit between parallel strands. Check for brazed joints wherever applicable. Measurement of voltage ratio to be carried out when core/yoke is completely restacked and all connections are ready. Conductor enamel test for checking of cracks, leakage and pin holes. Conductor flexibility test Heat shrink test for enamelled wire. Certification of all test results.
5.1.5 Checks Before Drying Process 5.1.5.1 Check condition of insulation on the conductor and between the windings. 5.1.5.2 Check insulation distance between high voltage connections, cables and earth and other live parts. 5.1.5.3 Check insulating distances between low voltage connections and earth and other parts. 5.1.5.4 Insulation of core shall be tested at 2 kV/minute between core to bolts and core to clamp plates. 5.1.5.5 Check for proper cleanliness and absence of dust etc. 5.1.5.6 Certification of all test results. 5.1.6 Checks During Drying Process 5.1.6.1 Measurement and recording of temperature, vacuum and drying time during vacuum treatment. 5.1.6.2 Check for completeness of drying by periodic monitoring of IR and Tan delta. 5.1.6.3 Certification of all test results. 5.1.7 Assembled Transformer 5.1.7.1 Check completed transformer against approved outline drawings, provision for all fittings, finish level etc. 5.1.7.2 Test to check effective shielding of the tank. 5.1.7.3 Jacking test with oil on all the assembled transformers. 5.1.7.4 Dye penetration test shall be carried out after the jacking test. 5.1.8 Bought Out Items 5.1.8.1 The makes of all major bought out items shall be subject to Employer's approval. 5.1.8.2 The Contractor shall also prepare a comprehensive inspection and testing programme for all bought out/sub-contracted items and shall submit the same to the Employer for approval. Such programme shall include the following components: a) Buchholz Relay. b) Axles and wheels. c) Winding temperature indicators for local and remote mounting. d) Oil temperature indicators. e) Bushings. f) Bushing current transformers. g) Cooler cabinet. h) ON Load / Off Load Tap change gear. i) Terminal connectors. j) Pressure relief device relay k) Cables used for interconnecting Turret CT, equipment relays (exposed) , with marshalling box. The above list is not exhaustive and the Contractor shall also include other bought out items in his programme.
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5.2
Factory Tests The manufacturer shall be fully equipped to perform all the required tests as specified. Bidder shall confirm the capabilities of the proposed manufacturing plant in this regard when submitting the bid. Any limitations shall be clearly stated in. The contractor shall bear all additional costs related to tests which are not possible to carry out at his own works. The contractor shall submit an Inspection and test plan (ITP) for approval. A typical test plan is indicated below.
No. 1 2 3 4 5 6 7 8 9 10 11a 11b 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Item Measurement of winding resistance Voltage ratio measurement Polarity test No-load loss and current measurement Impedance voltage and load loss measurement Measurement of insulation resistance Measurement of insulation power factor and capacitance between winding and earth Measurement of insulation power factor and capacitance of bushings Lightning impulse test ( 66 kV and above ) Separate source voltage withstand test Induced over voltage test with Partial Discharge Measurement Short duration (ACSD) Test Test of cooling device ( If applicable) On-load tap changer test( If applicable) Gas-in-oil analysis Core assembly dielectric and earthing continuity test Oil leakage test on transformer tank Appearance, construction and dimension check Magnetic circuit test Magnetic balance test ( for three phase Transformer only) Measurement of no load current with 415 V, 50 Hz AC on LV side. High voltage with stand test on auxiliary equipment and wiring after assembly Tank vacuum test Tank pressure test Temperature rise test Measurement of harmonic level in no load current Measurement of acoustic noise level Lightning Impulse Test on Neutral Measurement of Zero seq. reactance ( for three phase Transformer only) Dynamic Short circuit withstand test
Test Category Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Routine Type Type Type Type Type Type
First unit *
Other units NA NA NA NA NA NA
All tests shall be done in line with IEC: 60076 and the test procedures as mentioned in Annexure-A. Complete test report shall be submitted to purchaser after proper scrutiny and signing on each page by the test engineer of the contractor.
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* Means the first unit manufactured against the LOA at each manufacturing plant. However, dynamic short circuit withstand test shall be carried out only on one unit of same design manufactured in any of the works. 5.2.1 Measurement of capacitance and tan delta to determine capacitance between winding and earth. Tan delta value shall not be more than 0.5% corrected at 20deg C. Temperature correction factor table shall be given by the Contractor and shall form the part of test results. Measurement of capacitance and tan delta of bushings. Tan delta value shall not be more than 0.4% corrected at 20deg C. Temperature correction factor table shall be given by the Contractor and shall form the part of test results.
5.2.2
5.2.3 Type Tests on fittings: All the following fittings shall conform to type tests and the type test reports shall be furnished by the contractor along with the drawings of equipment/ fittings as per the clause no. 9.0 of the Section GTR. The list of fittings and the type test requirement is: 1. 2. 3. 4. 5. 6. 7. Bushing (Type Test as per IEC: 60137, including snap back/seismic test) Buchholz relay (Type Test as per IS: 3637 and IP-55 Test on terminal box) OLTC (Temperature Rise of contact, Short circuit current test, Mechanical test and Dielectric Test as per IEC: 60214 and IP-55 test on driving mechanism box). Cooling fan and motor assembly Free air delivery, Temperature rise, sound level, running at reduced voltage, IP-55 degree of protection for terminal box. Air Cell (Flexible air separator) Oil side coating, Air side under Coating, Air side outer coating and coated fabric as per IS: 3400/ BS: 903/ IS: 7016. Cooler Control cabinet (IP-55 test) Pressure Relief device Test The pressure Relief Device of each size shall be subjected to increase in oil pressure. It shall operate before reaching the test pressure specified in transformer tank pressure test above.. The operating pressure shall be recorded. The device shall seal off after excess pressure has been released. The terminal box / boxes of PRD should conform to degree of protection as per IP-55 of IS: 13947. Magnetic Oil Level gauge & Terminal Box for IP-55 degree of protection. OTI & WTI Switch setting & operation, switch differential, switch rating.
8. 9.
5.2.4 Pre-Shipment Checks at Manufacturer's Works 5.2.5 Check for interchangeability of components of similar transformers for mounting dimensions. 5.2.6 Check for proper packing and preservation of accessories like radiators, bushings, dehydrating breather, rollers, buchholz relay, fans, control cubicle, connecting pipes, conservator etc. 5.2.7 Check for proper provision for bracing to arrest the movement of core and winding assembly inside the tank. 5.2.8 Gas tightness test to confirm tightness and record of dew point of gas inside the tank. 5.2.9 Derivation of leakage rate and ensure the adequate reserve gas capacity. 5.2.10 Measure and record the dew point of dry air /Nitrogen at the time of filling and after 24 hours in the transformer tank. Dew point of dry air / nitrogen at the time of transformer despatch should be better than (-) 30 deg C. Also the dew point of dry air / nitrogen cylinders attached for make up during transportation should of the order of (-) 50 deg C. 5.3 Inspection and Testing at Site The Contractor/Manufacturer shall carry out a detailed inspection and testing programme for field activities covering areas right from the receipt of material stage upto commissioning stage. An indicative programme of inspection as envisaged by the
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Employer is given below and in the document No. D-2-01-03-01-01 (or latest revision) Pre commissioning Procedures and Formats for substation bay equipment, which will be available in the respective sites and shall be referred by the contractor. However, it is contractor's responsibility to draw up and carry out such a programme duly approved by the Employer. Testing of oil sample at site shall be carried out as per Cl 3.4 above 5.3.1 Receipt and Storage Checks 5.3.1.1 Check and record condition of each package, visible parts of the transformer etc. for any damage. 5.3.1.2 Check and record the gas pressure in the transformer tank as well as in the gas cylinder. Measure and record the dew point of dry air /nitrogen in the transformer tank. 5.3.1.3 Visual check for wedging of core and coils before filling up with oil and also check conditions of core and winding in general. 5.3.2 Installation Checks 5.3.2.1 Inspection and performance testing of accessories like tap changers etc. 5.3.2.2 (i) Check the direction of rotation of fans . (ii) Check the bearing lubrication. 5.3.2.3 Check whole assembly for tightness, general appearance etc. 5.3.2.4 Oil leakage test 5.3.2.5 Capacitance and tan delta measurement of bushing before fixing/connecting to the winding, contractor shall furnish these values for site reference. 5.3.2.6 Leakage test on bushing before erection. 5.3.2.7 Measure and record the dew point of nitrogen/dry air in the main tank before assembly. Manufacturer shall submit dew point acceptable limits along with temperature correction factor and shall form part of instruction manual. In case dew point values are not within permissible limit suitable drying out process shall be applied for dry out of active part in consultation with the Manufacturer. 5.3.2.8 5.3.2.8.1 5.3.2.8.2 Oil filling. Oil impregnation or drying under vacuum at site shall be done with the transformer and oil at a temperature not exceeding 70 deg C. The duration of the vacuum treatment shall be demonstrated as adequate by means of water measurement with a cold trap or other suitable method. The vacuum shall be measured on the top of the transformer tank and should be less than 1mbar. Vacuum shall not be broken until the transformer is oil filled up to the Buchholz relay. Whenever the active insulation or any paper insulated HV connections, especially those from the windings to the bushings are exposed, these shall be re-impregnated under vacuum along with the complete transformer. For this purpose the transformer shall first be drained to expose all insulation material. The minimum safe level of oil filling (if different from the Buchholz level) to which the transformer shall be oil filled under vacuum, shall be indicated in the manual. Procedures for site drying, oil purification, oil filling etc shall be submitted for approval and complete instructions shall form part of the manual.
5.3.2.8.3
5.3.2.8.4
5.3.2.8.5
5.3.3 Commissioning Checks 5.3.3.1 Check the colour of silicagel in silicagel breather. 5.3.3.2 Check the oil level in the breather housing, conservator tanks, cooling system, condenser bushing etc. 5.3.3.3 Check the bushing for conformity of connection to the lines etc, 5.3.3.4 Check for correct operation of all protection devices and alarms : (i) Buchholz relay. (ii) Excessive winding temperature. (iii) Excessive oil temperature.
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5.3.3.5 accessories. 5.3.3.6
(iv) Low oil level indication. Check for the adequate protection on the electric circuit supplying the Check resistance of all windings on all steps of the tap changer. Insulation resistance measurement for the following: (i) Control wiring. (ii) Main windings. Check for cleanliness of the transformer and the surroundings. Continuously observe the transformer operation at no load for 24 hours. Gradually put the transformer on load, check and measure increase in temperature n relation to the load and check the operation with respect to temperature rise and noise level etc. Phase out and vector group test. Ratio test on all taps. Magnetising current test. Capacitance and Tan delta measurement of winding and bushing. DGA of oil just before commissioning and after 24 hours energisation at site. Contractor shall prepare a comprehensive commissioning report including all commissioning test results and forward to Employer for future record.
5.3.3.7 5.3.3.8 5.3.3.9
5.3.3.10 5.3.3.11 5.3.3.12 5.3.3.13 5.3.3.14 5.3.3.15
6.0
Technical Parameters Technical Parameters 5 MVA, 1-Phase, Transformer 5 MVA ONAN Two winding transformer (132/3) /(33/ 3) kV 50 Hz Single
6.0.1 6.0.2 6.0.3 6.0.4 6.0.5 6.0.6 6.0.7
Rating ( HV/ LV) Cooling Type of Transformer Voltage ratio Frequency Phases Impedance HV-LV impedance at 75 deg C - Max. Voltage tap - Principal tap - Min. Voltage tap (IEC Tol. Applicable ) Service Duty Temperature rise over 50C Ambient Temp. Of top oil measured by thermometer Of winding measured by resistance method Max. design Ambient temp Windings i) System Fault level (kA) ii) 1.2/50 micro sec. impulse withstand voltage kVp iii) One minute power frequency withstand voltage kV(rms) v) Winding connection vi) Neutral vii) Insulation Vector Group Tap Changer Tap range Bushing
7.6 % 8.0 % 9.4% Outdoor Continuous 50C 55C 50C HV 31.5 550 230
6.0.8 6.0.9 6.0.10
6.0.11 6.0.12
LV 25 170 70
6.0.13 6.0.14
6.0.15
Star Star Solidly grounded Graded Uniform Ynyn0 Off circuit +2.5% to -7.5 % in the steps of 2.5% HV LV & N
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6.0.16 6.0.17 7.0 7.1 7.2
i) Rated voltage (kV) ii) Rated current (Amp) iii) 1.2/50 micro sec. lightning impulse withstand voltage (kVp). iv) One minute power frequency withstand voltage kV (rms) vi) Minimum total creepage distance (mm) vii) Mounting Maximum Partial discharge level Noise level
145 400 650 275 3625
36 630 170 70 900
Tank Tank 100 pico-coulomb As per NEMA-TR-1
7.3
7.4
7.5
Bushing Current Transformer Current transformers shall comply with IEC-60185. It shall be possible to remove the turret mounted current transformers from the tank without removing the tank cover. Necessary precautions shall be taken to minimize eddy currents and local heat generated in the turret. Current transformer secondary leads shall be brought out to a weather proof terminal box near each bushing. These terminals shall be wired out to cooler control cabinet/ marshalling box using separate cables for each core. Bushing Current transformer parameters indicated in this specification are tentative and liable to change within reasonable limits. The Contractor shall obtain Employer's approval before proceeding with the design of bushing current transformers. Technical Parameters for Bushing CT
7.5.1 Current Transformer Parameters for 1-ph., 5MVA, 132/33kV & 3 Ph. , 132/33 kV (on each phase) Transformer HV Side Line side Neutral side (a) Ratio Core - 1 100/1A Core 2 100/1A 100/1A 400/1A 400/1A LV side Line side 400/1 -
Neutral side
(b) Minimum knee point voltage and accuracy class: Core - 1 400V 400V 600V 600V Class PS Class PS Class PS Class PS Core 2 0.2 class 15 VA ISF 5 (c) Maximum CT Resistance Core 1 1.5 ohms 1.5 ohms Core 2 0.2 class 15 VA ISF 5
1.5 ohms -
1.5 ohms -
(d) Application Core - 1 Restricted Restricted Restricted Restricted (Near the wdg) earth fault earth fault earth fault earth fault Core-2 Metering Metering -
(e) Maximum magnetisation current (at knee point voltage) Core-1 100 mA 100 mA 100 mA Core2 7.6 NOTE : 7.6.1 Accuracy class PS as per IEC 60044. 7.6.2 Class (for the relevant protection and duties) as per IEC 60185.
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7.6.3 Parameters of WTI CT for each winding shall be provided by the contractor. 8.0 8.1 Oil Storage Tank General This specification covers supply of oil storage tank of 10 cubic meter capacity along with complete accessories. Standard The oil storage tank shall be designed and fabricated as per relevant Indian Standards e.g. IS: 803 or other internationally acceptable standards. Specifications Transformer oil storage tanks shall be towable on pneumatic tyres and rested on manual screw jacks of adequate quantity & size. The tank shall be cylindrical in shape and mounted horizontally and made of mild steel plate of adequate thickness. Size of the storage tank shall be as follows: Diameter : 1.5 meter Minimum Capacity : 10 cubic metre The tank shall be designed for storage of oil at a temperature of 100C. The Bidder may further note that maximum height of any part of the complete assembly of the storage tank shall not exceed 4.0 metres above road top. The tank shall have adequate number of jacking pad so that it can be kept on jack while completely filled with oil. The tank shall be provided with suitable saddles so that tank can be rested on ground after removing the pneumatic tyres. The tank shall also fitted with manhole, outside & inside access ladder, silicagel breather assembly, inlet & outlet valve, oil sampling valve with suitable adopter, oil drainage valve, air vent etc. Pulling hook on both ends of the tank shall be provided so that the tank can be pulled from either end while completely filled with oil. Bidder shall indicate the engine capacity in horse power to pull one tank completely fitted with oil. Oil level indicator shall be provided with calibration in terms of litre so that at any time operator can have an idea of oil in the tank. Suitable arrangement shall also be provided to prevent overflow in the tank.
8.2
8.3
8.3.1 8.3.2
8.3.3
8.3.4 The following shall form part of supply along with Oil storage tank i) Four numbers of suitable nominal bore rubber hoses for transformer oil application upto temperature of 100C, full vacuum and pressure up to 2.5 Kg/ cm2 with couplers and unions each not less than 10 metre long shall be provided. ii) Two numbers of suitable nominal bore vacuum hoses, suitable for full vacuum without collapsing and kinking, with couplers and unions each not less than 10 metre long shall also be provided. (iii) One number of digital vacuum gauge with sensor capable of reading up to 0.001 torr, operating on 240V 50Hz AC supply shall be supplied. Couplers and unions for sensor should block oil flow in the sensor. Sensor shall be provided with atleast 8 meter cable so as to suitably place the Vacuum gauge at ground level. 8.3.5 The painting of oil storage tank and its control panel shall be as per clause no 3.1.1.8. 8.3.6 The tank shall contain a self mounted centrifugal oil pump with inlet and outlet valves, with couplers -suitable for flexible rubber hoses and necessary switchgear for its control. There shall be no rigid connection to the pump. The pump shall be electric motor driven, and shall have a discharge of not less than 3.0 kl/hr. with a discharge head of 8.0m. The pump motor and the control cabinet shall be enclosed in a cubical with IP-55 enclosure. 9.0 9.1 OIL SAMPLING BOTTLE Oil sampling bottles shall be suitable for collecting oil samples from transformers and shunt reactors, for Dissolved Gas Analysis. Bottles shall be robust enough, so that no damage occurs during frequent transportation of samples from site to laboratory. Oil sampling bottles shall be made of stainless steel having a capacity of one litre.
9.2
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9.3 9.4 9.5
Oil Sampling bottles shall be capable of being sealed gas-tight and shall be fitted with cocks on both ends. The design of bottle & seal shall be such that loss of hydrogen shall not exceed 5% per week. An impermeable oil-proof, transparent plastic or rubber tube of about 5 mm diameter, and of sufficient length shall also be provided with each bottle along with suitable connectors to fit the tube on to the oil sampling valve of the equipment and the oil collecting bottles respectively.
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Annexure-A
Test Procedures 1. Magnetic Circuit Test After assembly each core shall be tested for 1 minute at 2000 Volts between all bolts, side plates and structural steel work. Tank Tests i) Oil Leakage Test All tanks and oil filled compartments shall be tested for oil tightness by being completely filled with air or oil of a viscosity not greater than that of insulating oil conforming to IEC 60296 at the ambient temperature and applying a pressure equal to the normal pressure plus 35 KN/Sq.m (5 psi) measured at the base of the tank. The pressure shall be maintained for a period of not less than 12 hours for oil and one hour for air during which time no leak shall occur. ii) Vacuum Test All transformer tanks shall be subjected to the specified vacuum. The tank designed for full vacuum shall be tested at an internal pressure of 3.33 KN/Sq.m absolute (25 torr) for one hour. The permanent deflection of flat plate after the vacuum has been released shall not exceed the values specified below: ------------------------------------------------------------------------------------Horizontal Length Permanent deflection of flat plate (in mm) (in mm) ------------------------------------------------------------------------------------Upto and including 750 5.0 751 to 1250 6.5 1251 to 1750 8.0 1751 to 2000 9.5 2001 to 2250 11.0 2251 to 2500 12.5 2501 to 3000 16.0 Above 3000 19.0 iii) Pressure Test All transformer tanks, its radiator, conservator vessel and other fittings together or separately shall be subjected to a pressure corresponding to twice the normal head of oil or to the normal pressure plus 35 KN/m2 whichever is lower measured at the base of the tank and maintained for one hour. The permanent deflection of flat plates after the excess pressure has been released shall not exceed the figure specified above for vacuum test. Temp. Rise Test as per IEC: 60076 The Contractor before carrying out such test shall submit detailed calculations showing alternatives possible, on various taps and for the all types of ratings of the transformer and shall recommend the combination that results in highest temperature rise for the test. The temperature rise test shall be conducted between HV-LV at a tap for the worst combination of loading of the transformer.
2.
3.
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Oil sample shall be drawn before and after heat run test and shall be tested for dissolved gas analysis. Oil sampling to be done 2 hours prior to commencement of temperature rise test. Take oil samples during this period. For ONAN/ONAF cooled transformers, sample shall not be taken earlier than 2 hours after shutdown. The acceptance norms with reference to various gas generation rates shall be as per IEC 61181. 4. Dynamic short circuit withstand test shall be carried out as per IEC 60076-5. Dynamic short circuit test shall be carried out at nominal & extreme tap positions. Type tests shall be carried out before short circuit test. Following shall also be conducted before and after Short Circuit test: i) Dissolved gas analysis ii) Frequency response analysis iii) All routine tests Detail test procedure shall be submitted by contractor & shall be approved before short circuit test. 5. Routine test on bushings shall be done as per IEC 60137.
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CIRCUIT BREAKERS
(CB)
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CHAPTER CIRCUIT BREAKERS TECHINCAL SPECIFICATION FOR CIRCUIT BREAKERS CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 Description General Duty requirements Total Break Time Constructional Features Sulphur Hexafluoride Gas (SF6 Gas) Insulators Spare Parts & Mandatory Maintenance Equipment Operating Mechanism & Control Support Structure Terminal Connector Pad Interpole Cabling Fittings & Accessories Additional Data to be furnished along with the Offer Tests Dead Tank Type Circuit Breaker Unit Compressed Air System for Circuit Breakers Technical Parameters Testing & Commissioning Page No. 87 87 88 88 90 90 90 90 94 94 94 94 95 96 96 97 99 100
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CHAPTER - CB
SECTION: CIRCUIT BREAKERS

GENERAL The circuit breakers and accessories shall conform to IEC: 62271-100, IEC: 60694 and other relevant IEC standards except to the extent explicitly modified in the specification and shall also be in accordance with requirements specified in Chapter-GTR. 145 kV circuit breakers offered would be of Sulphur Hexafluoride (SF6) type only and of class C1-M1 as per IEC. The bidder may also offer circuit breakers of either live tank type or dead tank type of proven design. The circuit breaker shall be complete with terminal connectors, operating mechanism, control cabinets, piping, inter-pole cable, cable accessories like glands, terminal blocks, marking ferrules, lugs, pressure gauges, density monitors (with graduated scale), galvanized support structure for CB and control cabinets, their foundation bolts and all other circuit breaker accessories required for carrying out all the functions the CB is required to perform. All necessary parts to provide a complete and operable circuit breaker installation such as main equipment, terminals, control parts, connectors and other devices whether specifically called for herein or not shall be provided. The support structure of circuit breaker as well as that of control cabinet shall be hot dip galvanized. All other parts shall be painted as per shade 697 of IS: 5. The circuit breakers shall be designed for use in the geographic and meteorological conditions as given in Chapter-GTR. 2.0 DUTY REQUIREMENTS: 2.1 2.2 The circuit breakers shall be capable of performing their duties without opening resistors. The circuit breaker shall meet the duty requirements for any type of fault or fault location also for line switching when used on a 145 kV effectively grounded system, and perform make and break operations as per the stipulated duty cycles satisfactorily. 2.2.1 PRE-INSERTION RESISTER Circuit Breakers wherever specified shall be provided with single step Preinsertion closing resistors to limit the switching surges to a value of less than 2.3 p.u. The value of the pre-insertion resistor and the duration of preinsertion time shall be as given in clause 17.0 of this chapter. The resistor shall have thermal rating for the following duties: i) TERMINAL FAULT Close ...1 Min ... Open ... Close open 2 min .. close.. 1 Min .. open close open. ii) RECLOSING AGAINST TRAPPED CHARGES Duty same as under (i) above. The first, third and fourth closures are to be on de-energized line while second closing is to be made with lines against trapped charge of 1.2 p.u. of opposite polarity. iii)
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One closing operation under phase opposition that is with twice the voltage across the terminals. iv) No allowance shall be made for heat dissipation of resistor during time interval between successive closing operations. The resistors and resistor supports shall perform all these duties without deterioration. Calculations and test reports of resistors proving thermal rating for duties specified above shall be furnished along with the bid. The calculations shall take care of adverse tolerances on resistance values and time settings.
2.3 2.4
The breaker shall be capable of interrupting the steady state and transient magnetizing current corresponding of power transformers. The circuit breaker shall also be capable of: i) ii) iii) Interrupting line/cable charging current as per IEC without use of opening resistors. Clearing short line fault (Kilometric faults) with source impedance behind the bus equivalent to symmetrical fault current specified. Breaking 25% of the rated fault current at twice rated voltage under phase opposition condition.
2.5
The Breaker shall satisfactorily withstand the high stresses imposed on them during fault clearing, load rejection and re-energisation of lines with trapped charges. The breaker shall also withstand the voltages specified under Clause 17 of this Chapter.
3.0
TOTAL BREAK TIME: 3.1 The total break time as specified under this Chapter shall not be exceeded under any of the following duties: i) Test duties 1, 2 ,3, 4, 5 ii) Short line fault L75, L90 3.2 (TRV as per IEC: 62271-100) (TRV as per IEC: 62271-100)
The Bidder may please note that total break time of the breaker shall not be exceeded under any duty conditions specified such as with the combined variation of the trip coil voltage, (70-110%), pneumatic/hydraulic pressure and arc extinguishing medium pressure etc. While furnishing the proof of the total break time of complete circuit breaker, the Bidders may specifically bring out the effect of non-simultaneity between contacts within a pole or between poles and show how it is covered in the guaranteed total break time.
3.3 The values guaranteed shall be supported with the type test reports. 4.0 CONSTRUCTIONAL FEATURES: The features and constructional details of circuit breakers shall be in accordance with requirements stated hereunder: 4.1 Contacts 4.1.1 The gap between the open contacts shall be such that it can withstand at least the rated phase to ground voltage for 8 hours at zero gauge pressure of SF6 gas due to the leakage. The breaker should be able to withstand all dielectric stresses imposed on it in open condition at lock out pressure continuously (i.e. 2 p.u. across the breaker continuously).
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4.2
If multi-break inter ruptures are used, these shall be so designed and augmented that a uniform voltage distribution is developed across them. Calculations/ test reports in support of the same shall be furnished. The thermal and voltage withstand of the grading elements shall be adequate for the service conditions and duty specified. The SF6 Circuit Breaker shall meet the following additional requirements: a) The circuit breaker shall be single pressure type. The design and construction of the circuit breaker shall be such that there is a minimum possibility of gas leakage and entry of moisture. There should not be any condensation of SF6 gas on the internal insulating surfaces of the circuit breaker. All gasketted surfaces shall be smooth, straight and reinforced, if necessary, to minimize distortion and to make a tight seal, the operating rod connecting the operating mechanism to the arc chamber (SF6 media) shall have adequate seals. The SF6 gas leakage should not exceed 1% per year. In case the leakage under the e specified conditions is found to be greater than 1% after one year of commissioning of circuit breaker, the manufacturer will have to supply free of cost, the total gas requirement for subsequent ten (10) years, based on actual leakage observed during first year of operation after commissioning. In the interrupter assembly there shall be an absorbing product box to minimize the effect of SF6 decomposition products and moisture. The material used in the construction of the circuit breakers shall be such as fully compatible with SF6 gas decomposition products. Each pole shall form an enclosure filled with SF6 gas independent of two other poles (for 420 & 245 kV CBs) and the SF6 density of each pole shall be monitored. However, for CBs of voltage class of 145 kV or less, a common SF6 scheme/density monitor shall be acceptable. The dial type SF6 density monitor shall be adequately temperature compensated to model the pressure changes due to variations in ambient temperature within the body of circuit breaker as a whole. The density monitor shall have graduated scale and shall meet the following requirements: i) It shall be possible to dismantle the density monitor for checking/replacement without draining the SF6 gas by providing suitable interlocked non return valve coupling.
4.3
b)
c)
d)
e)
f)
Each Circuit Breaker shall be capable of withstanding a vacuum of minimum 8 millibars without distortion or failure of any part.
g) Sufficient SF6 gas including that will be required for gas analysis during filling shall be provided to fill all the circuit breakers installed. In addition spare gas shall be supplied in separate unused cylinders as per requirement specified in Chapter-GTR. 4.4 Provisions shall be made for attaching an operational analyser after installation of circuit breakers at site to record contact travel, speed and making measurement of operating timings, preinsertion timings of closing resisters if used, synchronization of contacts in one pole. In case operation analyzer is already available at a particular site, the contractor shall have to supply a suitable adopter/transducer so that the offered circuit breaker can be used with the operational analyzer.
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5.0
SULPHUR HEXAFLUORIDE GAS (SF6 GAS): a) The SF6 gas shall comply with IEC 376, 376A and 376B and shall be suitable in all respects for use in the switchgear under the operating conditions. The high pressure cylinders in which the SF6 gas is shipped and stored at site shall comply with requirements of the relevant standards and regulations. Test: SF6 gas shall be tested for purity, dew point, air, hydrolysable fluorides and water content as per IEC 376, 376A and 376B and test certificates shall be furnished to Employer indicating all the tests as per IEC 376 for each lot of SF6 gas in stipulated copies as indicated in ChapterGTR. Gas bottles should be tested for leakage during receipt at site.
b)
c)
6.0
INSULATORS: a) b) c) The porcelain of the insulators shall conform to the requirements stipulated under Chapter-GTR. The mechanical characteristics of insulators shall match with the requirements specified under this Chapter. All insulators shall conform to IEC-61264 (for pressurized hollow column insulators) and IEC-233 (for others). All routine and sample tests shall be conducted on the hollow column insulators as per these standards with requirements and procedures modified as under: i) Pressure test as a routine test. ii) Bending load test as a routine test. iii) Bending load test as a sample test on each lot. iv) Burst pressure test as a sample test on each lot. v) In addition to above, ultrasonic test shall be carried out as additional routine test. d) Hollow Porcelain for pressurized columns/chambers should be in one integral piece in green and fired stage.
7.0
SPARE PARTS AND MANDATORY MAINTENANCE EQUIPMENT: The bidder shall include in his proposal spare parts and maintenance equipment in accordance with Section-Project. Calibration certificates of each maintenance equipment shall be supplied along with the equipment.
8.0
OPERATING MECHANISM AND CONTROL 8.1 General Requirements 8.1.1 Circuit breaker shall be operated by pneumatic mechanism or spring charged mechanism or hydraulic mechanism or a combination of these. The mechanism shall be housed in a weather proof and dust proof control cabinet as stipulated in Chapter-GTR. 8.1.2 The operating mechanism shall be strong, rigid, not subject to rebound and shall be readily accessible for maintenance for a man standing on ground.
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8.1.3 The mechanism shall be anti-pumping and trip free (as per IEC definition) under every method of closing. 8.1.4 The mechanism shall be such that the failure of an y auxiliary spring will not prevent tripping and will not cause trip or closing operation of the power operating devices. 8.1.5 A mechanical indicator shall be provided to show open and close position of the breaker. It shall be located in a position where it will be visible to a man standing on the ground level with the mechanism housing closed. An operation counter shall also be provided in the central control cabinet. 8.1.6 Working parts of the mechanism shall be corrosion resisting material, bearings which require grease shall be equipped with pressure type grease fittings. Bearing pin, bolts, nuts and other parts shall be adequately pinned or locked to prevent loosening or changing adjustment with repeated operation of the breaker. 8.1.7 The bidder shall furnish detailed operation and maintenance manual of the mechanism along with the operation manual for the circuit breaker. The instruction manuals shall contain exploded diagrams with complete storage, handling, erection, commissioning, troubleshooting, servicing and overhauling instructions. 8.2 Control: 8.2.1 The close and trip circuits shall be designed to permit use of momentary contact switches and push buttons. 8.2.2 Each breaker pole shall be provided with two (2) independent tripping circuits, pressures switches and coils each connected to a different set of protective relays. 8.2.3 The breaker shall normally be operated by remote electrical control. Electrical tripping shall be performed by shunt trip coils. However, provisions shall be made for local electrical control. For this purpose a local/remote selector switch and close and trip control switch/push buttons shall be provided in the Breaker central control cabinet. 8.2.4 The trip coils shall be suitable for trip circuit supervision during both open and close position of breaker. The trip circuit supervision relay would be provided on relay panels. 8.2.5 Closing coil and associated circuits shall operate correctly at all values of voltage between 85% and 110% of the rated voltage. Shunt trip coil and associated circuits shall operate correctly under all operating conditions of the circuit breaker up to the rated breaking capacity of the circuit breaker and at all values of supply voltage between 70% and 110% of rated voltage. However, even at 50% of rated voltage the breaker shall be able to open. If additional elements are introduced in the trip coil circuit their successful operation and reliability for similar applications on outdoor circuit breakers shall be clearly brought out in the additional information schedules. 8.2.6 Density Meter contacts and pressure switch contact shall be suitable for direct use as permissive in closing and tripping circuits. Separate contacts have to be used for each of tripping and closing circuits. If contacts are
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not suitably rated and multiplying relays are used then fail safe logic/schemes are to be employed. DC supplies for all auxiliary circuits shall be monitored and provision shall be made for remote annunciations and operation lockout in case of DC failures. Density monitors are to be so mounted that the contacts do not change on vibration during operation of circuit Breaker. 8.2.7 The auxiliary switch of the breaker shall be positively driven by the breaker operating rod. 8.2.8 The preferred basic control schematic of the Circuit breaker is enclosed with the bid documents and it is expected to be followed by the bidder. This, however, does not absolve the bidder from the responsibility for safe and reliable operation of the breaker in its lifetime. 8.3 Pneumatically operated mechanism: a) b) Each pneumatic operated breaker shall be equipped with compressed air system in accordance with Clause 16.0. The breaker local air receivers shall comply with the requirements under Clause 16.4 and shall have sufficient capacity for at least two CO operations of the breaker at the lowest pressure for auto reclosing duty without refilling. Independently adjustable pressure switches with potential free, ungrounded contacts to actuate a lock out device shall be provided. This lockout device with provision of remote alarm indication shall be incorporated in the circuit breaker to prevent operation whenever the pressure of the operating mechanism is below that required for satisfactory operation of the circuit breaker. The scheme should permit operation of all blocking and alarm relays as soon as the pressure transient present during the rapid pressure drop h as been damped and a reliable pressure measurement can be made. Such facilities shall be provided for following conditions: i) Trip lockout pressure ii) Close lockout pressure - 2 Nos. - 1 No.
c)
iii) Auto reclose lockout pressure - 1 No. iv) Extreme low pressure d) - 1 No.
The compressed air mechanism shall be capable of operating the circuit breaker under all duty conditions with the air pressure immediately before operation between 85% and 110% of the rated supply pressure. The make/break time at this supply pressure shall not exceed the specified make/break time within any value of trip coil supply voltage as specified. The compressed air piping shall comply to requirements under Clause 16.0.
e)
8.4 Spring operated mechanism: a) Spring operated mechanism shall be complete with motor in accordance with Chapter-GTR. Opening spring and closing spring with limit switch for automatic charging and other necessary accessories to make the mechanism a complete operating unit shall also be provided.
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b)
As long as power is available to the motor, a continuous sequence of the closing and opening operations shall be possible. The motor shall have adequate thermal rating for this duty. After failure of power supply to the motor one close open operation shall be possible with the energy contained in the operating mechanism. Breaker operation shall be independent of the motor which shall be used solely for compressing the closing spring. Facility for manual charging of the closing spring shall also be provided. The motor rating shall be such that it requires not more than 30 seconds for full charging of the closing spring. Closing action of circuit breaker shall compress the opening spring ready for tripping. When closing springs are discharged after closing a breaker, closing springs shall be automatically charged for the next operation and an indication of this shall be provided in the local and remote control cabinet. Provisions shall be made to prevent a closing operation of the breaker when the spring is in the partial charged condition. Mechanical interlocks shall be provided in the operating mechanism to prevent discharging of closing springs when the breaker is already in the closed position. The spring operating mechanism shall have adequate energy stored in the operating spring to close and latch the circuit breaker against the rated making current and also to provide the required energy for the tripping mechanism in case the tripping energy is derived from the operating mechanism.
c) d)
e) f)
g)
h)
8.5
Hydraulically operated mechanism: a) Hydraulically operated mechanism shall comprise of operating unit with power cylinder, control valves, high and low pressure reservoir, motor. Electrically driven motor shall comply with Chapter - GTR. b) The hydraulic oil used shall be fully compatible for the specified temperature range. c) The oil pressure switch controlling the oil pump and pressure in the high pressure reservoir shall have adequate number of spare contacts to be used for continuous monitoring of low pressure, high pressure etc. d) The mechanism shall be suitable for at least two close open operations after failure of AC supply to the motor starting at pressure equal to the lowest pressure of auto reclose duty plus pressure drop for one close open operation. e) The mechanism shall be capable of operating the circuit breaker correctly and performing the duty cycle specified under all conditions with the pressure of hydraulic operated fluid in the operating mechanism at the lowest permissible pressure before make up. The opening time at the lowest pressure for a particular operation shall not exceed the guar anteed operating time within any value of trip coil supply voltage as specified.
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f) Trip lockout shall be provided to prevent operations of the circuit breaker below the minimum specified hydraulic pressure. Alarm contacts for loss of Nitrogen shall be provided. g) All hydraulic joints shall have no oil leakage under the site conditions and joints shall be tested at factory against oil leakage at a minimum of 1.5 times maximum working pressure. 9.0 SUPPORT STRUCTURE: a) The structure design shall be such that during operation of circuit breaker vibrations are reduced to minimum.
b) If required, the Contractor shall provide suitable platform with steps on both sides of the circuit breaker for easy accessibility for monitoring the density/pressure of gas. 10.0 TERMINAL CONNECTOR PAD: The circuit breaker terminal pads shall be made up of high quality electrolytic copper or aluminum. The terminal pad shall have protective covers which shall be removed before interconnections. 11.0 INTERPOLE CABLING: 11.1 All cables to be used by contractor shall be armoured and shall be as per IS -1554 (1100 Volts Grad e). All cables within & between circuit breaker poles shall be supplied by the CB manufacturer. 11.2 Only stranded conductor shall be used. Minimum size of the conductor shall be 2.5 sq. mm. (Copper). 11.3 The cables shall be with oxygen index Min-29 and temp. Index as 250 C as per relevant standards. 12.0 FITTINGS AND ACCESSORIES 12.1 Following is a partial list of some of the major fittings and accessories to be furnished by Contractor in the Central Control cabinet. Number and exact location of these parts shall be indicated in the bid. i) ii) iii) iv) iv) v) vi) Cable glands (Double compression type), Lugs, Ferrules etc. Local/remote changeover switch. Operation counters Pneumatic/hydraulic pressure gauges. Control switches to cut off control power supply. Fuses as required. The number of terminals provided shall be adequate enough to wire out all contacts and control circuits plus 24 terminals spare for future use.
vii) Antipumping relay. viii) Pole discrepancy relay. ix) x) D.C. Supervision relays. Rating and diagram plate in accordance with IEC incorporating year of manufacture.
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12.2 Additional fittings for pneumatically operated circuit breaker a) b) c) d) Unit compressed air system in accordance with Clause 16.0. Breaker air receivers. Pressure gauge, spring loaded safety valve and pressure switch with adjustable contacts. Pressure switch to initiate an alarm if the pressure in the auxiliary reservoir remains below a preset level for longer than it is normally necessary to refill the reservoir. Stop, non-return and other control valves, pipings and all accessories up to breaker mechanism housing.
e)
13.0 ADDITIONAL DATA TO BE FURNISHED ALONGWITH THE OFFER: a) b) c) d) Drawing, showing contacts in close, arc initiation, full arcing, arc extinction and open position. The temperature v/s pressure curves for each setting of density monitor along with details of density monitor. Method of checking the healthiness of voltage distribution devices (condensers) provided across the breaks at site. Data on capabilities of circuit breakers in terms of time and number of operations at duties ranging from 100% fault currents to load currents of the lowest possible value without requiring any maintenance or checks. The effect of non-simultaneity between contacts between poles and also show how it is covered in the guaranteed total break time. Sectional view of non-return couplings if used for SF6 pipes. Details & type of filters used in interrupter assembly and also the operating experience with such filters. Details of SF6 gas: i) ii) The test methods used in controlling the quality of gas used in the circuit breakers particularly purity and moisture content. Proposed tests to assess the conditions of the SF6 within a circuit breaker after a period of service particularly with regard to moisture contents of the gas.
e) f) g) h)
i) j)
A complete catalogue on operation analyzer satisfying all the requirements of this Chapter. The bidders shall furnish along with the bid, curves supported by test data indicating the opening time under close open operation with combined variation of trip coil voltage and pneumatic/hydraulic pressure. Detailed literature and schematic diagrams of switching mechanism for closing resistor showing the duration of insertion shall also be furnished along with the calculations in respect of thermal rating of resistors for the duties specified under clause 2.2 of this chapter in case required so for the circuit breaker. All duty requirements as applicable to CBs specified under Clause 2.0 of this Chapter shall be provided with the support of adequate test reports to be furnished along with the bid failing which the bid is likely to be rejected.
k)
l)
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m)
Field test report or laboratory test report in case of CBs wherever required.
14.0 TESTS: 14.1 In accordance with the requirements stipulated under Chapter-GTR the circuit breaker along with its operating mechanism shall conform to IEC: 62271-100. 14.2 The test reports of the type tests and the following additional type tests shall also be submitted for Purchasers review: i) ii) iii) iv) Corona extinction voltage test (as per Annexure-A of Chapter- GTR). Out of phase closing test as per IEC: 62271-100. Line charging breaking current for proving parameters as per clause 17.9 of this Chapter. Test to demonstrate the Power Frequency withstand capability of breaker in open condition at Zero Gauge pressure (Ref. Clause 4.1.1) and at lockout pressure. Seismic withstand test (As per Annexure- B of Chapter-GTR) in unpressurised condition. Verification of the degree of protection.
v) vi)
vii) Low & high temperature test (if applicable). viii) Humidity tests (if applicable). ix) x) Static Terminal Lo ad test. Critical Currents test (if applicable).
14.3 Routine Tests Routine tests as per IEC: 62271-100 shall be performed on all circuit breakers. In addition to the mechanical and electrical tests specified by IEC, the following tests shall also be performed. 1) Speed curves for each breaker shall be obtained with the help of a suitable operation analyzer to determine the breaker contact movement during opening, closing, auto-reclosing and trip free operation under normal as well as limiting operating conditions (control voltage, pneumatic/hydraulic pressure etc.). The tests shall show the speed of contacts directly at various stages of operation, travel of contacts, opening time, closing time, shortest time between separation and meeting of contacts at break make operation etc. This test shall also be performed at site for which the necessary operation analyzer along with necessary transducers, cables, console, etc. where included in scope of supply shall be furnish ed and utilized. Measurement of Dynamic Contact resistance measurement for arcing & main contacts. Signature of Dynamic Contact resistance measurements shall be taken as reference for comparing the same during operation and maintenance in order to ascertain the healthiness of contacts.
2)
14.4 Site Tests: All routine tests except power frequency voltage dry withstand test on main circuit breaker shall be repeated on the completely assembled breaker at site.
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15.0 DEAD TANK TYPE CIRCUIT BREAKER 15.1 In case dead tank type circuit breaker is offered, the Bidder shall offer bushing type CTs (whose secondary parameters are given in either Chapter-INST) on either side of dead tank circuit breaker instead of conventional outdoor CTs. 15.2 The enclosure shall be made of either Al/Al Alloy or mild steel (suitably hot dip galvanized). The enclosure shall be designed for the mechanical and thermal loads to which it is subjected in service. The enclosure shall be manufactured and tested according to the pressure vessel codes {i.e., latest edition of the ASME code for pressure vessel - Section VIII of BS-5179, IS4379, IS-7311 (as applicable) and also shall meet Indian Boiler Regulations}. The maximum temperature of enclosure with CB breaker carrying full load current shall not exceed the ambient by more than 20 C. 15.3 The enclosure has to be tested as a routine test at 1.5 times the design pressure for one minute. A bursting pressure test shall be carried out at 5 times the design pressure as type test on the enclosure. 16.0 UNIT COMPRESSED AIR SYSTEM FOR CIRCUIT BREAKERS: 16.1 The unit compressed air system shall meet the following requirements: a) The compressed air system shall be provided with necessary piping, piping accessories, control valves, safety valves, filters, reducing valves, isolating valves, drain ports, etc. Also the Unit compressed air system shall be provided with suitable anti-vibration pads. The compressors or pumps shall be of the air cooled type and mounted within the operating mechanism housing or a separate weather-proof and dust-proof housing. The air receiver shall have stored energy for 2 CO operations of the breaker at the blocking pressure for auto reclosing duty without refilling. The unit compressor shall be capable of building up required pressure for another 2 CO operations within 30 minutes.
b)
c)
d) The size of the compressor shall be determined by the bidder. The compressor shall be of sufficient capacity for performing all the operations above mentioned. 16.2 Air Compressor: a) The air compressor shall be of air cooled type complete with cylinder lubrication, drive motor etc. The compressor shall be rated for the following duty: i) Total running time of compressor to build up the rated pressure from atmospheric pressure: Normal running air charging: Not exceeding 80 minutes.
ii)
b)
Air charging time after one closeopen operation from rated pressure: Compressor shall be driven by automatically controlled motors conforming to requirements of Chapter-GTR.
iii)
Not exceeding 15 minutes considering 10% leak age/day. Not exceeding 15 minutes.
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c) d)
The compressor shall be provided with automatic adjustable unloading device during starting. The compressor shall be equipped with a Time totaliser and a Pressure gauge.
16.3 Intercooler and after cooler: (If applicable) Intercooler between compressor stage and after cooler at discharge if any of H.P. Cylinder shall be included in Contractors scope. They shall be of air cooled type and shall be designed as per ASME Code of IEMA Standards. The design pressure on the air side of cooler shall be 1.25 times the working pressure. A corrosion allowance of 3 mm shall be included for all steel parts. 16.4 Air Receivers: a) Air receiver shall be designed in accordance with the latest edition of the ASME Code for Pressure Vessel - Section VIII of BS: 5179. A corrosion allowance of 3.0 mm shall be provided for shell and dished ends. Receivers shall be coated on the inside face with antirust medium if it is not hot dip galvanised. b) Connections for air inlet and outlet, drain and relief valves shall be flanged type or screwed type. Pressure gauge and pressure switch connections shall be screwed type only. Accessories such as suitable sized safety valve to relieve full compressor discharge at a set pressure equal to 1.1 times the maximum operating pressure, blow off valve, auto drain tap with isolating and bypass valve, dial type pressure gauge with isolating and drain valve and test connection shall be provided. Air receiver shall be offered with at least 50% spare capacity, calculated on the basis of total air requirement for 2 CO operations.
c)
d)
16.5 Quality of Air: Compressed air used shall be dry and free of dust particles and fully compatible with the materials used in the pneumatic operating mechanism. Arrangement for conditioning the compressed air if required shall be provided as an integral part of air compressor system. If situation warrants, because of the severe ambient conditions, the supplier may offer centralized compressed air system. 16.6 Control and Control Equipment: a) b) The compressor control shall be of automatic start/stop type initiated by pressure switches. Duplicate incoming supply of 415 V, AC shall be provided by the Employer at switchyard bay marshaling box from where the Contractor shall take the feed to the operating mechanism. All the necessary compressor control equipment shall be housed in a totally enclosed sheet steel cabinet also conforming to requirements of Chapter-GTR. Pressure gauges and other indicating devices, control switches shall be mounted on the control cabinet. A glass window shall be provided for viewing the indicating instrument/gauges. The maximum height shall be 2000 mm.
c)
d)
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16.7 Compressed Air Piping, Valves and Fittings: a) b) The flow capacity of all valves shall be at least 20% greater than the total compressor capacity. The high pressure pipe and air system shall be such that after one O-0.3 sec-CO-operation the breaker shall be capable of performing one CO operation within 3 minutes. All compressed air piping shall be bright annealed, seamless phosphorous Deoxidized Non-Arsenical Copper alloy as per BS: 2874 or stainless steel pipe (C - 106 of BS: 2871-1957). All joints and connections in the piping system shall be brazed or flared as necessary. All compressed air piping shall be carried out in accordance with BS: 162. Compressed air piping system shall be complete with saddle clamps to support the piping system at suitable intervals. Necessary bolts, nuts, pipe fixing clamps etc shall be included in the scope of Contractor.
c)
d) e) f)
16.8 Tests: In accordance with the requirements stipulated under Chapter-GTR, the compressors and its accessories shall conform to the type tests and shall be subjected to routine tests as per applicable standards. 17.0 TECHNICAL PARAMETERS: (In addition to those indicated in Chapter-GTR) 145 kV CIRCUIT BREAKER: 17.1 17.2 Rated continuous current at design ambient temperature (A): Rated short circuit current breaking capacity at rated voltage: 1250.
31.5 kA with percentage DC component as per IEC: 62271100 corresponding to minimum opening time under operating conditions specified.
17.3 17.4 17.5 17.6 17.7 17.8 17.9 17.10
Symmetrical interrupting capability (kA rms): Rated short circuit making current (k AP): Short time current carrying capability for one second (kA rms):
Out of phase braking current capacity (kA rms):
31.5. 80. 315.
17.11 17.12
As per IEC. Rated operating duty cycle: O-0.3sec-CO-3min-CO cycle. Reclosing: Three phase autoreclosing. First pole to clear factor: 1.3 Rated line/cable charging interrupting current As per IEC at 90 leading power factor angle (A. rms): (The breaker shall be able to interrupt the rated line/cable charging current with test voltage immediately before opening equal to the product of U/v3 & 1.4 as per IEC: 62271-10 0). Temperature rise over the design ambient As per IEC: 62271-100. temperature: a. Total break time as per Cl.3.0 of this 65. Chapter (ms):
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17.13 17.14 17.15
b. Rated break time as per IEC (ms): Total closing time (ms): Operating mechanism: Max. Difference in the instants of closing/opening of contacts (ms) between poles at rated control voltage and rated operating and quenching media pressures: Trip coil and closing voltage: Noise level at base and up to 50 m (distance from base of breaker): Rated terminal load:
60. Not more than 150. Pneumatic/spring/hydraulic or a combination of these. 3.3
17.16 17.17 17.18
220 V DC with variation as specified. 140 dB (Max.). As per IEC or as per the value calculated by Chapter-GTR, whichever is higher. Besides requirement of specification, the bidder shall wire up 5 NO + 5 NC contacts for future use of Purchaser. All contacts & control circuits to be wired out up to common control cabinet plus 24 terminals exclusively for Purchasers use. As per IEC. 0.5 to 10.
17.19
Auxiliary Contacts:
17.20
Number of Terminals in common control cabinet:
17.21 17.22
Maximum allowable switching over voltage under any switching condition: Rated small inductive current switching capability with over voltage less than 2.3 p.u. (A):
(Auxiliary switch shall also comply with requirements stipulated under Chapter-GTR).
18.0 TESTING AND COMMISSIONING 18.1 An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the field Q.P./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) (b) (c) (d) (e) (f) (g) (h) (i)
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Insulation resistance of each pole. Check adjustments, if any suggested by manufacturer. Breaker closing and opening time. Slow and Power closing operation and opening. Trip free and anti pumping operation. Minimum pick-up voltage of coils. Dynamic Contact resistance measurement. Functional checking of compressed air plant and all accessories. Functional checking of control circuits interlocks, tripping through protective relays and auto reclose operation.
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(j) (k) (l)
Insulation resistance of control circuits, motor etc. Resistance of closing and tripping coils. SF6 gas leakage check.
(m) Dew Point Measurement (n) (q) Calibration of pressure switches and gas density monitor. Checking of mechanical CLOSE interlock, wherever applicable. For details, refer O.S. Document no. OS/T&C/BAY/95.
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ISOLATORS
(ISO)
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Section-Technical Specifications-Isolators
103
CHAPTER ISOLATORS TECHNICAL SPECIFICATION FOR ISOLATORS CONTENTS Clause. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 Description General Duty requirements Constructional Features Earthing Switches Operating Mechanism Operation Terminal Connectors Support Structure Tests Spare Parts & Mandatory Maintenance Equipment Technical Parameters Testing & Commissioning Page No. 104 104 104 106 107 107 108 108 108 109 109 109
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CHAPTER ISOLATORS SECTION: ISOLATORS 1.0 GENERAL: 1.1 The isolators and accessories shall conform in general to IEC: 62271-102 (or IS: 9921) except to the extent explicitly modified in specification and shall be in accordance with requirement of Chapter-GTR. Isolators shall be outdoor, off-load type. Earth switches shall be provided on Isolators wherever called for. Complete isolator with all the necessary items for successful operation shall be supplied including but not limited to the following. 1.3.1 1.3.2 Isolator assembled with complete base frame, linkages, operating mechanism, control cabinet, interlocks etc. All necessary parts to provide a complete and operable isolator installation, control parts and other devices whether specifically called for herein or not. The isolator shall be designed for use in the geographic and meteorological conditions as given in Chapter-GTR.
1.2 1.3
1.3.3
2.0
DUTY REQUIREMENTS: 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. 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. 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 fail safe 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 in Chapter-GTR. The earthing switches shall be capable of discharging trapped charges of the associated lines. 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. The isolator shall be capable of making/breaking magnetizing current of 0.7A at 0.15 power factors and capacitive current of 0.7A at 0.15 power factors at rated voltage.
2)
3)
4) 5)
6)
3.0 CONSTRUCTIONAL FEATURES:
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The features and constructional details of Horizontal Center Break/Double Break Isolators, earth switches and accessories shall be in accordance with requirements stated hereunder: 3.1 Contacts: 1) 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. 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 loose their characteristics due to heating effects.
2)
3)
3.2 Base: Each single pole of the isolator shall be provided with a complete galvanized steel base provided with holes and designed for mounting on a supporting structure. 3.3 Blades: 1) All metal parts shall be of non-rusting and non-corroding material. All current carrying parts shall be made from high conductivity electrolytic copper/aluminum. 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. Corona shields/rings etc. shall be made up of aluminum/aluminum alloy. 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.
2)
3)
4)
3.4 Insulator: 1) The insulator shall conform to IS: 2544 and/or IEC-168. The porcelain of the insulator shall conform to the requirements stipulated under ChapterGTR and shall have a minimum cantilever strength of 600 kilograms. Pressure due to the contact shall not be transferred to the insulators after the main blades are fully closed.
2)
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3) 4)
The parameters of the insulators shall meet the requirements specified under Chapter-GTR. Insulator shall be type and routine tested as per IEC-168. Besides following additional tests shall also be conducted: a) b) c) d) Bending load test in four directions at 50% of minimum bending load guaranteed on all insulators, as a routine test. Bending load test in four directions at 100% of minimum bending load as a sample test on each lot. Torsional test on sample insulators of a lot. Ultrasonic test as a routine test.
5)
For 145 kV insulator: (For Isolator) Top PCD No. of holes Bottom PCD No. of holes = 127 mm. = 4 x M16. = 254 mm. = 8 x 18 dia.
3.5 Name Plate: The name plate shall conform to the requirements of IEC incorporating year of manufacture. 4.0 EARTHING SWITCHES: 1) 2) 3) 4) Where earthing switches are specified these shall include the complete operating mechanism and auxiliary contacts. The earthing switches shall form an integral part of the isolator and shall be mounted on the base frame of the isolator. Earthing switches shall be only locally operated. 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. 5) 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. The plane of movement and final position of the earth blades shall be such that adequate electrical clearances are obtained from adjacent live parts in the course of its movement between ON and OFF position. The frame of each isolator and earthing switches shall be provided with two reliable earth terminals for connection to the earth mat. 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. The earth switch should be able to carry the same fault current as the main blades of the isolators and shall withstand dynamic stresses.
6)
7) 8) 9)
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10) The earth switches shall also comply with the requirements of IEC-1129, 1992 in respect of induced current switching duty as defined for Class-B earthing switches. 5.0 OPERATING MECHANISM: 1) 2) The bidder shall offer motor operated isolators and earth switches. Control cabinet/operating mechanism box shall conform to the requirement stipulated in Chapter-GTR and shall be made of aluminum sheet of adequate thickness (minimum 3 mm). A Local/Remote selector switch and a set of open/close push buttons shall be provided on the control cabinet of the isolator to permit its operation through local or remote push buttons. Provision shall be made in the control cabinet to disconnect power supply to prevent local/remote power operation. Motor shall be an AC motor and conform to the requirements of Chapter-GTR. Suitable reduction gearing shall be provided between the motor and the drive shaft of the isolator. The mechanism shall stop immediately when motor supply is switched off. If necessary a quick electromechanical brake shall be fitted on the higher speed shaft to effect rapid braking. Manual operation facility (with handle) should be provided with necessary interlock to disconnect motor. 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. The test report for blocked rotor test of motor shall be submitted as per the requirement of Section: GTR of Technical Specification.
3)
4) 5) 6)
7) 8)
9)
6.0 OPERATION: 1) The main isolator and earth switches shall be individual-pole or gang operated. The operating mechanism of the three poles shall be well synchronized and interlocked. The design shall be such as to provide maximum reliability under all service conditions. All operating linkages carrying mechanical loads shall be designed for negligible deflection. The length of inter insulator and interpole operating rods shall be capable of adjustments, 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. Each isolator/pole of 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. The manual operating handle shall have provision for pad locking. The operating handle shall be located at a height of 1000 mm (approximately) from the base of isolator support structure. 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
2)
3)
4)
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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. 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. Signaling of closed position shall not take place unless it is 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 at least 80% of the isolating distance. 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. The contractor shall furnish the following details along with quality norms, during detailed engineering stage. a) b) Current transfer arrangement from main blades of isolator along with milli volt 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.
6)
7)
8)
7.0
TERMINAL CONNECTORS: The terminal connector shall meet the requirements as given in Chapter-GTR.
8.0
SUPPORT STRUCTURE: Isolators shall be suitable for mounting on support structures to be supplied in accordance with stipulations of Chapter-GTR.
9.0 TESTS: 9.1 In continuation to the requirements stipulated under Chapter-GTR the isolator along with its earthing switch and operating mechanism should have been type tested as per IEC/IS and shall be subjected to routine tests in accordance with IEC-129/IEC-1129. Power frequency voltage withstand tests shall be performed on at least one completely assembled isolator pole of each type. Alternatively, power frequency test may be performed on two numbers of Post Insulators (complete) for each voltage rating and type of isolator. Minimum 50 numbers mechanical operations will be carried out on 1 (one) isolator out of every ten isolators assembled completely with all accessories as acceptance test for the lot. 9.2 The test reports of the type tests and the following additional type tests shall also be submitted for the Purchasers review. 1) 2) Radio interference voltage test as per Annexure-A of Chapter-GTR. Seismic withstand test on isolator mounted on support structure as per Annexure-B of Chapter-GTR. The test shall be performed in the following position: Isolator opens
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Isolator opens Isolator Closed 9.3 Site Tests:
E/S Open E/S Open
All routine tests including 50 operation test, except power frequency dry voltage withstand test on isolator shall be repeated on completely assembled isolator of each type at site. 10.0 SPARE PARTS AND MAINTENANCE EQUIPMENT: Bidder shall include in his proposal mandatory spare parts in accordance with the requirements stipulated in Section - Project. 11.0 TECHNICAL PARAMETERS (145 kV ISOLATORS): (In addition to those specified under Chapter-GTR) 11.1 11.2 11.3 Type: Rated current at 50oC ambient temperature: Rated short time withstands current of isolator and earth switch: Rated dynamic short circuit withstand current of isolator and earth switch: Temperature rise over design ambient temperature: Rated mechanical terminal load: Outdoor 1250 A.
31.5 kA for 1 Seconds.
11.4
80 kAp. As per table V of IEC-694. As per table III of IEC-129(1984) or as per value calculated in Chapter- GTR whichever is higher. A.C. Motor operated. Besides requirement of this specification, 5 NO + 5 NC to contacts, wired to terminal block exclusively for Purchasers use in future. Besides requirement of this specification, the bidder shall wire up 3 NO + 3 NC to TBs (Reversible) for Purchasers future use. 12 seconds or less. All contacts & control circuits are to be wired up to control cabinet plus 24 spare terminals evenly distributed.
11.5 11.6
11.7 11.8
Operating mechanism of isolator/earth switch: Number of auxiliary contacts on each isolator:
11.9
Number of auxiliary contacts on each earthing switch:
11.10 Operating time: 11.11 Number of terminal in control cabinet (Inter-pole cabling shall be supplied by Contractor): 12.0 TESTING AND COMMISSIONING
12.1 An indicative list of tests on isolator and earth switch is given below. Contractor shall perform any additional test based on specialties of the items as per the field Q.R./instructions of the equipment Supplier or Purchaser without any extra cost to the Purchaser. The Contractor shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the Purchaser for approval.
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1) 2) 3) 4) 5) 6) 7) 8) 9)
Insulation resistance of each pole. Manual and electrical operation and interlocks. Insulation resistance of control circuits and motors. Ground connections. Contact resistance. Proper alignment so as to minimize to the extreme possible the vibration during operation. Measurement of operating torque for isolator and earth switch. Resistance of operating and interlocks coils. Functional check of the control schematic and electrical & mechanical interlocks. For details, refer O.S. Document no. OS/T&C/BAY/95.
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INSTRUMENT TRANSFORMERS
(ITF)
Part-III (Vol.2/2)
Section-Technical Specifications-Instrument Transformers
112
CHAPTER INSTRUMENT TRANSFORMERS TECHNICAL SPECIFICAITON FOR INSTRUMENT TRANSFORMERS CONTENTS Clause. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 Table-IA Table-IIA Table-IIB Description General Constructional Features Current Transformers Voltage Transformers Terminal Connectors Tests Spare Parts & Mandatory Maintenance Equipment Technical Parameters Testing & Commissioning Requirements of 145 kV CVT Requirements of 145 kV CT Requirements of 145 kV CT Page No. 113 113 114 115 116 116 118 118 119 120 120 121
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CHAPTER - (INST) SECTION: INSTRUMENT TRANSFORMERS 1.0 GENERAL: 1.1 The instrument transformers and accessories shall conform to the latest version of the standards specified below except to the extent explicitly modified in the specification and shall be in accordance with the requirements in Chapter-GTR. Current transformers IEC: 44-1 (or IS: 2705) Voltage transformers IEC: 186/358 (or IS: 3156) 1.2 1.3 1.4 1.5 2.0 The instrument transformers shall be complete with its terminal box and a common marshalling box for a set of 3 instrument transformers. The instrument transformer tank along with top metallic shall be hot dip galvanized. The impregnation details along with tests/checks to ensure successful completion of impregnation cycle shall be furnished for approval. The instrument transformers shall be designed for use in geographic and meteorological conditions as given in Chapter-GTR.
CONSTRUCTION FEATURES: The features and constructional details of instrument transformers shall be in accordance with requirements stipulated hereunder: 2.1 Bushing/Insulators: 1) Instrument transformers shall be of 145 kV class, oil filled/SF6 gas filled, with shedded porcelain/composite bushings/Insulators suitable for outdoor service and upright mounting on steel structures. Bushings/Insulators shall conform to requirements stipulated in ChapterGTR. The bushing/insulator for CT shall be one piece without any metallic flange joint. Bushings shall be provided with oil filling and drain plugs, oil sight glass of CT and for electromagnetic unit of CVT, etc. The bushing/insulator of instrument transformer shall have a cantilever strength of not less than 350 kg for instrument transformers respectively or as per the value obtained vide Chapter-GTR, whichever is higher. Oil filling and drain plugs are not required with SF6 gas filled CT. Instruments transformers shall be hermetically sealed units. Bidder/Manufacturer shall furnish details of the arrangements made for the sealing of instrument transformers along with the bid. Bidder/Manufacturer shall also furnish the details of site tests to check the effectiveness of hermetic sealing for approval. Polarity marks shall indelibly be marked on each instrument transformer and at the lead terminals at the associated terminal block.
2)
3)
4)
5)
2.2 Terminal box/Marshalling box: Terminal box shall conform to the requirements of Chapter-GTR.
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2.3 Insulating Oil: 1) 2) Insulating oil to be used for instrument transformers shall be of EHV grade and shall conform to IS: 335 (required for first filling). The SF6 gas shall comply with IEC-60376, 60376A and 60376B and shall be suitable in all respects for use in the switchgear under operating conditions.
2.4 Name Plate: Name plate shall conform to the requirements of IEC incorporating the year of manufacture. The rated current, extended current rating in case of current transformers and rated voltage, voltage factor in case of voltage transformers shall be clearly indicated on the name plate. The rated thermal current in case of CT shall also be marked on the name plate. The intermediate voltage in case of capacitor voltage transformer shall be indicated on the name plate. 3.0 CURRENT TRANSFORMERS: 1) Current transformers shall have single primary either ring type, or hair pin type and suitably designed for bringing out the secondary terminals in a weather proof (IP 55) terminal box at the bottom. These secondary terminals shall be terminated to stud type non disconnecting terminal blocks inside the terminal box. In case Bar primary inverted type current transformers are offered the manufacturer will meet following additional requirements: a) b) c) The secondaries shall be totally encased in metallic shielding providing a uniform equi-potential surface for even electric field distribution. The lowest part of the insulation assembly shall be properly secured to avoid any risk of damage due to transportation stresses. The upper part of insulation assembly resting on primary bar shall be properly secured to avoid any damage during transportation due to relative movement between insulation assembly & top dome. Nitrogen if used for hermetic sealing (in case of live tank design) should not come in direct contact with oil. Bidder/Manufacturer shall recommend whether any special storage facility is required for spare CT.
d) e) 2) 3)
Different ratios specified shall be achieved by secondary taps only and primary reconnection shall not be accepted. Core lamination shall be of cold rolled grain oriented silicon steel or other equivalent alloys. The cores used for protection shall produce undistorted secondary current under transient conditions at all ratios with specified CT parameters. The expansion chamber at the top of the porcelain insulators should be suitable for expansion of oil. Facilities shall be provided at terminal blocks in the marshalling box for star delta formation, short circuiting and grounding of CT secondary terminals. Current transformers guaranteed burdens and accuracy class are to be intended as simultaneous for all cores.
4) 5) 6)
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7) 8)
The rated extended primary current shall be 120% (or 150% if applicable) on all cores of the CTs as specified in the Section Project. Current transformer, characteristics shall be such as to provide satisfactory performance of burdens ranging from 25% to 100% of rated burden over a range of 10% to 100% of rated current in case of metering CTs and up to the accuracy limit factor/knee point voltage in case of relaying CTs. The current transformer shall be suitable for horizontal transportation. It shall be ensured that the CT is able to withstand all the stresses imposed on it while transporting and there shall be no damage in transit the Contractor shall submit the details of packing design to the Purchaser for review.
9)
10) For instrument security factor at all ratios shall be less than five (5) for metering core. If any auxiliary CTs/reactor are used in the current transformers then all parameters specified shall have to be met treating auxiliary CTs as an integral part of the current transformer. The auxiliary CTs/reactor shall preferably be inbuilt construction of the CTs. In case these are to be mounted separately these shall be mounted in the central marshalling box suitably wired up to the terminal blocks. 11) The wiring diagram plate for the interconnections of the three single phase CTs shall be provided inside the marshalling box. 12) The current transformers should be suitable for mounting on lattice support structure to be provided by the Contractor in accordance with stipulations of Chapter-GTR. 13) The CT shall be designed as to achieve the minimum risks of explosion in service. Bidder/Manufacturer shall bring out in his offer, the measures taken to achieve this. 14) Current transformers shall be suitable for high speed auto reclosing. 4.0 VOLTAGE TRANSFORMERS: 1) 2) Voltage transformers shall be capacitor voltage divider type with electromagnetic units and shall be suitable for carrier coupling. Voltage transformers secondaries shall be protected by HRC cartridge type fuses for all the windings. In addition fuses shall be provided for the protection and metering windings for fuse monitoring scheme. The secondary terminals of the CVTs shall be terminated to the stud type nondisconnecting terminal blocks in the individual phase secondary boxes via the fuse. CVTs shall be suitable for high frequency (HF) coupling required for power line carrier communication. Carrier signal must be prevented from flowing into potential transformer (EMU) circuit by means of a RF choke/reactor suitable for effectively blocking the carrier signals over the entire carrier frequency range i.e. 40 to 500 KHz. Details of the arrangement shall be furnished along with the bid. H.F. terminal of the CVT shall be brought out through a suitable bushing and shall be easily accessible for connection to the coupling filters of the carrier communication equipment, when utilized. Further, earthing link with fastener to be provided for HF terminal. The electromagnetic unit comprising compensating reactor, intermediate transformer and protective and damping devices should have separate terminal box with all the secondary terminals brought out.
3)
4)
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5)
The damping device which should be permanently connected to one of the secondary windings, should be capable of suppressing the ferroresonance oscillations. The accuracy of 0.2 on secondary III should be maintained through out the entire burden range up to 50 VA for 145 kV CVTs on all the windings without any adjustments during operation. CVTs shall be suitable for mounting on tubular GI pipe in accordance with stipulations of Chapter-GTR. It should be ensured that access to secondary terminals is without any danger of access to high voltage circuit. A protective surge arrester shall be provided to prevent breakdown of insulation by incoming surges and to limit abnormal rise of terminal voltage of shunt capacitor/primary winding, tuning reactor/RF choke etc. Due to short circuit in transformer secondaries. In case of an alternate arrangement, bidder shall bring out the details in the bid.
6)
7) 8) 9)
10) The wiring diagram for the interconnection of the three single phase CVTs shall be provided inside the marshalling box in such a manner that it does not deteriorate with time. 5.0 TERMINAL CONNECTORS: The terminal connectors shall meet the requirements as given in Chapter-GTR. 6.0 TESTS: 6.1 In accordance with the requirements in Chapter-GTR, Current and Voltage Transformers should have been type tested and shall be subjected to routine tests in accordance with IEC: 44-1/IS: 2705 and IEC: 186/IS: 3156 respectively. The test reports of the type tests and the following additional type tests shall also be submitted for the Purchasers review. 1) Current transformers: a) b) c) d) Radio interference test as per Annexure-A of Chapter-GTR. Seismic withstand test as per Annexure- B of Chapter-GTR. Thermal stability test, i.e. Application of rated voltage and rated extended thermal current simultaneously by synthetic test circuit. Thermal co-efficient test i.e. measurement of tan delta as a function of temperature (at ambient and between 80 C & 90 C) and voltage (at 0.3, 0.7, 1.0 and 1.1 Um/v3) The current transformer shall be subjected to Fast Transient test by any one of the following two methods given below to assess the CT performance in service to withstand the high frequency over voltage generated due to closing & opening operation of isolators. Alternatively, method as per IEC: 44-1 may be followed: Method I: 600 negative polarity lightning impulses chopped on crest will be applied to current transformer. The opposite polarity amplitude must be limited to 50% of crest value when the wav e is chopped. One impulse per minute shall be applied and every 50 impulse high
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6.2
e)
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frequency currents form the windings and total current to earth will be recorded and be compared with reference currents recorded applying one or more (max 20) reduced chopped impulses of 50% of test value. Oil samples will be taken before and 3 days after the test. Gas analysis must not show appreciable rate of increase in various gases related with the results of the analysis performed before test. Total sum of crest values of current through secondaries must not exceed 5% of the crest value of total current to earth. CT must withstand dielectric tests after this test to pass the test. Method II: 100 negative polarity impulses with a rise and fall time of less than 0.25 microsecond corrected to atmospheric condition shall be applied at one minute interval and total current through insulation of earth will be recorded. The amplitude of first opposite polarity should be limited to 50% of the chopped impulse crest value. Voltage and total current wave shapes shall be recorded after every 10 impulses, and will be compared with reference wave shapes recorded before test at 50% of test values. Oil sample shall be taken before and 3 days after the test and CT shall be deemed to have passed the test if the increase in gas content before and after test is not appreciable. 2) Voltage transformers: a) b) c) d) e) f) 6.3 High frequency capacitance and equivalent series resistance measurement (as per IEC-358). Seismic withstand test (as per Annexure-B of Chapter-GTR). Stray capacitance and stray conductance measurement of the low voltage terminal (as per IEC-358). Determination of temperature co-efficient test (as per IEC-358). Radio interference test as per Annexure-A of Chapter-GTR. The Ferro-resonance type test shall be carried out on the complete CVT.
The current and voltage transformer shall be subjected to the following routine/site tests in addition to routine tests as per IEC/IS. 1) CURRENT TRANSFORMERS: ROUTINE TESTS: a) b) c) d) e) Measurement of Capacitance. High voltage power frequency withstand test on Secondary Winding. Over-voltage inter turn test (as per BS: 3938). Oil leakage test. Measurement of tan delta at 0.3, 0.7, 1.0 and 1.1 Um/v3.
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f)
Measurement of partial discharge shall be carried out as per IEC.
SITE TESTS: Dissolved gas analysis to be carried out at the time of commissioning. CTs must have adequate provision for taking oil samples from the bottom of the CT without exposure to atmosphere. Bidder/Manufacturer shall recommend the frequency at which oil samples should be taken and norms for various gases in oil after being in operation for different durations. Bidder/Manufacturer should also indicate the total quantity of oil which can be withdrawn from CT for gas analysis before refilling or further treatment of CT becomes necessary. b) VOLTAGE TRANSFORMERS: a) b) c) 7.0 Capacitance and loss angle measurement before and after voltage test (as per IEC: 358). Partial discharge test on capacitor dividers (as per IEC-358). Sealing test (as per IEC-358).
SPARE PARTS AND MAINTENANCE EQUIPMENT: The Bidder shall include in his proposal spare parts equipment in accordance with Section-Project.
8.0
TECHNICAL PARAMETERS: A. 145 kV CURRENT TRANSFORMERS: A8.1 Rated Primary current: : 800A. : 600A (For Sub-Station having highest voltage 132 kV). 31.5 kA for 1 sec. 80 kA (peak) As per IEC: 44-1
A8.2 A8.3 A8.4 A8.5
A8.6
Rated short time thermal current: Rated dynamic current: Maximum temperature rise over design ambient temperature: One minute power frequency withstand voltage secondary terminal & earth: Number of terminals:
A8.7
Type of insulation:
5 kV All terminals of control circuits are to be wired up to marshaling box plus 20% spare terminals evenly distributed on all TBs. Class A
Current transformers shall also comply with requirements of Table IIA/or IIB as applicable. B. 145 KV VOLTAGE TRANSFORMERS: B8.1 B8.2 System fault level: Standard reference range of frequencies for which the accuracies are valid: High frequency capacitance for entire carrier frequency range: Equivalent series resistance over 31.5 kA for 1 second. 96% to 102% for protection and 99% to 101% for measurement. Within 80% to 150% of rated capacitance. Less than 40 ohms.
B8.3 B8.4
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B8.5
B8.6
B8.7 B8.8
B8.9
the entire carrier frequency range: Stray capacitance and stray As per IEC: 358. conductance of the LV terminal over entire carrier frequency range: One minute power frequency withstand voltage: i. Between LV (HF) terminal & 10 kV (rms) for exposed terminals earth terminal: and 4 kV (rms) for terminals enclosed in a weather proof box. ii. For secondary winding: 3 kV (rms). Maximum temperature rise over As per IEC: 186 designed ambient temperature: Number of terminals in control All terminals of control cabinet are cabinet: to be wired up to marshalling box plus 12 terminals exclusively for Purchasers use. Rated Total Thermal burden 300 (100VA/winding) (VA):
Voltage Transformers shall also comply with the requirements of Table-IA of this Chapter. 9.0 TESTING & COMMISSIONING 9.1 An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the field Q.P./Instructions of the equipment Supplier or Purchaser without any extra cost to the Purchaser. The Contractor shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the Purchaser for approval. Current Transformers: 1) 2) 3) 4) 5) 6) 7) 9.3 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). Magnetizing characteristics test. Tan delta and capacitance measurement Secondary winding resistance measurement
9.2
Voltage Transformers/Capacitive Voltage Transformers: 1) 2) 3) 4) 5) 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 between: a) HV - HF point
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b) c) 6)
HF Point - Ground point of Intermediate Transformer. HV - Ground point of Intermediate Transformer primary winding
Secondary winding resistance measurement. For details, refer O.S. Document no. OS/T&C/BAY/95.
TABLE - IA REQUIREMENTS OF 145 KV CAPACITIVE VOLTAGE TRANSFORMERS Sr. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Particulars 145 Single phase capacitor VT 3 1.2 Continuous 1.5-30 seconds + 20 minutes (For metering core) 8800 + 10%/-5% Secondary-I Secondary-II Secondary-III 132/0.11 132/0.11 132/0.11 Protection Protection Metering 3P 3P 0.2 50 50 50
Rated primary voltage (kV rms): Type: Number of secondaries: Rated voltage factor: Phase angle error: Capacitance (pf): Voltage ratio: Application: Accuracy: Output burden (Minimum VA)
TABLE - IIA REQUIREMENTS FOR 145 KV CURRENT TRANSFORMERS

No. of Core 5 Core No. 1 Application BUS DIFF CHECK BUS DIFF MAIN METERING TRANS. BACK UP/ LINE PROTN. TRANS. DIFF/LINE PROTN. Current Ratio 800-400/1 Output Burden (VA) Accuracy Class as per IEC441 Min. knee pt. Voltage (Vk) 800/400 Max. CT Sec. Wdg. Resistance (Ohms) 8/4 Maximum Excitation Current (mA) 25 on 800/1 Tap; 50 on 400/1 Tap 25 on 800/1 Tap; 50 on 400/1 Tap 25 on 800/1 Tap; 50 on 400/1 Tap 25 on 800/1 Tap; 50 on 400/1 Tap
800-400/1
800/400
8/4
5 5
3 4
800-400/1 800-400/1
20 -
0.2 -
800/400
8/4
800-400/1
800/400
8/4
All relaying CTs shall be of accuracy class PS as per IS: 2705.
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TABLE II B REQUIREMENTS FOR 145 kV CURRENT TRANSFORMERS

No. of Core 5 Core No. 1 Current Ratio 600300/1 Output Burden (VA) Accuracy Class as per IEC441 Min. knee pt. Voltage (Vk) 600/300 Max. CT Sec. Wdg. Resistance (Ohms) 6/3 Maximum Excitation Current (mA) 30 on 600/1 Tap; 60 on 300/1 Tap 30 on 600/1 Tap; 60 on 300/1 Tap 30 on 600/1 Tap; 60 on 300/1 Tap 30 on 600/1 Tap; 60 on 300/1 Tap
Application BUS DIFF CHECK
BUS DIFF MAIN
600300/1
600/300
6/3
5 5
3 4
METERING TRANS. BACK UP/ LINE PROTN. TRANS. DIFF/LINE PROTN.
300150/1 600300/1
20 -
0.2 -
600/300
6/3
600300/1
600/300
6/3
All relaying CTs shall be of accuracy class PS as per IS: 2705.
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SURGE ARRESTERS
(SA)
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Section-Technical Specifications-Surge Arrester
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CHAPTER SURGE ARRESTERS TECHNICAL SPECIFICATION FOR SURGE ARRESTERS CONTENTS Clause. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Description General Duty Requirements Constructional Features Fittings & Accessories Tests Spare Parts & Mandatory Maintenance Equipment Technical Parameters Testing & Commissioning Page No. 124 124 124 125 126 127 127 128
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CHAPTER - SA SECTION: SURGE ARRESTERS 1.0 GENERAL: 1.1 The Surge arresters shall conform to IEC: 60099-4 except to the extent modified in the specification and shall also be in accordance with requirements under Chapter-GTR. Arresters shall be of hermetically sealed units, self supporting construction, suitable for mounting on tubular support structures to be supplied by the Contractor. The Surge Arrestors shall be designed for use in the geographic and meteorological conditions as given in the Chapter-GTR.
1.2
1.3
2.0
DUTY REQUIREMENTS: 1) 2) 3) 4) 5) The surge arresters shall be of heavy duty station class and gapless type without any series or shunt gaps. The surge arresters shall be capable of discharging over-voltages occurring during switching of unloaded transformers and long lines. 145 kV class arrester shall be capable for discharging energy equivalent to class 3 of IEC for 145 kV system on two successive operations. The surge arresters shall be suitable for withstanding Chapter-GTR. forces as defined in
The reference current of the arresters shall b e high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage. The surge arresters are being provided to protect the following equipment whose insulation levels are indicated in the table given below: Equipment to be protected Power Transformer Instrument Transformer CB/Isolator Phase to ground Across open contacts Lightning impulse (kVp) for 145 kV system + 550 + 650 + 650 + 750
6)
The duty cycle of CB installed in 145 kV System of the Purchaser shall be O-0.3 sec-CO-3 min-CO. The Surge Arrester shall be suitable for such circuit breaker duties in the system. 3.0 CONSTRUCTIONAL FEATURES: The features and constructional details of surge arresters shall be in accordance with requirement stipulated hereunder: 1) The non-linear blocks shall be of sintered metal oxide material. These shall be provided in such a way as to obtain robust construction, with excellent mechanical and electrical properties even after repeated operations. The surge arresters shall be fitted with pressure relief devices suitable for preventing shattering of porcelain housing and providing path for flow of
2)
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rated fault currents in the event of arrester failure. Details shall be furnished in the bids along with quality checks. 3) 4) 5) The arresters shall not f ail due to arrester porcelain contamination. Seals shall be provided in such a way that these are always effectively maintained even when discharging rated lightning current. Outer insulator shall be porcelain conforming to requirements stipulated in Chapter-GTR. Terminal connectors shall conform to requirements stipulated under Chapter-GTR. Porcelain housing shall be so coordinated that external flashover will not occur due to application of any impulse or switching surge voltage up to the maximum design value for arrester. 6) 7) 8) The end fittings shall be made of corrosion proof material and preferably be nonmagnetic. The name plate shall conform to the requirements of IEC incorporating the year of manufacture. The heat treatment cycle details along with necessary quality checks used for individual blocks along with insulation layer formed across each block are to be furnished. Metalizing coating thickness for reduced resistance between adjacent discs is to be furnished with additional information schedule of bid proposal sheets along with procedure for checking the same. Details of thermal stability test for uniform distribution of current on individual disc is to be furnished. The manufacturer will submit Data for rejection rate of ZnO blocks during manufacturing/operation for the past three years.
9)
10) The sealing arrangement of the Surge Arrester stacks shall be done incorporating grooved flanges with the O-rings/elliptical cross-section gaskets of Neoprene or Butyl rubber. 4.0 FITTINGS AND ACCESSORIES: 1) 2) 120 kV Arresters shall be complete with insulating base having provision for bolting to flat surface of structure. Self contained discharge counters, suitably en closed for outdoor use and requiring no auxiliary or battery supply for operation shall be provided for each single pole unit along with necessary connection. Suitable leakage current meters should also be supplied within the same enclosure. The reading of milliammeter and counters shall be visible through an inspection glass panel. The terminals shall be robust and of adequate size and shall be so located that incoming and outgoing connections are made with minimum possible bends. Surge monitor consisting of discharge counters and milli-ammeters should be suitable to be mounted on support structure of the arrester and should be tested for IP: 66 degree of protection. The standard supporting structure for surge arrester should be provided with a mounting pad, for fixing the surge monitor. The surge monitor should be suitable for mounting on this standard mounting pad. Also all nuts, bolts, washers etc. required for fixing the surge monitor shall have to be supplied by the Contractor. The arrangement for Surge Monitor enclosure fixing to the structure shall be at its rear/bottom. Connection between the Surge Arrester base and Surge Monitor shall be
3)
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through a 2.0 m long insulated stranded cable. The cable shall be terminated at rear/bottom side of the Surge Monitor. The gaskets of the surge monitors shall be of Neoprene, Butyl or equivalent material. 4) Grading/corona rings shall be provided on each complete arrester unit as required. Suitable terminal connectors shall be supplied by the Contractor.
5.0
TESTS: 5.1 In accordance with the requirements stipulated under Chapter-GTR, the surge arresters should have been type tested as per IEC/IS and shall be subjected to routine and acceptance tests in accordance with IEC document. In the switching surge operating duty test, the samples shall be pre-heated to 70 C, (instead of 60 C as given in IEC) prior to application of long duration surges for contamination test procedures outlined in ANSI: 062-11-1987 may be followed until IEC brings out alternate test procedure for the same. The test reports of the type tests and the following additional type tests shall also be submitted for the Purchasers review. 1) 2) 3) 4) Radio interference voltage test as per Annexure-A of Chapter-GTR. Seismic withstand test as per Annexure-B of Chapter-GTR. Contamination test. Temporary over voltage withstand test procedure to be mutually agreed)
Each metal oxide block of surge arresters shall be tested for the guaranteed specific energy capability in addition to the routine/acceptance test as per IEC: 60099-4. 5.2 1) Acceptance Tests: a) Measurement of power frequency reference voltage of the arrester units. b) Lightning Impulse Residual voltage on arrester units. c) Internal Ionization or partial Discharge test. 2) Special Acceptance Test: a) Thermal stability test on three sections. b) Aging & Energy Capability test on blocks (procedure to be mutually agreed). c) Watt loss test. 3) Routine Tests: a) Sealing test: Water dip test at 1.5 meter depth from top of Surge Arrestor for 30 minutes shall be performed during assembly of Surge Arrester stacks (followed by other routine tests, i.e. P.D. Measurement, Reference Voltage, Residual Voltage & IR measurement). b) Measurement of reference voltage. c) Residual voltage test of arrester unit. d) Internal Ionization test or partial discharge test. e) Verticality check on completely assembled Surge arresters as a sample test on each lot. 4)
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The Surge monitors shall also be connected in series with the test specimens during residual voltage and current impulse withstand tests to verify efficacy of the same. Additional routine/functional tests with one 100A and 10kA current impulse, (8/20 micro sec.) Shall also be performed on the Surge monitor. Surge monitors shall be routinely tested for water dip test at 1.5 meter for 30 minutes. No water vapors shall be visible on the monitor glass. 5) Test on insulators All routine tests shall be conducted on the hollow column insulators as per IEC - 233. The following additional tests shall be carried out on 145 kV Insulators: a) b) c) d) e) 6.0 Ultrasonic test as a routine test. Pressure test as a routine test. Bending load test in 4 directions at 50% specified bending load as routine test. Bending load test in 4 directions at 100% specified bending load as a sample test on each lot. Burst pressure test as a sample test on each lot.
SPARE PARTS AND MAINTENANCE EQUIPMENT: Bidder shall include in his proposal spare parts and maintenance equipment, as mentioned in Section-Project.
7.0
TECHNICAL PARAMETERS: 145 kV CLASS SURGE ARRESTER Rated arrester voltage: 120 kV. Nominal discharge current: 10 kA of 8/20 microsecond wave. Minimum discharge capability: 5kJ/kV (referred to rated arrester voltage corresponding to minimum discharge characteristics. 4) Continuous operating voltage 102 kV rms. at 50 C: 5) Maximum switching surge residual voltage (1 kA): 280 kVp. 6) Max. residual voltage at a. 5 kA: 310 kVp b. 10 kA nominal discharge current: 330 kVp 7) Long duration discharge class: 2 8) High current short duration test value (4/10 micro second wave): 100 kAp. 9) Current for pressure relief test: 40 kA rms. 10) Low current long duration test value (2400 micro sec): As per IEC. 11) Pressure relief class: A. 1) 2) 3)
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8.0 TESTING AND COMMISSIONING: 8.1 An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the field Q.P./Instructions of the equipment Supplier or Purchaser without any extra cost to the Purchaser. The Contractor shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the Purchaser for approval. 1) 2) Leakage current measurement. Resistance of ground connection. For details, refer O.S. Document No. OS/T&C/BAY/95.
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STRUCTURES
(STR)
Part-III (Vol.2/2)
Section-Technical Specification-Structure
130
CHAPTER - STRUCTURES TECHNICAL SPECIFICATION FOR STRUCTURES
CONTENTS
Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 Description General Design Requirements for Structures not covered in Standardized List Design Drawings, Bill of Materials and Documents Fabrication of Steel Members Proto-Assembly Bolting Welding Foundation Bolts Stability of Structure Grouting Galvanizing Touch-up Painting Inspection Before Dispatch Test Certificate Erection Mode of Measurement Safety Precautions Page No. 131 132 133 134 134 134 135 135 135 135 135 135 136 136 136 136 136
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CHAPTER - STRUCTURES
SECTION: STRUCTURES
1.0 GENERAL 1.1 The scope of specification covers fabrication, proto-assembly, supply and erection of galvanized steel structures for towers, girders, lightning masts and equipment support structures. Towers, girders, lightning masts and equipment support structure shall be lattice type structure fabricated from structural steel conforming to IS: 2062 (latest). Line diagrams, standard fabrication drawings with bill of materials of towers, girders, lightning mast, equipment support structures for standard 132/33 kV structures shall be provided by the successful bidder within two weeks of the letter of award for approval. Contractor shall only use these approved standard drawings for fabrication. Any other structures of necessary to suit the layout of the sub-station to complete the work in all its requirements shall be designed by the contractor at detailed engineering stage and obtain approval from the owner. Design & drawing of structure other than 132/33 kV class shall also be prepared by the contractor at detailed engineering stage and obtain similar approval. It is the intent of the owner to provide structures which allow interchangeability of equipments at a later stage. Accordingly equipment support structure standardization shall required to be carried out with the provision of stool. Stools shall be provided by the Contractor between the equipment and its support structure to match the bus bar height. The top of stool shall be connected to the equipment and the bottom of the stool shall be connected to the support structure. Details of the stools shall be submitted to Owner for approval. The scope shall include supply and erection of all types of structures including bolts, nuts, washers, hangers, shackles, clamps anti climbing devices, bird guards, step bolts, inserts in concrete, gusset plates, equipment mounting bolts, structure earthing bolts, foundation bolts, spring washers, fixing plates, ground mounted marshalling boxes (AC/DC Marshalling box & equipment control cabinets), structure mounted marshalling boxes and any other items as required to complete the job. The connection of all structures to their foundations shall be by base plates and embedded anchor/foundation bolts. All steel structures and anchor/foundation bolts shall be fully galvanized. The weight of the zinc coating shall be at least 0.610 kg/m2 for anchor bolts/foundation bolts and for structural members. One additional nut shall be provided below the base plate which may be used for the purpose of leveling. Suitable modification shall be carried out in the drawings of equipment support structures by the Contractor in order to suit fixation of accessories such as marshalling boxes, MOM boxes, Control Cabinets, Junction box, surge counter, etc. in the standard structure fabrication drawings. Drawings of fixing of such accessories shall be submitted by the Contractor for approval.
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2.0
DESIGN REQUIREMENTS FOR STRUCTURES NOT COVERED IN STANDARDISED LIST: 2.1 For design of steel structures loads such as dead loads, live loads, wind loads etc. shall be based on IS: 875, Parts I to V. 2.2 For materials and permissible stresses IS: 802, Part-I, Section-2 shall be followed in general. However, additional requirements given in following paragraphs shall be also considered. 2.3 Minimum thickness of galvanized tower member shall be as follows: Members Leg members, Ground wire Peak members/Main members Other members Redundant members 2.4 2.5 2.6 2.7 Minimum thickness (mm) 5 4 4
Maximum slenderness ratios for leg members, other stressed members and redundant members for compression force shall be as per IS-802. Minimum distance from the hole center to edge shall be 1.5xbolt diameter. Minimum distance between center to center of holes shall be 2.5xbolt diameter. All bolts shall be M16 or higher as per design requirement. Step Bolts In order to facilitate inspection and maintenance, the structures shall be provided with climbing devices. Each tower shall be provided with M16 step bolts 175 mm long spaced not more than 450 mm apart, staggered on faces on one leg extending from about 0.5 meters above ground level to the top of the tower. The step bolt shall conform to IS: 10238. Ladders along with safety guard shall be provided for the Lightening Mast Tower.
2.8
Design Criteria (To be referred only for structures for which design is included in the scope of the Contractor) a) All structures shall be designed for the worst combination of dead loads, live loads, wind loads as per code IS: 875, seismic forces as per code IS: 1893 (latest), Importance factor of 1.5, loads due to deviation of conductor, load due to unbalanced tension in conductor, torsional load due to unbalanced vertical and horizontal forces, erection loads, short circuit forces including snatch in the case of bundled conductors etc. Short circuit forces shall be calculated considering a fault level of 40.0 kA. IEC865 may be followed for evaluation of short circuit forces. Switchyard gantry structures shall be designed for the two conditions i.e. normal condition and short circuit condition. In both conditions the design of all structures shall be based on the assumption that stringing is done only on one side i.e. all the three (phase) conductors broken on the other side. Factor of safety of 2.0 under normal conditions and 1.5 under short circuit condition shall be considered on all external loads for the design of switchyard structures. c) Vertical load of half the span of conductors/string and the earth wires on either side of the beam shall be taken into account for the purpose of design.
b)
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Weight of man with tools shall be considered as 150 kgs. for the design of structures. d) Terminal/line take off gantries shall be designed for a minimum conductor tension of 1 metric tonne per phase for 132 kV or as per requirements whichever is higher. The distance between terminal gantry and dead end tower shall be taken as 200 meters. The design of these terminal gantries shall also be checked considering +/- 30 deg deviation of conductor in both vertical and horizontal planes. For other gantries the structural layout requirements shall be adopted in design. The girders shall be connected with lattice columns by bolted joints. All Pipe support used for supporting equipments shall be designed for the worst combination of dead loads, erection load. Wind load/seismic forces, short circuit forces and operating forces acting on the equipment and associated bus bars as per IS: 806. The material specification shall be as per IS: 1161 read in conjunction with IS: 806. If luminaries are proposed to be fixed on gantries/towers, then the proper loading for the same shall be considered while designing. Also holes for fixing the brackets for luminaries should be provided wherever required. Foundation bolts shall be designed for the loads for which the structures are designed. Lightning Mast shall be 50m in height (47.5m lattice structure plus 2.5m pipe) and designed for diagonal wind condition. Lightning masts shall be provided with a structural steel ladder within its base up to a height of 25 meter. The ladder shall be provided with protection rings. Two platforms shall be provided one each at 12.5m and 25.0m height for mounting of lighting fixtures. The platforms shall also have protection railing. The details of lighting fixtures would be as per the approved drawings.
e) f)
g)
h) i)
3.0
DESIGN DRAWINGS, BILL OF MATETRIALS AND DOCUMENTS 3.1 FOR STANDARD STRUCTURES 3.1.1 Standard drawings and bill of materials for towers, girders, lightning masts, equipment support structures etc. shall be submitted by the successful bidder within two weeks of the letter of award for approval of the owner. 3.1.2 Contractor shall be responsible for the safety of the structure and good connections and any loss or damage occurring due to defective fabrication, erection or workmanship shall be borne by the Contractor. 3.2 FOR STRUCTURES DESIGNED BY CONTRACTOR (To be referred only for structures for which design is included in the scope of the Contractor) 3.2.1 The Contractor shall furnish design, drawing and BOMs and shop manufacturing drawings for every member to the owner after award of the Contract. The design drawing should indicate not only profile, but section, numbers and sizes of bolts and details of typical joints. In case owner feels that any design drawing, BOM are to be modified even after its approval, Contractor shall modify the designs & drawings and resubmit the design drawing, BOM as required in the specification. 3.2.2 The fabrication drawings to be prepared and furnished by the Contractor shall be based on the design approved by the owner. These fabrication drawings shall indicate complete details of fabrication and erection
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including all erection splicing details and typical fabrication splicing details, lacing details, weld sizes and lengths. Bolt details and all customary details in accordance with standard structural engineering practice whether or not given by the owner. The fabrication drawings shall be submitted to the owner. Proto shall be made only after approval of fabrication drawings. 3.2.3 Such approval shall, however, not relieve the Contractor of his responsibility for the safety of the structure and good connections and any loss or damage occurring due to defective fabrication, design or workmanship shall be borne by the Contractor. 3.3 The Mass fabrication work shall start only after the final approval to the proto corrected fabrication drawing is accorded by the owner. Proto-assembly shall be required to be carried out only for those structures that have not been protoassembled by the same fabricators for this contract. Wherever proto-assembly is not to be repeated, proto-corrected drawings shall be submitted directly with a note on the drawing stating that proto-assembly has been carried out under a particular previous contract.
4.0
FABRICATION OF STEEL MEMBERS 4.1 The fabrication and erection works shall be carried out generally in accordance with IS: 802. A reference however may be made to IS: 800 in case of nonstipulation of some particular provision in IS: 802. All materials shall be completely shop fabricated and finished with proper connection material and erection marks for ready assembly in the field.
5.0
PROTO-ASSEMBLY i) The component parts shall be assembled in such a manner that they are neither twisted nor otherwise damaged and shall be so prepared that the specified camber, if any, is provided. In order to minimize distortion in member the component parts shall be positioned by using the clamps, clips, dogs, jigs and other suitable means and fasteners (bolts and welds) shall be placed in a balanced pattern. If the individual components are to be bolted, paralleled and tapered drifts shall be used to align the part so that the bolts can be accurately positioned. Sample towers, beams and lightning masts and equipment support structures shall be trial assembled in the fabrication shop and shall be inspected and cleared by Contractor based on the approved fabrication drawing before mass fabrication. Owner may opt to witness such trial assembly. For all structures, Bill of Materials along with proto corrected fabrication drawings shall be prepared and submitted to owner as document for information. Such Bill of Materials, which shall be duly certified by the Contractor for its conformity to the drawings issued by Owner, shall be the basis for owner to carry out inspection.
ii)
6.0
BOLTING i) ii) iii) Every bolt shall be provided with a washer under the nut so that no part of the threaded portion of the bolt is within the thickness of the parts bolted together. All steel items, bolts, nuts and washers shall be hot dip galvanized. 2.0% extra nuts and bolts shall be supplied for erection.
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7.0
WELDING The work shall be done as per approved fabrication drawings which shall clearly indicate various details of joints to be welded, type of weld, length and size of weld, whether shop or site weld etc. Symbols for welding on erection and shop drawings shall be according to IS: 813. Efforts shall be made to reduce site welding so as to avoid improper joints due to constructional difficulties.
8.0
FOUNDATION BOLTS 8.1 Foundation bolts for the towers and equipment supporting structures and elsewhere shall be embedded in first stage concrete while the foundation is cast. The Contractor shall ensure the proper alignment of these bolts to match the holes in the base plate. The Contractor shall be responsible for the correct alignment and leveling of all steel work on site to ensure that the towers/structures are plumb. All foundation bolts for lattice structure, pipe structure are to be supplied by the Contractor. All foundation bolts shall be fully galvanized so as to achieve 0.61 kg. per sq. m. of Zinc coating as per specifications. All foundation bolts shall conform to IS: 5624 but the material, however shall be MS conforming to IS: 2062.
8.2 8.3 8.4 8.5
9.0 STABILITY OF STRUCTURE The Supplier shall be responsible for the stability of the structure at all stages of its erection at site and shall take all necessary measures by the additions of temporary bracings and guying to ensure adequate resistance to wind and also to loads due to erection equipment and their operations. 10.0 GROUTING The method of grouting the column bases shall be subject to approval of owner and shall be such as to ensure a complete uniformity of contact over the whole area of the steel base. The Contractor will be fully responsible for the grouting operations. 11.0 GALVANISING 11.1 All structural steel works and pipe fabrication. supports shall be galvanized after
11.2 Zinc required for galvanizing shall have to be arranged by the manufacturer. Purity of zinc to be used shall be 99.95% as per IS: 209. 11.3 The Contractor shall be required to make arrangement for frequent inspection by the owner as well as continuous inspection by a resident representative of the owner, if so desired for fabrication work. 12.0 TOUCH-UP PAINTING The touch up primers and paints shall consist of Red Oxide/Zinc chromate conforming to the requirements of IS: 2074 with a pigment to be specified by the owner.
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13.0 INSPECTION BEFORE DISPATCH Each part of the fabricated steel work shall be inspected as per approved quality plans and certified by the owner or his authorised representative as satisfactory before it is dispatched to the erection site. Such certification shall not relieve the Contractor of his responsibility regarding adequacy and completeness of fabrication. 14.0 TEST CERTIFICATE Copies of all test certificates relating to material procured by the Contractor for the works shall be forwarded to the owner. 15.0 ERECTION The Contractor should arrange on his own all plant and equipment, welding set, tools and tackles, scaffolding, trestles equipments and all other accessories and ancillaries required for carrying out erection without causing any stresses in the members which may cause deformation and permanent damage. 16.0 MODE OF MEASUREMENT The measurement of the standard lattice structures for towers, beams, equipment support structure etc. shall be made in numbers as well MT for each type of structures. This will include foundation bolts and nuts and therefore no separate payment shall be made for the same. The unit rate quoted structure shall be inclusive of supply, fabrication, galvanizing, erection, nuts, bolts, wastages etc. complete. Nothing extra shall be payable for substitution necessitated due to non-availability of sections indicated in the standard drawing. Nothing extra shall be payable for modifications or steel added to suit the contractors fixing arrangements for accessories etc. 17.0 SAFETY PRECAUTIONS The Contractor shall strictly follow at all stages of fabrication, transportation and erection of steel structures, raw materials and other tools and tackles, the stipulations contained in Indian Standard Code for Safety during erection of structural steel workIS: 7205. 18.0 All tests mentioned in standard field quality plans have to be carried out and conformity of materials and workmanship shall be ascertained.
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CIVIL WORKS
(CIVIL)
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CHAPTER-CIVIL WORKS
TECHNICAL SPECIFICATION FOR CIVIL WORKS
CONTENTS
Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 Description General Drawings Site Preparation Anti-weed Treatment & Stone Spreading Rainwater Harvesting Roads & Culverts Foundation/RCC Construction Chain link Fencing and Gate Water Supply (External) Technical Details of the Buildings Mode of Measurement Miscellaneous General Requirements Interfacing Statutory Rules Page No. 139 139 141 142 144 145 146 149 150 151 157 161 162 162
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CHAPTER-CW SECTION: CIVIL WORKS 1.0 GENERAL The intent of this technical specification covers the following: Construction of all civil works at sub-station shall be as covered in the scope of the turnkey contract. All civil works shall be carried out as per design/drawings furnished by the contractor and approved by the owner. All standard drawings shall be are furnished with the bid documents by the bidder. In case any item is not covered under specification then the same shall be carried out as per CPWD specification and applicable Standards and Codes. Any item for which specification is not provided herein and is not covered under CPWD specification shall be executed as per manufacturer guidelines. All materials shall be of best quality conforming to relevant Indian Standards and Codes. In case of any conflict between Standards/Code and Technical Specification, the provisions of Technical Specification shall prevail. The Contractor shall furnish all 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 drawings, specifications and direction of Owner. All materials including cement, reinforcement steel and structural steel etc. shall be arranged by the Contractor. All testing required shall be arranged by the Contractor at his own cost. The contractor shall execute the work as per the Field Quality Plan (FQP) furnished by them and approved by the owner. The bidder shall fully apprise himself of the prevailing conditions at the proposed site. Climatic conditions including monsoon patterns, local conditions and site specific parameters and shall include for all such conditions and contingent measures in the bid, including those which may not have been specifically brought out in the specifications. 2.0 Drawings Standard drawings developed by the contractor, as mentioned below, and enclosed with the bid documents & good for construction should be furnished within two weeks of award, 4 sets of these drawings, with a released for construction stamp, shall be issued by the Owner to the Contractor. The Contractor shall execute the work at Site as per these drawings only. Photocopies shall not be used at Site. Such drawings, those have been mentioned to be issued by the Owner after approval on submission by the Contractor during detailed Engineering shall be made available to the Contractor as per the agreed work schedule finalized after award. Also, further details required, if any, to complete the work in totality, shall be made available to the Contractor on similar approval of the submitted drawing as per the agreed work schedule finalized after award. 2.1 Control room building All construction drawings shall be enclosed with the bid documents by the bidder. 2.2 Fire fighting pump house building and fire water tank All construction drawings for the purpose shall be enclosed with the bid documents by the bidder.
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2.3
Tower & equipment foundations All standard and good for construction drawings for towers and equipments foundations shall be furnished with the bid documents by the bidder. Drawings for any non-standard tower or equipment foundation, if required, shall be designed by the contractor and made available to the owner for approval during detailed engineering. Foundations for any miscellaneous requirements like electric poles, kiosks etc. shall also be engineered by the Contractor and the design and drawings shall be submitted for owners approval. Drawings for transformer foundations and fire wall are not enclosed and shall be made available to the owner by the contractor after detailed engineering for owners approval. In case the site conditions warrant any special type of foundations to be used, the same shall be designed and furnished by the contractor to the owner after detailed engineering for approval.
2.4
Tower and equipment structures All construction drawings (line diagram) shall be submitted with the bid documents by the bidder. The fabrication drawings (structure assembly drawings) and Bill of Materials based on the line drawings of standard structures shall be provided by the successful bidder on award to the owner for approval within two weeks of award. Drawings for non-standard towers and beams (if any) shall be developed by contractor during detailed engineering and made available to the owner within the same time period of award for approval. Suitable modification shall be carried out in the drawings of equipment support structures by the contractor in order to suit fixation of accessories such as marshalling boxes, MOM boxes, control cabinets, junction box, surge counter etc. in the standard structure fabrication drawings. Drawings of fixing of such accessories shall be submitted by the contractor for approval.
2.5
Roads and rail cum Road All construction drawings for road as well as rail cum road, if any, shall be furnished by the contractor within two weeks of award of contract for owners approval.
2.6
Drains The construction drawing for the drain has to be similarly furnished for approval. The contractor shall develop an overall drainage layout for the entire sub-station during detailed engineering. The type of drains used shall be of the sections standardized and indicated in the drawings furnished with the bid documents by the bidder.
2.7
Chain link fencing and gate All construction drawings, wherever required shall be enclosed with the bid documents by the bidder.
2.8
Rain water harvesting All construction drawings for the purpose shall be enclosed with the bid documents by the bidder.
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2.9
External water supply from bore-well to fire water tank The drawing for the water supply from bore-well to fire water tank shall be developed by the contractor and submitted to owner for approval. Water supply is available at the vicinity of the site from Perennial River and stream. 80 mm dia GI pipe shall be provided by the Contractor from the bore-well to the fire water tank. From this a 25 mm dia tap off shall be connected by the Contractor the roof water tank provided for the control room building.
2.10 Septic tank and soak pit All construction drawings shall be enclosed with the bid documents by the bidder. 2.11 Stone spreading and anti-weed treatment The layout of the area where anti-weed treatment and stone spreading is to be provided shall be made available to the contractor during detailed engineering. 3.0 SITE PREPARATION: Leveled/sloped site shall be handed over to the contractor. The finished ground level (FGL) shall be the finished formation level furnished by the owner. The layout and levels of all structure etc shall be made by the Contractor at his own cost from the general grids of the plot and benchmarks set by the Contractor and approved by the Owner. The Contractor shall provide all assistance in instruments, materials and personnel to the Owner for checking the detailed layout and shall be solely responsible for the correctness of the layout and levels. 3.1 SCOPE This clause covers the execution of the work for site preparation, such as clearing of the site, the supply and compaction of fill material, excavation and compaction of backfill for foundation, road construction, drainage, trenches and final topping by stone (broken hard stone). 3.2 GENERAL 1) 2) Material unsuitable for founding of foundations shall be removed and replaced by suitable fill material and to be approved by the Owner. Backfill material around foundations or other works shall be suitable for the purpose for which it is used and compacted to the density described under Compaction. Excavated material not suitable or not required for backfill shall be disposed off in areas as directed by Owner up to a maximum lead of 2 km.
3.3 EXCAVATION AND BACKFILL 1. 2. Excavation and backfill for foundations shall be in accordance with the relevant code. Whenever water table is met during the excavation, it shall be dewatered and water table shall be maintained below the bottom of the excavation level during excavation, concreting and backfilling. 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.
3.
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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. 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.
5.
3.4
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 Proctors density at OMC. The sub grade for the roads and embankment filling shall be compacted to minimum 95% of the Standard Proctors density at OMC. Cohesion less material sub grade shall be compacted to 70% relative density (minimum). At all times unfinished construction shall have adequate drainage? Upon completion of the roads surface course, adjacent shoulders shall be given a final shaping, true alignment and grade. 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.
2.
3.
3.5
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.
4.0
ANTIWEED TREATMENT & STONE SPREADING 4.1 SCOPE OF WORK 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 along with cement concrete layer shall be done in the areas of the switchyard under present scope of work. However the stone spreading along with cement concrete layer in future areas within fenced area shall also be provided in case step potential without stone layer is not well within safe limits.
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4.2 GENERAL REQUIREMENT 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. 4.2.1 The material to be used for stone filling/site surfacing shall be uncrushed/crushed/broken stone of 40 mm nominal size (ungraded single size) conforming to Table 2 of IS: 3831970. Hardness, flakiness shall be as required for wearing courses are given below: (a) Sieve Analysis limits (Gradation) (IS: 383 Table 2) Sieve Size 63mm 40mm 20mm 10mm % passing by weight 100 85-100 0-20 0-5
One Test shall be conducted for every 500 cu. m. (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 cu. m. with a minimum of one test per source. (c) Flakiness Index One test shall be conducted per 500 cu. m. of aggregate as per IS: 2386 PartI and maximum value is 25%. 4.2.2 After all the structures/equipments are erected, anti-weed treatment shall be applied in the switchyard where ever stone spreading along with cement concrete is to be done and the area shall be thoroughly de-weeded including removal of roots. The recommendation of local agriculture or horticulture department may be sought where ever feasible while choosing the type of chemical to be used. The anti-weed chemical shall be procured from reputed manufacturers. The doses and application of chemical shall be strictly done as per manufacturers recommendation. Nevertheless the effectiveness of the chemical shall be demonstrated by the contractor in a test area of 10MX10M (approx.) and shall be sprinkled with water at least once in the afternoon everyday after forty eight hours of application of chemical. The treated area shall be monitored over a period of two to three weeks for any growth of weeds by the Engineer incharge. The final approval shall be given by Engineer in charge based on the results. 4.2.3 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 approved drawing. 4.2.4 After 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-in-charge. The sub grade shall be consolidated by using half ton roller with suitable water sprinkling arrangement to form a smooth and
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compact surface. The roller shall run over the sub grade till the soil is evenly and densely consolidated and behaves as an elastic mass. 4.2.5 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. 4.2.6 The sub grade shall be in moist condition at the time the cement concrete is placed. If necessary, it should be saturated with water for not less than 6 hours but not exceeding 20 hours before placing of cement concrete. If it becomes dry prior to the actual placing of cement concrete, it shall be sprinkled with water and it shall be ensured that no pools of water or soft patches are formed on the surface. 4.2.7 Over the prepared sub grade, 75mm thick base layer of cement concrete in 1:5:10 (1 cement: 5 fine/coarse sand: 10 burnt brick aggregate) shall be provided in the area excluding roads, drains, cable trenches as per detailed engineering drawing. For easy drainage of water, the slope of 1:1000 is to be provided from the ridge to the nearest drain. The ridge shall be suitably located at the centre of the area between the nearest drains. The above slope shall be provided at the top of base layer of cement concrete in 1:5:10. A layer of cement slurry of mix 1:6 (1 cement: 6 fine sand) shall be laid uniformly over cement concrete layer. The cement consumption for cement slurry shall not be less than 150 kg. per 100 sq. mm. 4.2.8 A final layer of 100 mm thickness of uncrushed/crushed/broken stone of 40mm nominal size (ungraded size) shall be spread uniformly over cement concrete layer after curing is complete. 5.0 RAINWATER HARVESTING: 5.1 In addition to drainage of rainwater, the contractor shall make arrangement for rainwater harvesting also.
5.2 Rainwater harvesting shall be done by providing two numbers recharge structures with bore wells. The recharge structures shall be suitably located within the substation. Branch drains from the main drain carrying rainwater from entire switchyard shall be connected to the recharge structures. 5.3 The internal diameter of recharge shafts shall be 4.5 meter with 230mm thick lining of brick work up to a depth of 2.0 meter from ground level and 345mm thick brickwork below 2.0 meter depth. The brickwork shall be constructed with cement mortar 1:6 (1 cement: 6 coarse sand). The overall depth of shaft shall be 5.0 meter below invert level of drain. The shaft shall be covered with RCC slab for a live load of 300 kg. per sq. m. Two openings of size 0.7 x 0.7 meter shall be provided in the RCC cover slab as shown in the drawing. An iron cover made of 5mm thick chequered plate with hinges shall be provided on the openings. Galvanized M.S. rungs of 20mm diameter at spacing of 300 mm shall be provided in the wall of shaft below the opening in the RCC slab to facilitate cleaning of shaft.
5.4 A 300 mm diameter bore well shall be drilled in the centre of the shaft. The depth of bore well shall be 5.0 meter more than the depth of sub soil water.
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5.5 A 100 mm dia medium duty MS pipe conforming to IS 1161 shall be lowered in the bore well keeping bail plug towards bottom of bore well. The pipe shall have 1.58 mm holes for 4.0 meter length starting from 1.0 meter from bottom of bore well. Holes of 3.0mm dia shall be provided for a length of 2.0 meter starting from the bottom level of coarse sand and down wards. The overall length of pipe be equal to total depth of bore well plus depth of shaft. 5.6 Gravel of size 3mm to 6mm shall be filled around 100 dia MS pipe in the bore well. The shaft shall be filled with 500 mm thick layers each from the bottom of shaft with boulders of size 50mm to 150mm, gravel of size 5mm to 10mm, coarse sand having particle size 1.5mm to 2.0mm and boulders of size not less than 200mm respectively. A drawing showing details of recharge structure for rainwater harvesting is enclosed. 6.0 ROADS AND CULVERTS 6.1 6.2 All the roads in the scope of contract shall be of concrete road. There would be two types of Roads. The wider road shall be 5.5m wide and the other road shall be 3.75m wide. The road outside the switchyard fenced area shall have shoulder of 1.75 m in case of 5.5 m wide road and 1.3 m in case of 3.75 m wide road with kerb stone at the two side ends of the road. Interlocking tiles shall be laid on this shoulder. Kerb stone with channel are to be provided at both the side of the roads. The kerb stone on both sides of the roads shall be painted yellow and black alternatively. In case of switchyard road the shoulder would be compacted earth 600mm wide on the sides of both types of road. 6.3 Layout of the roads shall be as shown in the General Arrangement drawing for the substation issued along with the tender documents. Adequate turning space for vehicles shall be provided and bend radii shall be set accordingly. Road to the Autotransformer/Reactor shall be as short and straight as possible. 6.4 The road shall have 100 mm thick RCC (1:1.5:3 nominal mix with reinforcement of 8 mm dia. 300 C/C both ways) on the top. Below it 100mm thick PCC (1:4:8) shall be provided. 300 mm thick water bound mecadam (WBM) in three equal layers of 100mm each at the bottom. PCC and WBM shall extend upto the shoulder width on both sides of the road outside switchyard area as per the drawing. In case of road within the switchyard PCC and WBM shall placed only upto the width of the road. Polythene sheet of 125 microns shall be placed between the RCC and PCC slab. Expansion joint (12mm thick) shall be provided at every 8.0 m. In addition, in case of 5.5 m wide road, expansion joint shall also be provided longitudinally at the center. 100 mm dia RCC Hume pipe (NP-3) shall be provided at every 100m interval across the length of the road for cable crossing. 6.5 The details are furnished in the drawing enclosed with tender document. 6.6 In case of extension of existing substation, the road shall be matching with the road provided in the existing substation. In case, bituminous road is provided in the existing substation, the same type of road shall be provided in the extension area. The drawing for the bituminous road is enclosed with the tender document.
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7.0
FOUNDATION /RCC CONSTRUCTION 7.1 GENERAL 1. Work covered under this Clause of the Specification comprises the construction of foundations and other RCC constructions for switchyard structures, equipment supports, trenches, drains, jacking pad, pulling block, control cubicles, bus supports, Autotransformer/Reactors, marshalling kiosks, auxiliary equipments & systems buildings, tanks 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 RCC constructions. 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: 1.5: 3 mix) shall be used for all structural/load bearing members as per latest IS: 456. 3. 4. 5. If the site is sloping, the foundation height will be adjusted to maintain the exact level of the top of structures to compensate such slopes. The switchyard foundations plinths and building plinths shall be minimum 300mm above finished ground level respectively. Minimum 75mm thick lean concrete (1:4:8) shall be provided below all underground structures, foundations, trenches etc. to provide a base for construction. 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. 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 foundation or pile foundation as may be required based on soil/sub-soil conditions and superimposed loads shall be provided. If pile foundations are adopted, the same shall be cast-in-situ bored or precast or under reamed type as per relevant parts of IS Code 2911. Only RCC piles shall be provided. Necessary initial load test shall be carried out by the Contractor 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 for the piles shall also be conducted. All the testing work shall be planned in such a way that these shall not cause any delay in project completion.
2.
6.
7.
8.
7.2
DESIGN The following clauses shall be applicable only for the foundation which the contractor may have to design as mentioned at Clause 2.3. 1. 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.
2.
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3.
For detailing of reinforcement IS: 2502 and SP: 34 shall be followed. Cold twisted deformed bars (Fe=415 N/mm2) conforming to IS: 1786 or TMT bars as per CPWD specifications 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 & slab sections having thickness of 150 mm and above. Clear cover to reinforcement shall be as per IS: 456 (latest). 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.
4.
5.
6. 7.
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. Earth pressure for all underground structures shall be calculated using coefficient of earth pressure at rest, co-efficient 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. In 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 & ground water pressure & surcharge pressure from outside (application only to structures which are liable to be filled up with water or any other liquid).
8. 9.
10.
11.
12.
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b) c)
Full earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside. 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 s hall be ensured ignoring the superimposed loadings.
13.
Base slab of any underground enclosure shall also be designed for empty condition during construction and maintenance stages with maximum ground water table (GWT). Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the super-imposed loadings. Base slab of any underground enclosure like water storage tank shall also be designed for the condition of different combination of pump sumps being empty during maintenance stages with maximum GWT. Intermediate dividing piers of such enclosures shall be designed considering water in one pump sump only and the other pumps sump being empty for maintenance. 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/reactor 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 over loads in limit state design also.
14.
15.
16.
17.
7.3
ADMIXTURES & ADDITIVES 1. 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. Concrete Admixtures/ Additives shall be approved by Owner. 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.
2.
3.
4. 5.
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8.0
Chain link Fencing and Gate: Fencing and gate shall be provided as per details given below: 8.1 Areas requiring Fencing a) b) Fencing shall be provided for complete switchyard as per drawing. Separate gate shall be provided for men and equipment. Internal fence surrounding the various equipments (if) mounted on ground or a height lower than 2.5m. Necessary gates shall be provided for each area so surrounded.
8.2 Product materials The minimum requirements are as follows: a) Chain link fence fabric (without galvanization) in accordance to IS: 2721. 1. 2. 3. 4. Size of mesh: Nominal wire size: 75mm 3.15mm dia meter
Width of chain link: 1500mm Painting: Two or more coats of approved standard make synthetic enamel paint over a coat of standard steel primer.
a)
Posts i) The posts shall be of medium M.S. tubes of 50mm diameter conforming to grade Yst-22 (Kg/mm2). The tubes shall also conform to IS: 1161/IS 806. The length of tubular post shall be 2600 mm as shown in the tender drawing enclosed with bid documents.
ii)
An M.S. base plate of size 160 X 160 X 6mm thick shall be welded with the tubular post. The post shall be provided on the top with M S plate as shown in the drawing. The tubular post shall be welded with 8 number of M S flat of size 50 x 6mm 75mm long as shown in the drawing. Two number of 13.5 mm diameter holes on each cleats shall be provided to bolt the fence fabric panel. The cleats shall be welded at equal spacing in such a way that 4 numbers of cleats are on one side and remaining 4 cleats are on the opposite side of the post. The cleats on the corner posts shall be welded in such a way that it suits the site requirement.
iii)
iv) The whole assembly of tubular post shall be hot dip galvanized. The zinc coating shall be minimum 610 gram per sq. meter. The purity of zinc shall be 99.95% as per IS: 209. c) Fence Fabric Panel Chain link fencing shall be fabricated in the form of panel 1300 X 2928 mm. An M.S. flat of at least 50x6 mm size shall be welded all-round fence fabric to form a panel. Four pairs of 13.5mm diameter holes on the vertical M S flat matching the spacing of holes in cleats fixed with pipe as shown in the drawing shall be provided to fix the fence panel with the tubular posts. A washer shall also be provided below each nut. The contractor, for fixing the panels, shall supply the 12mm diameter bolts including nuts and washers. All nuts, bolts and washers shall be hot dip galvanized.
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The fence panel shall be provided with two or more coats of approved standard synthetic enamel paint over approved standard steel primer. 8.3 Installation 1. 2. 3. 4. Fence shall be installed along the switchyard line as shown in the General Arrangement drawing. Post holes shall be excavated by approved method. All posts shall be 3.0m apart measured parallel to ground surface. Posts shall be set in 1:2:4 Plain Cement Concrete block of minimum 0.40x0.40x1.2m depth. 75mm thick plain cement concrete 1:4:8 shall be provided below concrete blocks. Posts shall be braced and held in plumb position and true alignment and elevation until concrete has set. Fence fabric shall not be installed until concrete has cured a minimum of 7 days. Fence fabric panel shall be fixed to the post at 4 nos. MS flat each of 50x6, 75 long through 2 nos. of bolts (12 diameters) on each flat. The painting pattern of fence panels shall be decided by Engineer-incharge. It shall be preferable to paint the panel in different colour pattern such that it gives better aesthetic look.
5. 6. 7.
8.4
Gate 1. The gate shall be made of medium duty M.S. pipe conforming to relevant I.S. with welded joints. The main frame (outer frame) of the gate shall be made of 40mm dia pipe and vertical pipes of 15mm dia @ 125mm spacing (maximum) shall be welded with the main frame. Other details shall be as shown in the drawing. The gates shall be fabricated with welded joints to achieve rigid connections. The gate frames shall be painted with one coat of approved steel primer and two coats of synthetic enamel paint. The gates shall be provided with suitable locking arrangement. The main gate shall be 5.0m wide and shall be of double leaf type (as shown in the drawing). Next to the main gate, a side gate (1.25m wide single leaf) shall also be provided. Steel roller shall be provided with the gate. Gate shall be installed in location as shown in approved G.A. drawing.
2.
3. 4.
5. 6. 9.0
WATER SUPPLY (EXTERNAL) (i) Water shall is available at the vicinity of the site in perennial river and stream. Contractor shall make their own arrangement for drawing such water for the work. The contractor shall carry out all the external plumbing/erection works required for supply of water to the control room building from the available point as at (i).
(ii)
(iii) The contractor shall carry out all the plumbing/erection works required for supply of water to fire water tank beyond the point as at (i). (v) A scheme shall be prepared by the contractor indicating the layout and details of water supply which shall be got approved from the Owner before actual start of
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work including all other incidental items not shown or specified but as may be required for complete performance of the works. (vi) Bore wells and pumps for water supply are not in the scope of contractor. 10.0 TECHNICAL DETAILS OF THE BUILDINGS 1. 2. 3. 4. 12 mm cement plaster of mix 1:6 (1 cement: 6 fine sand) shall be provided on the smooth side of internal walls. 6 mm cement plaster of mix 1:3 (1 cement: 3 fine sand) to all ceiling. 15mm cement plaster of mix 1:6 (1 cement: 6 fine sand) on rough side of single or half brick wall. 12 mm thick prelaminated three layer medium density (exterior grade) particle board GRdeI, Type II conforming to IS: 12823 bonded with phenol formaldehyde synthetic resin, of approved brand and manufacture shall be provided in paneling fixed in aluminum doors, windows shutters and partition frames with C.P brass/stainless steel screws etc. complete as per architectural drawings and directions of engineer-in-charge. Distempering on all internal walls and ceilings with oil bound washable distemper of approved brand and manufacture to give an even shade (two or more coats) over and including priming coat with cement primer. Enamel Painting with synthetic enamel paint of approved brand and manufacture of required colour to give an even shade shall be provided on the steel glazed doors, windows, ventilators and rolling shutters in various buildings as specified in drawings. Two or more coats over an under coat of suitable shade with primer paint of approved brand and manufacture. Two or more coats of French spirit polishing with a coat of wood filler shall be provided on the wooden doors of Control Room building. ACDB and DCDB room in Control Room building and FFPH building shall be provided 52 mm thick cement concrete flooring with "Hardcrete" concrete hardener topping under layer 40 mm thick cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 graded stone aggregate 20 mm nominal size) and top layer 12 mm thick metallic concrete hardener consisting of mix 1: 2 ( 1 cement hardener mix : 2 stone aggregate 6 mm nominal size) by volume with which "Hardcrete" hardening compound of "Snowcem India Ltd" or equivalent is mixed @ 2 litre "Hardcrete" per 50kg of cement including cement slurry, complete. (In ACDB/DCDB Room and FFPH building only). Cement plaster skirting (up to 15 cm height) with cement mortar 1:3 (1 cement: 3 coarse sand) mixed with metallic concrete hardener in same ratio as for floor finished with a floating coat of neat cement. 21 mm thick in ACDB/DCDB room Floor tiles of Polished porcelain (vitrified) in different sizes with water absorption less than 1 % and flexural strength not less than 30 N/mm2 in all colours and shades, laid on 20 mm thick cement mortar 1:4 ( 1 cement: 4 coarse sand) including grouting the joints with white cement and matching pigments shall be provided as mentioned in drawings. Size of Tile shall be 50X50 cm 1st Quality Ceramic glazed floor tiles (anti-skid) 300x 300 mm (thickness to be specified by the manufacturer) of 1st quality conforming to IS: 13755 of NITCO, ORIENT, SOMANY, KAJARIA or equivalent shall be provided in toilet/pantry area in all colour shades as approved by Engineer-in-Charge laid
5.
6.
7. 8.
9.
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on 20mm thick cement mortar 1:4 (1 cement: 4 coarse sand) including pointing the joints with white cement and matching pigment etc complete. 1st quality ceramic glazed tiles conforming to IS : 13753 of minimum thickness 5mmof approved make like NITCO, ORIENT, SOMANY, KAJARIA or equivalent make shall be provided in toilet/pantry area in all colours shade of any size as approved by engineer-in-charge in dados (height as specified in drawings) over 12mm thick bed of cement mortar 1:3 (1cement : 3 coarse sand) and jointing with grey cement slurry @3.3kg per sq. mm. including pointing in white cement mixed with pigment of matching shade complete. 18mm polished granite in cement mortar 1:4, 20 mm thick made to a level cut to size shall be provided and laid as specified in drawings. The joints are filled with jointing compound matching to the tiles. Wherever granite tiles are specified for the floor, 100mm granite skirting shall be provided with the walls. The granite outer surface shall be flushed to the plaster finish of the wall. Granite counter shall be provided and fixed in the pantry with 18mm granite slab mounted on 75mm RCC slab supported by 115 mm brick wall plastered on all sides as per the drawing. The shelves are made of 18mm thick well cut and polished white marble slabs. The outer side of the brick wall and the RCC slab visible in the front is finished with 18mm granite with edges moulded on the exposed end. The shutters shall be finished with 19 mm particle finished laminate edge lapping. The shutters are to be provided with 100mm handles and shutter locks. The inside of the shutter shall be painted with synthetic enamel paint. All Brickwork shall be with cement mortar 1:6 (1cement: 6 coarse sand). Half brick work masonry shall be with cement mortar 1:4 (1cement: 4 coarse sand). Bricks used shall be of class 75. Anti termite treatment shall be carried out for all buildings. M.S. Rolling shutters as per drawing shall be provided and fixed interlocked together through their entire length and jointed together at the end by end locks mounted on specially designed pipe shaft with brackets along with ball bearing for rolling shutter, side guides and arrangements for inside and outside locking with push & pull operation including the cost of providing and fixing necessary 27.5 cm long wire springs grade No. 2 and M. S top cover of required thickness for rolling shutters. 80 x 1.25 mm M. S laths with 1.25 mm thick top cover. Circular/hexagonal M.S. sheet ceiling fan box shall be provided in the ceiling with clamp of internal dia. 140 mm, 73 mm height, 3 mm thick rim, top and bottom lid of 1.5 mm M.S. Sheet. Lids shall be screwed in to M. S. box by means of 3 mm round headed screws; clamps shall be made of 12 mm dia. M. S. bar bent to shape as per standard drawing with overall length as 80 cm. Anodized aluminum work for doors, windows, ventilators and partitions shall be provided and fixed in control room building with extruded built up standard tubular and other sections of approved make conforming to IS:733 and IS : 1285, anodized transparent or dyed to required shade according to IS : 1868. (Minimum anodic coating of grade AC 15) fixed with rawl plugs and screws or with fixing clips, or with expansion hold fasteners including necessary filling up of gaps at junctions at top, bottom and sides with required PVC/neoprene felt etc and joined mechanically wherever required including cleat angle,
12.
13.
14.
15.
16. 17.
18.
19.
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Aluminum snap beading for glazing / paneling, C.P. brass/ stainless steel screws including glazing and fittings as specified. Shutters of doors, windows and ventilators shall be provided and fixed with hinges/pivots fittings wherever required including PVC/neoprene gasket. SECTION FOR AL. WINDOWS: Shutters bottom section- 61.85X37X45.5 WS 1027, 1.058 Kg/mt, side and top section61.85X31.75, WS 1029, 0.650 Kg/mt, shutter sections, one side and both side open 40X18X10 WS 1023, 0.43 Kg/mt, Interlock sections 40X18X26.5X10, WS 1022, 0.530 Kg/mt, with 4 mm plain float glasses, PVC gaskets, Nylon wheels, Aluminium handles cum locks. Jindal/ Indal/ Hindalco make as per drawing. SECTION FOR AL. DOORS: 2-1/2 X 1-1/2 sections for outer frame for fixed partition 63.5 X 38.1 X 1.5 mm, DP 1212, 0.700 Kg/mt, with glazing clips 17.27 X 19.05 X 1 mm, 0.098 Kg/mt, (equivalent section) with 5.5 mm plain float glasses and rubber gasket with bottom three feet pre-laminated sheet of 12 mm thick of colour grey, ivory. Jindal/Indal/ Hindalco make as per drawing. SECTION FOR AL. PARTITION: Outer frames 2-1/2 X 1-1/2, 63.5 X 38.10 X 1.5 mm, DP 1212, 0.700 Kg/mt, to work as fixed partition & door with door verticals 44.45 X 47.62 X 1.5 mm, DP 2022, 0.850 Kg/mt, top and centre pieces as per drawing. 20. Cement based water proofing treatment of roofs, balconies, terraces etc. shall be provided with average thickness of 120mm and minimum thickness at Khurra as 65mm and laid consisting of following operations: (a) A slurry coat of neat cement using 2.75 kg/m2 of cement admixed with proprietary water proofing compounds conforming to IS: 2645 shall be applied and grouted over the RCC slab including cleaning the surface before treatment. Plain Cement concrete 1:5:10 (1 Cement: 5 fine sand: 10 burnt brick aggregate of 40mm nominal size) admixed with proprietary water proofing compound conforming to IS: 2645 over 20mm thick layer of cement mortar of min 1:5 (Cement: 5 coarse sand) admixed with proprietary water proofing compound conforming to IS: 2645 to required slope and treating similarly the adjoining walls upto 300mm height including rounding of junctions of walls and slabs. After two days of proper curing, a second coat of cement slurry admixed with proprietary water proofing compound conforming to IS: 2645 shall be applied. The surface shall be finished with 20mm thick joint less cement mortar of mix 1:4 (1 cement : 4 course sand) admixed with proprietary water proofing compound conforming to IS: 2645 and finally the surface shall be finished with trowel with neat cement slurry and making of 300 x 300 mm square. The whole terrace so finished shall be flooded with water for a minimum period of two weeks for curing and for final test. All above operations shall be done in order and as directed and specified by the Engineer-incharge.
(b)
(c)
(d)
(e)
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21.
Unplasticised rigid PVC rain water pipes 110mm dia shall be provided and fixed on the wall face conforming to IS: 13592 type A as per drawing including jointing with seal ring conforming to IS: 5382 leaving 10 mm gap for thermal expansion single socketed pipes. Unplasticised PVC Moulded fittings/accessories including 110mm bend and 110mm shoes shall be provided and fixed for unplasticised rigid PVC rain water pipes conforming to IS:13592 type A including jointing with seal ring conforming to IS: 5382 leaving 10mm gap for thermal expansion. Unplasticised PVC pipe clips of approved design shall be provided and fixed to unplasticised 110mm PVC rain water pipes by means of 50x50x50mm hard wood plugs, screwed with MS screws of required length including cutting brick work and fixing in cement mortar1:4 (1 cement : 4 coarse sand) and making good the wall etc. Double action hydraulic floor spring of approved brand and manufacture IS:6315 marked "hardwyn" make(Model 3000) or equivalent for doors shall be provided and fixed at the following door including cost of cutting floors as required, embedding in floors and cover plates with brass pivot and single piece MS sheet outer box with slide plate etc. As per the direction of Engineer-inCharge. With stainless steel cover plate: a. b. c. d. Main Entrance to Control Room Building. DGM room Conference Room Control Room
22.
23.
24.
25.
Plinth protection 50 mm thick of cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 graded stone) aggregate 20 mm nominal size) shall be laid over 75 mm bed of dry brick ballast 40 mm nominal size well rammed and consolidated and shall be grouted with fine sand including finishing the top smooth. Coloured vitreous china pedestal type water closet (European type) with seat and lid, 40mm flush bend, overflow arrangement with specials of standard make and mosquito proof coupling of approved municipal design including painting of fittings and brackets, cutting and making good the walls and floors shall be provided for all toilets. Coloured vitreous china wash basin of size 630 x 450 mm with C.I/M.S brackets along with single 15 mm C.P brass pillar taps, Kingston/Gem/Techno/Parko, 32 mm C.P brass waste of standard pattern, shall be provided and fixed in the toilets including painting of fittings and brackets, cutting and making good the walls wherever required along with C. P brass trap and C.P brass union. All urinals shall be coloured vitreous china flat back half stall urinal of 580x380x350mm with 10 litre PVC automatic flushing cistern, Parryware/Hindware/Seabird/Orient (Coral) with fittings, standard size C.P. brass flush pipe, spreaders with unions and clamps (all in C.P. brass) with waste fitting as per IS: 2556 C.I. trap with outlet grating and other couplings in C.P. brass including painting of fittings and cutting and making good the walls and floors wherever required.
26.
27.
28.
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29.
Following fittings shall be provided in all the toilets: i) ii) iii) Toilet paper roll holder. Double type coat & hat hooks with flanges, fixed to wall / shutter, etc. with necessary screws, washers & plugs. CP/PP liquid soap holder of approved make fixed with each wash basin to the wall with necessary CP /PP brackets, CP screws, washers, plugs etc. 100 mm dia vitreous chinaware half round channel of approved make fixed to correct grade, level, opening for floor trap below urinals set in CM 1:3 & pointed using white cement etc . CP brass bib cock 15mm nominal bore of approved quality conforming to IS: 8931. CP brass angle valve of 15mm nominal bore provided and fixed in position for basin and cistern points of approved quality conforming IS :8931.
iv)
v) vi)
vii) Best quality marble partition slab provided and fixed in position for urinals, of size 610x1150mm, 20mm thick, polished on both sides & machine cut, exposed corners rounded etc. viii) Towel rail of approved make of 600mm length, 25mm dia with a pair of brackets or flanges provided and fixed to wall beside each wash basin/set of wash basin with necessary screws, plugs, etc. ix) 6mm thick beveled edge mirror 1000x600mm shall be provided and fixed mounted on 12mm thick water proof plywood backing and hardwood beading all-round and mirror fixed to the backing with 4 Nos. of CP cap screws & washers, including fixing the mirror to the wall with necessary screws, plugs & washers etc, with each wash basin.
30.
Salem Stainless steel A ISI 304 (18/8) Kitchen sink of 510x1040mm bowl depth 178mm with drain board shall be provided and fixed as per IS 13983 with C.I brackets, and stainless steel plug 40mm including painting of fittings and brackets, cutting and making good the wall. GI Pipe work for Internal and External works: i) ii) All concealed GI pipe shall be painted with anticorrosive bitumastic paint including cutting of chases and making good the wall. All exposed GI pipes and fittings shall be painted with synthetic enamel paint of desired shade over a ready mixed priming coat, both of approved quality for new work. Wherever GI pipes are buried the same shall be provided and laid in position including trenching sand cushion and refilling, painted with anticorrosive bitumastic paint etc. Gun metal ball valve with operating levers, non-return valves conforming to IS specification shall be provided and fixed in position as per drawing or direction of Engineer-in-charge.
31.
iii)
iv)
32.
Masonry chamber for sluice valve shall be 600x600mm size in plan and depth 750mm, or matching with the site condition inside with 50 class designation brick work in cement mortar 1:5 (1 cement : 5 fine sand) with CI surface box 100 mm. Top diameter, 160 mm bottom dia and 180 mm deep (inside) with
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chained lid and RCC top slab 1:2:4 mix (1cement : 2 coarse sand: 4 graded stone aggregate 20 mm nominal size) necessary excavation foundation concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate 40 mm nominal size) and inside plastering with cement mortar 1:3 (1 cement : 3 coarse sand) 12 mm thick finished with a floating coat of neat cement complete as per standard design with FPS bricks of class 75. 33. Polyethylene water storage tanks ( 2 nos. of 2000 litres capacity each) shall be provided and placed on roof of control room building of approved brand and manufacture with cover and suitable locking arrangement, float value and making necessary holes for inlet , outlet and overflow pipes. PVC floor traps of self cleansing design shall be provided & fixed in position with outlet size of 75mm diameter of approved make, including making connection with PVC soil/waste pipes using rubber gaskets, embedding the trap in 150 mm thick PCC 1:2:4, providing & fixing of top tile & strainer of CP or PVC on top of the trap etc. Square-mouth SW gully trap grade 'A' 100x100mm size P type with FPS Bricks class designation 75 shall be provided and fixed complete with CI grating brick masonry chamber with water tight C.I. cover with frame of 300X300mm size (inside) the weight of cover to be not less than 4.5 Kg and frame to be not less than 2.70 Kg as per standard design Glazed stoneware pipes of 150mm diameter grade 'A' shall be provided, laid and jointed with stiff mixture of cement mortar in the proportion of 1:1 (1cement :1 fine sand) including testing of joints etc. complete. Cement concrete 1:5:10 (1 cement: 5 coarse sand: 10 graded stone aggregate 40 mm nominal size) shall be provided and laid around S.W pipes including bed concrete. Brick masonry manhole shall be constructed in cement mortar 1:4 (1 cement :4 coarse sand) RCC top slab with 1:2:4 mix (1 cement : 2coarse sand : 4 graded stone aggregate 20 mm nominal size) foundation concrete 1:4:8 mix (1cement : 4 coarse sand :8 graded stone aggregate 40 mm nominal size) inside plastering 12 mm thick with cement mortar 1:3 (1 cement : 3 coarse sand ) finished with floating coat of neat cement and making channels in cement concrete 1:2:4 (1 cement: 2 coarse sand :4 graded stone aggregate 20 mm nominal size) finished with a floating coat of neat cement complete as per standard design. a) Inside size shall be 90 x 80 cm and 60 cm deep including CI cover with frame (light duty) 455 x 610 mm internal dimensions total weight of cover and frame shall not be less than 38 kg (weight of cover 23 kg and weight of frame 15 kg) and shall be constructed with F.P.S. bricks with class designation 75. Inside size shall be 120 x 90 cm and 90 cm or more deep including CI cover with frame (medium duty) 500mm internal diameter total weight of cover and frame to be not less than 116 kg (weight of cover 58 kg and weight of frame 58 kg) with FPS Bricks class designation 75.
34.
35.
36.
37.
38.
b)
39.
MS foot of 20 x 20mm square rests shall be provided and fixed in manholes with 20 x 20 x 10 c m cement concrete blocks 1:3:6 ( 1 cement :3 coarse sand :6 graded stone aggregate 20 mm nominal size ) as per standard design. Steel glazed doors, windows and ventilators of standard rolled steel sections shall be provided and fixed in FFPH building, joints mitred and welded with 15 x 3 mm lugs, 10cm long, embedded in cement concrete blocks 15 x 10 x10
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cm of 1:3:6 (1 cement 3 coarse sand : 6 graded stone aggregate 20mm nominal size) or with wooden plugs and screws or rawl plugs and screws or with fixing clips or with bolts and nuts as required, including providing and fixing of glass panes with glazing clips and special metal sash putty of approved make complete including applying a priming coat of approved steel primer, necessary hinges or pivots as required. 41. Pressed steel door frames manufactured from commercial mild steel sheet of 1.25mm thickness shall be provided and fixed in FFPH building including hinges jamb, lock jamb, bead and if required angle threshold of mild steel angle of section 50x25mm, or base ties of 1.25 mm pressed mild steel welded or rigidly mixed together by mechanical means, adjustable lugs with split end tail to each jamb including steel butt hinges 2.5mm thick with mortar guards, lock strike-plate and shock absorbers as specified and applying a coat of approved steel primer after pre-treatment of the surface as directed by Engineer-inCharge. Asbestos cement 6mm thick corrugated sheets roofing shall be provided and fixed with G, I, J or L hooks, bolts and nuts 8mm diameter G, I plain and bitumen washers complete excluding the cost of purlins, rafters and trusses for water tank. MODE OF MEASUREMENT 11.1 Earthwork This shall include excavation in all kinds of soil including rock, all leads and lifts including back filling, compacting, dewatering (if required) and disposal of surplus earth to a suitable location. The quantity of excavation for foundations of towers, equipment structures, all transformers, rail-cum-road, firewall, cable trenches, water tank, reactors and buildings s hall only be measured. The quantity of excavation for roads, drains, rainwater harvesting, septic tank, soak pit, external water supply system, site surfacing (gravelling), chain link fencing (including gate) shall not be measured separately and shall be deemed to be included in the composite rates quoted by the bidder for the respective works. All other excavation required for the completion of the work including fixing of lamp posts, plinth protection, flooring, sewerage system, manholes, pipes, earthmat etc. shall also not be paid for. The measurement of excavation of all concrete works shall be made considering dimension of the pit leaving 150mm gap around the base pad (lean concrete) or actually excavated pit, whichever is less. The quantity shall be measured in cubic meters. 11.2 PCC Providing and laying Plain Cement Concrete of all types and at all locations including all leads and lifts. The quantity shall be measured in cubic meters as per lines and levels indicated in the drawings. 11.2.1 PCC 1:2:4 (1 cement : 2 sand : 4 coarse aggregate 20 mm nominal size) shall be measured in flooring of buildings, plinth protection, fencing, transformer foundation, reactor foundation, rail track, drain, culverts, septic tank, chain link fencing, gate etc. as indicated in the drawings. 11.2.2 PCC 1:4:8 (1 cement : 4 coarse sand : 8 stone aggregate, 40mm nominal size) shall be measured below all foundations of buildings, cable trench, roads, under flooring, rail-cum-road, transformer foundation, reactor
42.
11.0
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foundation, drain, water tank, culverts, drawings.
gate etc. as indicated in the
11.2.3 PCC 1:5:10 (1 cement: 5 sand: 10 burnt brick aggregate, 40mm nominal size) shall be provided for site surfacing in switchyard, roof water proofing etc. All other PCC required for the completion of the work including hold fasts of doors/windows/rolling shutters, fixing of plumbing pipes, bedding concrete for sewer lines, embedment of electrical conduits etc. shall not be measured and deemed included in the composite rates quoted by the bidder for respective works. Water proofing compound wherever specified shall be added without any extra cost. 11.3 RCC Measurement of reinforced cement concrete at all locations shall be made and shall include all leads, lifts, formwork, grouting of pockets and underpinning, (but shall exclude reinforcement), of mix 1:1.5:3 (1cement : 1.5 coarse sand : 3 stone aggregate 20mm nominal size). This shall also include pre-cast RCC work and addition of water proofing compound wherever required for which no additional payment shall be made. The quantity shall be measured in cubic meters as per lines and levels indicated in the drawings. No deduction shall be made for volume occupied by reinforcement/inserts/sleeves and for openings having cross-sectional area up to 0.1 sq. m. 11.4 Steel Reinforcement Reinforcement shall be measured in length (actual or theoretical as per drawing whichever is less) including hooks, if any, separately for different diameters as actually used in work, excluding overlaps. From the length so measured, the weight of reinforcement shall be calculated in tones on the basis of sectional weights as adopted by Indian Standards. Wastage, overlaps, couplings, welded joints, spacer bars, chairs, stays, hangers and annealed steel wire or other methods for binding and placing shall not be measured and cost of these items shall be deemed to be included in the rates for reinforcement. 11.5 Stone filling Measurement of stone (40mm nominal size) for transformer foundations shall be made as per theoretical volume of the space to be filled in the transformer foundation as per drawings. This shall be measured in cu. m. 11.6 Miscellaneous structural steel Measurement for Supply, fabrication, transportation and erection of all miscellaneous structural steel work for mono rails (RS joists), rails for transformers/ reactors, trusses, frame work, purlins, gratings, steel tubes, built up sections along with all other steel fittings and fixtures, inserts and embedments in concrete shall be made as per drawings. The unit rate for this item shall be inclusive of cutting, grinding, drilling, bolting, welding, pre- heating of the welded joints, applying a priming coat of steel primer and anti corrosive bitumastic paint/ synthetic enamel paint etc. (wherever specified), setting of all types of embedments in concrete, etc. Steel required for foundation bolts, nuts and bolt, doors, windows, ventilators, louvers, rolling shutters, chain
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link fencing, gratings in drains, soil pipes, plumbing pipes, floor traps, embedments required for rainwater harvesting, septic tank, soak pit, roof truss and purlins required for fire water tank, etc. shall not be considered for payment and measurements. Quantity shall be measured in Kg. 11.7 Roads The measurement for the concrete roads shall be made in running metres measured along the centre line of the road and shall include all items such as excavation, compaction, rolling, watering, WBM, Kerb stone, grating, inter locking tiles etc. complete as per drawing but excluding concrete and reinforcement. The measurement of bituminous road shall be made in running metres measured along the centre line of the road and shall include all items such as excavation, compaction, rolling, watering, sub base course, WBM, Bitumen, pre mix carpet complete as per drawing. 11.8 Drain The measurement of drains shall be made in running metres measured along the centre line of the drain and shall include excavation, compaction, brickwork, plastering, grating, weep holes etc. complete as per drawing but excluding concrete. 11.9 Anti-weed Treatment and Stone Spreading The measurement shall be done for the actual area in square meters of stone spreading provided in the switchyard and shall include anti-weed treatment including material and providing and spreading of 100mm thickness of uncrushed/crushed/broken stone of 40mm nominal size as per the specification for the specified area. 11.10 Chain Link Fencing and gate The measurement shall be made in running meters of the fence provided as per drawing. The rate shall be including the post, fencing, MS Flat etc. complete but excluding the concrete. The gate shall be measured in numbers. 11.11 External Finishing: This is a lump sum item. Contractor has to assess the quantity as per drawings of Control room cum administrative building, Fire Fighting Pump House and quote for the same for each building separately. This shall include following items. 1) 2) External plastering: 18 mm cement plaster of mix: 1:4 (1 cement: 4 coarse sand) including all grooves as specified. Providing and applying two or more coats of Novakote exterior flat paint over an under coat of suitable pliolite based primer nova prime on new cement plaster surfaces of the buildings inclusive of required tools, scaffolding, materials and other painting accessories etc. as per recommendations of manufacturer.
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11.12 Hume Pipe Hume pipe shall be measured diameter-wise and laid as per the drawings and shall be measured in running meters. The item shall be inclusive of excavation, laying, back filling, jointing etc. but excluding concrete and reinforcement (if any).
11.13 Building This is a lump sum item for each building. However, the quantity of excavation, concrete, reinforcement below the plinth level shall be measured as per item nos. 11.1, 11.2, 11.3 & 11.4 described above. Quantity of concrete and reinforcement above the plinth level of the buildings shall be measured and paid under item no. 11.2, 11.3 & 11.4 mentioned above respectively. External Finishing shall be measured and paid as per item no. 11.11 mentioned above. The rest of the entire work required to complete the building in all respect as per the drawings furnished by the Owner shall be deemed to be included in this lump sum rate. 11.14 Rain Water Harvesting This is a lump sum item. The contractor shall be required to complete the work in all respect as per drawings furnished by the Owner. All the items including excavation, miscellaneous steel, brick work, fillings of boulders, gravel, sand, pipes etc. shall be deemed to be included in this lump sum rate. However, the concrete (all types) and the reinforcement shall be measured and paid under the item no. 11.2, 11.3 & 11.4 mentioned above. 11.15 Septic Tank and Soak Pit This is a lump sum item. The contractor shall be required to complete the work in all respect as per drawings furnished by the Owner. All the items including excavation, masonry work, all types of fillings, all types of pipes including plumbing and vent pipes, all type of fittings etc. shall be deemed to be included in this lump sum rate. However, the concrete (all types) and the reinforcement shall be measured and paid under the item no. 11.2, 11.3 & 11.4 mentioned above. 11.16 Fire Water Tank This is a lump sum item. The contractor shall be required to complete the work in all respect as per drawings furnished by the Owner. All the items including excavation, compaction, brick work, roof truss, corrugated AC Sheet roofing, all types of miscellaneous steel, internal and external plastering, painting etc. shall be deemed to be included in this lump sum cost. However, the concrete (all types), reinforcement and the steel embedments (except roof truss and purlins) shall be measured and paid under the item no. 11.2, 11.3 and 11.6 mentioned above. 11.17 External water supply from Bore-well to Fire water tank. The external water supply from Bore-well shall be measured diameterwise in running meters. It shall include all the items such as excavation, piping, pipe fittings, painting, brickwork, sand filling, concrete, valves,
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chambers cutting chases in walls, openings in RCC and repairs, etc. required to complete the job. 12.0 MISCELLANEOUS GENERAL REQUIREMENTS 12.1 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 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 IS: 2633. The galvanizing shall be followed by the application of an etching primer and dipping in black bitumen in accordance with BS: 3416. Bricks having minimum 75 kg/cm2 compressive strength can only be used for masonry work. Contractor shall ascertain himself at site regarding the availability of bricks of minimum 75 kg/cm2 compressive strength before submitting his offer. Angles 50x50x5 mm (minimum) with lugs shall be provided for edge protection all round cut outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe trenches supporting covers, edges of manholes supporting covers, supporting edges of manhole precast cover and any other place where breakage of corners of concrete is expected. Anti termite chemical treatment shall be given to column pits, wall trenches, foundations of buildings, filling below the floors etc. as per IS: 6313 and other relevant Indian Standards. For all civil works covered under this specification, nominal mix by volume batching as per CPWD specification is intended. The relationship of grade of concrete and ratio of ingredients shall be as below: Sl. No. 1. 2. 3. Mix Cement Sand Coarse aggregate of 20 mm down grade as per IS: 383 6 4 3
12.2
12.3
12.4
12.5
12.6
12.7
M 10 M 15 M 20
1 1 1
3 2 1.5
The material specification, workmanship and acceptance criteria shall be as per relevant clauses of CPWD specification and approved standard Field Quality Plan.
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12.8
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.
13.0 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 cut outs etc. shall be the sole responsibility of the Contractor. He shall plan all such activities in advance and execute in such a manner that interfacing activities do not become bottlenecks and dismantling, breakage etc. is reduced to minimum. 14.0 STATUTORY RULES 14.1 Contractor 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. 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. All building/construction materials shall conform to the best quality specified in CPWD specifications if not otherwise mentioned in this specification. All tests as required in the standard field quality plans have to be carried out.
14.2 14.3
14.4 14.5
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BATTERY & BATTERY CHARGER
(B&BC)
Part-III (Vol. 2/2)
Section-Technical Specification-Battery and Battery Charger
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CHAPTER - BATTERY AND BATTERY CHARGER

TECHNICAL SPECIFICATION FOR BATTERY AN BATTERY CHARGER
CONTENTS
Clause No. 1.0 2.0 3.0 Description General Technical Requirements Battery Battery Charger Annexure-I Page No. 165 165 169 174
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CHAPTER B&BC
SECTION: BATTERY & BATTERY CHARGER

1.0 GENERAL TECHNICAL REQUIREMENTS 1.1 All materials/components used in battery chargers and batteries shall be free from flaws and defects and shall conform to the relevant Indian/IEC standards and good engineering practice. 1.1.1 For 132 kV sub-stations, DC System shall consist of two (2) float-cumboost chargers and two (2) battery sets for 220V/110V system. For 48 V systems, DC scheme shall consist of one (1) battery and two (2) float-cumboost chargers. The standard scheme drawing shall be enclosed/furnished by the contractor with the bid document. 1.1.2 Bidder shall select number of cells, float and Boost voltage to achieve following system requirement: System Voltage Maximum Voltage during Float operation 220 Volt 242 Volt 110 Volt 121 Volt 48 Volt 52.8 Volt Minimum voltage available when no charger working and battery fully discharged up to 1.85 V per cell. 198 Volt 99 Volt 43.2 Volt Minimum Nos. of cell 107 54 23
Bidder shall furnish calculation in support of battery sizing, selection of number of cells, float and Boost voltages during detailed engineering for Owners acceptance. Battery sizing calculations shall be done as per IEEE- 485 on the basis of following duty cycle: Load Continuous Load 220 V DC System Duration 3 hours Type of Loads Relays, IEDs, Station HMIs, spring charging, Isolator interlocking load, miscellaneous permanently connected loads etc. Sub-Station emergency lighting loads. Breaker closing, Tripping loads (taking simultaneous occurrence as per system) Continuous load associated with PLCs (when speech is not working Loads associated with PLCs (when speech is working)
Emergency Load Momentary Load
1 hour 1 minute
Continuous Load 48 V DC System
3 hours
Momentary Load
15 minute
2.0 Battery 2.1 Type The DC Batteries shall be VRLA (Valve Regulated Lead-Acid) type and shall be Normal Discharge type. These shall be suitable for a long life under continuous float operations and occasional discharges. Air-conditioning shall be provided in Battery room the requirement of which has been specified elsewhere in the Technical Specification. The 220 V DC system is unearth and 48 V DC system is + ve earth system.
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2.2 Constructional Requirements The design of battery shall be as per field proven practices. Partial plating of cells is not permitted. Paralleling of cells externally for enhancement of capacity is not permitted. Protective transparent front covers with each module shall be provided to prevent accidental contact with live module/electrical connections. 2.3 Containers The container material shall have chemical and electro-chemical compatibility and shall be acid resistant. The material shall meet all the requirements of VRLA batteries and be consistent with the life of battery. The container shall be fire retardant and shall have an Oxygen Index of at least 28 %. The porosity of the container shall be such as not to allow any gases to escape except from the regulation valve. The tensile strength of the material of the container shall be such as to handle the internal cell pressure of the cells in the worst working condition. Cell shall not show any deformity or bulge on the sides under all working conditions. The container shall be capable of withstanding the rigours of transport, storage and handling. The containers shall be enclosed in a steel tray. 2.4 Cell Covers The cell covers shall be made of suitable material compatible with the container material and permanently fixed with the container. It shall be capable to withstand internal pressure without bulging or cracking. It shall also be fire retardant. Fixing of Pressure Regulation Valve & terminal posts in the cover shall be such that the seepage of electrolyte, gas escapes and entry of electro-static spark are prevented. 2.5 Separators The separators used in manufacturing of battery cells, shall be of glass mat or synthetic material having high acid absorption capability, resistant to sulphuric acid and good insulating properties. The design of separators shall ensure that there is no misalignment during normal operation and handling. 2.6 Pressure Regulation Valve Each cell shall be provided with a pressure regulation valve. The valve shall be self re-sealable and flame retardant. The valve unit shall be such that it cannot be opened without a proper tool. The valve shall be capable to withstand the internal cell pressure specified by the manufacturer. 2.7 Terminal Posts Both the +ve and ve terminals of the cells shall be capable of proper termination and shall ensure its consistency with the life of the battery. The surface of the terminal post extending above the cell cover including bolt hole shall be coated with an acid resistant and corrosion retarding material. Terminal posts or any other metal part which is in contact with the electrolyte shall be made of the same alloy as that of the plates or of a proven material that does not have any harmful effect on cell performance. Both +ve and ve posts shall be clearly and unambiguously identifiable. 2.8 Connectors, Nuts & Bolts, Heat Shrinkable Sleeves Where it is not possible to bolt the cell terminals directly to assemble a battery, separate non-corroding lead or copper connectors of suitable size shall be provided to enable connection of the cells. Copper connections shall be suitably lead coated to withstand corrosion due to sulphuric acid at a very high rate of charge or discharge. Nuts and bolts for connecting the cells shall be made of
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copper, brass or stainless steel. Copper or brass nuts and bolts shall be effectively lead coated to prevent corrosion. Stainless steel bolts and nuts can be used without lead coating. All inter cell connectors shall be protected with heat shrinkable silicon sleeves for reducing the environmental impact including a corrosive environment. 2.9 Flame Arrestors Each cell shall be equipped with a Flame Arrestor to defuse the Hydrogen gas escaped during charge and discharge. Material of the flame arrestor shall not affect the performance of the cell. 2.10 Battery Bank Stand All batteries shall be mounted in a suitable metallic stand/frame. The frame shall be properly painted with the acid resistant paint. The suitable insulation shall be provided between stand/frame and floor to avoid the grounding of the frame/stand. 2.11 Capacity Requirements When the battery is discharged at 10 hour rate, it shall deliver 80% of C (rated capacity, corrected at 27 Celsius) before any of the cells in the battery bank reaches 1.85V/cell. The battery shall be capable of being recharged from the fully exhausted condition (1.75V/cell) within 10 hrs up to 90% state of charge. All the cells in a battery shall be designed for continuous float operation at the specified float voltage throughout the life. The capacity (corrected at 27Celcius) shall also not be less than C and not more than 120% of C before any cell in the battery bank reaches 1.75V/cell. The battery voltage shall not be less than the following values, when a fully charged battery is put to discharge at C/10 rate: (a) (b) (c) (d) After Six minutes of discharge: After Six hours of discharge: After 8 hours of discharge: After 10 hours of discharge: 1.98V/cell 1.92V/cell 1.85V/cell 1.75V/cell
Loss in capacity during storage at an average ambient temperature of 35C for a period of 6 months shall not be more than 60% and the cell/battery shall achieve 85% of its rated capacity within 3 charge/discharge cycles and full rated capacity within 5 cycles, after the storage period of 6 months. Voltage of each cell in the battery set shall be within 0.05V of the average voltage throughout the storage period. Ampere hour efficiency shall be better than 90% and watt hour efficiency shall be better than 80%. 2.12 Expected Battery Life The battery shall be capable of giving 1200 or more charge/discharge cycles at 80% Depth of discharge (DOD) at an average temperature of 27 Celsius. DOD (Depth of Discharge) is defined as the ratio of the quantity of electricity (in Ampere-hour) removed from a cell or battery on discharge to its rated capacity. The battery sets shall have a minimum expected life of 20 years at float operation.
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2.13 Routine Maintenance of Battery system For routine maintenance of battery system, the contractor shall supply 1 set of following tools: a) Torque wrench. b) Cell test voltmeter (-3-0-+3) volts with least count of 0.01Volt. 2.14 Type Test of Battery 2.14.1 Contractor shall submit type test reports of following tests as per IEC 60896-21 & IEC 60896-22, 2004. The type test reports shall be submitted in accordance with the requirements stipulated in clause no. 9.2 of Technical Specification, Section: GTR except that the requirement of tests having been conducted within last five years as mentioned therein shall not be applicable). Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Description of Test Gas Emission High current tolerance Short circuit current and d.c. internal resistance Protection against internal ignition from external spark sources Protection against ground short propensity Content & durability of required markings Material identification Valve operation Flammability rating of materials Intercell connector performance Discharge Capacity Charge retention during storage Float service with daily discharges for reliable mains power Recharge behaviour Service life at an operating temperature of 400 C for brief duration exposure item. Impact of a stress temperature of 600 C for brief duration exposure time with 3 h rate discharge test. Abusive over-discharge Thermal runaway sensitivity Low temperature sensitivity. Dimensional sensitivity at elevated internal pressure and temperature Stability against mechanical abuse of units during installation
Tests shall be conducted in accordance with IEC 60896-21 & IEC 6089622, 2004 2.14.2 List of Factory & Site Tests for Battery Sl. No. 1. 2. 3. Test Physical Verification C/10 Capacity test on the cell 8 Hrs. Charge and 15 minutes discharge test at full rated load Factory Tests Site Tests
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2.15 Installation and commissioning 2.15.1 Manufacturer of Battery shall supervise the installation and commissioning and perform commissioning tests as recommended in O&M manual/or relevant standards. All necessary instruments, material, tools and tackles required for installation, testing at site and commissioning are to be arranged by Battery manufacturer/ Contractor 2.16 Contractor shall submit the following documents for approval: a) b) c) Data sheet as per Annexure-I GA of cell and layout drawing Discharge Data for 10 Hour, 8 Hour, 3 Hour, 2 Hour, 1 Hour, 15 Minutes and One Minute indicating capacity factors for end cell voltage of 1.75 V & 1.85 V. Temperature correction factors Installation and commissioning Instructions O & M Manual
d) e) f) 3.0
Battery Charger The DC system for 220 V DC is unearthed and for 48 V DC is +ve earthed. The Battery Chargers as well as their automatic regulators shall be of static type and shall be compatible with offered VRLA batteries. All battery chargers shall be capable of continuous operation at the respective rated load in float charging mode, i.e. float charging the associated Lead-Acid Batteries at 2.13 to 2.27 Volts per cell while supplying the DC load. The chargers shall also be capable of Boost charging the associated DC Battery at 2.28 to 2.32 volts per cell at the desired rate. Charger shall regulate the float/boost voltage in case of prescribed temperature rise of battery as per manufacturers recommendation to avoid thermal runaway. Necessary temperature sensors shall be provided in mid location of battery banks and shall be wired up to the respective charger for feedback control. The manufacturer shall demonstrate this feature during testing of each charger. 3.1 All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. When on automatic control mode during Float charging, the Charger output voltage shall remain within +1% of the set value, for AC input voltage variation of +10%, frequency variation of +5%, a combined voltage and frequency variation of +10%, and a DC load variation from zero to full load.
3.2 All battery chargers shall have a constant voltage characteristic throughout the range (from zero to full load) at the floating value of the voltage so as to keep the battery fully charged but without harmful overcharge. 3.3 All chargers shall have load limiters having drooping characteristic, which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the Load limiter setting of the Charger. The Load-limiter characteristics shall be such that any sustained overload or short circuit in DC System shall not damage the Charger, nor shall it cause blowing of any of the Charger fuses. The Charger shall not trip on overload or external short circuit.
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3.4 Uniform and step less adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire float charging output range specified. Step less adjustments of the Load-limiter setting shall also be possible from 80% to 100% of the rated output current for charging mode. 3.5 During Boost Charging, the Battery Charger shall operate on constant current mode (when automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. 3.6 The Charger output voltage shall automatically go on rising, when it is operating on Boost mode, as the Battery charges up. For limiting the output voltage of the Charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage any where in the output range specified for Boost Charging mode. 3.7 The Charger manufacturer may offer an arrangement in which the voltage setting device for Float charging mode is also used as output voltage limit setting device for Boost charging mode and the Load-limiter of Float charging mode is used as current setting device in boost charging mode. 3.8 Suitable filter circuits shall be provided in all the chargers to limit the ripple content (Peak to Peak) in the output voltage to 1%, irrespective of the DC load level, when they are not connected to a Battery. MCCB All Battery Chargers shall have 2 Nos. MCCBs on the input side to receive cables from two sources. Mechanical interlock should be provided such that only one shall be closed at a time. It shall be of P2 duty and suitable for continuous duty. MCCBs should have auxiliary contacts for annunciation. 3.10 Rectifier Transformer The rectifier transformer shall be continuously rated, dry air cooled (A.N) and of class F insulation type. The rating of the rectifier transformer shall have 10% overload capacity. 3.11 Rectifier Assembly The rectifier assembly shall be fully/half controlled bridge type and shall be designed to meet the duty as required by the respective Charger. The rectifier shall be provided with heat sink having their own heat dissipation arrangements with natural air cooling. Necessary surge protection devices and rectifier type fast acting HRC fuses shall be provided in each arm of the rectifier connections. 3.12 Instruments One AC voltmeter and one AC ammeter along with selector switches shall be provided for all chargers. One DC voltmeter and DC ammeter (with shunt) shall be provided for all Chargers. The instruments shall be flush type, dust proof and moisture resistant. The instruments shall have easily accessible means for zero adjustment. The instruments shall be of 1.5 accuracy classes. In addition to the above a centre zero voltmeter with selector switch shall also be provided for 220 V chargers for testing purpose.
3.9
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3.13 Air Break Switches One DC output switch shall be provided in all chargers. They shall be air break type suitable for 500 volts AC/ 250 DC. The contacts of the switches shall open and close with a snap action. The operating handle of the switch shall be fully insulated from circuit. ÒN and ÒFF position on the switch shall be clearly indicated. Rating of switches shall be suitable for their continuous load. Alternatively, MCCBs of suitable ratings shall also acceptable in place of Air Break Switch. 3.14 Fuses All fuses shall be HRC Link type. Fuses shall be mounted on fuse carriers which are in turn mounted on fuse bases. Wherever it is not possible to mount fuses on carriers, fuses shall be directly mounted on plug-in type base. In such case one insulated fuse pulling handle shall be supplied for each charger. Fuse rating shall be chosen by the Bidder depending on the circuit requirement. All fuses in the chargers shall be monitored. Fuse failure annunciation shall be provided on the failure of any fuse. 3.15 Blocking Diode Blocking diode shall be provided in the positive pole of the output circuit of each charger to prevent current flow from the DC Battery into the Charger. 3.16 Annunciation System Audio-visual indications through bright LEDs shall be provided in all Chargers for the following abnormalities: a) b) c) d) e) AC power failure Rectifier/chargers fuse blown. Over voltage across the battery when boost charging. Abnormal voltage (High/Low) Any other annunciation if required.
Potential free NO Contacts of above abnormal conditions shall also be provided for common remote indication CHARGER TROUBLE in Owners Control Board. Indication for charger in float mode and boost mode through indication lamps shall be provided for chargers. A potential free contact for float/boost mode shall be provided for external interlocks. 3.17 Name Plates and Marking The name plates shall be white with black engraved letters. On top of each Charger, on front as well as rear sides, larger and bold name plates shall be provided to identify the Charger. Name plates with full and clear inscriptions shall also be provided on and inside of the panels for identification of the various equipments and ease of operation and maintenance. 3.18 Charger Construction The Chargers shall be indoor, floor-mounted, self-supporting sheet metal enclosed cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and hardware. The Chargers shall be fabricated from 2.0mm cold rolled sheet steel and shall have folded type of construction. Removable gland plates for all cables and lugs for power cables shall be supplied by the Contractor. The lugs for power cables shall be made of electrolytic copper with tin coat. Power cable sizes shall be advised to the Contractor at a later date for provision
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of suitable lugs and drilling of gland plates. The Charger shall be tropicalised and vermin proof. Ventilation louvers, if provided shall be backed with screens. All doors and covers shall be fitted with synthetic rubber gaskets. The chargers shall have hinged double leaf doors provided on front and on backside for adequate access to the Chargers internals. All the charger cubicle doors shall be properly earthed. The degree of protection of Charger enclosure shall be at least IP-42 as per IS: 13947 Part I. 3.18.1 3.18.2 All indicating instruments, control switches and indicating lamps shall be mounted on the front side of the Charger. Each Charger shall be furnished completely wired up to power cable lugs and terminal blocks and ready for external connections. The control wiring shall be carried out with PVC insulated, 1.5 sq. mm. stranded copper wires. Control terminals shall be suitable for connecting two wires, with 2.5 sq. mm stranded copper conductors. All terminals shall be numbered for ease of connections and identification. Each wire shall bear a ferrule or tag on each end for identification. At least 20% spare terminals shall be provided for control circuits. The insulation of all circuits, except the low voltage electronic circuits shall withstand test voltage of 2 KV AC for one minute. An air clearance of at least ten (10) mm shall be maintained throughout for such circuits, right up to the terminal lugs. Whenever this clearance is not available, the live parts shall be insulated or shrouded.
3.18.3
3.19 Painting All sheet steel work shall be pre-treated, 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 phosphate coating shall be `Class-C as specified in IS: 6005. Welding shall not be done after phosphating. The phosphating surfaces shall be rinsed and passivated prior to application of stoved lead oxide primer coating. After primer application, two coats of finishing synthetic enamel paint of shade-692 (smoke grey) of IS: 5 shall be applied, unless required otherwise by the Owner. The inside of the chargers shall be glossy white. Each coat of finishing synthetic enamel paint shall be properly staved. The paint thickness shall not be less than fifty (50) microns. 3.20 TESTS 3.20.1 Battery chargers shall conform to all type tests as per relevant Indian Standard. Performance test on the Chargers as per Specification shall also be carried out on each Charger as per specification. Rectifier transformer shall conform to all type tests specified in IS: 4540 and short circuit test as per IS: 2026. Following type tests shall be carried out for compliance of specification requirements: i) ii) iii) iv) v) vi)
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Voltage regulation test Load limiter characteristics test Efficiency tests High voltage tests Temperature rise test Short circuit test at no load and full load at rated voltage for sustained short-circuit.
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vii) Degree of protection test viii) Measurement of ripple by oscilloscope. ix) Temperature compensation feature demonstration
3.20.2 The Contractor may be required to demonstrate to the OWNER that the Chargers conform to the specification particularly regarding continuous rating, ripple free output, voltage regulation and load limiting characteristic, before despatch as well as after installation at site. At site the following tests shall be carried out: i) ii) Insulation resistance test Checking of proper annunciation system operation.
3.20.3 If a Charger fails to meet the specified requirements, the Contractor shall replace the same with appropriate Charger without affecting the commissioning schedule of the Sub-station, and without any extra cost to the OWNER. 3.20.4 The Contractor shall present for inspection, the type and routine test certificates for the following components whenever required by the OWNER. (i) (ii) Switches. Relays/ MCCBs
(iii) Instruments. (iv) DC fuses. (v) SCR.
(vi) Diodes. (vii) Condensers. (viii) Potentiometers. (ix) Semiconductor (x) Annunciator.
(xi) Control wiring (xii) Push buttons and contactors. Makes of above equipment shall be subject to Owners approval.
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Annexure-I BATTERY SYSTEM DATA SHEETS Sl. Description of Data No. 1. General Data a) Battery Type: Grid alloy: Pure lead (Pb), Lead calcium (Pb-Ca), lead antimony (Pb-Sb), Or lead selenium (Pb-Se) or other pl. specify Sellers type number Number of positive plates per cell b) Does each battery and battery (rack)/(Cabinet) meet the seismic requirements c) Manufacturers Designed Life of Battery d) Recommended Battery Charger Data: Floating charge Boost charge Current rating Recharge time e) Heat Released During: Discharge duty cycle Float charge Boost charge f) Maximum Amount of Hydrogen Gas Evolved During Battery-Boost Charge (2.33 V per cell) at Maximum Battery Temperature Hydrogen Gas Evolution at Float g) Time Battery may be stored without a Freshening Charge h) Temperature Compensation Provided and its Details 2. Physical Description a) Battery Cell: Size (L x W x H) Weight Volume of electrolyte gal
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Unit
220 V/110 V
48 V
[Yes] [No]
Yrs
V V Amps. Hr. Watt Watt Watt
(Litre/h)
(Litre/h) months
Mm Kg L
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b)
c)
d)
e)
f) g)
Jar cover material Jar container material Separator material Retainer material Limiting-oxygen index (LOI) Battery [Rack] [Cabinet]: Outline or catalog number Quantity of [racks][cabinets] for the battery Description (tier or step type) Total Net Weight of kG. Battery including [Racks][Cabinets] Total Shipping weight of KG. each Battery Jar and Associated Equipment Connectors: Intercell: Type Material No. per Connection Inter-[Tier][Step:] Type Material No. per connection Terminal Detail: Type Material Terminal Lugs for Power Cable: Torque Data:
Initial Torque Value
Retorque Value
Retorque Value
3.
Intercell Connectors Inter-[Tier][Step]: Performance Data Battery String Designation No. [1][ ] Float Voltage without Boost Float Voltage with Boost Boost Charge Voltage Recommended Frequency of Boost Charge Recommended Duration of Boost Charge Open-Circuit Voltage
V/cell V/cell V/cell
V/cell
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4.
Short-Circuit Current (at Battery Terminals at Float Voltage at (27C): Battery Discharge Characteristics Guaranteed Amp-Hour Capacity (at the 10-hr rate) to Specified Final Voltage One-minute Fifteen-minute One-hour Two-hour Three-hour Eight-hour Ten-hour Required operating environment Battery Room Ambient Temperature Range Battery Room Ambient Design Temperature Battery Room Minimum/Maximum Design Temperature Maximum temperature at which battery can be stored
A or A/ positive plate AH
A/cell A/cell A/cell A/cell A/cell A/cell A/cell
(C to C) C (C to C)
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BATTERY & BATTERY CHARGER
(B&BC)
Part-III (Vol. 2/2)
164
CHAPTER - BATTERY AND BATTERY CHARGER

TECHNICAL SPECIFICATION FOR BATTERY AN BATTERY CHARGER
CONTENTS
Clause No. 1.0 2.0 3.0 Description General Technical Requirements Battery Battery Charger Annexure-I Page No. 165 165 169 174
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CHAPTER B&BC
SECTION: BATTERY & BATTERY CHARGER

1.0 GENERAL TECHNICAL REQUIREMENTS 1.1 All materials/components used in battery chargers and batteries shall be free from flaws and defects and shall conform to the relevant Indian/IEC standards and good engineering practice. 1.1.1 For 132 kV sub-stations, DC System shall consist of two (2) float-cumboost chargers and two (2) battery sets for 220V/110V system. For 48 V systems, DC scheme shall consist of one (1) battery and two (2) float-cumboost chargers. The standard scheme drawing shall be enclosed/furnished by the contractor with the bid document. 1.1.2 Bidder shall select number of cells, float and Boost voltage to achieve following system requirement: System Voltage Maximum Voltage during Float operation 220 Volt 242 Volt 110 Volt 121 Volt 48 Volt 52.8 Volt Minimum voltage available when no charger working and battery fully discharged up to 1.85 V per cell. 198 Volt 99 Volt 43.2 Volt Minimum Nos. of cell 107 54 23
Bidder shall furnish calculation in support of battery sizing, selection of number of cells, float and Boost voltages during detailed engineering for Owners acceptance. Battery sizing calculations shall be done as per IEEE- 485 on the basis of following duty cycle: Load Continuous Load 220 V DC System Duration 3 hours Type of Loads Relays, IEDs, Station HMIs, spring charging, Isolator interlocking load, miscellaneous permanently connected loads etc. Sub-Station emergency lighting loads. Breaker closing, Tripping loads (taking simultaneous occurrence as per system) Continuous load associated with PLCs (when speech is not working Loads associated with PLCs (when speech is working)
Emergency Load Momentary Load
1 hour 1 minute
Continuous Load 48 V DC System
3 hours
Momentary Load
15 minute
2.0 Battery 2.1 Type The DC Batteries shall be VRLA (Valve Regulated Lead-Acid) type and shall be Normal Discharge type. These shall be suitable for a long life under continuous float operations and occasional discharges. Air-conditioning shall be provided in Battery room the requirement of which has been specified elsewhere in the Technical Specification. The 220 V DC system is unearth and 48 V DC system is + ve earth system.
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2.2 Constructional Requirements The design of battery shall be as per field proven practices. Partial plating of cells is not permitted. Paralleling of cells externally for enhancement of capacity is not permitted. Protective transparent front covers with each module shall be provided to prevent accidental contact with live module/electrical connections. 2.3 Containers The container material shall have chemical and electro-chemical compatibility and shall be acid resistant. The material shall meet all the requirements of VRLA batteries and be consistent with the life of battery. The container shall be fire retardant and shall have an Oxygen Index of at least 28 %. The porosity of the container shall be such as not to allow any gases to escape except from the regulation valve. The tensile strength of the material of the container shall be such as to handle the internal cell pressure of the cells in the worst working condition. Cell shall not show any deformity or bulge on the sides under all working conditions. The container shall be capable of withstanding the rigours of transport, storage and handling. The containers shall be enclosed in a steel tray. 2.4 Cell Covers The cell covers shall be made of suitable material compatible with the container material and permanently fixed with the container. It shall be capable to withstand internal pressure without bulging or cracking. It shall also be fire retardant. Fixing of Pressure Regulation Valve & terminal posts in the cover shall be such that the seepage of electrolyte, gas escapes and entry of electro-static spark are prevented. 2.5 Separators The separators used in manufacturing of battery cells, shall be of glass mat or synthetic material having high acid absorption capability, resistant to sulphuric acid and good insulating properties. The design of separators shall ensure that there is no misalignment during normal operation and handling. 2.6 Pressure Regulation Valve Each cell shall be provided with a pressure regulation valve. The valve shall be self re-sealable and flame retardant. The valve unit shall be such that it cannot be opened without a proper tool. The valve shall be capable to withstand the internal cell pressure specified by the manufacturer. 2.7 Terminal Posts Both the +ve and ve terminals of the cells shall be capable of proper termination and shall ensure its consistency with the life of the battery. The surface of the terminal post extending above the cell cover including bolt hole shall be coated with an acid resistant and corrosion retarding material. Terminal posts or any other metal part which is in contact with the electrolyte shall be made of the same alloy as that of the plates or of a proven material that does not have any harmful effect on cell performance. Both +ve and ve posts shall be clearly and unambiguously identifiable. 2.8 Connectors, Nuts & Bolts, Heat Shrinkable Sleeves Where it is not possible to bolt the cell terminals directly to assemble a battery, separate non-corroding lead or copper connectors of suitable size shall be provided to enable connection of the cells. Copper connections shall be suitably lead coated to withstand corrosion due to sulphuric acid at a very high rate of charge or discharge. Nuts and bolts for connecting the cells shall be made of
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copper, brass or stainless steel. Copper or brass nuts and bolts shall be effectively lead coated to prevent corrosion. Stainless steel bolts and nuts can be used without lead coating. All inter cell connectors shall be protected with heat shrinkable silicon sleeves for reducing the environmental impact including a corrosive environment. 2.9 Flame Arrestors Each cell shall be equipped with a Flame Arrestor to defuse the Hydrogen gas escaped during charge and discharge. Material of the flame arrestor shall not affect the performance of the cell. 2.10 Battery Bank Stand All batteries shall be mounted in a suitable metallic stand/frame. The frame shall be properly painted with the acid resistant paint. The suitable insulation shall be provided between stand/frame and floor to avoid the grounding of the frame/stand. 2.11 Capacity Requirements When the battery is discharged at 10 hour rate, it shall deliver 80% of C (rated capacity, corrected at 27 Celsius) before any of the cells in the battery bank reaches 1.85V/cell. The battery shall be capable of being recharged from the fully exhausted condition (1.75V/cell) within 10 hrs up to 90% state of charge. All the cells in a battery shall be designed for continuous float operation at the specified float voltage throughout the life. The capacity (corrected at 27Celcius) shall also not be less than C and not more than 120% of C before any cell in the battery bank reaches 1.75V/cell. The battery voltage shall not be less than the following values, when a fully charged battery is put to discharge at C/10 rate: (a) (b) (c) (d) After Six minutes of discharge: After Six hours of discharge: After 8 hours of discharge: After 10 hours of discharge: 1.98V/cell 1.92V/cell 1.85V/cell 1.75V/cell
Loss in capacity during storage at an average ambient temperature of 35C for a period of 6 months shall not be more than 60% and the cell/battery shall achieve 85% of its rated capacity within 3 charge/discharge cycles and full rated capacity within 5 cycles, after the storage period of 6 months. Voltage of each cell in the battery set shall be within 0.05V of the average voltage throughout the storage period. Ampere hour efficiency shall be better than 90% and watt hour efficiency shall be better than 80%. 2.12 Expected Battery Life The battery shall be capable of giving 1200 or more charge/discharge cycles at 80% Depth of discharge (DOD) at an average temperature of 27 Celsius. DOD (Depth of Discharge) is defined as the ratio of the quantity of electricity (in Ampere-hour) removed from a cell or battery on discharge to its rated capacity. The battery sets shall have a minimum expected life of 20 years at float operation.
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2.13 Routine Maintenance of Battery system For routine maintenance of battery system, the contractor shall supply 1 set of following tools: a) Torque wrench. b) Cell test voltmeter (-3-0-+3) volts with least count of 0.01Volt. 2.14 Type Test of Battery 2.14.1 Contractor shall submit type test reports of following tests as per IEC 60896-21 & IEC 60896-22, 2004. The type test reports shall be submitted in accordance with the requirements stipulated in clause no. 9.2 of Technical Specification, Section: GTR except that the requirement of tests having been conducted within last five years as mentioned therein shall not be applicable). Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Description of Test Gas Emission High current tolerance Short circuit current and d.c. internal resistance Protection against internal ignition from external spark sources Protection against ground short propensity Content & durability of required markings Material identification Valve operation Flammability rating of materials Intercell connector performance Discharge Capacity Charge retention during storage Float service with daily discharges for reliable mains power Recharge behaviour Service life at an operating temperature of 400 C for brief duration exposure item. Impact of a stress temperature of 600 C for brief duration exposure time with 3 h rate discharge test. Abusive over-discharge Thermal runaway sensitivity Low temperature sensitivity. Dimensional sensitivity at elevated internal pressure and temperature Stability against mechanical abuse of units during installation
Tests shall be conducted in accordance with IEC 60896-21 & IEC 6089622, 2004 2.14.2 List of Factory & Site Tests for Battery Sl. No. 1. 2. 3. Test Physical Verification C/10 Capacity test on the cell 8 Hrs. Charge and 15 minutes discharge test at full rated load Factory Tests Site Tests
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2.15 Installation and commissioning 2.15.1 Manufacturer of Battery shall supervise the installation and commissioning and perform commissioning tests as recommended in O&M manual/or relevant standards. All necessary instruments, material, tools and tackles required for installation, testing at site and commissioning are to be arranged by Battery manufacturer/ Contractor 2.16 Contractor shall submit the following documents for approval: a) b) c) Data sheet as per Annexure-I GA of cell and layout drawing Discharge Data for 10 Hour, 8 Hour, 3 Hour, 2 Hour, 1 Hour, 15 Minutes and One Minute indicating capacity factors for end cell voltage of 1.75 V & 1.85 V. Temperature correction factors Installation and commissioning Instructions O & M Manual
d) e) f) 3.0
Battery Charger The DC system for 220 V DC is unearthed and for 48 V DC is +ve earthed. The Battery Chargers as well as their automatic regulators shall be of static type and shall be compatible with offered VRLA batteries. All battery chargers shall be capable of continuous operation at the respective rated load in float charging mode, i.e. float charging the associated Lead-Acid Batteries at 2.13 to 2.27 Volts per cell while supplying the DC load. The chargers shall also be capable of Boost charging the associated DC Battery at 2.28 to 2.32 volts per cell at the desired rate. Charger shall regulate the float/boost voltage in case of prescribed temperature rise of battery as per manufacturers recommendation to avoid thermal runaway. Necessary temperature sensors shall be provided in mid location of battery banks and shall be wired up to the respective charger for feedback control. The manufacturer shall demonstrate this feature during testing of each charger. 3.1 All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. When on automatic control mode during Float charging, the Charger output voltage shall remain within +1% of the set value, for AC input voltage variation of +10%, frequency variation of +5%, a combined voltage and frequency variation of +10%, and a DC load variation from zero to full load.
3.2 All battery chargers shall have a constant voltage characteristic throughout the range (from zero to full load) at the floating value of the voltage so as to keep the battery fully charged but without harmful overcharge. 3.3 All chargers shall have load limiters having drooping characteristic, which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the Load limiter setting of the Charger. The Load-limiter characteristics shall be such that any sustained overload or short circuit in DC System shall not damage the Charger, nor shall it cause blowing of any of the Charger fuses. The Charger shall not trip on overload or external short circuit.
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3.4 Uniform and step less adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire float charging output range specified. Step less adjustments of the Load-limiter setting shall also be possible from 80% to 100% of the rated output current for charging mode. 3.5 During Boost Charging, the Battery Charger shall operate on constant current mode (when automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. 3.6 The Charger output voltage shall automatically go on rising, when it is operating on Boost mode, as the Battery charges up. For limiting the output voltage of the Charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage any where in the output range specified for Boost Charging mode. 3.7 The Charger manufacturer may offer an arrangement in which the voltage setting device for Float charging mode is also used as output voltage limit setting device for Boost charging mode and the Load-limiter of Float charging mode is used as current setting device in boost charging mode. 3.8 Suitable filter circuits shall be provided in all the chargers to limit the ripple content (Peak to Peak) in the output voltage to 1%, irrespective of the DC load level, when they are not connected to a Battery. MCCB All Battery Chargers shall have 2 Nos. MCCBs on the input side to receive cables from two sources. Mechanical interlock should be provided such that only one shall be closed at a time. It shall be of P2 duty and suitable for continuous duty. MCCBs should have auxiliary contacts for annunciation. 3.10 Rectifier Transformer The rectifier transformer shall be continuously rated, dry air cooled (A.N) and of class F insulation type. The rating of the rectifier transformer shall have 10% overload capacity. 3.11 Rectifier Assembly The rectifier assembly shall be fully/half controlled bridge type and shall be designed to meet the duty as required by the respective Charger. The rectifier shall be provided with heat sink having their own heat dissipation arrangements with natural air cooling. Necessary surge protection devices and rectifier type fast acting HRC fuses shall be provided in each arm of the rectifier connections. 3.12 Instruments One AC voltmeter and one AC ammeter along with selector switches shall be provided for all chargers. One DC voltmeter and DC ammeter (with shunt) shall be provided for all Chargers. The instruments shall be flush type, dust proof and moisture resistant. The instruments shall have easily accessible means for zero adjustment. The instruments shall be of 1.5 accuracy classes. In addition to the above a centre zero voltmeter with selector switch shall also be provided for 220 V chargers for testing purpose.
3.9
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3.13 Air Break Switches One DC output switch shall be provided in all chargers. They shall be air break type suitable for 500 volts AC/ 250 DC. The contacts of the switches shall open and close with a snap action. The operating handle of the switch shall be fully insulated from circuit. ÒN and ÒFF position on the switch shall be clearly indicated. Rating of switches shall be suitable for their continuous load. Alternatively, MCCBs of suitable ratings shall also acceptable in place of Air Break Switch. 3.14 Fuses All fuses shall be HRC Link type. Fuses shall be mounted on fuse carriers which are in turn mounted on fuse bases. Wherever it is not possible to mount fuses on carriers, fuses shall be directly mounted on plug-in type base. In such case one insulated fuse pulling handle shall be supplied for each charger. Fuse rating shall be chosen by the Bidder depending on the circuit requirement. All fuses in the chargers shall be monitored. Fuse failure annunciation shall be provided on the failure of any fuse. 3.15 Blocking Diode Blocking diode shall be provided in the positive pole of the output circuit of each charger to prevent current flow from the DC Battery into the Charger. 3.16 Annunciation System Audio-visual indications through bright LEDs shall be provided in all Chargers for the following abnormalities: a) b) c) d) e) AC power failure Rectifier/chargers fuse blown. Over voltage across the battery when boost charging. Abnormal voltage (High/Low) Any other annunciation if required.
Potential free NO Contacts of above abnormal conditions shall also be provided for common remote indication CHARGER TROUBLE in Owners Control Board. Indication for charger in float mode and boost mode through indication lamps shall be provided for chargers. A potential free contact for float/boost mode shall be provided for external interlocks. 3.17 Name Plates and Marking The name plates shall be white with black engraved letters. On top of each Charger, on front as well as rear sides, larger and bold name plates shall be provided to identify the Charger. Name plates with full and clear inscriptions shall also be provided on and inside of the panels for identification of the various equipments and ease of operation and maintenance. 3.18 Charger Construction The Chargers shall be indoor, floor-mounted, self-supporting sheet metal enclosed cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and hardware. The Chargers shall be fabricated from 2.0mm cold rolled sheet steel and shall have folded type of construction. Removable gland plates for all cables and lugs for power cables shall be supplied by the Contractor. The lugs for power cables shall be made of electrolytic copper with tin coat. Power cable sizes shall be advised to the Contractor at a later date for provision
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of suitable lugs and drilling of gland plates. The Charger shall be tropicalised and vermin proof. Ventilation louvers, if provided shall be backed with screens. All doors and covers shall be fitted with synthetic rubber gaskets. The chargers shall have hinged double leaf doors provided on front and on backside for adequate access to the Chargers internals. All the charger cubicle doors shall be properly earthed. The degree of protection of Charger enclosure shall be at least IP-42 as per IS: 13947 Part I. 3.18.1 3.18.2 All indicating instruments, control switches and indicating lamps shall be mounted on the front side of the Charger. Each Charger shall be furnished completely wired up to power cable lugs and terminal blocks and ready for external connections. The control wiring shall be carried out with PVC insulated, 1.5 sq. mm. stranded copper wires. Control terminals shall be suitable for connecting two wires, with 2.5 sq. mm stranded copper conductors. All terminals shall be numbered for ease of connections and identification. Each wire shall bear a ferrule or tag on each end for identification. At least 20% spare terminals shall be provided for control circuits. The insulation of all circuits, except the low voltage electronic circuits shall withstand test voltage of 2 KV AC for one minute. An air clearance of at least ten (10) mm shall be maintained throughout for such circuits, right up to the terminal lugs. Whenever this clearance is not available, the live parts shall be insulated or shrouded.
3.18.3
3.19 Painting All sheet steel work shall be pre-treated, 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 phosphate coating shall be `Class-C as specified in IS: 6005. Welding shall not be done after phosphating. The phosphating surfaces shall be rinsed and passivated prior to application of stoved lead oxide primer coating. After primer application, two coats of finishing synthetic enamel paint of shade-692 (smoke grey) of IS: 5 shall be applied, unless required otherwise by the Owner. The inside of the chargers shall be glossy white. Each coat of finishing synthetic enamel paint shall be properly staved. The paint thickness shall not be less than fifty (50) microns. 3.20 TESTS 3.20.1 Battery chargers shall conform to all type tests as per relevant Indian Standard. Performance test on the Chargers as per Specification shall also be carried out on each Charger as per specification. Rectifier transformer shall conform to all type tests specified in IS: 4540 and short circuit test as per IS: 2026. Following type tests shall be carried out for compliance of specification requirements: i) ii) iii) iv) v) vi)
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Voltage regulation test Load limiter characteristics test Efficiency tests High voltage tests Temperature rise test Short circuit test at no load and full load at rated voltage for sustained short-circuit.
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vii) Degree of protection test viii) Measurement of ripple by oscilloscope. ix) Temperature compensation feature demonstration
3.20.2 The Contractor may be required to demonstrate to the OWNER that the Chargers conform to the specification particularly regarding continuous rating, ripple free output, voltage regulation and load limiting characteristic, before despatch as well as after installation at site. At site the following tests shall be carried out: i) ii) Insulation resistance test Checking of proper annunciation system operation.
3.20.3 If a Charger fails to meet the specified requirements, the Contractor shall replace the same with appropriate Charger without affecting the commissioning schedule of the Sub-station, and without any extra cost to the OWNER. 3.20.4 The Contractor shall present for inspection, the type and routine test certificates for the following components whenever required by the OWNER. (i) (ii) Switches. Relays/ MCCBs
(iii) Instruments. (iv) DC fuses. (v) SCR.
(vi) Diodes. (vii) Condensers. (viii) Potentiometers. (ix) Semiconductor (x) Annunciator.
(xi) Control wiring (xii) Push buttons and contactors. Makes of above equipment shall be subject to Owners approval.
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Annexure-I BATTERY SYSTEM DATA SHEETS Sl. Description of Data No. 1. General Data a) Battery Type: Grid alloy: Pure lead (Pb), Lead calcium (Pb-Ca), lead antimony (Pb-Sb), Or lead selenium (Pb-Se) or other pl. specify Sellers type number Number of positive plates per cell b) Does each battery and battery (rack)/(Cabinet) meet the seismic requirements c) Manufacturers Designed Life of Battery d) Recommended Battery Charger Data: Floating charge Boost charge Current rating Recharge time e) Heat Released During: Discharge duty cycle Float charge Boost charge f) Maximum Amount of Hydrogen Gas Evolved During Battery-Boost Charge (2.33 V per cell) at Maximum Battery Temperature Hydrogen Gas Evolution at Float g) Time Battery may be stored without a Freshening Charge h) Temperature Compensation Provided and its Details 2. Physical Description a) Battery Cell: Size (L x W x H) Weight Volume of electrolyte gal
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Unit
220 V/110 V
48 V
[Yes] [No]
Yrs
V V Amps. Hr. Watt Watt Watt
(Litre/h)
(Litre/h) months
Mm Kg L
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b)
c)
d)
e)
f) g)
Jar cover material Jar container material Separator material Retainer material Limiting-oxygen index (LOI) Battery [Rack] [Cabinet]: Outline or catalog number Quantity of [racks][cabinets] for the battery Description (tier or step type) Total Net Weight of kG. Battery including [Racks][Cabinets] Total Shipping weight of KG. each Battery Jar and Associated Equipment Connectors: Intercell: Type Material No. per Connection Inter-[Tier][Step:] Type Material No. per connection Terminal Detail: Type Material Terminal Lugs for Power Cable: Torque Data:
Retorque Value
Retorque Value
3.
Intercell Connectors Inter-[Tier][Step]: Performance Data Battery String Designation No. [1][ ] Float Voltage without Boost Float Voltage with Boost Boost Charge Voltage Recommended Frequency of Boost Charge Recommended Duration of Boost Charge Open-Circuit Voltage
V/cell V/cell V/cell
V/cell
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4.
Short-Circuit Current (at Battery Terminals at Float Voltage at (27C): Battery Discharge Characteristics Guaranteed Amp-Hour Capacity (at the 10-hr rate) to Specified Final Voltage One-minute Fifteen-minute One-hour Two-hour Three-hour Eight-hour Ten-hour Required operating environment Battery Room Ambient Temperature Range Battery Room Ambient Design Temperature Battery Room Minimum/Maximum Design Temperature Maximum temperature at which battery can be stored
A or A/ positive plate AH
A/cell A/cell A/cell A/cell A/cell A/cell A/cell
(C to C) C (C to C)
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LT TRANSFORMER
(LT TF)
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Section-Technical Specification- LT Transformer
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CHAPTER - LT TRANSFORMER TECHNICAL SPECIFICATION FOR LT TRANSFORMER
CONTENTS
Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 Description Intent Scope of Work General Information Technical Requirements Inspection and Testing Inspection Factory Test Fittings Spare Parts Technical Parameters Page No. 179 179 179 179 180 180 181 182 183 183
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CHAPTER - LT TRANSFORMER SECTION: LT TRANSFORMER 1.0 INTENT This specification is intended to cover outdoor type oil filled 33/0.433KV, 250 kVA transformer. 2.0 Scope of Work 2.1 2.2 Scope of Supply Transformers as listed above, with insulating oil, all materials and accessories, and complete in all respects. Gland plates, power cable, lugs, anchor bolts and hardwares. Mandatory & optional spares and special maintenance equipments if any. Scope of Service The scope includes but is not limited to the following items of work to be performed for all equipment and materials furnished under this section: a) b) c) d) e) f) 3.0 Design, manufacturing, shop testing, packing & despatch Transportation inclusive of insurance and delivery, FOR site basis Unloading, handling, storing, transportation at site up to foundations, oil filling and treatment, erection, testing and commissioning Civil Works Supply of external cables and termination as required. Fire protection system.
General Information 3.1 All temperature indicators, Buchholz relays and other auxiliary devices shall be suitable for 220 V DC Control supply. All alarm and trip Contacts shall also be suitable for connection in 220V DC Circuits. 3.2 Bidders may specifically note that Purchaser proposes to insist on short circuit test as per Clause 16.11 of IS: 2026 (Part-I)-1977 and dielectric test as per IS2026. Any deviation in this regard shall be sufficient ground for rejection of the bid.
4.0
TECHNICAL REQUIREMENTS 4.1 Core The core shall be constructed from high grade, nonaging, cold rolled grainoriented silicon steel laminations. The maximum flux density in any part of the cores and yoke at normal voltage and frequency shall be such that the flux density at any tap position with 10% voltage variation from the voltage corresponding to the tap shall not exceed 1.9 Wb/sq-m. 4.2 Windings The conductor shall be of electrolytic copper, free from scales and burrs.
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4.3 Insulating Oil The oil supplied with transformer shall be unused and have the parameters for unused new oil conforming to IS: 335 while tested at oil Contractor's premises, No inhibitors shall be used in oil. Ten percent extra oil shall be supplied for topping up after commissioning in non returnable containers suitable for outdoor storage. 4.4 Terminal Arrangement a) Bushing terminals shall be provided with suitable terminal connectors of approved type and size for cable/overhead conductors termination of HV side and cable termination on LV side. The neutral terminals of 433V winding shall be brought out on a bushing along with the 433 volt phase terminals to form a 4 wire system for the 415 volt. Additional neutral bushing shall also be provided for earthing.
b)
4.5 Of f Circuit Tap Changing Equipment The tap change switch shall be three phase, hand operated for simultaneous switching of similar taps on the three phases by operating an external hand wheel. 4.6 Marshalling Box A metal enclosed, weather, vermin & dust proof marshalling box shall be provided with each transformer to accommodate temperature indicators, terminal blocks etc. It shall have a degree of protection of IP: 55 as per IS: 2147 4.7 Cable boxes Whenever cable connections are required, suitable cable boxes shall be provided and shall be air insulated. They shall be of sufficient size to accommodate Purchasers cables and shall have suitable removable side/top cover to facilitate cable termination and inspection. Cable boxes shall be dust & vermin proof. 5.0 Inspection and Testing a) The Contractor shall draw up and carry out a comprehensive inspection and testing program during manufacture and commissioning of the transformer. The programme shall be duly approved by the Purchaser. The Contractor shall carryout all type tests and routine tests on the transformers as per relevant standards. Type tests shall be carried out on one transformer of each type and routine tests shall be carried out on all transformers.
b)
6.0
Inspection 6.1 Tank and Accessories a) b) 6.2 Core a) b) c) Physical inspection and check of quality of varnish, if used. Sample testing of core material for checking specific loss, bend properties, magnestisation, characteristics and thickness. Check on completed core for measurement of iron loss and check for any hot spot by exciting the core so as to induce the designed value of flux density in the core.
Physical and dimensional check of transformer tank and accessories. Crack detection of major strength weld seams by dye penetration test.
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d)
HV Test
6.3 Insulating Material a) b) c) Sample checks for physical properties of the material Check for dielectric strength Check for the reaction of hot oil on insulating material
6.4 Winding a) b) Sample check on winding conductor for mechanical and electrical conductivity and on installation covering. properties
Sample check on insulation paper for pH value, Bursting strength, Electric strength.
6.5 Assembled Transformer a) b) 6.6 Oil All standard tests in accordance with relevant Standards shall be carried out on oil samples taken from the transformer before and after testing of the transformer. The contractor shall also prepare a comprehensive inspection and testing programme for all bought out sub-contracted items and shall submit the same to the Purchaser for approval. Such programme shall include the following components: a) b) c) d) e) f) 7.0 Buchholz Relay Winding temperature Indicator Bushings Marshaling Box Tap changer switch Oil temperature indicator Check complete transformer against approved outline drawing provision for all fittings, finish etc. Jacking test on all the assembled transformers.
Factory Test 7.1 All standard routine tests in accordance with latest issue of IS: 2026 shall be carried out on each transformer. 7.2 All the type tests in accordance with latest issues of IS: 2026 shall be conducted on one transformer of each rating. 7.3 In addition to all type and routine tests, following additional type tests shall also be carried out on one transformer of each rating as per IS : 2026. a) b) c) d) e) Measurement of zero sequence impedance Short circuit test Measurement of acoustic noise level. This shall conform to NEMA standard publication TR-1. Measurement of capacitance and tan delta of transformer winding. Test on oil samples.
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Sequence of testing shall be mutually agreed between Purchaser and Contractor after award. 7.4 All auxiliary equipment shall be tested as per the relevant IS Test Certificates shall be submitted for bought out items. 7.5 High voltage withstand test shall be performed on auxiliary equipment and wiring after complete assembly. 7.6 Tank Tests: a) b) Routine Tests: As per CBIP Manual on Transformers Type Tests: i) ii) Vacuum Tests: As per CBIP Manual on Transformers Pressure Test: As per CBIP Manual on Transformers
7.7 In addition to the above, the following checks should be carried out at manufacturer's works before despatch for all transformers: a) b) Check for interchangeability of components of similar transformers and for mounting dimensions. Check for proper packing and preservation of accessories like radiators, bushings explosion vent, dehydrating breather, Buchholz relay, conservator etc. Check for proper provision of bracings to arrest the movements of core and winding assembly inside the tank. Test for gas tightness and derivation of leakage rate. To ensure adequate reserve gas capacity during transit and storage.
c) d)
7.8 The Contractor shall submit a detailed inspection and testing programme for field activities, covering areas right from the receipt of material stage up to commissioning stage as per IS : 1886 - Code of practice for installation and maintenance of transformers. The indicative checks and tests are given below. a) b) c) d) e) f) g) h) 8.0 Fittings The following fittings shall be provided with each transformer covered under this specification. i) ii) iii) Conservator with drain plug and oil filling hole with blanking plate Plain oil Gauge Silica gel Breather
Physical checks on each transformer on receipt at site for any damage or short supply. Tests on oil samples Oil leakage test Physical checks for colour of silica in breather Check for oil level in breather housing, conservator tank, etc. Check for correct operation of all protections and alarms. Insulation Resistance Measurement for Main Winding, control wiring etc. Continuously observe the transformer operation at no load for 24 hour s.
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iv) v) vi)
Pressure Relief vent Pocket on tank cover for Thermometer Valves
vii) Earthing Terminals viii) Rating & Terminal Marking Plates ix) x) xi) Lifting Lugs Rollers Air Release Plug
The fittings listed above are only indicative and any other fittings which generally are required for satisfactory operation of transformer are deemed to be included. 9.0 Spare Parts 9.1 The list of spares for outdoor type transformers covered under this section shall be as specified in Section-Project 9.2 In addition, the Bidder shall also recommend optional spare parts and maintenance equipment necessary for three (3) years of successful operation of the equipment. The prices of these shall be indicated in respective schedules and these shall not be considered for the purpose of evaluation.
10.0 Technical Parameters

Sl. No. Description Parameters
a) b) c) d) e) f) g) h) i) j) i) ii) k) i) ii) iii) iv) v)
Type Service Number of phases Frequency Type of Cooling Rating Ratio Impedance at 75oC with tolerance Duty Overload Maximum Temp. rise over 50oC Oil (Temp. rise measurement by thermometer) Winding (Temp. rise measured by resistance method) Windings System Apparent short circuit level (kA) Winding connection Vector Group Insulation Insulation level (kV)
Two winding Outdoor Three 50 Hz ONAN 250 kVA 33/0.433 kVA 0.05 10% Continuous As per IS: 6600 50oC 55oC 33 kV 250 kVA As per IS: 2026 (Part-I) Delta Dynl Uniform 36
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a) Power frequency test level (kV rms) b) Basic impulse level (kV peak) vi) Highest voltage (kV) for each winding vii) Method of earthing l) Tap Changer i) Tap range ii) Tap control m) H.V. Bushings
70 170 36 Solidly earthed +5%/-10% in steps of 2.5% on HV side Off circuit tap change switch 250 kVA 33 kV 36 100 A 170 70 900 Tank/Transformer body 1100 1000 Suitable for 33 kV/11 kV cable or O/H Conductor Cable box 33 kV 250 kVA 350 320
i) ii) iii) iv) v) vi) n) i) ii) o) i) ii) p) i) ii)
Rated Voltage, kV Rated current, kV Basic impulse Level (kV) Wet and dry power frequency withstand voltage (kV rms) Minimum total Creepage distance (mm) Mounting L.V. and Neutral bushing Rated Voltage (Volts) Rated current (amps) Terminal details High Voltage Low Voltage phase and neutral Minimum Clearance (mm) in AIR Phase to Phase Phase to Earth
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POWER & CONTROL CABLES
(CABLES)
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Section-Technical Specification- 1.1 kV Power & Control Cable
186
CHAPTER - POWER AND CONTROL CABLES TECHNICAL SPECIFICATION FOR POWER AND CONTROL CABLES CONTENTS Clause No. 1.0 1.1 Description 1.1 kV Grade Power & Control Cables Criteria for Selection of Power & Control Cable CABLE 1.2 1.2.1 1.2.2 1.2.3 1.2.4 2.0 3.0 4.0 Technical Requirements General XLPE Power Cables PVC Power Cables PVC Control Cables HT Cable for Auxiliary Supply Cable Drums Type Tests 187 189 189 190 190 190 190 191 191 Page No. 187
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CHAPTER - PCC SECTION: POWER & CONTROL CABLES 1.0 1.1 KV GRADE POWER & CONTROL CABLES 1.1 CRITERIA FOR SELECTION OF POWER & CONTROL CABLES 1.1.1 Aluminium conductor XLPE insulated armoured cables shall be used for main power supply purpose from LT Aux. Transformers to control room, between distribution boards and for supply for colony lighting from control room. 1.1.2 Aluminium conductor PVC insulated armoured power cables shall be used for various other applications in switchyard area/control room except for control/protection purposes.
1.1.3 For all control/protection/instrumentation purposes PVC insulated armoured control cables of minimum 2.5 sq. mm. size with stranded Copper conductors shall be used. 1.1.4 Following are certain standardised sizes of power cables for various feeders. Bidders are to estimate the quantity of cables and quote accordingly. The sizes of power cables to be used per feeder in different application shall be as follows:
Sl. No. 1. From Main switch Board To LT Transformer Cable size 2-1C s 630 mm2 per phase IICx630 mm2 for neutral 2-3 Cx300 mm2 1-3 Cx300 mm2 1-3 Cx300 mm2 1-3 Cx300 mm2 1-3 Cx300 mm2 1-3 Cx300 mm2 1-3 Cx300 mm2 Cable type XLPE
2. 3. 4. 5. 6. 7. 8.
Main switch Board Main switch Board Main switch Board Main switch Board Main switch Board Main switch Board Lighting transformer
9. 10.
AC Distribution Board AC Distribution Board Emergency Lighting Transformer AC Distribution Board ACDB ACDB DCDB DCDB DCDB
11. 12. 13. 14. 15. 16. 17.
ACDB Air Conditioning Board Oil Filtration Unit Colony Lighting HVW pump LCP Lighting transformer Main Lighting Distribution Board DG set AMF Panel Emergency lighting transformer Emergency Lighting DB ICT MB Bay MB Battery Charger Battery Battery Charger Protection/PLCC panel
XLPE XLPE XLPE XLPE XLPE XLPE XLPE
2-3 Cx300 mm2 1-3 Cx70 mm2
XLPE PVC
1-3 Cx70 mm2 1-3 Cx70 mm2 1-3 Cx35 mm2 1-3 Cx70 mm2 2-I Cx150 mm2 2-I Cx150 mm2 1-2 Cx6 mm2
PVC PVC PVC PVC PVC PVC PVC
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18. 19. 20. 21. 22. 23. 24. 25.
Main Lighting DB Main Lighting DB Main Lighting DB Main Lighting DB Lighting Panel Lighting Panel Lighting Panel/ Sub Lighting Panels Bay MB
Lighting panels (Indoor) Receptacles (Indoor) Receptacles (Outdoor) Receptacles (Outdoor) Sub Lighting panels Street Lighting Poles Lighting Fixtures (Outdoor) Equipments
1-3 Cx35 mm2 1-3 Cx70 mm2 1-3 Cx35 mm2 1-3 Cx70 mm2 1-4 Cx16 mm2 1-4 Cx16 mm2 1-2 Cx6 mm2 1-4 Cx16 mm2 1-4 Cx6 mm2 1-2 Cx6 mm2 1-3 Cx70 mm2 1-3 Cx35 mm2 1-3 Cx35 mm2 1-3 Cx35 mm2
PVC PVC PVC PVC PVC PVC PVC PVC
26. 27. 28. 29.
Air Conditioning Board Air Conditioning Board Air Conditioning Board Air Conditioning Board
A/C Unit Panel AHU Heater Chiller pump
PVC PVC PVC PVC
1.1.5
Bidder may offer sizes other than the sizes specified in clause 1.1.4. In such case and for other application where sizes of cables have not been indicated in the specification, sizing of power cables shall be done keeping in view continuous current, voltage drop & short-circuit consideration of the system. Relevant calculations shall be submitted by bidder during detailed engineering for purchasers approval. Cables shall be laid conforming to IS: 1255. While preparing cable schedules for control/protection purpose following shall be ensured: 1.1.7.1 1.1.7.2 Separate cables shall be used for AC & DC. Separate cables shall be used for DC1 & DC2.
1.1.6 1.1.7
1.1.8 1.1.9
For different cores of CT & 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.
1.1.10 For control cabling, including CT/VT circuits, 2.5 sq. mm. size copper cables shall be used per connection. However, if required from voltage drop/VA burden consideration additional cores shall be used. Further for potential circuits of energy meters separate connections by 2 cores of 2.5 sq. mm. size shall be provided.
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1.2
TECHNICAL REQUIREMENTS 1.2.1. General 1.2.1.1 The cables shall be suitable for laying in racks, ducts, trenches, conduits and underground buried installation with uncontrolled back fill and chances of flooding by water. They shall be designed to withstand all mechanical, electrical and thermal stresses under steady state and transient operating conditions. The XLPE /PVC insulated L.T. power cables of sizes 240 sq. mm. and above shall withstand without damage a 3 phase fault current of at least 45 kA for at least 0.12 second, with an initial peak of 105 kA in one of the phases. The armour for these power cables shall be capable of carrying 45 kA for at least 0.12 seconds without exceeding the maximum allowable temperature of PVC outer sheath.
1.2.1.2
1.2.1.3 The XLPE insulated cables shall be capable of withstanding a conductor temperature of 250C during a short circuit without any damage. The PVC insulated cables shall be capable of withstanding a conductor temperature of 160C during a short circuit. 1.2.1.4 The Aluminium/Copper wires used for manufacturing the cables shall be true circular in shape before stranding and shall be uniformly good quality, free from defects. All aluminium used in the cables shall be of H2 grade. The fillers and inner sheath shall be of non-hygroscopic, fire retardant material, shall be softer than insulation and outer sheath shall be suitable for the operating temperature of the cable. Progressive sequential marking of the length of cable in metres at every one metre shall be provided on the outer sheath of all cables. Strip wire armouring method (a) mentioned in Table 5, Page-6 of IS: 1554 (Part 1)1988 shall not be accepted for any of the cables. For control cables only round wire armouring shall be used. The cables shall have outer sheath of a material with an oxygen index of not less than 29 and a temperature index of not less than 250C. All the cables shall pass fire resistance test as per IS: 1554 (PartI)
1.2.1.5
1.2.1.6
1.2.1.7
1.2.1.8
1.2.1.9
1.2.1.10 The normal current rating of all PVC insulated cables shall be as per IS: 3961. 1.2.1.11 Repaired cables shall not be accepted. 1.2.1.12 Allowable tolerance on the overall diameter of the cables shall be plus or minus 2 mm.
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1.2.2
XLPE Power Cables 1.2.2.1 The XLPE insulated cables shall be of FR type, C1 category conforming to IS: 7098 (Part-I) and its amendments read along with this specification. The conductor shall be stranded aluminium circular/sector shaped and compacted. In multi-core cables, the core shall be identified by red, yellow, blue and black coloured strips or colouring of insulation. A distinct inner sheath shall be provided in all multi-core cables. For XLPE cables, the inner sheath shall be of extruded PVC to type ST-2 of IS: 5831. When armouring is specified for single core cables, the same shall consist of aluminium wires/strips. The outer sheath shall be extruded PVC to Type ST-2 of IS: 5831 for all XLPE cables.
1.2.3
PVC Power Cables 1.2.3.1 The PVC (70C) insulated 1100V grade power cables shall be of FR type, C1 category, conforming to IS: 1554 (Part-I) and its amendments, read along with this specification and shall be suitable for a steady conductor temperature of 70C. The conductor shall be stranded aluminium. The Insulation shall be extruded PVC to type-A of IS: 5831. A distinct inner sheath shall be provided in all multi-core cables. For multi-core armoured cables, the inner sheath shall be of extruded PVC. The outer sheath shall be extruded PVC to Type ST-1 of IS: 5831 for all cables.
1.2.4
PVC Control Cables 1.2.4.1 The 1100V grade control cables shall be of FR type C1 category conforming to IS: 1554 (Part-1) and its amendments, read along with this specification. The conductor shall be stranded copper. The insulation shall be extruded PVC to type A of IS: 5831. A distinct inner sheath shall be provided in all cables whether armoured or not. The over sheath shall be extruded PVC to type ST-1 of IS: 5831 and shall be grey in colour except where specifically advised by the Owner to be black.
1.2.4.2 Cores shall be identified as per IS: 1554 (Part-1) for the cables up to five (5) cores and for cables with more than five (5) cores the identification of cores shall be done by printing legible Hindu Arabic Numerals on all cores as per clause 10.3 of IS 1554 (Part-1). 2.0 HT CABLE FOR AUXILIARY POWER SUPPLY 2.1 (a) The HT cable of 1Cx185 mm2 (Aluminium Conductor) or 1Cx120mm2 (Copper Conductor) of voltage class as specified for 630kVA LT transformer for interconnecting 630kVA LT transformer to the SEB feeder shall be, XLPE insulated, armoured cable conforming to IS 7098 (Part-II) and IEC 60502-2 1998. Terminating accessories shall conform to IEC 61442 1997/IEC 60502-4 1998. The HT cable of 3Cx95 mm2 (Aluminium Conductor) or 3Cx70mm2 (Copper Conductor) of voltage class as specified for 250kVA LT transformer for interconnecting 250kVA LT transformer to the SEB feeder shall be, XLPE insulated, armoured cable conforming to IS 7098
(b)
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(Part-II) and IEC 60502-2 1998. Terminating accessories shall conform to IEC 61442 1997/IEC 60502-4 1998. 2.2 Only overhead connection has been foreseen for interconnecting 800 kVA, LT transformer to the tertiary of the ICT. However, HT cable connections in place of overhead connection, if necessary shall also be in the scope of contractor. In this case contractor shall provide 1C x 185 mm2 (Aluminium Conductor) or 1Cx120mm2 (Copper Conductor), 38/66kV HT cable along with necessary terminating accessories. The construction of XLPE insulated, armoured HT cable shall be generally conforming to IS 7098 (Part-III). Terminating accessories shall conform to IEC 60840 1999. 2.3 Bidder may offer sizes other than the sizes specified in clause 2.1 and 2.2. In such case sizing of power cables shall be done keeping in view continuous current, voltage drop & short-circuit consideration of the system. Relevant calculations shall be submitted by bidder during detailed engineering for purchasers approval. 3.0 CABLE DRUMS 3.1 Cables shall be supplied non-returnable wooden or steel drums of heavy construction. Wooden drum shall be properly seasoned sound and free from defects. Wood preservative shall be applied to the entire drum. 3.2 Standard lengths for each size of power and control cables shall be 500/1000 meters. The cable length per drum shall be subject to a tolerance of plus or minus 5% of the standard drum length. The owner shall have the option of rejecting cable drums with shorter lengths. However, the total quantity of cables after taking into consideration of all cable drums for each size shall be within the tolerance of 2%. 3.3 A layer of water proof paper shall be applied to the surface of the drums and over the outer most cable layer. 3.4 A clear space of at least 40 mm shall be left between the cables and the lagging. 3.5 Each drum shall carry the manufacturer's name, the purchaser's name, address and contract number and type, size and length of the cable, net and gross weight stenciled on both sides of drum. A tag containing the same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled. 3.6 Packing shall be sturdy and adequate to protect the cables, from any injury due to mishandling or other conditions encountered during transportation, handling and storage. Both cable ends shall be sealed with PVC/Rubber caps so as to eliminate ingress of water during transportation and erection.
4.0
TYPE TESTS 4.1 All cables shall conform to all type, routine and acceptance tests listed in the relevant IS. 4.2 The type tests on cables shall be conducted on each type and size of cables offered. 4.3 Following type tests as per IS: 7098 (Part 1) 1988 including its amendments and additional type tests shall be carried out on 1.1 kV grade XLPE insulated cables:
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a)
Tests on conductor i) ii) iii) iv) Annealing test (for Copper) Tensile test (for aluminium) Wrapping test (for aluminium) Resistance test
b) c) d)
Test for armouring wires/strips Test for thickness of insulation and sheath Physical tests for insulation i) ii) iii) iv) Tensile strength and elongation at break Ageing in air oven Hot set test Shrinkage test
e)
Physical tests for outer sheath i) ii) iii) iv) v) vi) Tensile strength and elongation at break Ageing in air oven Loss of mass in air oven Shrinkage test Hot deformation Heat shock test
vii) Thermal stability f) g) h) i) j) Insulation resistance (volume resistivity test) High voltage test Flammability test Oxygen index and temperature index test on outer sheath Short time current test on power cables of sizes 240 sq. mm and above. i) ii) On conductor(s). On armours.
4.4 Following type tests as per IS: 1554 (Part 1) - 1988 including its amendments and additional type tests shall be carried out on 1.1 kV grade PVC insulated cables: a) Tests on conductor i) ii) iii) iv) b) c) d)
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Annealing test (for Copper) Tensile test (for aluminium) Wrapping test (for aluminium) Conductor Resistance test
Test for armouring wires/strips Test for thickness of insulation and sheath Physical tests for insulation and outer sheath i) Tensile strength and elongation at break
193
ii) iii) iv) v) vi)
Ageing in air oven Shrinkage test Hot deformation Loss of mass Heat shock test
vii) Thermal stability e) f) Insulation resistance High voltage test (water immersion test only a.c. test as per clause no. 16.3.1) g) h) i) j) High voltage test at room temperature Flammability test Oxygen index and temperature index test on outer sheath Short time current test on power cables of sizes 240 sq. mm and above. i) ii) 4.5 On conductor(s). On armours.
Following type tests as per IS: 7098 (Part 2) - 1988 including its amendments and additional type tests shall be carried out on XLPE insulated HT cable up to 33kV earthed system: a) Tests on conductor i) ii) iii) iv) b) c) d) e) f) g) h) i) j) k) l) Annealing test (for Copper) Tensile test (for aluminium) Wrapping test (for aluminium) Resistance test
Test for armouring wires/strips Test for thickness of insulation and sheath Physical tests for insulation Physical tests for outer sheath Partial discharge test Bending test Dielectric power factor test Heating cycle test Impulse withstand test High voltage test Oxygen index and temperature index test on outer sheath
4.6
Following type tests as per IS: 7098 (Part 3) 1993 including its amendments and additional type tests and additional type tests shall be carried out on XLPE insulated HT cable from 66kV up to and including 220kV: a) Tests on conductor
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i) ii) iii) iv) b)
Annealing test (for Copper) Resistance test Tensile test (for aluminium) Wrapping test (for aluminium)
Physical tests for insulation i) ii) iii) iv) v) Test for thickness and dimensions of insulation Tensile strength and elongation at break Thermal Ageing in air oven Hot set test Shrinkage test
c) d)
Resistivity test for semi-conducting layers Test for concentric metallic screen: i) ii) Test for concentric copper wire Test for concentric copper tape
e) f) i) h)
Thickness of metallic sheath Test for armouring material: Dimensions Physical tests for outer sheath: 1. 2. Measurement of thickness PVC sheath i) ii) iii) iv) v) vi) Tensile strength and elongation at break Ageing in air oven Loss of mass in air oven only for PVC sheath Heat shock test Hot deformation test Shrinkage test
vii) Thermal stability 3. PE sheath i) ii) iii) i) j) k) Carbon black content Tensile strength and elongation at break before and after ageing Hot-deformation
Flammability test (for PVC outer sheathed cables only) Water tightness test 1) Thermal ageing on complete cable sample 2) Tensile strength and elongation at break for insulation and outer sheath 3) Resistivity test for semi-conducting layer
l)
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Bending test followed by P.D. test

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m) n) o) p) 4.7
Dielectric power factor and capacitance measurement at ambient temperature Dielectric power factor measurement at elevated temperature Impulse withstand test followed by HV test Oxygen index and temperature index test on outer sheath
Contractor shall submit type test reports as per clause no. 9.2 of Technical Specification, Section: GTR for which test conducted once are acceptable (i.e. the requirement of test conducted within last five years shall not be applicable) for the following: 4.7.1 1.1 kV grade PVC insulated cables a) High voltage test (water immersion d.c. test as per clause no. 16.3.2 of IS: 1554 (Part 1) - 1988) 4.7.2 4.7.3 4.7.4 1.1 kV grade XLPE insulated cables a) Water absorption (gravimetric) test as per IS: 7098 (Part 1) 1988 XLPE insulated HT cable from 66kV up to and including 220kV a) Load cycle test followed by P.D. measurement as per IS: 7098(Part 3) Terminating/jointing accessories as per IEC 60840:1999 a) Partial discharge test at ambient temperature; b) Heating cycle voltage test c) Partial discharge tests At ambient temperature At high temperature
d) Impulse voltage test followed by power frequency test e) Test of outer protection for buried joints
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LT SWITCHGEAR
(LT SG)
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Section-Technical Specification-LT Switchgear
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CHAPTER - LT SWITCHGEAR TECHNICAL SPECIFICATION FOR LT SWITCHGEAR CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 Description Constructional Details of Switchboards and Distribution Boards Derating of Equipments Power Bus Bars and Insulators Earth Bus Air Circuit Breakers Moulded Case Circuit Breaker (MCCB) and MCB Relays Contactors Instrument Transformers Indicating Instruments Control & Selector Switches Air Break Switches Push Buttons Indicating Lamps Fuses Terminal Blocks Name Plates and Labels Space Heater Control and Secondary Wiring Power Cables Termination Type Tests Erection, Testing and Commissioning Commissioning Check Tests Special Tools and Tackles Equipment to be Furnished Parameters Automatic Control of Outdoor Lighting Automatic Supply Changeover Page No. 198 200 200 201 202 203 204 204 204 205 205 206 206 206 207 207 208 208 208 208 209 209 210 211 212 215 218 218
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CHAPTER - LT SWITCHGEAR
SECTION: LT SWITCHGEAR
1.0 CONSTRUCTIONAL DETAILS OF SWITCHBOARDS AND DISTRIBUTION BOARDS 1.1 All boards shall be of metal enclosed, indoor floor mounted, compartmentalized construction and freestanding type. 1.2 All board frames, shall be fabricated using suitable mild steel structural sections or pressed and shaped cold-rolled sheet steel of thickness not less than 2.0 mm. Frames shall be enclosed in cold-rolled sheet steel of thickness not less than 1.6 mm. Doors and covers shall also be of cold rolled sheet steel of thickness not less than 1.6 mm. Stiffeners shall be provided wherever necessary. 1.3 All panel edges and cover/door edges shall be reinforced against distortion by rolling, bending or by the addition of welded reinforcement members. 1.4 The complete structures shall be rigid, self-supporting, free from flaws, twists and bends. All cut-outs shall be true in shape and devoid of sharp edges. 1.5 All boards shall be of dust and vermin proof construction and shall be provided with a degree of protection of IP: 52 as per IS 13947 (Part-1). However, the bus bar chamber shaving a degree of protection of IP: 42, in accordance with IS 13947 (Part-1), are also acceptable where continuous bus bar rating exceeds 1000 Amp. Provision shall be made in all compartments for providing IP: 52 degree of protection, when Circuit breaker or module trolley, has been removed. All cutouts shall be provided with neoprene gaskets. 1.6 Provision of louvers on boards would not be preferred. However, louvers backed with metal screen are acceptable on the bus bar chambers where continuous bus bar rating exceeds 1000 Amps. 1.7 All boards shall be of uniform height not exceeding 2450 mm. 1.8 Boards shall be easily extendible on both sides, by the addition of the vertical sections after removing the end covers. 1.9 Boards shall be supplied with base frames made of structural steel sections, along with all necessary mounting hardware required for welding the base frames to the insert plates. 1.10 All boards shall be of double front construction and shall have (i) A completely enclosed bus bar compartment for running horizontal bus bars and vertical bus bars. Bus bar chambers shall be completely enclosed with metallic portions. Bolted covers shall be provided for access to horizontal and vertical bus bars for repair and maintenance, which shall be feasible without disturbing feeder compartment. Vertical bus bar chambers shall be accessible from front as well as back side of the panel. One set of vertical bus bars shall be used in between two adjacent sections for switchgear connections. In case of Incomer(s), Bus-coupler and ACB feeders, vertical bus bars located in rear side shall be additionally covered with metallic perforated bolted sheets to avoid direct access after opening rear door of chamber. Completely enclosed switchgear compartment(s) one for each circuit for housing circuit breaker or MCCB or motor starter.
(ii)
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(iii) A distinct compartment or alley for power and control cables on each side of panel. Cable alley compartment shall have a through metallic partition for segregating cables on both sides. Cable alley door shall preferably be hinged. Cable alley shall have no exposed live parts. Any live terminals shall be fully shrouded/insulated from safety aspects. However it shall be of at least 350mm width. (iv) A compartment for relays and other control devices associated with a circuit breaker. 1.11 Sheet steel barriers shall be provided between two adjacent vertical panels running to the full height of the switchboard, except for the horizontal bus bar compartment. Each shipping section shall have full metal sheets at both ends for transport and storage. 1.12 All equipments associated with a single circuit except MCB circuits shall be housed in a separate compartment of the vertical section. The Compartment shall be sheet steel enclosed on all sides with the withdrawal units in position or removed. The front of the compartment shall be provided with the hinged single leaf door, with locking facilities. In case of circuits controlled by MCBs, group of MCB feeders can be offered in common compartment. In such case number of MCB feeder to be used in a common compartment shall not exceed 4 (four) and front of MCB compartment, shall have a viewing port of toughen glass sheet for viewing and sheet steel door of module shall be lockable with star knob/panel key. 1.13 After isolation of power and control circuit connections it shall be possible to safely carryout maintenance in a compartment with the bus bar and adjacent circuit live. Necessary shrouding arrangement shall be provided for this purpose over the cable terminations located in cable alley. 1.14 The minimum clearance in air between phases and between phase and earth for the entire run of horizontal and vertical bus bars shall be 25 mm. For all other components, the clearance between "two live parts", " A live part and an earthed part" and isolating distance shall be at least ten (10) mm throughout. Wherever it is not possible to maintain these clearances, insulation shall be provided by sleeving or barriers. However, for horizontal run of bus bar minimum clearance of 25 mm should be maintained even if they are sleeved. 1.15 The temperature rise of horizontal & vertical bus bars when carrying rated current along its full run shall in no case exceed 55C, with silver plated joints and 40C with all other type of joints over an outside ambient temperature of 50C. 1.16 All bus bar chambers shall be provided with removable bolted covers. The covers shall be provided with danger labels. 1.17 All identical circuit breakers and module chassis of same test size shall be fully interchangeable without having to carryout modifications. 1.18 All Circuit breaker boards shall be of Single Front type, with fully draw out circuit breakers, which can be drawn out without having to unscrew any connections. The circuit breakers shall be mounted on rollers and guides for smooth movement between SERVICE, TEST and ISOLATED positions and for withdrawal from the Switchboard. Testing of the breaker shall be possible in the TEST position. 1.19 Wherever two breaker compartments are provided in the same vertical section, insulating barriers and shrouds shall be provided in the rear cable compartment to
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avoid accidental touch with the live parts of one circuit when working on the other circuit. 1.20 All disconnecting contacts for power circuits shall be of robust design and fully self aligning. Fixed and moving contacts of the power draw out contact system shall be silver plated. Both fixed and moving contacts shall be replaceable. 1.21 All AC & DC boards shall be of double Front type. 1.22 All modules shall be fixed type except air circuit breaker module, which shall be draw out type. 1.23 The connections from bus bars to the main switch shall be fully insulated/shrouded, and securely bolted. The partition between the feeder compartment and cable alley may be non-metallic and shall be of such construction as to allow cable cores with lugs to be easily inserted in the feeder compartment for termination. 1.24 All equipment and components shall be neatly arranged and shall be easily accessible for operation and maintenance. The internal layout of all modules shall be subject to PURCHASER approval. Bidder shall submit dimensional drawings showing complete internal details of Bus bars and module components, for each type and rating for approval. 1.25 The tentative power and control cable entries shall be from bottom. However, Purchaser reserves the right to alter the cable entries, if required, during detailed engineering, without any additional commercial implication. 1.26 Adopter panels and dummy panels required to meet the various bus bar arrangements and layouts required shall be included in Bidder's scope of work. 2.0 DERATING OF EQUIPMENTS 2.1 The current ratings of all equipments as specified in the `Bill of Materials are the minimum standards current ratings at a reference ambient temperature of 50C as per relevant Indian Standards. The Bidder shall indicate clearly the derating factors employed for each component and furnish the basis for arriving at these derating factors duly considering the specified ambient temperature of 50C.
2.2
3.0
POWER BUS BARS AND INSULATORS 3.1 3.2 All AC Distribution Boards shall be provided with three phase buses and neutral bus bars and the DC Distribution Boards shall be provided with two bus bars. All bus bars and jumper connections shall be of high conductivity aluminium/copper of adequate size the bus bar size calculation shall be submitted for approval. The Cross-Section of the bus bars shall be uniform through out the length of Switchgear and shall be adequately supported and braced to withstand the stresses due to the specified short circuit currents. All bus bars shall be adequately supported by Non-hygroscopic, noncombustible, track-resistant & high strength type Polyester fiber glass Moulded Insulators. Separate supports shall be provided for each phase and neutral bus bar. If a common support is provided anti-tracking barriers shall be provided between the supports.
3.3
3.4
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3.5
All bus bars joints shall be provided with high tensile steel bolts. Belleville/spring washers and nuts, so as to ensure good contacts at the joints. Non-silver plated bus bars joints shall be thoroughly cleaned at the joint locations and suitable contact grease shall be applied just before making a joint. All bus bars shall be colour coded as per IS: 11353 The Bidder shall furnish calculations along with the bid, establishing the adequacy of bus bar sizes for specified current ratings, On the basis of short circuit current and temperature rise consideration at specified ambient temp.
3.6 3.7
4.0
EARTH BUS 4.1 A galvanised steel earthing shall be provided at the bottom of each panel and shall extend throughout the length of each switchboard. It shall be welded/bolted to the frame work of each panel and breaker earthing contact bar vertical bus shall be provided in each vertical section which shall in turn be bolted/welded to main horizontal ground bus. The earth bus shall have sufficient cross-section to carry the momentary short circuit and short time fault currents to earth as indicated in `Bill of Materials' without exceeding the allowable temperature rise. Suitable arrangements shall be provided at each end of the horizontal earth bus for bolting to Purchaser's earthing conductors. The horizontal earth bus shall project out the switchboard ends and shall have predrilled holes for this connection. A joint spaced and taps to earth bus shall be made through at least two bolts. All non-current metal work of the Switchboard shall be effectively bonded to the earth bus. Electrical conductivity of the whole switchgear enclosures frame work and the truck shall be maintained even after painting. The truck and breaker frame shall get earthed while the truck is being inserted in the panel and positive earthing of the truck and breaker frame shall be maintained in all positions, SERVICES & ISOLATED, as well as through out the intermediate travel. Each module frame shall get engaged to the vertical earth bus. Before the disconnecting contacts on these module are engaged to the vertical bus bar. All metallic cases of relays, instruments and other panel mounted equipments shall be connected to earth by independent stranded copper wires of size not less than 2.5 mm2. Insulation colour code of earthing wires shall be green. Earthing wires shall be connected to terminals with suitable clamp connectors and soldering is not acceptable. Looping of earth Connection which would result in loss of earth connection to the devices when a device is removed is not acceptable. However, looping of earth connections between equipment to provide alternative paths or earth bus is acceptable. VT and CT secondary neutral point earthing shall be at one place only, on the terminal block. Such earthing shall be made through links so that earthing of one secondary circuit shall be removed without disturbing the earthing of other circuit. All hinged doors shall be earthed through flexible earthing braid.
4.2
4.3
4.4
4.5
4.6 4.7
4.8
4.9
4.10 Caution nameplate `Caution-Live Terminals' shall be provided at all points where the terminals are like to remain live and isolation is possible only at remote end.
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5.0 AIR CIRCUIT BREAKERS 5.1 Circuit breakers shall be three-pole air break horizontal draw out type and shall have inherent fault making and breaking capacities as specified in "Technical Parameters". The circuit breakers which meet specified parameter only after provision of releases or any other devices shall not be acceptable. 5.2 Circuit breakers shall be mounted along with it operating mechanism on a wheeled carriage. Suitable guides shall be provided to minimize misalignment of the breaker. 5.3 There shall be `Service', `Test' and `Fully withdrawn positions for the breakers. In `Test' position the circuit breaker shall be capable of being tested for operation without energizing the power circuits i.e. the power Contacts shall be disconnected while the Control circuits shall remain undisturbed. Locking facilities shall be provided so as to prevent movement of the circuit breaker from the `SERVICE', `TEST' OR FULLY WITHDRAWN' position. It shall be possible to close the door in TEST position. 5.4 All circuit breakers shall be provided with 4 NO and 4 NC potentially free auxiliary contacts. These contacts shall be in addition to those required for internal mechanism of the breaker. Separate limit switches each having required number of contacts shall be provided in both `SERVICE' & `TEST' position of the breaker. All contacts shall be rated for making continuously carrying and breaking 10 Amps at 240V AC and 1 Amp (Inductive) at 220V DC. 5.5 Suitable mechanical indications shall be provided on all circuit breakers to show ÒPEN'. `CLOSE', `SERVICE', `TEST' and `SPRING CHARGED' positions. 5.6 Main poles of the circuit breakers shall operate simultaneously in such a way that the maximum difference between the instants of contacts touching during closing shall not exceed half cycle of rated frequency. 5.7 All circuit breakers shall be provided with the interlocks as explained in further clauses. 5.8 Movement of a circuit breaker between SERVICE AND TEST positions shall not be possible unless it is in OPEN position. Attempted with drawl of a closed circuit breaker shall trip the circuit breaker. 5.9 Closing of a circuit breaker shall not be possible unless it is in SERVICE, TEST POSITION or in FULLY WITHDRAWN POSITION. 5.10 Circuit breaker cubicles shall be provided with safety shutters operated automatically by the movement of the circuit breaker carriage to cover the stationary isolated contacts when the breaker is withdrawn. It shall however, be possible to open the shutters intentionally, against spring pressure for testing purpose. 5.11 A breaker of particular rating shall be prevented from insertion in a cubicle of a different rating. 5.12 Circuit breakers shall be provided with electrical anti-pumping and trip free feature, even if mechanical anti pumping feature is provided. 5.13 Mechanical tripping shall be possible by means of front mounted RED `Trip' push-button. In case of electrically operated breakers these push buttons shall be shrouded to prevent accidental operation. 5.14 Breaker controlled motors shall operate satisfactorily under the following conditions:
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(i)
Direct on-line starting of Induction Motors rated 110 kW to 220 kW with a locked rotor current of seven times the rated current, and starting time of up to 30 seconds. Breaking on-load, full load and locked rotor currents of Induction Motors for rated 100 kW to 220 kW.
(ii)
5.15 Means shall be provided to slowly close the circuit breaker in withdrawn position. If required for inspection and setting of Contacts, in service position slow closing shall not be possible. 5.16 Power operated mechanism shall be provided with a universal motor suitable for operation 220V DC Control supply with voltage variation from 90% to 110% rated voltage. Motor insulation shall be class È' or better. 5.17 The motor shall be such that it requires not more than 30 seconds for fully charging the closing spring. 5.18 Once the closing springs are discharged, after the one closing operation of circuit breaker, it shall automatically initiate, recharging of the spring. 5.19 The mechanism shall be such that as long as power is available to the motor, a continuous sequence of closing and opening operations shall be possible. After failure of power supply at least one open-close-open operation shall be possible. 5.20 Provision shall be made for emergency manual charging and as soon as this manual charging handle is coupled, the motor shall automatically get mechanically decoupled. 5.21 All circuit breakers shall be provided with closing and trip coils. The closing coils shall operate correctly at all values of Voltage between 85% to 110% at rated control voltage. The trip coil shall operate satisfactorily under all values of supply voltage between 70% to 110% of rated control voltage. 5.22 Provision for mechanical closing of the breaker only in `TEST' and `WITHDRAWN' positions shall be made. 5.23 PROTECTION CO-ORDINATION 5.23.1 It shall be the responsibility of the Contractor to fully co-ordinate the overload and short circuit tripping of the circuit breakers with the upstream and down stream circuit breakers/fuses/motor starters, to provide satisfactory discrimination. 6.0 MOULDED CASE CIRCUIT BREAKER (MCCB) AND MCB 6.1 6.2 6.3 MCCB shall in general conform to IS: 13947 Part-2. All MCCB shall be of P2 duty. MCCB shall be flush mounted on the AC/DC distribution boards. MCCBs shall be provided with thermo-magnetic type release for over current and short circuit protection. The setting of the thermal release shall be adjustable between 75% to 100% of the rated current. The MCCB shall have breaking capacity not less than 20kA. MCCBs used for ACDB incomers and Bus coupler shall be equipped with stored energy mechanism for electrical closing and tripping. All other MCCBs shall be manually operated. The operating handle should give a clear trip indication. Miniature circuit breaker (MCB) shall conform to IEC: 898-1987 and IS: 8828.
6.4
6.5
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7.0 RELAYS 7.1 All relays and timers in protective circuits shall be flush mounted on panel front with connections from the inside. They shall have transparent dust tight covers removable from the front. All protective relays shall have a draw out construction for easy replacement from the front. They shall either have built-in test facilities, or shall be provided with necessary test blocks and test switches located immediately below each relay. The auxiliary relays and timers may be furnished in non-draw out cases. All AC relays shall be suitable for operation, at 50 Hz with 110 volts VT secondary and 1 amp or 5 amps CT secondary. All protective relays and timers shall have at least two potentially free output contacts. Relays shall have contacts as required for protection schemes. Contacts of relays and timers shall be silver faced and shall have a spring action. Adequate number of terminals shall be available on the relay cases for applicable relaying schemes. All protective relays auxiliary relays and timers shall be provided with hand reset operation indicators (Flags) for analyzing the cause of operation. All relays shall withstand a test voltage of 2 KV (rms) for one minute. Motor starters shall be provided with three elements, ambient temperature compensated, time lagged, hand reset type overload relays with adjustable settings. The setting ranges shall be properly selected to suit the motor ratings. These relays shall have a separate black coloured hand reset push button mounted on compartment door and shall have at least one changeover contact. All fuse-protected contactor-controlled motors shall have single phasing protection, either as a distinct feature in the overload relays (by differential movement of bimetallic strips), or as a separate device. The single phasing protection shall operate even with 80% of the set current flowing in two of the phases.
7.2 7.3
7.4 7.5 7.6
7.7
8.0
CONTACTORS 8.1 8.2 8.3 8.4 8.5 Motor starter contactors shall be of air break, electromagnetic type rated for uninterrupted duty as per IS: 13947 (Part 4). Contactors shall be double break, non-gravity type and their main contacts shall be silver faced. Direct on line starter contactors shall be of utilization category AC2. These contactors shall be as per IS: 13947 (Part 4). Each contactor shall be provided with two (2) normally open (NO) and two (2) normally close (NC) auxiliary contacts. Operating coils of contactors shall be of 240V AC unless otherwise specified elsewhere. The Contactors shall operate satisfactorily between 85% to 110% of the rated voltage. The Contactor shall drop out at 70% of the rated voltage.
9.0 INSTRUMENT TRANSFORMERS 9.1 All current and voltage transformers shall be completely encapsulated cast resin insulated type suitable for continuous operation at the temperature prevailing inside the switchgear enclosure, when the switchboard is operating at its rated condition and the outside ambient temperature is 50C.
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9.2
All instrument transformers shall be able to withstand the thermal and mechanical stresses resulting from the maximum short circuit and momentary current ratings of the associated switchgear. All instrument transformers shall have clear indelible polarity markings. All secondary terminals shall be wired to a separate terminal on an accessible terminal block where star-point formation and earthing shall be done. Current transformers may be multi or single core type. All voltage transformers shall be single phase type. The Bus VTs shall be housed in a separate compartment. All VTs shall have readily accessible HRC current limiting fuses on both primary and secondary sides.
9.3
9.4
9.5
10.0 INDICATING INSTRUMENTS 10.1 All indicating and integrating meters shall be flush mounted on panel front. The instruments shall be of at least 96 mm square size with 90 degree scales, and shall have an accuracy class of 2.5 or better. The covers and cases of instruments and meters shall provide a dust and vermin proof construction. 10.2 All instruments shall be compensated for temperature errors and factory calibrated to directly read the primary quantities. Means shall be provided for zero adjustment without removing or dismantling the instruments. 10.3 All instruments shall have white dials with black numerals and lettering. Black knife edge pointer with parallax free dials will be preferred. 10.4 Ammeters provided on Motor feeders shall have a compressed scale at the upper current region to cover the starting current. 10.5 Watt-hour meters shall be of 3 phase three element type, Maximum demand indicators need not be provided. 11.0 CONTROL & SELECTOR SWITCHES 11.1 Control & Selector switches shall be of rotary type with escutcheon plates clearly marked to show the function and positions. The switches shall be of sturdy construction suitable for mounting on panel front. Switches with shrouding of live parts and sealing of contacts against dust ingress shall be preferred. 11.2 Circuit breaker selector switches for breaker Controlled motor shall have three stay put positions marked `Switchgear', `Normal' and `Trial' respectively. They shall have two contacts of each of the three positions and shall have black shade handles. 11.3 Ammeter and voltmeter selector switches shall have four stay put position with adequate number of contacts for three phase 4 wire system. These shall have oval handles. Ammeter selector switches shall have make before break type contacts to prevent open circuiting of CT secondaries. 11.4 Contacts of the switches shall be spring assisted and shall be of suitable material to give a long trouble free service. 11.5 The contact ratings shall be at least the following: (i) (ii) Make and carry continuously: Breaking current at 220V DC: 10 Amp. 1 Amp (Inductive) 5 Amp (at 0.3 pf lagging)
(iii) Breaking current at 240V AC:

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12.0 AIR BREAK SWITCHES 12.1 Air breaker switch shall be of the heavy duty, single throw group operated, load break, fault make type complying with IS: 4064. 12.2 The Bidder shall ensure that all switches are adequately rated so as to be fully protected by the associated fuses during all abnormal operating conditions such as overload, locked motor, short circuit etc. 12.3 Switch operating handles shall be provided with padlocking facilities to lock them in ÒFF' position. 12.4 Interlocks shall be provided such that it is possible to open the cubicle door only when the switch is in ÒFF' position and to close the switch only when the door is closed. However suitable means shall be provided to intentionally defeat the interlocks explained above. 12.5 Switches and fuses for AC/DC control supply and heater supply wherever required shall be mounted inside and cubicles. 13.0 PUSH BUTTONS 13.1 Push-buttons shall be of spring return, push to actuate type. Their contacts shall be rated to make, continuously carry and break 10A at 240V and 0.5A (inductive) at 220V DC. 13.2 All push-buttons shall have one normally open and one normally closed contact, unless specified otherwise. The contact faces shall be of silver or silver alloy. 13.3 All push-buttons shall be provided with integral escutcheon plates marked with its function. 13.4 The colour of the button shall be as follows: (i) (ii) GREEN: RED: For motor START, Breaker CLOSE For motor TRIP, Breaker OPEN For overload reset.
(iii) BLACK:
13.5 All push-buttons on panels shall be located in such a way that Red-push-buttons shall always be to the left of green push-buttons. 14.0 INDICATING LAMPS 14.1 Indicating lamps shall be of the panel mounting cluster LED type. The lamps shall have escutcheon plates marked with its function, wherever necessary. 14.2 Lamps shall have translucent lamp-covers of the following colours, as warranted by the application: (i) (ii) RED: GREEN: For motor ON, Breaker CLOSED For motor OFF, Breaker OPEN For motor Auto-Trip For all healthy conditions (e.g. control supply, and also for 'SPRING CHARGED"
(iii) WHITE: (iv) BLUE: (v) AMBER:
For all alarm conditions (e.g. overload) Also for `SERVICE' and `TEST' positions indicators. 14.3 Lamps shall be easily replaceable from the front of the cubicle.
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14.4 Indication lamps should be located just above the associated push buttons/control switches. Red lamps shall invariable be located to the right of green lamps. In case a white lamp is also provided, it shall be placed between the red and green lamps along with the centre line of control switch/push button pair. Blue and Amber lamps should normally be located above the Red and Green lamps. 14.5 When associated with push-buttons, red lamps shall be directly above the green push button, and green lamps shall be directly above the red push-button. All indicating lamps shall be suitable for continuous operation at 90 to 110% of their rated voltage. 15.0 FUSES 15.1 All fuses shall be of HRC cartridge fuse link type. Screw type fuses shall not be accepted. Fuses for AC Circuits shall be of class 2 type, 20 kA (RMS) breaking current at 415 AC, and for DC circuits Class 1 type 4 kA breaking current. 15.2 Fuses shall have visible operation indicators. 15.3 Fuses shall be mounted on fuses carriers, which are mounted on fuse bases, wherever it is not possible to mount fuses on carriers fuses shall be directly mounted on plug in type of bases. In such cases one set of insulated fuse pulling handles shall be supplied with each switchgear. 15.4 Fuse rating shall be chosen by the Bidder depending upon the circuit requirements and these shall be subject to approval of PURCHASER. 16.0 TERMINAL BLOCKS 16.1 Terminal blocks shall be of 750 volts grade and have continuous rating to carry the maximum expected current on the terminals. It shall be complete with insulating barriers, clip-on-type/stud type terminals for Control Cables and identification strips. Marking on terminal strip shall correspond to the terminal numbering on wiring on diagrams. It shall be similar to ÈLEMEX' standard type terminals, cage clamp type of Phoenix or WAGO or equivalent 16.2 Terminal blocks for CT and VT secondary leads shall be provided with test links and isolating facilities. CT secondary leads shall be provided with short circuiting and earthing facilities. It shall be similar to Èlem.' `CATD' - Type. 16.3 In all circuit breaker panels at least 10% spare terminals for external connections shall be provided and these spare terminals shall be uniformly distributed on all terminal blocks. Space for adding another 10% spare terminals shall also be available. 16.4 All terminal blocks shall be suitable for terminating on each side, two (2) Nos. of 2.5 mm square size standard copper conductors. 16.5 All terminals shall be numbered for identification and grouped according to the function. Engraved white-on-black labels shall be provided on the terminal blocks. 16.6 Wherever duplication of a terminal block is necessary it shall be achieved by solid bonding links. 16.7 Terminal blocks shall be arranged with at least 100 mm clearance between two sets of terminal block. The minimum clearance between the first row of terminal block and the associated cable gland plate shall be 250 mm.
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17.0 NAME PLATES AND LABELS 17.1 All switchgears, AC/DC distribution boards, shall be provided with prominent, engraved identification plates. The module identification plate shall clearly give the feeder number and feeder designation. For single front switchboards, similar panel and board identification labels shall be provided at the rear also. 17.2 All name plates shall be of non-rusting metal or 3-ply lamicoid with white engraved lettering on black back ground. Inscriptions and lettering sizes shall be subject to PURCHASER approval. 17.3 Suitable plastic sticker labels shall be provided for easy identification of all equipments, located inside the panel/module. These labels shall be positioned so as to be clearly visible and shall give the device number as mentioned in the module wiring drawings. 18.0 SPACE HEATER 18.1 Space heater shall be provided in all the boards for preventing harmful moisture condensation. 18.2 The space heaters shall be suitable for continuous operation on 240V AC, 50 Hz, single phase supply, and shall be automatically controlled by thermostats. Necessary isolating switches and fuses shall also be provided. 19.0 CONTROL AND SECONDARY WIRING 19.1 All switchboards shall be supplied completely wired internally unto the terminal blocks ready to receive Purchaser's control cables. 19.2 All inter cubicle and inter panel wiring and connections between panels of same switchboard including all bus wiring for AC and DC supplies shall be provided by the bidder. 19.3 All internal wiring shall be carried out with 1100 V grade, single core, 1.5 square mm or larger stranded copper wires having colour coded, PVC insulation. CT circuits shall be wired with 2.5 square mm copper wires. Voltage grade and insulation shall be same as above. 19.4 Extra-flexible wires shall be used for wiring to device mounted on moving parts such as hinged doors. 19.5 All wiring shall be properly supported, neatly arranged, readily accessible and securely connected to equipment terminals and terminals blocks. 20.0 POWER CABLES TERMINATION 20.1 Cable termination compartment and arrangement for power cables shall be suitable for stranded aluminium conductor, armoured XLPE/PVC insulated and sheathed, single core/three core, 1100 V grade cables. 20.2 All necessary cable terminating accessories such as Gland plates, supporting clamps and brackets, power cable lugs, hardware etc. shall be provided by the successful bidder, to suit the final cable sizes which would be advised later. 20.3 The gland plate shall be of removable type and shall cover the entire cable alley. Bidder shall also ensure that sufficient space is provided for all cable glands. Gland plates shall be factory-drilled according to the cable gland sizes and number which shall be informed to the Contractor later. For all single core cables, gland plates shall be of non-magnetic Material.
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21.0 TYPE TESTS 21.1 Type tests reports on Panels (Switchgear and Control gear assemblies) as per IS 8623 Part-I shall be submitted for the following tests in line with clause 9.0 of Section GTR before the fabrication of switchgear is started: i) ii) iii) iv) v) vi) vii) Verification of temperature rise limits Verification of the dielectric properties Verification of short circuit strength Verification of the continuity of the protective circuit Verification of clearances and creepage distances Verification of mechanical operation Verification of degree of protection
21.2 Contractor shall submit type test reports for the following Switchgear and Control gears before the fabrication of switchgear is started: 1. 2. Circuit breakers/MCCB as per IS 13947 Part-II Protective Relays as per IEC: 60255
For above equipments, test conducted once are acceptable (i.e. the requirement of test conducted within last five years shall not be applicable) 22.0 ERECTION, TESTING AND COMMISSIONING 22.1 The Contractor shall unload, erect, install, test and put into commercial use all electrical equipment included in this specification. 22.2 Equipment shall be installed in a neat, workman like manner so that it is level, plumb, square and properly aligned and oriented. Tolerance shall be as established in Contractor's drawings or as stipulated by purchaser. No equipment shall be permanently bolted down to foundations until the alignment has been checked and found acceptable by the purchaser. 22.3 Contractor shall furnish all supervision, labour tools equipment rigging materials, bolts, wedges, anchors, concrete inserts etc. in proper time required to completely install, test and commission the equipment. 22.4 Manufacturer's and purchaser's instructions and recommendations shall be correctly followed in handling, setting, testing and commissioning of all equipment. 22.5 Contractor shall move all equipment into the respective room through the regular door or openings specifically provided for this purpose. No part of the structure shall be utilized to lift or erect any equipment without prior permission of Purchaser. 22.6 All boards shall be installed in accordance with Indian Standards IS: 3072 and at Purchaser's instructions. All boards shall be installed on finished surfaces, concrete or steel stills. Contractor shall be required to install and align any channel sills which form part of foundations. In joining shipping sections of switchboards together adjacent housing of panel sections or flanged throat sections shall be bolted together after alignment has been completed. Power bus, enclosures ground and control splices of conventional nature shall be cleaned and bolted together being drawn up with torque spanner of proper size or by other approved means. 22.7 All boards shall be made completely vermin proof.
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22.8 Contractor shall take utmost care in holding instruments, relaying and other delicate mechanism wherever the instruments and relays are supplied separately they shall be mentioned only after the associated panels have been erected and aligned. The packing materials employed for safe transit of instrument and relays shall be removed after ensuring that panel have been completely installed and to further movement of the same should be necessary. Any damage shall be immediately reported to Purchaser. 22.9 Equipment furnished with finished coats of paint shall be touched by up Contractor if their surface is specified or marred while handling. 22.10 After installation of panels, power and control wiring and connections, Contractor shall perform operational tests on all switchboards, to verify proper operation of switch-boards/panels and correctness of all equipment in each and every respect. The cable opening and cables entries for cables terminating to the panels shall be sealed with fire sealing materials. 23.0 COMMISSIONING CHECK TESTS The Contractor shall carry out the following commissioning checks, in addition to the other checks and tests recommended by the manufacturers. 23.1 General 23.1.1 23.1.2 23.1.3 23.1.4 23.1.5 23.1.6 23.1.7 23.2.1 23.2.2 Check name plate details according to the specification. Check for physical damage. Check tightness of all bolts, clamps, joints connecting terminals. Check earth connection. Check cleanliness of insulators and bushings. Check all moving parts for proper lubrication. Check settings of all the relays.
23.2 Circuit Breakers Check alignment of breaker truck for free movement. Check correct operation of shutters.
23.2.3 Check control wiring for correctness of connections, continuity and IR values. 23.2.4 23.2.5 23.2.6 23.2.7 23.2.8 23.2.9 23.2.10 23.2.11 23.2.12 23.2.13
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Manual operation of breaker completely assembled. Power closing/opening operation, manually and electrically. Breaker closing and tripping time. Trip free and anti-pumping operation. IR values, minimum pick up voltage and resistance of coils. Contact resistance Simultaneous closing of all the three phases. Check electrical & mechanical interlocks provided. Check on spring charging motor, correct operation of limit switches, and time of charging. All functional checks.
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23.3 Current Transformers 23.3.1 23.3.2 23.3.3 23.3.4 23.4.1 23.4.2 23.4.3 23.4.4 23.5.1 23.5.2 Megger between winding and winding terminals to body. Polarity test Ratio identification checking of all ratios on all cores by primary injection of current. Spare CT cores, if available, to be shorted and earthed.
23.4 Voltage Transformer Insulation resistance test Ratio test on all cores. Polarity test. Line connections as per connection diagram.
23.5 Cubicle Wiring Check all switch developments. Each wire shall be traced by continuity tests and it should be made sure that the wiring is as per relevant drawing. All interconnections between panels/equipment shall be similarly checked. All the wires shall be meggered to earth. Functional checking of all control circuit e.g. closing, tripping control, interlock, supervision and alarm circuit.
23.5.3 23.5.4 23.6 Relays 23.6.1 23.6.2 23.6.3 23.6.4 23.6.5 23.6.6 23.6.7 23.6.8 23.7 Meters 23.7.1 23.7.2 23.7.3
Check connections and wiring. Megger all terminals to body. Megger AC to DC terminals. Check operating characteristics by secondary injection. Check minimum pick up voltage of DC coils. Check operation of electrical/mechanical targets. Relays settings. Check CT and VT connections with particular reference to their polarities for directional relays, wherever required.
Check calibration by comparing it with a sub-standard. Megger all insulated portions. Check CT and VT connections with particular reference to their polarities for power type meters.
24.0 SPECIAL TOOLS AND TACKLES 24.1 The Bidder shall include in his proposal any special tools and tackles required for erection, testing commissioning and maintenance of the equipments offered. 24.2 The list of these special tools and tackles shall be given in the bid proposal sheets along with their respective prices.
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24.3 The total price of the special tools and tackles shall be included in proposal sheets. 25.0 EQUIPMENT TO BE FURNISHED 25.1 The Bidder shall quote for various AC/DC distribution boards in accordance with this specification 25.2 Standard scheme of interconnection of switchboards and distribution boards along with tentative feeder disposition for each board is indicated in Standard SLD of AC & DC system enclosed along with bid documents. The bidder shall quote board prices on the basis of standard SLD and their estimation of feeders for entire present and future bays requirement. Any other feeder required as per system requirement for efficient and reliable operation shall be deemed to be included in bidder's scope. 25.3 The Bill of Materials for each type of module shall be as under. These are minimum indicative requirement of the system. The necessary auxiliary relays, push buttons and indicating lamps shall be provided as per scheme requirement. Any other item/component required with in a module for efficient and reliable operation shall be deemed to be included in bidder's scope. The scheme shall have provision for remote annunciation for the followings: a) b) c) d) e) Station LT (415V) AC incomer supply unhealthy 220V DCDB U/V, O/V & Earth leakage relay operated 50V DCDB U/V & O/V relay operated DG set start DG set protection operated.
25.4 Module Type AE (Electrically controlled circuit breaker for incoming and Bus Coupler Circuit). (i) (ii) One (1) Two (2) Triple pole air circuit breaker complete with all accessories and power operated mechanism as specified. Neutral link. Current Transformer for metering. Ammeter with selector switch. Current Transformer for relaying. Triple pole instantaneous over-current relay having the setting range of 200-800% or 500-2000% of CT secondary and adjustable definite minimum time. Instantaneous earth fault relay having an adjustable setting range of 10-40% or 20 - 80% of CT secondary current and adjustable definite minimum time. The earth fault relay shall be provided with a stabilizing resistor.
(iii) Three (3) (iv) One (1) (v) Three (3)
(vi) One (1)
(vii) One (1)
25.5 Module Type - M1 (Circuit Breaker Controlled Motor Feeder) (i) (ii) One (1) One (1) Triple pole Air Circuit Breaker complete with accessories, and power operated mechanism as specified. Three position 6 pole selector switch 'SWITCHGEAR/ NORMAL/TRIAL'. Current Transformer for metering.
(iii) Three (3)

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(iv) One (1) (v) Three (3)
Ammeter with Ammeter Selector Switch Current Transformer for relaying. Triple pole instantaneous over-current relay for providing positive sequence current protection in all the three phases. The relay setting range shall be continuously adjustable between 200-800% or 400-1600% of CT secondary rated current as required. Double pole inverse definite minimum time over current relays connected in R & B phases for over current protection of motor rated 110 kW - 200 kW. The relay shall have an adjustable setting range of 50% - 200% of CT Secondary current and time setting range of 0-30 second. The relay shall be CDGM-22 of EE or equivalent. Single pole adjustable definite time delay relay for motor overload alarm connected in Y-phase only. The relay shall have resetting ratio of not less than 90%. The relay shall have continuously adjustable time delay range of 2.5 to 25 Sec. Instantaneous earth fault relay having an adjustable setting range of 10-40% or 20-80% of CT secondary current. The earth fault relay shall be provided with a stabilizing resistor.
(vi) One (1)
(vii) One (1)
(viii) One (1)
(ix) One (1)
25.6 Module Type E (i) One (1) Four pole MCCB 25.7 Module G-1 (VT Module with under Voltage Relay) (i) Three (3) 415 / 110 volts single phase voltage transformer star/star 3 3 connect with star point solidly earthed mounted on common draw out chassis. Accuracy Class 0.5 for protection and metering with 50VA Burden. HRC Fuses mounted on the above chassis. Four position voltmeter selector switch. Voltmeter (0-500V) Double pole instantaneous under voltage relays with continuous variable setting range of 40-80% of 110 Volts. Time delay pick up relay having a time setting range of 0.5 to 3 secs. with 3 `NO'. Self reset contacts, suitable for 220V DC. Auxiliary relay 220V DC with 2 NO. self reset contacts. Indicating lamps with series resistor and colour lenses (Red, Blue & Yellow).
(ii)
Six (6)
(iii) One (1) (iv) One (1) (v) One (1)
(vi) One (1) (vii) One (1) (viii) Three (3)
25.8 Module Type G-2 (i) (ii) Three (3) One (1) HRC Fuse Voltmeter (0-500V) Voltmeter selector switch four positions (R-Y, Y-B, B-R Indication lamps (Red, Blue & Yellow)
(iii) One (1) OFF). (iv) Three (3)

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25.9 Module Type H & H (BC) (Isolating Switch Controlled Incoming Circuit) (i) (ii) One (1) One (1) Four pole MCCB Red Indicating lamp to indicate isolating switch closed position.
25.10 Module Type S: (DC Metering and Protection Module) (i) (ii) One (1) One (1) Voltmeter 300-0-300V DC for 220V DC DB/Voltmeter 0-75V DC for 50V DCDB Three (3) position voltmeter selector switch Instantaneous under voltage relay with 95% of 220V DC. The resetting ratio of relay of relay should not be more than 1.25. The relay shall be provided with a series resistor and a push button across if for resetting (pick up) the relay at about 105% of the drop out voltage. Instantaneous over voltage relay with setting range of 110% of 220V DC. The resetting ratio of relay should not be less than 0.8. The relay shall have a push button in series of resetting the relay at about 95% of the operating voltage. Earth leakage relay only for 220V DC system having adjustable pick up range between 3 to 7 milliamps the relay shall be suitable for 220V DC/240V AC Auxiliary supply.
(iii) One (1)
(iv) One (1)
(v)
One (1)
25.11 Module Type X One (1) Double pole 250 V MCB 25.12 Module Type-DC (Incomer from Battery & Chargers) (i) (ii) One (1) One (1) Double pole 250V DC MCCB for incomer from Battery. DC ammeter with shunt and range of 90-0-400 Amps. For 220V DC DB and 90-0-200 Amp for 50V DC DB. Double pole 250V DC MCCB/MCB Double pole single throw 250V DC air break switch connecting battery & charger sections to DC DB.
(iii) Two (2) (iv) One (1)
25.13 Module Type DG-1 (Electrically Controlled Circuit Breaker for Incomer from DG Set) a) b) c) d) e) f) One (1) One (1) One (1) One (1) Three (3) Six (6) Triple pole circuit breaker complete with all accessories and power operated mechanism as specified. Frequency meter. Voltmeter with selector switch. Remote/Local Selector switch. Current transformer for metering. Current Transformers for differential protection (out of this 3 Nos. will be supplied loose for mounting in DG set panel). Current transformer for relaying. Ammeter Selector Switch.
g) h)
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i) j) k)
One (1) One (1) One (1)
Ammeter Wattmeter of range 0-300 KW. Three pole voltage controlled definite time delay relay having current setting range of 50-200% of CT secondary current and adjustable time delay 0.3 to 3 secs. Watt hour meter with six (6) digits and minimum count of one (1) kWh. Single pole definite time over current relay having a continuous setting range of 50-200% of CT secondary current and a time delay of 2.5-25 seconds connected in CT of Y phase for overload alarm. The relay shall have a setting ratio of not less than 90%. Three pole differential protection relay having an operating current setting range of 10-40% of generator full load current. The relay shall be of high impedance type, with necessary stabilizing resistors. Push buttons for Remote starting & stopping of DG Set (Red, Green).
l) m)
One (1) One (1)
n)
One (1)
o)
Two (2)
25.14 Module Type H1 One (1) 25.15 Module Type EL (i) One (1) Four pole MCCB Contactor (ii) One (1) Double pole DC Switch with pad locking facility in off position.
(iii) Electronic Timer suitable for continuous operation, push button and selector switch be as per scheme requirement 26.0 PARAMETERS 26.1 Power Supply 26.1.1 AC System a) Voltage b) Frequency c) Combined variation d) Fault Level 26.1.2 DC System a) System b) Fault Level c) System Voltage 26.2 Control Supply Voltage a) Trip and closing coils
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3 phase, 4 wire, solidly earthed 415 Volts, 10% 50 Hz 5% 10% Absolute Sum in Voltage & frequency 20 kA (rms) 2 Wire, unearthed 220V 10% voltage 4 kA 50V 10%
220V DC Unearthed
216
b) Spring charging 26.3 Cubicle Data 26.3.1 Bus bar Rating a) Continuous for Vertical panels. b) Short time (1 sec. kA (rms) c) Momentary (kA) PEAK d) Ambient Temperature
220V DC Unearthed
As specified in `Bill of Materials' 20 kA 45 kA 50C
e) One Minute Power Frequency Withstand I. Power Circuit: II. Control Circuit: 26.3.2 Cubicle Colour Finish a) Interior b) Exterior 26.4 Circuit Breaker a) Type b) No. of poles c) Voltage & Frequency d) Rated Operating Duty e) Rated service short-circuit Breaking capacity (Ics) f) Short Circuit making current g) Short time withstand current for 1 sec. duration. h) Operating Mechanism current for 1 sec. duration. i) No. of auxiliary contacts j) Short Circuit breaking current I. II. AC Component DC Component 20 kA (RMS) As per IS: 13947 (Part 2) Air Break 3 415 10%, 50 HZ + 5% As per IS 20 kA (RMS) 45 kA (Peak) 20 kA (RMS) for 1 sec. Smoke Grey shade No.692 of IS: 5 Smoke Grey shade No.692 of IS: 5 2500 Volts (rms) 2500 Volts (rms)
20 kA (RMS) for 1 sec.
4 NO & 4 NC contacts for Purchaser's use on fixed portion of the cubicle
26.5 MOULDED CASE CIRCUIT BREAKER AC System a) No. of poles b) Voltage & Frequency
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50 HZ + 5% c) Rated Operating Duty d) Rated service short-circuit Breaking capacity (Ics) e) Short Circuit making current f) No. of auxiliary contacts g) Short Circuit breaking current I. II. 26.6 Meters a) Accuracy class b) One minute power frequency withstand test voltage in KV 26.7 Current Transformers a) Type b) Voltage class and frequency c) Class of Insulation d) Accuracy class metering CT e) Accuracy class protection CT f) Accuracy class differential protection g) Short Time Current Rating (for CTs Associated with circuit breakers) I. II. III. IV. Current Duration Dynamic Rating One minute power frequency withstand test voltage. 20 kA (RMS) One Second 45 kA (Peak) 2.5 kV (rms) Cast resin, Bar primary 650V, 50 Hz E or better Class 1, VA adequate for application but not less than 7.5 VA. 5 P 15, VA adequate for application, but not less than 7.5 VA. PS, KPV = 300V 2.5 2.0 AC Component DC Component 20 kA (RMS) As per IS 13947 As per IS As per IS 13947 As per IS 20 kA (RMS) 45 kA (Peak) 2 NO & 2 NC 4 kA 2 NO & 2 NC
26.8 Voltage Transformer a) Type b) Rated Voltage

Cast Resin
218
Primary Secondary c) Method of connection Primary Secondary d) Rated voltage factor e) Class of insulation f) One minute power frequency withstand voltage g) Accuracy class 26.9 Relay a) One minute power frequency withstand test
415/3 V 110/3 V
Star Star 1.1 continuous, 1.5 for 3 seconds E or better 2.5 KV (RMS)
0.5, not less than 20VA
2 kV (rms)
27.0 AUTOMATIC CONTROL OF OUTDOOR LIGHTING 27.1 EL-type module of 415V Main lighting distribution board and Emergency lighting distribution board and shall be controlled by timer and contactor module to facilitate its operation automatically. 28.0 AUTOMATIC SUPPLY CHANGEOVER Automatic changeover between Incomer I, Incomer II, and DG set is to be carried out during the failure of supply in one/or both the incomers. After the restoration of the supply, system shall be restored to normal condition automatically. The requirement of changeover under various conditions are as below: (i) Under normal conditions i.e. when supply is available in both the incomers, incomers I&II of 415 V Main switchboard, ACDB shall be in closed condition and Bus couplers and DG set breaker shall be in open condition. In case of failure of either of the sources, the incomer of that source shall trip and Bus-coupler shall get closed. On restoration of supply, normal conditions described above are to be established automatically. In case of failure of supply in both the sources, both incomers, incomers of ACDBs and ACDB Bus coupler shall trip and DG set breaker switched on. On restoration of one or both sources, DG set breaker shall trip, DG set stopped and conditions described in paragraph (i) /(ii) shall be restored.
(ii)
iii)
To avoid unnecessary operation of switchgear for momentary disturbances all changeovers from one state to another shall be initiated after a time delay, after the conditions warranting such change has been detected.
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CONTROL & RELAY PANEL
(RCP-W/O AUTO)
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CHAPTER - CONTROL & RELAY PANEL TECHNICAL SPECIFICATION FOR CONTROL & RELAY PANEL CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0
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Description Types of Panels Constructional Features Mounting Panel Internal Wiring Terminal Blocks Painting Mimic Diagram Name Plates and Markings Miscellaneous Accessories Earthing Indicating Instruments, Recorders & Transducers Annunciation System Switches Indicating Lamps Position Indicators Synchronizing Equipment Relays Transmission Line Protection Auto Reclosing Relay Line over Voltage Protection Relay Transformer Protection TEE Protection Differential Relays Tripping Relay Flag Relays Trip Circuit Supervision Relay DC Supply Supervision Relay Bus Bar Protection Weather Proof Relay Panels Disturbance Recorder Event Logger Distance of Fault Locator Time Synchronization Equipment
Page No. 222 222 223 223 224 225 225 226 226 227 227 229 231 232 232 233 234 235 238 239 239 242 242 243 243 243 243 244 245 248 249 250
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33.0 34.0 35.0 36.0 37.0
Relay Test Kit Type Tests Configuration of C&R Panels Erection and Maintenance Tool Equipments Tropicalisation
250 251 251 253 253
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CHAPTER - CRP
SECTON: CONTROL & PROTECTION PANELS

1.0 TYPE OF PANELS 1.1 Simplex Panel Simplex panel shall consist of a vertical front panel with equipment mounted thereon and having wiring access from rear for control panels & either front or rear for relay panels. In case of panel having width more than 800mm, double leaf-doors shall be provided. Doors shall have handles with either builtin locking facility or will be provided with pad-lock. 1.2 Duplex Panel Duplex panel shall be walk-in tunnel type comprising two vertical front and rear panel sections connected back-on-back by formed sheet steel roof tie members and a central corridor in between. The corridor shall facilitate access to internal wiring and external cable connections. In case of number of duplex panels located in a row side by side, the central corridor shall be aligned to form a continuous passage. Both ends of the corridor shall be provided with double leaf doors with lift off hinges. Doors shall have handles either with built-in locking facility or shall be provided with pad-locks. Separate cable entries shall be provided for the front and rear panels. However, inter-connections between front and back panels shall be by means of inter panel wiring at the top of the panel. 2.0 CONSTRUCTIONAL FEATURES 2.1 Control and Relay Board shall be of panels of simplex or duplex type design as indicated in bill of quantity. It is the responsibility of the Contractor to ensure that the equipment specified and such unspecified complementary equipment required for completeness of the protective/control schemes be properly accommodated in the panels without congestion and if necessary, provide panels with larger dimensions. No price increase at a later date on this account shall be allowed. However, the width of panels that are being offered to be placed in existing switchyard control rooms, should be in conformity with the space availability in the control room. 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-31 in accordance with IS: 2147. Panels shall be free standing, floor mounting type and shall comprise structural frames completely enclosed 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 base frame, front sheet and door frames, and 2.0mm for sides, door, top and bottom portions. There shall be sufficient reinforcement to provide level transportation and installation. All doors, removable covers and panels shall be gasketed all around with synthetic rubber gaskets Neoprene/EPDM generally conforming with provision of IS: 11149. However, XLPE gaskets can also be used for fixing protective glass doors. Ventilating louvers, if provided shall have screens and filters. The screens shall be made of either brass or GI wire mesh
2.2
2.3
2.4
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2.5
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 tune and smooth. Panels shall have base frame with smooth bearing surface, which shall be fixed on the embedded foundation channels/insert plates. Anti vibration strips made of shock absorbing materials that shall be supplied by the contractor, shall be placed between panel & base frame. Cable entries to the panels shall be from the bottom. Cable gland plate fitted on the bottom of the panel shall be connected to earthing of the panel/station through a flexible braided copper conductor rigidly. Relay panels of modern modular construction would also be acceptable.
2.6
2.7
2.8 3.0
MOUNTING 3.1 All equipment on and in panels shall be mounted and completely wired to the terminal blocks ready for external connections. The equipment on front of panel shall be mounted flush. 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 on the equipment shall be clearly visible. The Contractor shall carry out cut out, mounting and wiring of the free issue items supplied by others which are to be mounted in his panel in accordance with the corresponding equipment manufacturer's drawings. Cut outs if any, provided for future mounting of equipment shall be properly blanked off with blanking plate. The centre lines of switches, push buttons and indicating lamps shall be not less than 750mm from the bottom of the panel. The centre lines of relays, meters and recorders shall be not less than 450mm from the bottom of the panel The centre lines of switches, push buttons and indicating lamps shall be matched to give a neat and uniform appearance. Like wise the top lines of all meters, relays and recorders etc. shall be matched. No equipment shall be mounted on the doors. At existing station, panels shall be matched with other panels in the control room in respect of dimensions, colour, appearance and arrangement of equipment (centre lines of switches, push buttons and other equipment) on the front of the panel.
3.2
3.3
3.4
3.5
3.6 3.7.
4.0
PANEL INTERNAL WIRING 4.1 Panels shall be supplied complete 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 All wiring shall be carried out with 650V grade, single core, stranded copper conductor wires with PVC insulation. The minimum size of the multistranded copper conductor used for internal wiring shall be as follows:
4.2
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4.3
All circuits except current transformer circuits and voltage transfer circuits meant for energy metering - one 1.5 sq. mm per lead. All current transformer circuits - one 2.5 sq. mm per lead. Voltage transformer circuit (for energy meters): Two 2.5 sq. mm per lead.
All internal wiring shall be securely supported, neatly arranged, readily accessible and connected to equipment terminals and terminal blocks. Wiring gutters & troughs shall be used for this purpose. 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. Wire termination shall be made with solderless crimping type and tinned copper lugs, which firmly grip the conductor. Insulated 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. All wires directly connected to trip circuit breaker or device shall be distinguished by the addition of red coloured unlettered ferrule. Longitudinal troughs extending throughout the full length of the panel shall be preferred for inter panel wiring. Inter-connections to adjacent panel shall be brought out to a separate set of terminal blocks located near the slots of holes meant for taking the inter-connecting wires. Contractor shall be solely responsible for the completeness and correctness of the internal wiring and for the proper functioning of the connected equipments
4.4
4.5
4.6
4.7 5.0
TERMINAL BLOCKS 5.1 All internal wiring to be connected to external equipment shall terminate on terminal blocks. Terminal blocks shall be 650 V grade and have 10 Amps. continuous rating, moulded piece, complete with insulated barriers, stud type terminals, washers, nuts and lock nuts. Markings on the terminal blocks shall correspond to wire number and terminal numbers on the wiring diagrams. All terminal blocks shall have shrouding with transparent unbreakable material. Disconnecting type terminal blocks for current transformer and voltage transformer secondary leads shall be provided. Also current transformer secondary leads shall be provided with short circuiting and earthing facilities. At least 20% spare terminals shall be provided on each panel and these spare terminals shall be uniformly distributed on all terminal blocks. Unless otherwise specified, terminal blocks shall be suitable for connecting the following conductors of external cable on each side 5.5 All CT & PT circuits: minimum of two of 2.5 sq. mm copper. AC/DC Power Supply Circuits: One of 6 sq. mm aluminium. All other circuits: minimum of one of 2.5 sq. mm copper.
5.2
5.3 5.4
There shall be a minimum clearance of 250mm between the first row of terminal blocks and the associated cable gland plate or panel side wall. Also the clearance between two rows of terminal blocks edges shall be minimum of 150mm.
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5.6
Arrangement of the terminal block assemblies and the wiring channel within the enclosure shall be such that a row of terminal blocks is run in parallel and close proximity along each side of the wiring-duct to provide for convenient attachment of internal panel wiring. The side of the terminal block opposite the wiring duct shall be reserved for the owners external cable connections. All adjacent terminal blocks shall also share this field wiring corridor. All wiring shall be provided with adequate support inside the panels to hold them firmly and to enable free and flexible termination without causing strain on terminals. The number and sizes of the Owner's multi core incoming external cables will be furnished to the Contractor after placement of the order. All necessary cable terminating accessories such as gland plates, supporting clamps & brackets, wiring troughs and gutters etc. (except glands & lugs) for external cables shall be included the scope of supply.
5.7
6.0
PAINTING 6.1 6.2 6.3 All sheet steel work shall be phosphated in accordance with the IS: 6005 "Code of practice for phosphating iron and steel". Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with dilute acid followed by washing with running water rinsing with a slightly alkaline hot water and drying. After phosphating, thorough rinsing shall be carried out with clean 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 "flashing dried" while the second coat shall be stoved. 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 inspection of first coat of painting. The exterior colour of paint shall be of a slightly different shade to enable inspection of the painting. A small quantity of finished paint shall be supplied for minor touching up required at site after installation of the panels. In case the bidder proposes to follow any other established painting procedure like electrostatic painting, the procedure shall be submitted for owners review and approval.
6.4 6.5
6.6
6.7 6.8
7.0
MIMIC DIAGRAM 7.1 7.2 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 anodised aluminium or plastic of approved fast colour material, which shall be screwed on to the panel and can be easily cleaned. Painted overlaid mimic 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. Mimic bus colour will be decided by the owner/purchaser and shall be furnished to the successful bidder during engineering.
7.3
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7.4
When semaphore indicators are used for equipment position they shall be so mounted in the mimic that the equipment close 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
7.5 8.0
NAME PLATES AND MARKINGS 8.1 All equipment mounted on front and rear side as well as equipment mounted inside the panels shall be provided with individual name plates with equipment designation engraved. Also on the top of each panel on front as well as rear side, large and bold nameplates shall be provided for circuit/feeder designation. All front mounted equipment shall also be provided at the rear with individual name plates engraved with tag numbers corresponding to the one shown in the panel internal wiring to facilitate easy tracing of the wiring. Each instrument and meter shall be prominently marked with the quantity measured e.g. KV, A, MW, etc. All relays and other devices shall be clearly marked with manufacturer's name, manufacturer's type, serial number and electrical rating data. Name Plates shall be made of non-rusting metal or 3 ply lamicoid. Name plates shall be black with white engraving lettering. Each switch shall bear clear inscription identifying its function e.g. 'BREAKER' '52A', "SYNCHRONISING" etc. Similar inscription shall also be provided on each device whose function is not other-wise 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 indication e.g. "Trip- Neutral-Close", "ON-OFF", "R-Y-BOFF" etc. All the panels shall be provided with name plate mounted inside the panel bearing LOA No & Date , Name of the Substation & feeder and reference drawing number.
8.2
8.3
8.4 8.5
8.6
9.0
MISCELLANEOUS ACCESSORIES 9.1 Plug Point: 240V, Single phase 50Hz, AC socket with switch suitable to accept 5 Amps and 15 Amps pin round standard Indian plug, shall be provided in the interior of each cubicle with ON-OFF switch. Interior Lighting: Each panel shall be provided with a fluorescent lighting fixture rated for 240 Volts, single phase, 50 Hz supply for the interior illumination of the panel controlled by the respective panel door switch. Adequate lighting shall also be provided for the corridor in Duplex panels.
9.2
9.3 Switches and Fuses : Each panel shall be provided with necessary arrangements for receiving, distributing and isolating of DC and AC supplies for various control, signaling, lighting and space heater circuits. The incoming and sub-circuits shall be separately provided with miniature circuit breakers (MCB). Selection of the main and sub-circuit MCB rating shall be such as to ensure selective clearance of sub-circuit faults. MCBs shall confirm to IS: 13947. Each MCB shall be provided with one potential free contact and the same shall be wired for annunciation purpose. However voltage transformer circuits for relaying and metering shall be protected by
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fuses. All fuses shall be HRC cartridge type conforming to IS: 13703 mounted on plug-in type fuse bases. Fuse carrier base as well as MCBs shall have imprints of the fuse 'rating' and 'voltage'. 9.4 Space Heater: Each panel shall be provided with a space heater rated for 240V, single phase , 50 Hz Ac supply for the internal heating of the panel to prevent condensation of moisture. The fittings shall be complete with switch unit.
10.0 EARTHING 10.1 All panels shall be equipped with an earth bus securely fixed. 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 25x6 sq. mm perforated copper with threaded holes at a gap of 50mm with a provision of bolts and nuts for connection with cable armours and mounted equipment etc for effective earthing. 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. Provision shall be made on each bus bar of the end panels for connecting Substation earthling grid. Necessary terminal clamps and connectors for this purpose shall be included in the scope of supply of Contractor. All metallic cases of relays, instruments and other panel mounted equipment including gland plate, shall be connected to the earth bus by copper wires of size not less than 2.5 sq. mm. The colour code of earthing wires shall be green. Looping of earth connections which would result in loss of earth connection to other devices when 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. 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.
10.2
10.3
10.4
10.5
11.0 INDICATING INSTRUMENTS, RECORDERS & TRANSDUCERS All instruments, meters, recorders and transducers shall be enclosed in dust proof, moisture resistant, black finished cases and shall be suitable for tropical use. All megawatt, megaVAR, bus voltage and frequency indicating instruments shall be provided with individual transducers and these shall be calibrated along with transducers 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. The supplier shall submit calibration certificates at the time of delivery. However no separate transducers are envisaged for digital bus voltmeters and digital frequency meters and the indicating meters provided in the synchronising equipment. 11.1 Indicating Instruments 11.1.1 Unless otherwise specified, all electrical indicating instruments shall be of digital type suitable for flush mounting.
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11.1.2 11.1.3
Instruments shall have 4-digit display; display height being not less than 25 mm. Instrument shall confirm to relevant IS and shall have an accuracy class of 1.5 or better Watt and VAR meters shall have an indication of (+) and (-) to indicate EXPORT and IMPORT respectively. Digital voltage and frequency meters shall be of class: 0.5 and shall have digital display of 5 and 4 digits respectively, with display size, not less than 25mm (height).
11.1.4
11.2
Bus Voltage & Frequency Recording Instruments 11.2.1 Recording instruments shall be square or rectangular in shape and shall be suitable for flush mounting on panels. They shall be of draw out type and suitable for back connection. Recorders shall be furnished in dust tight metal cases with gasketed doors and they shall be designed so as to require minimum maintenance. The recorder shall i. ii. iii. iv. v. vi. be single pen type employing potentionmeteric servo drive principle. be of continuous recording type with disposable fibre tip cartridge pens, employing ink on paper. have a Calibrated Chart width of at least 100 mm and a viewing area of 100x50 mm, at least. have an accuracy of + 1.0% span. have full span response time of less than 2 seconds. have maximum chart speed facility of 60mm per hour.
11.2.2
11.2.3
vii. be directly calibrated for CT and PT ratios in use. viii. be provided with chart rolls of adequate length requiring replacement, not earlier than 27 days. The quantity of chart rolls and ink included with the offer shall be 1000 metre length of paper and five pens with each recorder. ix. be suitable for operation with station DC source, in case of AC supply (230 volts, 1 phase, 50Hz) failure (inverter may be included, if required).
11.2.4
Alternatively, Static/Digital type frequency recorder and voltage recorder either as individual units or composite unit for total substation with time tagged information shall also be acceptable if it meets the accuracy of + 1.0% span and full span response time of less than 2 seconds. The static/digital shall also meet the high voltage susceptibility test, impulse voltage with stand test, high frequency disturbance test class III and fast transient disturbance test level III as per IEC: 60255.
11.3
Transducers 11.3.1 Transducers (for use with Indicating Instruments and Telemetry/Data Communication application) shall in general conform to IEC: 688-1
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11.3.2
The transducers shall be suitable for measurement of active power, reactive power, voltage, current and frequency in three phase four wire unbalanced system. The input to the transducers will be from sub-station current & potential transformers. The output shall be in milli ampere D.C. proportional to the input & it shall be possible to feed the output current directly to the telemetry terminal or indicating instruments. The transducer characteristic shall be linear throughout the measuring range. The transducer output shall be load independent. The input & output of the transducer shall be galvanically isolated. The transducer shall derive its auxiliary supply from the quantity to be measured without need for any external auxiliary supply. Each transducer shall be housed in a separate compact case and have suitable terminals for inputs & outputs. The transducers shall be suitably protected against transient high peaks of voltage & current.
11.3.3
11.3.4 11.3.5 11.3.6 11.3.7 11.3.8 11.3.9
11.3.10 The transducer shall withstand indefinitely without damage and work satisfactorily at 120% of the rated voltage and 120% of the rated input current as applicable. 11.3.11 The voltage, frequency & current transducers shall have an output of 0-10mA and the active & reactive power transducer shall have an output of 10-0-10 mA. 11.3.12 The response time of the transducers shall be less than 1 second. 11.3.13 The accuracy class of transducers shall be 1.0 or better for voltage/current transducer, 0.5 or better for watt/VAR transducer and 0.2 or better for frequency transducer. 11.3.14 The transducers shall have a low AC ripple on output less than 1%. 11.3.15 The transducers shall be suitable for load resistance of 1000-1500 11.3.16 The transducer shall have dual output. 12.0 ANNUNCIATION SYSTEM 12.1 Alarm annunciation system shall be provided in 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 on the voltages specified in this specification. The visual annunciation shall be provided by annunciation facia, mounted flush on the top of the control panels. The annunciator facia shall be provided with translucent plastic window for alarm point with approximate size of 35mm x 50mm. The facia plates shall be engraved in black lettering with respective inscriptions. Alarm inscriptions shall be engraved on each window in not more than three lines and size of the lettering shall not be less than 5 mm. Each annunciation window shall be provided with two white lamps in parallel to provide safety against lamp failure. Long life lamps shall be
12.2 12.3
12.4
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used. The transparency of cover plates and wattage of the lamps provided in the facia windows shall be adequate to ensure clear visibility of the inscriptions in the control room having high illumination intensity (350 Lux), from the location of the operator's desk. 12.5 12.6 All Trip facia shall have red colour and all Non-trip facia shall have white colour. The audible alarm shall be provided by Buzzer/ Hooter /Bell having different sounds and shall be used as follows. Hooter Bell Buzzer 12.7 Alarm Annunciation Annunciation DC failure AC supply failure
Sequence of operation of the annunciator shall be as follows:

Sl. Alarm Condition No. 1. Normal 2. Abnormal 3. Accept Push Button Pressed 4. 5. Reset Push Button Pressed Lamp Test Push Button Pressed Fault Contact Open Close Close Open Close Open Open Visual Annunciation OFF Flashing Steady On Steady On On Off Steady On Audible Annunciation OFF ON OFF OFF OFF OFF OFF
12.8
Audible annunciation for the failure of DC supply to the annunciation system shall be provided and this annunciation shall operate on 240 Volts AC supply. On failure of the DC to the annunciation system for more than 2 or 3 seconds. (adjustable setting), a bell shall sound. A separate push button shall be provided for the cancellation of this audible alarm alone but the facia window shall remain steadily lighted till the supply to annunciation system is restored. A separate voltage check relay shall be provided to monitor the failure of supply (240V AC) to the scheme mentioned in Clause above. If the failure of supply exists for more than 2 to 3 seconds. This relay shall initiate visual and audible annunciation. Visual and audible annunciation for the failure of AC supply to the annunciation system shall be provided and this annunciation shall operate on Annunciation DC and buzzer shall sound.
12.9
12.10 The annunciation system described above shall meet the following additional requirements: a) The annunciation system shall be capable of catering to at least 20 simultaneous signals at a time. b) One set of the following push buttons shall be provided on each control panel: Reset push button for annunciation system. Accept push button for annunciation system. Lamp test push button for testing the facia windows
c) One set of the following items shall be provided common for all the control panel (not applicable for extension of substation) :
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231
Push button for Flasher test. Three Push buttons for test of all audible alarm systems
d) These testing circuits shall be so connected that while testing is being done it shall not prevent the registering of any new annunciation that may land during the test e) The annunciation shall be repetitive type and shall be capable of registering the fleeting signal. Minimum duration of the fleeting signal registered by the system shall be 15 milli seconds. f) In case of static annunciator scheme, special precaution shall be taken to ensure that spurious alarm condition does not appear due to influence of external electromagnetic/ electrostatic interference on the annunciator wiring and switching disturbances from the neighbouring circuits within the panels and the static annunciator shall meet the high voltage susceptibility test , impulse voltage with stand test , high frequency disturbance test class III and fast transient disturbance test level III as per IEC 60255. 12.11 The annunciation system to be supplied for existing sub-stations shall be engineered as an extension to the existing scheme. 13.0 SWITCHES 13.1 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. The selection of operating handles for the different types of switches shall be as follows: Breaker, Isolator: Synchronising: Pistol grip, black control switches Oval, Black, Keyed handle switches (one common removable handle for a group of synchronising switches or locking facility having common key). Oval or knob, black Round, knurled, black Pistol grip, lockable and switch black.
13.2
Selector switches: Instrument switches: Protection Transfer: 13.3
The control switch of breaker and isolator shall be of spring return to neutral type. The 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 have make-before-break type contacts so as to prevent open circuiting of CT secondary when changing the position of the switch. Voltmeter transfer switches for AC shall be suitable for reading all line- to-line and line-to-neutral voltages for none effectively earthed systems and for reading all line to line voltages for effectively earthed systems. Synchronizing switches shall be of maintained contact (stay put) type having a common removable handle for a group of switches. The handle shall be removable only in the OFF position and it shall be coordinated to fit in to all the synchronising switches. These switches shall be arranged to connect the synchronising equipment when turned to the ON position. One contact of
13.4
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each switch shall be connected in the closing circuit of the respective breaker so that the breaker cannot be closed until the switch is turned to the 'ON' position. 13.6 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 minimise arcing. Contacts of switches shall be spring assisted and contact faces shall be with rivets of pure silver or silver alloy. Springs shall not 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: Sl. No. 1. 2. 3. 4. Description Make and carry Continuously Make and carry for 0.5 sec. Break for: Resistive load Inductive load with L/R=40m sec. Contact rating in Amps. 220 V DC 50V DC 240V AC 10 10 10 30 30 30 3 20 7 0.2 -
13.7
13.8 13.9
14.0 INDICATING LAMPS 14.1 Indicating lamps shall be of cluster LED type suitable for panel mounting with rear terminal connections. .Lamps shall be provided with series connected resistors preferably built in the lamp assembly. Lamps shall have translucent lamp covers to diffuse lights coloured red ,green, amber ,clear white or blue as specified .The lamp cover shall be preferably of screwed type ,unbreakable and moulded from heat resisting material. The lamps shall be provided with suitable resistors. Lamps 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 the supply. The indicating lamps with resistors shall withstand 120% of rated voltage on a continuous basis.
14.2 14.3
14.4
15.0 POSITION INDICATORS 15.1 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. Position indicator shall be suitable for DC Voltage 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 mimic bus bars, and at right angles to them when the object is in the open position. When the supply failure to the indicator occurs, the pointer shall take up an intermediate position to indicate the supply failure.
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15.3 15.4
The rating of the indicator shall not exceed 2.5 W. The position indicators shall withstand 120% of rated voltage on a continuous basis.
16.0 SYNCHRONISING EQUIPMENT 16.1 The synchronising instruments shall be mounted either on a synchronising trolley or on a synchronising panel. The panel/ trolley shall be equipped with double analog voltmeters and double analog frequency meters, synchroscope and lamps fully wired. The size of voltmeters and frequency meters provided in the synchronising panel shall not be less than 144x144 sq. mm. Suitable auxiliary voltage transformers wherever necessary shall also be provided for synchronising condition. In case the synchroscope is not continuously rated, a synchroscope cut-off switch shall be provided and an indicating lamp to indicate that the synchroscope is energised, shall also be provided Synchronising check relay with necessary ancillary equipments shall be provided which shall permit breakers to close after checking the requirements of synchronising of incoming and running supply. The phase angle setting shall not exceed 35 degree and have voltage difference setting not exceeding 10%. This relay shall have a response time of less than 200 milliseconds when the two system conditions are met within present limits and with the timer disconnected. The relay shall have a frequency difference setting not exceeding 0.45% at rated value and at the minimum time setting. The relay shall have a continuously adjustable time setting range of 0.5-20 seconds. A guard relay shall be provided to prevent the closing attempt by means of synchronising check relay when control switch is kept in closed position long before the two systems are in synchronism The synchronising panel shall be draw out and swing type which can be swiveled in left and right direction. The synchronising panel shall be placed along with control panels and the number of synchronising panel shall be as indicated in BPS. The incoming and running bus wires of VT secondary shall be connected and run as bus wires in the control panels and will be extended to synchronising panel for synchronisation of circuit breakers. The selector switch provided for each circuit breaker in respective control panels shall be lockable type with a common key so that only one selector switch is kept in synchronising mode at a time. Alternatively, the trolley shall be of mobile type with four rubberpadding wheels capable of rotating in 360 degree around the vertical axis. Suitable bumpers with rubber padding shall be provided all around the trolley to prevent any accidental damage to any panel in the control room while the trolley is in movement. The trolley shall have two meter long flexible cord fully wired to the instruments and terminated in a plug in order to facilitate connecting the trolley to any of the panels. The receptacle to accept the plug shall be provided on the panel. At existing sub-stations, the synchronising scheme shall be engineered to be compatible with the existing synchronising scheme and synchronising socket/switch on the panel. In substations, where synchronising panels are available, the bidder shall carry out the shifting of the above panels, if required , to facilitate the extension of control panel placement .
16.2
16.3
16.4
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17.0 RELAYS 17.1 All relays shall conform to the requirements of IS: 3231/IEC-60255 or other applicable standards. Relays shall be suitable for flush or semi-flush mounting on the front with connections from the rear. All protective relays shall be in draw out or plug-in type/modular cases with proper testing facilities. Necessary test plugs/test handles shall be supplied loose and shall be included in contractor's scope of supply. All AC operated relays shall be suitable for operation at 50 Hz. AC Voltage operated relays shall be suitable for 110 Volts VT secondary and current operated relays for 1 amp CT secondary. All DC operated relays and timers shall be designed for the DC voltage specified, and shall operate satisfactorily between 80% and 110% of rated voltage. Voltage operated relays shall have adequate thermal capacity for continuous operation. 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 circuits etc. also required for the complete protection schemes described in the specification shall be provided. 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 case shall have adequate number of terminals for making potential free external connections to the relay coils and contacts, including spare contacts. 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 with inscription. All protective relays which do not have built-in hand-reset operation indicators shall have additional auxiliary relays with operating indicators (Flag relays) for this purpose. Similarly, separate operating indicator (auxiliary relays) shall also be provided in the trip circuits of protections located outside the board such as Buchholtz relays, oil and winding temperature protection, sudden pressure devices, fire protection etc. Timers shall be 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 preferred and shall be avoided to the extent possible. No control relay which shall trip the power circuit breaker when the relay is deenergised shall be employed in the circuits. Provision shall be made for easy isolation of trip circuits of each relay for the purpose of testing and maintenance. 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:
17.2
17.3
17.4
17.5
17.6
17.7 17.8 17.9
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(a)
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. Seal-in-unit shall obtain adequate current for operation when one or more relays operate simultaneously. Impedance of the seal-in-unit shall be small enough to permit satisfactory operation of the trip coil on trip relays when the D.C. Supply Voltage is minimum.
(b) (c)
17.10 All protective relays and alarm relays shall be provided with one extra isolated pair of contacts wired to terminals exclusively for future use. 17.11 The setting ranges of the relays offered, if different from the ones specified shall also be acceptable if they meet the functional requirements. 17.12 Any alternative/additional protections or relays considered necessary for providing complete effective and reliable protection shall also be offered separately. The acceptance of this alternative/ additional equipment shall lie with the owner. 17.13 The bidder shall include in his bid a list of installations where the relays quoted have been in satisfactory operation. 17.14 All relays and their drawings shall have phase indications as R-Red, Y-yellow, B-blue 17.15 Wherever numerical relays are used, the scope shall include the following: a) Necessary software and hardware to up/down load the data to/from the relay from/to the personal computer installed in the substation. However, the supply of PC is not covered under this clause. The relay shall have suitable communication facility for future connectivity to SCADA. The relay shall be capable of supporting IEC: 870-5-103 protocol Neither the interface hardware nor the software for connectivity to SCADA will form part of the scope of this specification. 18.0 TRANSMISSION LINE PROTECTION 18.1 The line protection relays are required to protect the line and clear the faults on line within shortest possible time with reliability, selectivity and full sensitivity to all type of faults on lines. The general concept is to have two main protections having equal performance requirement especially in respect of time as called Main-I and Main-II and back up protection for 132 kV lines. The Transmission system for which the line protection equipment are required is shown in the reference drawing/document(s). The length of lines and the line parameters (Electrical Constants) are also indicated there. The maximum fault current could be as high as 40 kA but the minimum fault current could be as low as 20% of rated current of CT secondary. The starting & measuring relays characteristics should be satisfactory under these extremely varying conditions. The protective relays shall be suitable for use with capacitor voltage transformers having non-electronic damping and transient response as per IEC. 18.5. Disturbance Recorder, Distance to fault Locator and Over voltage relay (stage -1) functions if offered as an integral part of line protection
b)
18.2
18.3
18.4
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relay, shall be acceptable provided these meet the technical requirements as specified in the respective clauses. 18.6 Auto reclose relay function if offered as an integral part of line distance protection relay, shall be acceptable for 132 KV lines provided the auto reclose relay feature meets the technical requirements as specified in the respective clause. The following protections shall be provided for each of the Transmission lines: For 132 kV Main: Numerical distance protection scheme
18.7
Back up: Directional over current and Earth fault Protection 18.8 However, Phase segregated phase/direction comparison protection, Protection based on directional wave detection principle, phase segregated line differential protection as Main 2 protection in place of static distance protection scheme shall be provided if specified in the SectionProject . The technical specifications of the above protections are spelt in APPENDIX - A to this chapter. Further, if specified in the Section- Project , back up Over current and Earth fault protection shall be provided instead of Main -II protection scheme for 132 kV lines to match with requirements at the remote ends.
18.9
18.10 The detailed description of the above line protections is given here under. 18.10.1 Main-I & Main-II Numerical Distance Protection scheme: (a) (b) (c) (d) (e) shall be numerical type and shall have continuous self monitoring and diagnostic feature. shall be non-switched type with separate measurements for all phase to phase and phase to ground faults shall have stepped time-distance characteristics and three independent zones (zone 1, zone-2 and zone-3) shall have mho or quadrilateral or other suitably shaped characteristics for zone-1, zone-2 and zone- 3. shall have following maximum operating time (including trip relay time, if any) under given set of conditions and with CVT being used on line (with all filters included). For 132 KV lines:
Source to Impedance ratio Relay setting (Ohms) Fault Locations (as % of relay setting) Fault resistance (Ohms) Maximum operating time (Milliseconds) 4 15 (10 or 20) and 2 50 0 45 for all faults 50 0 50 for 3 ph. Faults & 65 for all other faults. 2
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(f)
The relay shall have an adjustable characteristics angle setting range of 30-75 degree or shall have independent resistance (R) and reactance (X) setting. shall have two independent continuously variable time setting range of 0-3 seconds for zone-2 and 0-5 seconds for zone-3. shall have resetting time of less than 55 milli-second (including the resetting time of trip relays) shall have facilities for offset features with adjustable 1020% of Zone-3 setting. shall have variable residual compensation. shall have memory circuits with defined characteristics in all three phases to ensure correct operation during close-up 3 phase faults and other adverse conditions and shall operate instantaneously when circuit breaker is closed to zero-volt 3 phase fault shall have weak end in-feed feature
(g) (h) (i) (j) (k)
(l)
(m) shall be suitable for single & three phase tripping. (n) shall have a continuous current rating of two times of rated current. The voltage circuit shall be capable of operation at 1.2 times rated voltage. The relay shall also be capable of carrying a high short time current of 70 times rated current without damage for a period of 1 sec. shall be provided with necessary self reset type trip duty contacts for completion of the scheme (Minimum number of these trip duty contacts shall be four per phase) either through built in or through separate high speed trip relays . Making capacity of these trip contacts shall be 30 amp for 0.2 seconds with an inductive load of L/R > 10 mill seconds. If separate high speed trip relays are used, the operating time of the same shall not be more than 10 milliseconds shall be suitable for use in permissive under reach / over reach /blocking communication mode . shall have suitable number of potential free contacts for Carrier aided Tripping, Auto reclosing, Event Logger, Disturbance recorder & Data acquisition system. include power swing blocking protection which shall (s) have suitable setting range to encircle the distance protection described above. block tripping during power swing conditions.
(o)
(p) (q)
(r)
include fuse failure protection which shall monitor all the three fuses of C.V.T. and associated cable against open circuit. inhibit trip circuits on operation and initiate annunciation. have an operating time less than 7 milliseconds remain inoperative for system earth faults
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(t)
include a directional back up Inverse Definite Minimum Time (IDMT) earth fault relay with normal inverse characteristics as per IEC: 60255-3 as a built in feature. In case the numerical distance relay is not having the built in feature as per above clause (t), the same can be supplied as an independent relay
(u)
18.10.2 Back-up Directional Over Current and Earth fault protection scheme (a) (b) (c) (d) shall have three over current and one earth fault element(s) which shall be either independent or composite unit(s shall be electromechanical /static/ Numerical type The scheme shall include necessary VT fuse failure relays for alarm purposes . Directional over current relay shall (e) have IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting have a variable setting range of 50-200% of rated current have a characteristic angle of 30/45 degree lead include hand reset flag indicators or LEDs.
Directional earth fault relay shall have IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting have a variable setting range of 20-80% of rated current have a characteristic angle of 45/60 degree lag include hand reset flag indicators or LEDs. include necessary separate interposing voltage transformers or have internal feature in the relay for open delta voltage to the relay.
18.10.3 All trip relays used in transmission line protection scheme shall be of self/electrical reset type depending on application requirement. 19.0 AUTO RECLOSING RELAY shall (a) (b) (c) (d) (e) have single phase or/and three phase reclosing facilities. have a continuously variable single phase dead time range of 0.1-2 seconds. have a continuously variable three phase dead time range of 0.1-2 seconds. have a continuously variable reclaim time range of 5-25 seconds. incorporate a four-position selector switch/ from which single phase/three phase/single and three phase auto reclosure and non-auto reclosure mode can be selected. Alternatively, the mode of auto reclosing can be selected through programming.
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(f)
have facilities for selecting check synchronising or dead line charging features. It shall be possible at any time to change the required feature by reconnection of links. be of single shot type. have priority circuit to closing of both circuit breakers in case one and half breaker arrangements to allow sequential closing of breakers be acceptable as built in with line distance relay for 132 KV include check synchronising relay which shall have a time setting continuously variable between facility of additional 10 seconds. 0.5-5 seconds. With a
(g) (h) (i) (j)
have a response time within 200 milli seconds with the timer disconnected. have a phase angle setting not exceeding 35 degree have a voltage difference setting not exceeding 10%
(k)
include dead line charging relay which shall have two sets of relays and each set shall be able to monitor the three phase voltage where one set shall be connected to the line CVTs with a fixed setting of 20% of rated voltage and the other set shall be connected to the bus CVTs with a fixed setting of 80% of rated voltage. incorporate necessary auxiliary relays and timers to give comprehensive scheme.
20.0 LINE OVER VOLTAGE PROTECTION RELAY shall (a) (b) (c) (d) (e) (f) (g) (h) monitor all three phases have two independent stages and stage- 1 & II relay are acceptable as built in with line distance relays Main I & II respectively . have an adjustable setting range of 100-170% of rated voltage with an adjustable time delay range of 1 to 60 seconds for the first stage. have an adjustable setting range of 100-170% of rated voltage with a time delay of 100-200 mill seconds for the second stage. be tuned to power frequency provided with separate operation indicators (flag target) for each stage relays. have a drop-off to pick-up ratio greater than 95%. provide separate out-put contacts for each 'Phase' and stage for breaker trip relays, event logger and other scheme requirements.
21.0 TRANSFORMER PROTECTION 21.1 Transformer differential protection scheme shall (a) (b) (c) (d)
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240
(e) (f)
be suitable for rated current of 1 Amp. have second harmonic or other inrush proof features and also should be stable under normal over fluxing conditions. Magnetising inrush proof feature shall not be achieved through any intentional time delay e.g. use of timers to block relay operation or using disc operated relays. have an operating current setting of 15% or less include necessary separate interposing current transformers for angle and ratio correction or have internal feature in the relay to take care of the angle & ratio correction. shall be numerical type and shall have continuous self monitoring and diagnostic feature have a disturbance recording feature to record graphic form of instantaneous values of current in all three windings in 6 analogue channels during faults and disturbances for the pre fault and post fault period. The disturbance recorder shall have the facility to record the following external digital channel signals apart from the digital signals pertaining to differential relay. 1. REF protection operated 2. HV breaker status (Main and tie) 3. LV breaker status 4. Bucholtz /OLTC Bucholtz alarm / trip 5. WTI/OTI/PRD alarm/trip of transformer Necessary hardware and software for down loading the data captured by disturbance recorder to the personal computer available in the substation shall be included in the scope .
(g) (h)
(i) (j)
(k)
be acceptable with built in features of definite time over load protection (alarm) relay provided the technical requirements of these relays specified under the relevant clauses are met.
21.2
Over fluxing protection Relays shall (a) (b) (c) (d) operate on the principle of Voltage to frequency ratio and shall be phase to phase connected have inverse time characteristics, matching with transformer over fluxing withstand capability curve provide an independent 'alarm' with the time delay continuously adjustable between 0.1 to 6.0 seconds at values of 'v/f' between 100% to 130% of rated values tripping time shall be governed by 'v/f' Vs. time characteristics of the relay have a set of characteristics for various time multiplier settings. The maximum operating time of the relay shall not exceed 3 seconds and 1.5 seconds at 'v/f' values of 1.4 and 1.5 times, the rated values, respectively. have an accuracy of operating time, better than 10%.
(e) (f)
(g)
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(h) 21.3
have a resetting ratio of 95 % or better.
Restricted Earth Fault Protection shall (a) (b) (c) (d) (e) be single pole type be of current/voltage operated high impedance type have a current setting range of 10-40% of 1 Amp./ have a suitable voltage setting range. be tuned to the system frequency have suitable non-linear resistor to limit the peak voltage to 1000 Volts.
21.4
Back-up Over Current and Earth fault protection scheme with high set feature (a) (b) (c) (d) Shall have three over current and one earth fault element(s) which shall be either independent or composite unit(s). shall be electromechanical /static/ Numerical type The scheme shall include necessary VT fuse failure relays for alarm purposes Over current relay shall have directional IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting and have a variable setting range of 50-200% of rated current have low transient, over reach high set instantaneous unit of continuously variable setting range 500-2000 % of rated current have a characteristic angle of 30/45 degree lead include hand reset flag indicators or LEDs.
(e)
Earth fault relay shall have directional IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting and have a variable setting range of 20-80% of rated current have low transient, over reach high set instantaneous unit of continuously variable setting range 200-800 % of rated current have a characteristic angle of 45/60 degree lag include hand reset flag indicators or LEDs include necessary separate interposing voltage transformers or have internal feature in the relay for open delta voltage to the relay
21.5
Transformer Overload Protection Relay shall (a) (b) (c) (d) be of single pole type be of definite time over-current type and built in feature with differential relay shall also be acceptable . have one set of over-current relay element, with continuously adjustable setting range of 50-200% of rated current have one adjustable time delay relay for alarm having setting range of 1 to 10.0 seconds, continuously.
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(e) 21.6
have a drop-off/pick-up ratio greater than 95%.
LOCAL BREAKER BACK-UP PROTECTION SCHEME shall (a) (b) (c) be triple pole type be of solid-state type have an operating time of less than 15 milli seconds
(d) (e) (f)
have a resetting time of less than 15 milli seconds have three over current elements be arranged to get individual initiation from the corresponding phase of main protections of line for each over current element. However, common three phase initiation is acceptable for other protections and transformer /reactor equipment protections have a setting range of 20-80% of rated current have a continuous thermal withstand two times rated current irrespective of the setting have a timer with continuously adjustable setting range of 0.1-1 seconds have necessary auxiliary relays to make a comprehensive scheme.
(g) (h) (i) (j)
22.0 TEE PROTECTION DIFFERENTIAL RELAYS 22.1 TEE-1 differential protection relays shall (a) (b) (c) (d) (e) 22.2 be triple pole type have an operating time less than 30 milliseconds at 5 times the rated current. have three instantaneous high set over current units have an adjustable bias setting range of 20-50% have an operating current setting of 15% of 1 Amp or less
TEE-2 Differential relay shall (a) (b) (c) (d) (e) (f) (g) be triple pole type have operating time less than 25 milliseconds at 5 times setting be tuned to system frequency have current setting range of 20 to 80% of 1 Amp be voltage operated, high impedance type be stable for all external faults be provided with suitable non linear resistors across the relay to limit the peak voltage to 1000 volts
23.0 TRIPPING RELAY High Speed Tripping Relay shall (a) (b) be instantaneous (operating time not to exceed 10 milli-seconds). reset within 20 milli seconds
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(c) (d)
be D.C. operated have adequate contacts to meet the requirement of scheme, other functions like auto-reclose relay, LBB relay as well as cater to associated equipment like event logger, Disturbance recorder, fault Locator, etc. be provided with operation indicators for each element/coil.
(e)
24.0 FLAG RELAYS These shall have (a) (b) hand reset flag indication have minimum two contacts (NO or NC or combination as required) for each relay
25.0 TRIP CIRCUIT SUPERVISION RELAY (a) The relay shall be capable of monitoring the healthiness of each 'phase' trip-coil and associated circuit of circuit breaker during 'ON' and 'OFF' conditions. The relay shall have adequate contacts for providing connection to alarm and event logger. The relay shall have time delay on drop-off of not less than 200 milli seconds and be provided with operation indications for each phase.
(b) (c)
26.0 DC SUPPLY SUPERIVISION RELAY (a) (b) (c) The relay shall be capable of monitoring the failure of D.C. supply to which, it is connected. It shall have adequate potential free contacts to meet the scheme requirement. The relay shall have a 'time delay on drop-off' of not less than 100 milli seconds and be provided with operation indicator/flag.
27.0 BUS BAR PROTECTION 27.1 27.3 Single bus bar protection scheme shall be provided for each main and transfer bus. Each Bus Bar protection scheme shall (a) (b) (c) (d) have maximum operating time up to trip impulse to trip relay for all types of faults of 25 milli seconds at 5 times setting value. operate selectively for each bus bar give hundred percent securities up to 31.5 kA for 132 kV. incorporate continuous supervision for CT secondary against any possible open circuit and if it occurs, shall render the relevant zone of protection inoperative and initiate an alarm not give false operation during normal load flow in bus bars. incorporate clear zone indication. be of phase segregated and triple pole type
(e) (f) (g)
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(h)
provide independent zones of protection (including transfer bus if any). If the bus section is provided then each side of bus section shall have separate set of bus bar protection schemes include individual high speed hand reset tripping relays for each feeder be transient free in operation include continuous D.C. supplies supervision. not cause tripping for the differential current below the load current of heaviest loaded feeder. Bidder shall submit application check for the same.
(i) (j) (k) (l)
(m) shall include necessary C.T. switching relays wherever C.T. switching is involved and have 'CT' selection incomplete alarm (n) (o) include protection 'IN/OUT' switch for each zone shall include trip relays, CT switching relays(if applicable), auxiliary CTs (if applicable) as well as additional power supply modules, input modules etc. as may be required to provide a Bus-bar protection scheme for the complete bus arrangement i.e. for all the bay or breakers under this specification as well as for the future bays as per the Single line diagram for new substations. However for extension of bus bar protection scheme (if specified in BPS) in existing substations, scope shall be limited to the bay or breakers covered under this specification. Suitable panels to mount these are also included in the scope of the work.
27.4 27.5
Built-in Local Breaker Backup protection feature as a part of bus bar protection scheme shall also be acceptable. At existing substations, Bus-bar protection scheme with independent zones for each bus will be available. All necessary co-ordination for 'AC' and 'DC' interconnections between existing schemes (Panels) and the bays proposed under the scope of this contract shall be fully covered by the bidder. Any auxiliary relay, trip relay, flag relay and multi tap auxiliary CTs (in case of biased differential protection) required to facilitate the operation of the bays covered under this contract shall be fully covered in the scope of the bidder.
28.0 WEATHER PROOF RELAY PANELS (a) This panel shall include necessary number of electrically reset relays each with at least eight contacts for isolator auxiliary contacts multiplication and for changing the CT and DC circuits to relevant zones of bus bar protection. The panel shall be sheet steel enclosed and shall be dust, weather and vermin proof. Sheet steel used shall be at least 2.0 mm thick and properly braced to prevent wobbling. The enclosures of the panel shall provide a degree of protection of not less than IP-55 (as per IS: 2147). The panel shall be of free standing floor mounting type or pedestal mounting type as per requirement. The panel shall be provided with double hinged doors with padlocking arrangement. All doors, removable covers and panels shall be gasketed all around with synthetic rubber gaskets Neoprene/EPDM generally conforming to provision of
(b)
(c) (d) (e) (f)
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IS: 11149. However, XLPE gaskets can also be used for fixing protective glass doors. Ventilating louvers, if provided shall have screens and filters. The screens shall be made of either brass or GI wire mesh (g) Cable entries shall be from bottom. Suitable removable cable gland plate shall be provided on the cabinet for this purpose. (h) All sheet steel work shall be degreased, pickled, phosphated and then applied with two coats of zinc chromates primer and two coats of finishing synthetic enamel paint, both inside and outside. The colour of the finishing paint shall be light grey in accordance with shade no.697 of IS: 5. (i) Suitable heaters shall be mounted in the panel to prevent condensation. Heaters shall be controlled by thermostats so that the cubicle temperature does not exceed 30oC. On-off switch and fuse shall be provided. Heater shall be suitable for 240V AC supply Voltage. The test terminal blocks (TTB) to be provided shall be fully enclosed with removable covers and made of moulded, non-inflammable plastic material with boxes and barriers moulded integrally. All terminals shall be clearly marked with identification numbers or letters to facilitate connection to external wiring. Terminal block shall have shorting, disconnecting and testing facilities for CT circuits.
(j)
29.0 DISTURBANCE RECORDER 29.1 Disturbance recorder shall be microprocessor based and shall be used to record the graphic form of instantaneous values of voltage and current in all three phases, open delta voltage & neutral current, open or closed position of relay contacts and breakers during the system disturbances and built in feature of line distance relay is acceptable provided the requirements of following clauses are met The disturbance recorder shall consist of individual acquisition units, one for each feeder and an Evaluation unit which is common for the entire Substation. Whenever, more than one acquisition units are connected to an Evaluation unit, necessary hardware and software shall also be supplied for on line transfer of data from all acquisition units to Evaluation unit. If there are any constraints for one Evaluation unit to accept the data from number of acquisition units under the present scope, adequate number of Evaluation units shall be supplied. In case of extension of existing substation(s), one set of Evaluation unit shall be supplied for each substation where ever disturbance recorders are specified. Disturbance recorder shall have 8 analogue and 16 digital channels for each feeder. Acquisition units shall acquire the fault data for the pre fault and post fault period and transfer them to Evaluation unit automatically to store in the hard disk. The acquisition units shall be located in the protection panels of the respective feeders.
29.2
29.3 29.4
29.5. The acquisition unit shall be suitable for inputs from current transformers with 1A rated secondary and capacitive voltage transformers with 63.5V (phase to neutral voltage) rated secondary. Any device required for processing of input signals in order to make the signals compatible to the Disturbance recorder equipment shall form an integral part of it. However, such processing of input signals shall in no way distort its waveform.
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29.6
The equipment shall be carefully screened, shielded, earthed and protected as may be required for its safe functioning. Also, the disturbance recorder shall have stable software, reliable hardware, simplicity of maintenance and immunity from the effects of the hostile environment of EHV switchyard which are prone to various interference signals typically from large switching transients. The Evaluation unit shall consist of a desktop personal computer (including VGA colour monitor, mouse and keyboard) and printer. The desktop PC shall have Pentium - III processor or better and having a clock speed 400 MHz or better. The hard disk capacity of PC shall not be less than 2 GB and RAM capacity shall not be less than 64 MB. Necessary software for transferring the data automatically from local evaluation unit to a remote station and receiving the same at the remote station through owners PLCC/VSAT/LEASED LINE shall be provided.
29.7
29.8
Evaluation software shall be provided for the analysis and evaluation of the recorded data made available in the PC under DOS/WINDOWS environment. The Software features shall include repositioning of analog and digital signals, selection and amplification of time and amplitude scales of each analog and digital channel, calculation of MAX/MIN frequency, phase difference values, recording of MAX/MIN values etc. of analog channel, group of signal to be drawn on the same axis etc, listing and numbering of all analog and digital channels and current, voltage, frequency and phase difference values at the time of fault/tripping. Also, the software should be capable of carrying out Fourier /Harmonic analysis of the current and voltage wave forms. The disturbance records shall also be available in COMTRADE format (IEEE standard- Common Format for Transient data Exchange for Power System) The Evaluation unit shall be connected to the printer to obtain the graphic form of disturbances whenever desired by the operator.
29.9
29.10 Disturbance recorder acquisition units shall be suitable to operate from 220V DC or 110V DC as available at sub-station Evaluation unit along with the printer shall normally be connected to 230V, single phase AC supply. In case of failure of AC supply, Evaluation unit and printer shall be switched automatically to the station DC through Inverter of adequate capacity which shall form a part of Disturbance recorder system . 29.11 The acquisition unit shall have the following features (a) Facility shall exist to alarm operator in case of any internal faults in the acquisition units such as power supply fail, processor / memory fail etc and same shall be wired to annunciation system. The frequency response shall be 5 Hz on lower side and 250 Hz or better on upper side. Scan rate shall be 1000 Hz/channel or better. Pre-fault time shall not be less than 100 milliseconds and the post fault time shall not be less than 2 seconds (adjustable). If another system disturbance occurs during one post-fault run time, the recorder shall also be able to record the same. However, the total memory of acquisition unit shall not be less than 5.0 seconds
(b) (c) (d)
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(e)
The open delta voltage and neutral current shall be derived either through software or externally by providing necessary auxiliary transformers. The acquisition unit shall be typically digital channels: 1. Main CB R phase open 2. Main CB Y phase open 3. Main CB B phase open 4. Main-1 carrier received 5. Main-1 protection operated 6. Main/Tie /TBC Auto reclosed operated 7. Over Voltage -Stage-1 /2 operated 8. Reactor / Stub/TEE-1/2/UF protection operated 9. Direct Trip received 10. Main-2 carrier received 11. Main- 2/ Back Up protection operated 12. Bus bar protection operated 13. LBB operated of main /tie/TBC circuit breaker 14. Tie/TBC CB R phase open 15. Tie/TBC CB Y phase open 16. Tie/TBC CB B phase open used to record the following
(f)
(g)
In case the disturbance recorder is in-built part of line distance protection, above digital channels may be interfaced either externally or internally. Any digital signal can be programmed to act as trigger for the acquisition unit. Analog channels should have programmable threshold levels for triggers and selection for over or under levels should be possible.
(h)
29.12 The printer shall be compatible with the desktop PC and shall use Plain paper. The print out shall contain the Feeder identity, Date and time (in hour, minute and second up to 100th of a second), identity of trigger source and Graphic form of analog and digital signals of all the channels. Two packets of paper (500 sheets in each packet) suitable for printer shall be supplied. 29.13 Each disturbance recorder shall have its own time generator and the clock of the time generator shall be such that the drift is limited +0.5 sec/day, if allowed to run without synchronisation. Further, Disturbance recorder shall have facility to synchronise its time generator from Time Synchronisation Equipment having output of following types
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RS232C
The recorder shall give annunciation in case of absence of synchronising pulse within a specified time. 29.14 Substations where Time Synchronisation Equipment is not available, time generator of any one of the disturbance recorders can be taken as master and time generators of other disturbance recorders and Event loggers in that station shall be synchronised to follow the master. 30.0 EVENT LOGGER 30.1 The event logger shall be used to record Open and Close states of switchyard equipment, relays and changes of alarms. The event logger shall include Video Display unit (VDU), printer and keyboard. Alternatively, desktop PC with VDU, printer and keyboard can be supplied with Event Logger. The equipment is used to record changes in digital events. When such changes occur, a display in VDU as well as print out on printer should result. The equipment should be constructed in clearly defined plug-in modules. A monitor module should be provided for indicating internal faults such as Processor failure, memory failure and other internal hardware failures. These failures should be displayed on the LED's mounted on the monitor module and facility shall exist to alarm the operator. The event logger shall have stable software, reliable hardware, simplicity of maintenance. The equipment shall be carefully screened, shielded, earthed and protected against severe hostile electrical environment of EHV switchyard which are prone to various interference signals typically from large switching transients. The event Logger equipment shall meet the following requirements (a) (b) (c) (d) (e) At least 500 digital event inputs shall be accommodated in single equipment. The time resolution shall be 1 milli second. Cope with up to 40 changes in any one 10 milli seconds interval. The date and time should be printed to the nearest 1 milli second followed by a message describing the point which has operated. The operator shall be able to change the date and time from the key board and allow normal inputs of Accept, Alarm demand log, Plant state demand log and date & time. Events occurring whilst a previous event is in process of being printed are to be stored to await printing. Over 100 such events must be stored. Necessary facility to change the text of the event by the operator shall exist.
30.2 30.3
30.4
30.5
(f) (g) 30.6
Event Logger shall its own time generator and the clock of the time generator shall be such that the drift is limited to 0.5 seconds/day, if allowed to run with out synchronisation. Further, Event Logger shall have facility to synchronise its time generator from Time Synchronisation Equipment having output of following types
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Voltage signal: (0-5V continuously settable, with 50 milli seconds minimum pulse duration) Potential free contact (Minimum pulse duration of 50 milli seconds) IRIG-B RS232C
The Event Logger shall give annunciation in case of absence of Synchronising pulse within a specified time. 30.7 The printer shall be compatible with event logger and VDU/ desktop personal computer and shall use plain paper. Two packets of paper (500 sheets in each packet) suitable for printer shall be supplied. The printout of the events shall contain at least the station identification, date & time (in hour, minutes, seconds & milliseconds), event number and event description (at least 40 characters). Event Logger shall be suitable to operate from 220V DC or 110V DC as available at sub-station. VDU along with the printer shall normally be connected to 230V, single phase AC supply .In case of failure of AC supply, VDU and printer shall be switched automatically to the station DC through Inverter of adequate capacity. The inverter supplied along with Disturbance Recorder can be shared for the Event Logger also.
30.8
30.9
30.10 At existing sub-stations where Event logger is provided, necessary potential free contacts of various relays/equipment for plant and alarm states shall be provided and co-ordinated with existing Event logger for proper logging of events. The drawings containing schedule of events with necessary termination details shall be submitted during Engineering of the project. 30.11 Necessary software for transferring the data automatically from the local Event logger to a remote station and receiving the same at the remote station through owners PLCC/VSAT/LEASED LINE shall be provided . 31.0 DISTANCE TO FAULT LOCATOR a) b) c) d) e) f) g) be electronic or microprocessor based type. be 'On-line' type be suitable for breaker operating time of 2 cycles have built-in display unit the display shall be directly in percent of line length or kilometres without requiring any further calculations have an accuracy of 3% or better for the typical conditions defined for operating timings measurement of distance relays . The above accuracy should not be impaired under the following conditions: h) presence of remote end infeed predominant D.C. component in fault current high fault arc resistance severe CVT transients
shall have mutual zero sequence compensation unit if fault locator is to be used on double circuit transmission line.
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i)
built in feature of line distance relay is acceptable provided the requirements of above clauses are met
32.0 TIME SYNCHRONISATION EQUPMENT 32.1 The Time synchronisation equipment shall receive the coordinated Universal Time (UTC) transmitted through Geo Positioning Satellite System (GPS) and synchronise equipments to the Indian Standard Time in a substation. Time synchronisation equipment shall include antenna, all special cables and processing equipment etc. It shall be compatible for synchronisation of Event Loggers, Disturbance recorders and SCADA at a substation. Equipment shall operate up to the ambient temperature of 50 degree centigrade and 100% humidity. The synchronisation equipment shall have 2 micro second accuracy. Equipment shall give real time corresponding to IST (taking into consideration all factors like voltage, & temperature variations, propagation & processing delays etc). Equipment shall meet the requirement of IEC 60255 for storage & operation. The system shall be able to track the satellites to ensure no interruption of synchronisation signal. The output signal from each port shall be programmable at site for either one hour, half hour, minute or second pulse, as per requirement. The equipment offered shall have six (6) output ports. Various combinations of output ports shall be selected by the customer, during detailed engineering, from the following : Voltage signal: Normally 0-5V with 50 milli seconds minimum pulse duration. In case any other voltage signal required, it shall be decided during detailed engineering. Potential free contact (Minimum pulse duration of 50 milli Seconds.) IRIG-B RS232C
32.2 32.3 32.4 32.5
32.6 32.7 32.8 32.9
32.10 The equipment shall have a periodic time correction facility of one second periodicity. 32.11 Time synchronisation equipment shall be suitable to operate from 220V DC or 110V DC as available at Substation. 32.12 Equipment shall have real time digital display in hour, minute, second (24 hour mode) & have a separate time display unit to be mounted on the top of control panels having display size of approx. 100 mm height. 33.0 RELAY TEST KIT 33.1 One relay test kit shall here under comprise of the following equipment as detailed
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3 set 2 nos. 1 no.
Relay tools kits. Test plugs Special type test plugs for using with modular type cases (if applicable)
34.0 TYPE TESTS 34.1 The reports for following type tests shall be submitted by the bidder for the Protective relays, Fault locator, Disturbance recorder and Event Logger a) b) c) d) Insulation tests as per IEC: 60255-5 High frequency disturbance test as per IEC: 60255-4 (Appendix -E) Class III (not applicable for electromechanical relays) Fast transient test as per IEC 1000-4, Level III(not applicable for electromechanical relays) Relay characteristics, performance and accuracy test as per IEC 60255 e) f) g) 34.2 Steady state Characteristics and operating time Dynamic Characteristics and operating time for distance protection relays and current differential protection relays For Disturbance recorder and Event logger are intended under this item. only performance tests
Tests for thermal and mechanical requirements as per IEC: 60255-6 Tests for rated burden as per IEC: 60255-6 Contact performance test as per IEC 60255-0-20 (not applicable for Event logger, Distance to fault locator and Disturbance recorder)
Steady state & Dynamic characteristics test reports on the distance protection relays, as type test, shall be based on test programme specified in Appendix A on simulator/network analyser/PTL. Alternatively, the files generated using Electromagnetic transient Programme (EMTP) can also be used for carrying out the above tests. Single source dynamic tests on transformer differential relay shall be/ should have been conducted based on general guidelines specified in CIGRE committee 34 report on Evaluation of characteristics and performance of Power system protection relays and protective systems.
35.0 CONFIGURATION OF C&R PANELS The following is the general criteria for the selection of the equipments to be provided in each type of panel. CONTROL PANEL Various types of control panels shall consist of the following
a. b. c. d. e. f. g. Ammeter Ammeter with Selector switch Wattmeter with transducer Varmeter with transducer Varmeter with transducer CB Control switch Isolator Control switch 3 Set 1 Set 1 Set 1 Set 1 Set 1 No. 1 No. For each Line, BC, TBC Bus section, Bus Reactor and Transformer For each line reactor For each line, transformer For each line, transformer, Bus reactor For each Line Reactor For each Circuit Breaker For each Isolator
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h. i. j. k. l. m. n. o. p. q. r. s. t.
Note: 1. 2.
Semophore Red indicating lamp Red indicating lamp Green indicating lamp Green indicating lamp White indicating lamp (DC healthy lamp) Annunciation windows with associated annunciation relays Push button for alarm Accept/reset/lamp test Synchronising Socket Synchronising selector Protection Transfer Mimic to represent SLD Voltmeter with selector switch Cut out, mounting and wiring for RWTI and selector switch
1 No. 1 No. 1 No. 1 No. 1 No. 2 Nos. 18 Nos. 3 Nos. 1 No. 1 No. Lot 1 No. Lot
For each earth switch For each Circuit Breaker For each Isolator For each Circuit Breaker For each Isolator For each Feeder For each feeder For each Control Panel For each Circuit Breaker if required For each Circuit Breaker switch if required In all control panels For each line, transformer, bus reactor For transformers/reactors
For transformer feeders, all equipments of control panel shall be provided separately for HV and MV sides. In case of incomplete diameter (D and I type layouts), control panel shall be equipped fully as if the diameter is complete, unless otherwise specified. Annunciation relays shall also be provided for the same and if required, necessary panel shall be supplied to accommodate the same. The above list of equipments mentioned for control panel is generally applicable unless it is defined elsewhere and in case of bay extension in existing substations, necessary equipments for matching the existing control panel shall be supplied Common synchronising switch is also acceptable in synchronising trolley for new sub-stations. In this case, individual synchronising selector switch is not required for each Circuit Breaker in control panel Each line/HV side of transformer/MV/LV side of transformer/Bus reactor/TBC/BC/Bus Section shall be considered as one feeder for above purpose.
3.
4.
5.
LINE PROTECTION PANEL The Line Protection panel for transmission lines shall consist of following relays and protection schemes
Sr. No. 1. 2. 3. 4. Description Main 1 Numerical distance Protection Scheme Distance to Fault Locator 3-Phase trip relays (Hand Reset) Flag relays, carrier receive relays, auxiliary relays timers etc. as per scheme requirements. Under voltage relay for isolator/earth switch Cutout wiring with TTB for standard energy meters. Directional back up over current relay and Earth fault Protection Scheme 1 Set 1 Set 1 No. Lot Quantity (132 kV)
5. 6. 7.
2 Nos. 1 Set 1 Set
TRANSFORMER PROTECTION PANEL The protection panel for Transformer shall consist of the following equipments:
253
Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9.
Particulars Item Transformer Differential Protection Scheme Restricted Earth fault Protection Scheme Directional back up Over current and E/F Relay with non directional high set feature Over fluxing protection scheme Over load protection Scheme Three phase trip relays CVT selection relay as per scheme requirement Flag relays, auxiliary relays, timers etc. as per scheme requirements including transformer alarms and trip functions Cutout wiring with TTB for standard energy meters.
HV side 1 No. 1 No. 1 Set 1 No. 1 No. 2 No. Lot Lot 1 Set
MV/LV side Nil 1 No. 1 Set Nil 2 No. Lot Lot 1 Set
BREAKER RELAY PANEL The breaker relay panel shall comprise of the following:
Sr. No. 1. 2. 3. 4. 5. Particulars Item Breaker Failure Protection Scheme DC supply supervision relay Trip circuit supervision relays Auto reclose scheme with check synchronising and dead line charging relay Flag relays, auxiliary relays, timers, trip relays etc. as per scheme requirements With A/R 1 No. 2 Nos. 2 Nos. 1 No. Lot Without A/R 1 No. 2 Nos. 2 Nos. Nil
COMMON EQUIPMENTS The following common equipments shall be provided for each new substation. These equipments shall be mounted and wired in the C& R panel offered.
Sr. No. 1. 2. 3. 4. 5. 6. Particulars Common Annunciation Scheme Bus voltage recorder Bus frequency recorder Bus voltmeter (Digital) Bus frequency meter (Digital) requirements Bus healthy indication lamps Quantity 1 Set. 1 No. for each main bus. 1 No. for each main bus. 1 No. for each main bus. 1 No. for each main bus. 3 Nos. for each bus.
36.
ERECTION AND MAINTENANCE TOOL EQUIPMENTS All special testing equipment required for the installation and maintenance of the apparatus, instruments devices shall be furnished in relevant schedule.
37.
TROPICALISATION Control room will be normally air-cooled/air-conditioned. All equipments shall however be suitable for installation in a tropical monsoon area having hot, humid climate and dry and dusty seasons with ambient conditions specified in the specification. All control wiring, equipment and accessories shall be protected against fungus growth, condensation, vermin and other harmful effects due to tropical environment.
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APPENDIX- A
Test programme for distance relays

General Comments: 1. These test cases are evolved from the report of working group 04 of study committee 34 (Protection) on evaluation of characteristics and performance of power system protection relays and protective systems. For any further guidelines required for carrying out the tests, reference may be made to the above document. The fault inception angles are referred to R- N voltage for all types of faults The fault inception angle is zero degree unless otherwise specified. Where not stated specifically, the fault resistance (Rf) shall be zero or minimum as possible in simulator. Single pole circuit breakers are to be used. The power flow in double source test is 500 MW
2. 3. 4. 5. 6.
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CONTROL & RELAY PANEL
(RCP-WITH AUTO)
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CHAPTER - CONTROL AND RELAY PANELS TECHNICAL SPECIFICATION FOR CONTROL & RELAY PANEL CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 Description Constructional Features Mounting Panel Internal Wiring Terminal Blocks Painting Name Plates and Markings Miscellaneous Accessories Earthing Relays Transmission Line Protection Circuit Breaker Protection Line over Voltage Protection Relay Transformer Protection Tripping Relay DC Supply Supervision Relay Bus Bar Protection Fault Recorder Distance to Fault Locator Time Synchronization Equipment Relay Test Kit Type Tests Configuration of Relay and Protection Panels Erection and Maintenance Tool Equipments Tropicalization Page No. 257 258 258 259 260 260 261 261 262 264 267 268 269 271 271 272 273 276 276 277 277 278 279 279
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CHAPTER - RCP SECTION: RELAY AND PROTECTION PANELS 1.0 CONSTRUCTIONAL FEATURES 1.1 Simplex panel shall consist of a vertical front panel with equipment mounted thereon and having wiring access from rear for control panels & either front or rear for relay panels. In case of panel having width more than 800mm, double leaf-doors shall be provided. Doors shall have handles with either built-in locking facility or will be provided with pad-lock. Relay panels shall be of simplex type design as indicated.. It is the responsibility of the Contractor to ensure that the equipment specified and such unspecified complementary equipment required for completeness of the protective/control schemes is properly accommodated in the panels without congestion and if necessary, provide panels with larger dimensions. No price increase at a later date on this account shall be allowed. However, the width of panels that are being offered to be placed in existing switchyard control rooms, should be in conformity with the space availability in the control room. 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-31 in accordance with IS: 2147. Panels shall be free standing, floor mounting type and shall comprise structural frames completely enclosed 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 base frame, front sheet and door frames, and 2.0mm for sides, door, top and bottom portions. There shall be sufficient reinforcement to provide level transportation and installation. All doors, removable covers and panels shall be gasketed all around with synthetic rubber gaskets Neoprene/EPDM generally conforming to provision of IS: 11149. However, XLPE gaskets can also be used for fixing protective glass doors. Ventilating louvers, if provided shall have screens and filters. The screens shall be made of either brass or GI wire mesh 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 tune and smooth. Panels shall have base frame with smooth bearing surface, which shall be fixed on the embedded foundation channels/insert plates. Anti vibration strips made of shock absorbing materials which shall be supplied by the contractor, shall be placed between panel & base frame. Cable entries to the panels shall be from the bottom. Cable gland plate fitted on the bottom of the panel shall be connected to earthing of the panel/station through a flexible braided copper conductor rigidly. Relay panels of modern modular construction would also be acceptable.
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
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2.0
MOUNTING 2.1 All equipment on and in panels shall be mounted and completely wired to the terminal blocks ready for external connections. The equipment on front of panel shall be mounted flush. No equipment shall be mounted on the doors. 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 on the equipment shall be clearly visible. The Contractor shall carry out cut out, mounting and wiring of the free issue items supplied by others which are to be mounted in his panel in accordance with the corresponding equipment manufacturer's drawings. Cut outs if any, provided for future mounting of equipment shall be properly blanked off with blanking plate. The centre lines of switches, push buttons and indicating lamps shall be not less than 750mm from the bottom of the panel. The centre lines of relays, meters and recorders shall be not less than 450mm from the bottom of the panel The centre lines of switches, push buttons and indicating lamps shall be matched to give a neat and uniform appearance. Like wise the top lines of all meters, relays and recorders etc. shall be matched. No equipment shall be mounted on the doors. At existing station, panels shall be matched with other panels in the control room in respect of dimensions, colour, appearance and arrangement of equipment (centre lines of switches, push buttons and other equipment) on the front of the panel.
2.2
2.3
2.4
2.5
2.6 2.7
3.0
PANEL INTERNAL WIRING 3.1 Panels shall be supplied complete 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 All wiring shall be carried out with 650V grade, single core, stranded copper conductor wires with PVC insulation. The minimum size of the multistranded copper conductor used for internal wiring shall be as follows: 3.3 All circuits except current transformer circuits and voltage transfer circuits meant for energy metering - one 1.5 mm sq. per lead. All current transformer circuits one 2.5 sq. mm lead. Voltage transformer circuit (for energy meters): Two 2.5 sq. mm. per lead.
3.2
All internal wiring shall be securely supported, neatly arranged, readily accessible and connected to equipment terminals and terminal blocks. Wiring gutters & troughs shall be used for this purpose. Auxiliary bus wiring for AC and DC supplies, voltage transformer circuits, annunciation circuits and other common services shall be
3.4
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provided near the top of the panels running throughout the entire length of the panels. 3.5 Wire termination shall be made with solderless crimping type and tinned copper lugs, which firmly grip the conductor. Insulated 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. All wires directly connected to trip circuit breaker or device shall be distinguished by the addition of red coloured unlettered ferrule. Longitudinal troughs extending throughout the full length of the panel shall be preferred for inter panel wiring. Inter-connections to adjacent panel shall be brought out to a separate set of terminal blocks located near the slots of holes meant for taking the inter-connecting wires. Contractor shall be solely responsible for the completeness and correctness of the internal wiring and for the proper functioning of the connected equipments
3.6
3.7 4.0
TERMINAL BLOCKS 4.1 All internal wiring to be connected to external equipment shall terminate on terminal blocks. Terminal blocks shall be 650 V grade and have 10 Amps. continuous rating, moulded piece, complete with insulated barriers, stud type terminals, washers, nuts and lock nuts. Markings on the terminal blocks shall correspond to wire number and terminal numbers on the wiring diagrams. All terminal blocks shall have shrouding with transparent unbreakable material. Disconnecting type terminal blocks for current transformer and voltage transformer secondary leads shall be provided. Also current transformer secondary leads shall be provided with short circuiting and earthing facilities. At least 20% spare terminals shall be provided on each panel and these spare terminals shall be uniformly distributed on all terminal blocks. Unless otherwise specified, terminal blocks shall be suitable connecting the following conductors of external cable on each side 4.5 All CT & PT circuits: minimum of two of 2.5mm Sq. copper. AC/DC Power Supply Circuits: One of 6 mm sq. aluminium. All other circuits: minimum of one of 2.5mm Sq. Copper. for
4.2
4.3 4.4
There shall be a minimum clearance of 250mm between the first row of terminal blocks and the associated cable gland plate or panel side wall. Also the clearance between two rows of terminal blocks edges shall be minimum of 150mm. Arrangement of the terminal block assemblies and the wiring channel within the enclosure shall be such that a row of terminal blocks is run in parallel and close proximity along each side of the wiring-duct to provide for convenient attachment of internal panel wiring. The side of the terminal block opposite the wiring duct shall be reserved for the Owner's external cable connections. All adjacent terminal blocks shall also share this field wiring corridor. All wiring shall be provided with adequate support inside the panels to hold them firmly and to enable free and flexible termination without causing strain on terminals.
4.6
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4.7
The number and sizes of the Owner's multi core incoming external cables will be furnished to the Contractor after placement of the order. All necessary cable terminating accessories such as gland plates, supporting clamps & brackets, wiring troughs and gutters etc. (except glands & lugs) for external cables shall be included the scope of supply.
5.0
PAINTING 5.1 5.2 5.3 All sheet steel work shall be phosphated in accordance with the IS: 6005 "Code of practice for phosphating iron and steel". Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with dilute acid followed by washing with running water rinsing with a slightly alkaline hot water and drying. After phosphating, thorough rinsing shall be carried out with clean 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. 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 inspection of first coat of painting. The exterior colour of paint shall be of a slightly different shade to enable inspection of the painting. A small quantity of finished paint shall be supplied for minor touching up required at site after installation of the panels. In case the bidder proposes to follow any other established painting procedure like electrostatic painting , the procedure shall be submitted for owners review and approval.
5.4 5.5
5.6
5.7 5.8
6.0
NAME PLATES AND MARKINGS 6.1 All equipment mounted on front and rear side as well as equipment mounted inside the panels shall be provided with individual name plates with equipment designation engraved. Also on the top of each panel on front as well as rear side, large and bold nameplates shall be provided for circuit/feeder designation. All front mounted equipment shall also be provided at the rear with individual name plates engraved with tag numbers corresponding to the one shown in the panel internal wiring to facilitate easy tracing of the wiring. All relays and other devices shall be clearly marked with manufacturer's name, manufacturer's type, serial number and electrical rating data. Name Plates shall be made of non-rusting metal or 3 ply lamicoid. Name plates shall be black with white engraving lettering. All the panels shall be provided with name plate mounted inside the panel bearing LOA No & Date, Name of the Substation & feeder and reference drawing number.
6.2
6.3 6.4 6.5
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7.0
MISCELLANEOUS ACCESSORIES 7.1 Plug Point: 240V, Single phase 50Hz, AC socket with switch suitable to accept 5 Amps and 15 Amps pin round standard Indian plug, shall be provided in the interior of each cubicle with ON-OFF switch. Interior Lighting: Each panel shall be provided with a fluorescent lighting fixture rated for 240 Volts, single phase, 50 Hz supply for the interior illumination of the panel controlled by the respective panel door switch. Adequate lighting shall also be provided for the corridor in Duplex panels. Switches and Fuses: Each panel shall be provided with necessary arrangements for receiving, distributing and isolating of DC and AC supplies for various control, signaling, lighting and space heater circuits. The incoming and sub-circuits shall be separately provided with miniature circuit breakers (MCB). Selection of the main and sub-circuit MCB rating shall be such as to ensure selective clearance of sub-circuit faults. MCBs shall confirm to IS: 13947. Each MCB shall be provided with one potential free contact and the same shall be wired for annunciation purpose. However voltage transformer circuits for relaying and metering shall be protected by fuses. All fuses shall be HRC cartridge type conforming to IS: 13703 mounted on plug-in type fuse bases. Fuse carrier base as well as MCBs shall have imprints of the fuse 'rating' and 'voltage'. Space Heater: Each panel shall be provided with a space heater rated for 240V, single phase, 50 Hz Ac supply for the internal heating of the panel to prevent condensation of moisture. The fittings shall be complete with switch unit.
7.2
7.3
7.4
8.0
EARTHING 8.1 All panels shall be equipped with an earth bus securely fixed. 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 25x6 sq. mm perforated copper with threaded holes at a gap of 50mm with a provision of bolts and nuts for connection with cable armours and mounted equipment etc for effective earthing. 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. Provision shall be made on each bus bar of the end panels for connecting Substation earthing grid. Necessary terminal clamps and connectors for this purpose shall be included in the scope of supply of Contractor. All metallic cases of relays, instruments and other panel mounted equipment including gland plate, shall be connected to the earth bus by copper wires of size not less than 2.5 sq. mm. The colour code of earthing wires shall be green. Looping of earth connections which would result in loss of earth connection to other devices when the loop is broken, shall not be permitted. Earthing may be done in such a manner that no circulating current shall flow in the panel.
8.2
8.3
8.4
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8.5
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. An electrostatic discharge point shall be provided in each panel connected to earth bus via 1 Mega Ohm resistor.
8.6 9.0
RELAYS 9.1 All relays shall conform to the requirements of IS: 3231/IEC-60255/IEC 61000 or other applicable standards. Relays shall be suitable for flush or semi-flush mounting on the front with connections from the rear. All main protective relays shall be of numerical type and communication protocol shall be as per IEC: 61850. Further , the test levels of EMI as indicated in IEC: 61850 shall be applicable to these . All protective relays shall be in draw out or plug-in type/modular cases with proper testing facilities. Necessary test plugs/test handles shall be supplied loose and shall be included in contractor's scope of supply. All AC operated relays shall be suitable for operation at 50 Hz. AC Voltage operated relays shall be suitable for 110 Volts VT secondary and current operated relays for 1 amp CT secondary. All DC operated relays and timers shall be designed for the DC voltage specified, and shall operate satisfactorily between 80% and 110% of rated voltage. Voltage operated relays shall have adequate thermal capacity for continuous operation. 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 circuits etc. also required for the complete protection schemes described in the specification shall be provided. 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 case shall have adequate number of terminals for making potential free external connections to the relay coils and contacts, including spare contacts. 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 with inscription. All protective relays which do not have built-in hand-reset operation indicators shall have additional auxiliary relays with operating indicators (Flag relays) for this purpose. Similarly, separate operating indicator (auxiliary relays) shall also be provided in the trip circuits of protections located outside the board such as Buchholz relays, oil and winding temperature protection, sudden pressure devices, fire protection etc. Timers shall be of solid state type. Time delay in terms of milliseconds obtained by the external capacitor resistor combination is not preferred and shall be avoided.
9.2
9.3
9.4
9.5
9.6
9.7
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9.8 9.9 9.10
No control relay which shall trip the power circuit breaker when the relay is de-energised shall be employed in the circuits. Provision shall be made for easy isolation of trip circuits of each relay for the purpose of testing and maintenance. 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: (a) 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. Seal-in-unit shall obtain adequate current for operation when one or more relays operate simultaneously. Impedance of the seal-in-unit shall be small enough to permit satisfactory operation of the trip coil on trip relays when the D.C. Supply Voltage is minimum. Trip-circuit seal-in is required for all trip outputs, irrespective of the magnitude of the interrupted current. The trip-circuit seal-in logic shall not only seal-in the trip output(s),but also the relevant initiation signals to other scheme functions, (e.g. initiate signals to the circuitbreaker failure function, reclosing function etc.), and the alarm output signals. Two methods of seal-in are required, one based on the measurement of AC current, catering for those circumstances for which the interrupted current is above a set threshold, and one based on a fixed time duration, catering for those circumstances for which the interrupted current is small (below the set threshold). For the current seal-in method, the seal-in shall be maintained until the circuit-breaker opens, at which time the seal-in shall reset and the seal-in method shall not now revert to the fixed time duration method. For this seal-in method, the seal-in shall be maintained for the set time duration. For the line protection schemes, this time duration shall be independently settable for single- and three-pole tripping. Seal-in by way of current or by way of the fixed duration timer shall occur irrespective of whether the trip command originates from within the main protection device itself (from any of the internal protection functions), or from an external device with its trip output routed through the main protection device for tripping. Trip-circuit seal-in shall not take place under sub-harmonic conditions (e.g. Reactor ring down).
(b) (c)
(d)
(e)
(f)
(g)
9.11 9.12 9.13
All protective relays and alarm relays shall be provided with one extra isolated pair of contacts wired to terminals exclusively for future use. The setting ranges of the relays offered, if different from the ones specified shall also be acceptable if they meet the functional requirements. Any alternative/additional protections or relays considered necessary for providing complete effective and reliable protection shall also be offered separately. The acceptance of this alternative/additional equipment shall lie with the owner.
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9.14 9.15 9.16
The bidder shall include in his bid a list of installations where the relays quoted have been in satisfactory operation. All relays and their drawings shall have phase indications as R-Red, Y-yellow, B-blue For numerical relays, the scope shall include the following: a) Necessary software and hardware to up/down load the data to/from the relay from/to the personal computer installed in the substation. However, the supply of PC is not covered under this clause. The relay shall have suitable communication facility for future connectivity to SCADA. The relay shall be capable of supporting IEC: 870-5-103 and 61850 protocol.
b)
10.0 TRANSMISSION LINE PROTECTION 10.1 10.2 All relays shall be suitable for series compensated line. The line protection relays are required to protect the line and clear the faults on line within shortest possible time with reliability, selectivity and full sensitivity to all type of faults on lines. The general concept is to have two main protections having equal performance requirement specially in respect of time as called Main and back up protection for 132 KV transmission lines. The Transmission system for which the line protection equipment are required is shown in the reference drawing/document(s). The length of lines and the line parameters (Electrical Constants) are also indicated there. The maximum fault current could be as high as 40 kA but the minimum fault current could be as low as 20% of rated current of CT secondary. The starting & measuring relays characteristics should be satisfactory under these extremely varying conditions. The protective relays shall be suitable for use with capacitor voltage transformers having non-electronic damping and transient response as per IEC. Fault Recorder, Distance to fault Locator and Over voltage relay (stage 1) functions if offered as an integral part of line protection relay, shall be acceptable provided these meet the technical requirements as specified in the respective clauses. Auto reclose relay function if offered as an integral part of line distance protection relay, shall be acceptable for 132 kV lines only provided the auto reclose relay feature meets the technical requirements as specified in the respective clause. The following protections shall be provided for each of the Transmission lines: For 132 kV Main: Numerical distance protection scheme Back up: Directional over current and Earth fault Protection 10.9 Further, if specified in the Section- Project, back up Over current and Earth fault protection shall be provided to match with requirements at the remote ends.
10.3
10.4
10.5 10.6
10.7
10.8
10.10 The detailed description of the above line protections is given here under.
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10.10.1 Main-I and Main-II Numerical Distance Protection scheme: (a) (b) (c) (d) (e) shall have continuous self monitoring and diagnostic feature. shall be non-switched type with separate measurements for all phase to phase and phase to ground faults shall have stepped time-distance characteristics and three independent zones (zone 1, zone-2 and zone-3) shall have mho or quadrilateral or other suitably shaped characteristics for zone-1, zone-2 and zone- 3. shall have following maximum operating time (including trip relay time , if any) under given set of conditions and with CVT being used on line (with all filters included) . (i) for 132 KV lines:
Source to Impedance ratio Relay setting (Ohms) Fault Locations (as % of relay setting) Fault resistance (Ohms) Maximum operating time (Milliseconds) 4 15 (10 or 20) and 2 50 0 45 for all faults 50 0 50 for 3 ph. Faults & 65 for all other faults. 2
(f)
The relay shall have an adjustable characteristics angle setting range of 30-85 degree or shall have independent resistance(R ) and reactance (X) setting. shall have two independent continuously variable time setting range of 0-3 seconds for zone-2 and 0-5 seconds for zone-3. shall have resetting time of less than 55 milli-seconds (including the resetting time of trip relays) shall have facilities for offset features with adjustable 10-20% of Zone-3 setting. shall have variable residual compensation. shall have memory circuits with defined characteristics in all three phases to ensure correct operation during close-up 3 phase faults and other adverse conditions and shall operate instantaneously when circuit breaker is closed to zero-volt 3 phase fault shall have weak end in-feed feature
(g) (h) (i) (j) (k)
(l)
(m) shall be suitable for single & three phase tripping. However relays offered for 132 kV lines provided with mechanically ganged circuit breakers single pole tripping need not be provided. (n) shall have a continuous current rating of two times of rated current. The voltage circuit shall be capable of operation at 1.2 times rated voltage. The relay shall also be capable of
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carrying a high short time current of 70 times rated current without damage for a period of 1 sec. (o) shall be provided with necessary self reset type trip duty contacts for completion of the scheme (Minimum number of these trip duty contacts shall be four per phase) either through built in or through separate high speed trip relays . Making capacity of these trip contacts shall be 30 amp for 0.2 seconds with an inductive load of L/R > 10 mill seconds. If separate high speed trip relays are used, the operating time of the same shall not be more than 10 milliseconds shall be suitable for use in permissive under reach/over reach/blocking communication mode. shall have suitable number of potential free contacts for Carrier aided Tripping, Auto reclosing, CB failure, Disturbance recorder & Data acquisition system. include power swing blocking protection which shall (s) have suitable setting range to encircle the distance protection described above. block tripping during power swing conditions. release blocking in the event of actual fault.
(p) (q)
(r)
include fuse failure protection which shall monitor all the three fuses of C.V.T. and associated cable against open circuit. inhibit trip circuits on operation and initiate annunciation. have an operating time less than 7 milliseconds. remain inoperative for system earth faults.
(t)
include a directional back up Inverse Definite Minimum Time (IDMT) earth fault relay with normal inverse characteristics as per IEC: 60255-3 as a built in feature or as a separate unit. In case the numerical distance relay is not having the built in feature as per above clause (t), the same can be supplied as an independent relay. Must have a current reversal guard feature.
(u)
(v)
10.10.2 Back-up Directional Over Current and Earth fault protection scheme (a) (b) (c) (d) shall have three over current and one earth fault element(s) which shall be either independent or composite unit(s shall be of Numerical type shall include necessary VT fuse failure relays for alarm purposes. shall
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have IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting have a variable setting range of 50-200% of rated current have a characteristic angle of 30/45 degree lead
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(e)
include hand reset flag indicators or LEDs.
shall have IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting have a variable setting range of 20-80% of rated current have a characteristic angle of 45/60 degree lag include hand reset flag indicators or LEDs include necessary separate interposing voltage transformers or have internal feature in the relay for open delta voltage to the relay.
10.10.3 All trip relays used in transmission line protection scheme shall be of self/electrical reset type depending on application requirement. 11.0 Circuit Breaker Protection: This shall include following function: 11.1 AUTO RECLOSING function shall be separate from Main-I and Main-II protection and shall: (a) (b) (c) (d) (e) have single phase or/and three phase reclosing facilities. have a continuously variable single phase dead time range of 0.1-2 seconds. have a continuously variable three phase dead time range of 0.1-2 seconds. have a continuously variable reclaim time range of 5-300 seconds. incorporate a four-position selector switch/ from which single phase/three phase/single and three phase auto reclosure and non-auto reclosure mode can be selected. Alternatively, the mode of auto reclosing can be selected through programming. have facilities for selecting check synchronising or dead line charging features. It shall be possible at any time to change the required feature by reconnection of links. be of single shot type. have priority circuit to closing of both circuit breakers in case one and half breaker arrangements to allow sequential closing of breakers be acceptable as built in with line distance relay for 132 KV lines include check synchronising relay which shall
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(f)
(g) (h) (i) (j)
have a time setting continuously variable between 0.5-5 seconds. with a facility of additional 10 seconds. have a response time within 200 milli seconds with the timer disconnected. have a phase angle setting not exceeding 35 degree have a voltage difference setting not exceeding 10% include dead line charging relay which shall have two sets of relays and each set shall be able to monitor the three phase voltage where one set shall be connected to the
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line CVTs with a fixed setting of 20% of rated voltage and the other set shall be connected to the bus CVTs with a fixed setting of 80% of rated voltage. 11.2 incorporate necessary comprehensive scheme. auxiliary relays and timers to give
LOCAL BREAKER BACK-UP PROTECTION SCHEME shall (a) (b) (c) (d) (e) be triple pole type have an operating time of less than 15 milli seconds have a resetting time of less than 15 milli seconds have three over current elements be arranged to get individual initiation from the corresponding phase of main protections of line for each over current element. However, common three phase initiation is acceptable for other protections and transformer /reactor equipment protections have a setting range of 20-80% of rated current have a continuous thermal withstand two times rated current irrespective of the setting have a timer with continuously adjustable setting range of 0.1-1 seconds have necessary auxiliary relays to make a comprehensive scheme.
(f) (g) (h) (i) 11.3
TRIP CIRCUIT SUPERVISION RELAY (a) The relay shall be capable of monitoring the healthiness of each 'phase' trip-coil and associated circuit of circuit breaker during 'ON' and 'OFF' conditions. The relay shall have adequate contacts for providing connection to alarm and event logger. The relay shall have time delay on drop-off of not less than 200 milli seconds and be provided with operation indications for each phase.
(b) (c)
12.0 LINE OVER VOLTAGE PROTECTION RELAY shall (a) (b) (c) (d) (e) (f) (g) (h) monitor all three phases have two independent stages and stage- 1 & II relay are built in with line distance relays Main I & II respectively . acceptable as
have an adjustable setting range of 100-170% of rated voltage with an adjustable time delay range of 1 to 60 seconds for the first stage. have an adjustable setting range of 100-170% of rated voltage with a time delay of 100-200 mill seconds for the second stage. be tuned to power frequency provided with separate operation indicators (flag target) for each stage relays. have a drop-off to pick-up ratio greater than 95%. provide separate out-put contacts for each 'Phase' and stage for breaker trip relays, event logger and other scheme requirements.
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13.0 TRANSFORMER PROTECTION 13.1 Numerical Transformer differential protection scheme shall (a) (b) (c) (d) (e) (f) be triple pole type, with faulty phase identification/ indication have an operating time not greater than 30 milli seconds at 5 times the rated current . have three instantaneous high set over-current units have an adjustable bias setting range of 20-50% be suitable for rated current of 1 Amp. have second harmonic or other inrush proof features and also should be stable under normal over fluxing conditions. Magnetising inrush proof feature shall not be achieved through any intentional time delay e.g. use of timers to block relay operation or using disc operated relays have an operating current setting of 15% or less include necessary separate interposing current transformers for angle and ratio correction or have internal feature in the relay to take care of the angle & ratio correction have a disturbance recording feature to record graphic form of instantaneous values of current in all three windings in nine analogue channels in case of 400 kV class and above transformers and 6 analogue channels for lower voltage transformers, during faults and disturbances for the pre fault and post fault period. The disturbance recorder shall have the facility to record the following external digital channel signals apart from the digital signals pertaining to differential relay. 1. REF protection operated 2. HV breaker status (Main and tie) 3. LV breaker status 4. Bucholz /OLTC Bucholz alarm/trip 5. WTI/OTI/PRD alarm/trip of transformer Necessary hardware and software for down loading the data captured by disturbance recorder to the personal computer available in the substation shall be included in the scope. 13.2 Over fluxing protection Relays shall (a) (b) (c) operate on the principle of Voltage to frequency ratio and shall be phase to phase connected have inverse time characteristics, matching with transformer over fluxing withstand capability curve. provide an independent 'alarm' with the time delay continuously adjustable between 0.1 to 6.0 seconds at values of 'v/f' between 100% to 130% of rated values tripping time shall be governed by 'v/f' Vs. time characteristics of the relay
(g) (g)
(h)
(d)
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(e)
have a set of characteristics for Various time multiplier settings. The maximum operating time of the relay shall not exceed 3 seconds and 1.5 seconds at 'v/f' values of 1.4 and 1.5 times, the rated values, respectively. have an accuracy of operating time, better than 10%. have a resetting ratio of 95 % or better. Be acceptable as a built in feature of numerical transformer differential relay.
(f) (g) (h) 13.3
Numerical Restricted Earth Fault Protection shall (a) (b) (c) (d) be single pole type be of current/voltage operated high impedance type have a current setting range of 10-40% of 1 Amp./ have a suitable voltage setting range. be tuned to the system frequency
13.4
Numerical Back-up Over Current and Earth fault protection scheme with high set feature (a) (b) (c) Shall have three over current and one earth fault element(s) which shall be either independent or composite unit(s). The scheme shall include necessary VT fuse failure relays for alarm purposes Over current relay shall have directional IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting and have a variable setting range of 50-200% of rated current have low transient, over reach high set instantaneous unit of continuously variable setting range 500-2000 % of rated current have a characteristic angle of 30/45 degree lead include hand reset flag indicators or LEDs.
(d)
Earth fault relay shall have directional IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting and have a variable setting range of 20-80% of rated current have low transient, over reach high set instantaneous unit of continuously variable setting range 200-800 % of rated current have a characteristic angle of 45/60 degree lag include hand reset flag indicators or LEDs include necessary separate interposing voltage transformers or have internal feature in the relay for open delta voltage to the relay
13.5
Transformer Overload Protection Relay shall (a) (b) be of single pole type be of definite time over-current type
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(c) (d) (e) (f) 13.6
have one set of over-current relay element, with continuously adjustable setting range of 50-200% of rated current have one adjustable time delay relay for alarm having setting range of 1 to 10.0 seconds, continuously. have a drop-off/pick-up ratio greater than 95%. be acceptable as built in feature of numerical transformer differential relay
TEE PROTECTION DIFFERENTIAL RELAYS 13.6.1 TEE-1 differential protection relays shall (a) (b) (c) (d) (e) 13.6.2 be triple pole type have an operating time less than 30 milliseconds at 5 times the rated current. have three instantaneous high set over current units have an adjustable bias setting range of 20-50% have an operating current setting of 15% of 1 Amp or less
TEE-2 Differential relay shall (a) (b) (c) (d) (e) (f) (g) be triple pole type have operating time less than 25 milliseconds at 5 times setting be tuned to system frequency have current setting range of 20 to 80% of 1 Amp be voltage operated, high impedance type be stable for all external faults be provided with suitable non linear resistors across the relay to limit the peak voltage to 1000 volts
14.0 TRIPPING RELAY High Speed Tripping Relay shall (a) (b) (c) (d) be instantaneous (operating time not to exceed 10 milli-seconds). reset within 20 milli seconds be D.C. operated have adequate contacts to meet the requirement of scheme, other functions like auto-reclose relay, LBB relay as well as cater to associated equipment like event logger, Disturbance recorder, fault Locator, etc. be provided with operation indicators for each element/coil.
(e)
15.0 DC SUPPLY SUPERIVISION RELAY (a) (b) (c) The relay shall be capable of monitoring the failure of D.C. supply to which, it is connected. It shall have adequate potential free contacts to meet the scheme requirement. The relay shall have a 'time delay on drop-off' of not less than 100 milli seconds and be provided with operation indicator/flag.
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16.0 BUS BAR PROTECTION 16.1 Redundant (1+1) numerical Bus Bar protection scheme for each bus system (Bus1+Bus2+Transfer Bus wherever applicable) for 400kV and 765kV shall be provided. The scheme shall be engineered so as to ensure that operation of any one out of two schemes connected to main faulty bus shall result in tripping of the same. Single bus bar protection scheme shall be provided for each main and transfer bus for 132 KV voltage levels Each Bus Bar protection scheme shall (a) (b) (c) (d) have maximum operating time up to trip impulse to trip relay for all types of faults of 25 milli seconds at 5 times setting value. operate selectively for each bus bar give hundred percent securities up to 31.5 kA for 132 KV incorporate continuous supervision for CT secondary against any possible open circuit and if it occurs, shall render the relevant zone of protection inoperative and initiate an alarm not give false operation during normal load flow in bus bars. incorporate clear zone indication. be of phase segregated and triple pole type provide independent zones of protection (including transfer bus if any). If the bus section is provided then each side of bus section shall have separate set of bus bar protection schemes include individual high speed electrically reset tripping relays for each feeder be transient free in operation include continuous D.C. supplies supervision. not cause tripping for the differential current below the load current of heaviest loaded feeder . Bidder shall submit application check for the same.
16.2 16.3
(e) (f) (g) (h)
(i) (j) (k) (l)
(m) shall include necessary C.T. switching relays wherever C.T. switching is involved and has 'CT' selection incomplete alarm (n) (o) include protection 'IN/OUT' switch for each zone shall include trip relays, CT switching relays(if applicable) , auxiliary CTs (if applicable) as well as additional power supply modules, input modules etc. as may be required to provide a Bus-bar protection scheme for the complete bus arrangement i.e. for all the bay or breakers under this specification as per the Single line diagram for new substations. However for extension of bus bar protection scheme in existing substations, scope shall be limited to the bay or breakers covered under this specification. Suitable panels (if required) to mount these are also included in the scope of the work.
16.4
Built-in Local Breaker Backup protection feature as a part of bus bar protection scheme shall also be acceptable.
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16.5
At existing substations, Bus-bar protection scheme with independent zones for each bus will be available. All necessary co-ordination for AC and 'DC' interconnections between existing schemes (Panels) and the bays proposed under the scope of this contract shall be fully covered by the bidder. Any auxiliary relay, trip relay, flag relay and multi tap auxiliary CTs (in case of biased differential protection) required to facilitate the operation of the bays covered under this contract shall be fully covered in the scope of the bidder. (a) The test terminal blocks (TTB) to be provided shall be fully enclosed with removable covers and made of moulded, non-inflammable plastic material with boxes and barriers moulded integrally. All terminals shall be clearly marked with identification numbers or letters to facilitate connection to external wiring. Terminal block shall have shorting, disconnecting and testing facilities for CT circuits.
17.0 FAULT RECORDER 17.1 Fault recorder shall be microprocessor based and shall be used to record the graphic form of instantaneous values of voltage and current in all three phases, open delta voltage & neutral current, open or closed position of relay contacts and breakers during the system disturbances and built in feature of line distance relay is acceptable provided the requirements of following clauses are met The fault recorder shall consist of individual acquisition units, one for each feeder and an Evaluation unit which is common for the entire Substation. Whenever, more than one acquisition units are connected to an Evaluation unit, necessary hardware and software shall also be supplied for on line transfer of data from all acquisition units to Evaluation unit. If there are any constraints for one Evaluation unit to accept the data from number of acquisition units under the present scope, adequate number of Evaluation units shall be supplied. In case of extension of existing substation(s), one set of Evaluation unit shall be supplied for each substation where ever Fault recorders are specified. Fault recorder shall have 8 analog and 16 digital channels for each feeder. Acquisition units shall acquire the fault data for the pre fault and post fault period and transfer them to Evaluation unit automatically to store in the hard disk. The acquisition units shall be located in the protection panels of the respective feeders. The acquisition unit shall be suitable for inputs from current transformers with 1A rated secondary and capacitive voltage transformers with 63.5V (phase to neutral voltage) rated secondary. Any device required for processing of input signals in order to make the signals compatible to the Fault recorder equipment shall form an integral part of it. However, such processing of input signals shall in no way distort its waveform. The equipment shall be carefully screened, shielded, earthed and protected as may be required for its safe functioning. Also, the Fault recorder shall have stable software, reliable hardware, simplicity of maintenance and immunity from the effects of the hostile environment of EHV switchyard which are prone to various interference signals typically from large switching transients.
17.2
17.3 17.4
17.5
17.6
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17.7
The Evaluation unit shall consist of a desktop personal computer (including VGA colour monitor, mouse and keyboard) and printer. The desktop PC shall have Pentium-III processor or better and having a clock speed 400 MHz or better. The hard disk capacity of PC shall not be less than 2 GB and RAM capacity shall not be less than 64 MB. Necessary software for transferring the data automatically from local evaluation unit to a remote station and receiving the same at the remote station through owners PLCC/VSAT/LEASED LINE shall be provided. Evaluation software shall be provided for the analysis and evaluation of the recorded data made available in the PC under DOS/WINDOWS environment. The Software features shall include repositioning of analog and digital signals, selection and amplification of time and amplitude scales of each analog and digital channel, calculation of MAX/MIN frequency, phase difference values, recording of MAX/MIN values etc. of analog channel, group of signal to be drawn on the same axis etc, listing and numbering of all analog and digital channels and current, voltage, frequency and phase difference values at the time of fault/tripping. Also, the software should be capable of carrying out Fourier /Harmonic analysis of the current and voltage wave forms. The Fault records shall also be available in COMTRADE format ( IEEE standard- Common Format for Transient data Exchange for Power System )
17.8
17.9
17.10 The Evaluation unit shall be connected to the printer to obtain the graphic form of disturbances whenever desired by the operator. 17.11 Fault recorder acquisition units shall be suitable to operate from 220V DC or 110V DC as available at sub-station Evaluation unit along with the printer shall normally be connected to 230V, single phase AC supply. In case of failure of AC supply, Evaluation unit and printer shall be switched automatically to the station DC through Inverter of adequate capacity which shall form a part of Fault recorder system . 17.12 The acquisition unit shall have the following features (a) Facility shall exist to alarm operator in case of any internal faults in the acquisition units such as power supply fail, processor / memory fail etc and same shall be wired to annunciation system. The frequency response shall be 5 Hz on lower side and 250 Hz or better on upper side. Scan rate shall be 1000 Hz/channel or better. Pre-fault time shall not be less than 100 milliseconds and the post fault time shall not be less than 2 seconds (adjustable). If another system disturbance occurs during one post-fault run time, the recorder shall also be able to record the same. However, the total memory of acquisition unit shall not be less than 5.0 seconds The open delta voltage and neutral current shall be derived either through software or externally by providing necessary auxiliary transformers. The acquisition unit shall be typically used to record the following digital channels: 1. 2.
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(b) (c) (d)
(e) (f)
Main CB R phase open. Main CB Y phase open.

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3. 4. 5. 6. 7. 8. 9.
Main CB B phase open. Main-1 carrier received. Main-1 protection operated. Main/Tie /TBC Auto reclosed operated. Over Voltage -Stage-1 /2 operated. Reactor / Stub/TEE-1/2/UF protection operated. Direct Trip received.
10. Main-2 carrier received. 11. Main- 2/ Back Up protection operated. 12. Bus bar protection operated. 13. LBB operated of main /tie/TBC circuit breaker. 14. Tie/TBC CB R phase open. 15. Tie/TBC CB Y phase open. 16. Tie/TBC CB B phase open. (g) (h) In case the Fault recorder is in-built part of line distance protection, above digital channels may be interfaced either externally or internally. Any digital signal can be programmed to act as trigger for the acquisition unit. Analog channels should have programmable threshold levels for triggers and selection for over or under levels should be possible.
17.13 The printer shall be compatible with the desktop PC and shall use Plain paper. The print out shall contain the Feeder identity, Date and time (in hour, minute and second up to 100th of a second), identity of trigger source and Graphic form of analogue and digital signals of all the channels. Two packets of paper (500 sheets in each packet) suitable for printer shall be supplied. 17.14 Each Fault recorder shall have its own time generator and the clock of the time generator shall be such that the drift is limited to +0.5 seconds/day, if allowed to run without synchronisation. Further, Fault recorder shall have facility to synchronise its time generator from Time Synchronisation Equipment having output of following types Voltage signal: (0-5V continuously settable, with 50 m seconds minimum pulse duration) Potential free contact (Minimum pulse duration of 50 m Sec.) IRIG-B RS232C
The recorder shall give annunciation in case of absence of synchronising within a specified time. 17.15 Substations where Time Synchronisation Equipment is not available, time generator of any one of the Fault recorders can be taken as master and time generators of other Fault recorders and Event loggers in that station shall be synchronised to follow the master.
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18.0 DISTANCE TO FAULT LOCATOR a) b) c) d) e) f) g) be electronic or microprocessor based type. be 'On-line' type be suitable for breaker operating time of 2 cycles have built-in display unit the display shall be directly in percent of line length or kilometres without requiring any further calculations have an accuracy of 3% or better for the typical conditions defined for operating timings measurement of distance relays . The above accuracy should not be impaired under the following conditions: h) i) presence of remote end infeed predominant D.C. component in fault current high fault arc resistance severe CVT transients
shall have mutual zero sequence compensation unit if fault locator is to be used on double circuit transmission line. built in feature of line distance relay is acceptable provided the requirements of above clauses are met
19.0 TIME SYNCHRONISATION EQUPMENT 19.1 The Time synchronization equipment shall receive the coordinated Universal Time (UTC) transmitted through Geo Positioning Satellite System (GPS) and synchronize equipments to the Indian Standard Time in a substation. Time synchronization equipment shall include antenna, all special cables and processing equipment etc. It shall be compatible for synchronization of Event Loggers, Disturbance recorders and SCADA at a substation through individual port or through Ethernet realized through optic fiber bus. Equipment shall operate up to the ambient temperature of 50 degree centigrade and 100% humidity. The synchronization equipment shall have 2 micro second accuracy. Equipment shall give real time corresponding to IST (taking into consideration all factors like voltage, & temperature variations, propagation & processing delays etc). Equipment shall meet the requirement of IEC 60255 for storage & operation. The system shall be able to track the satellites to ensure no interruption of synchronization signal. The output signal from each port shall be programmable at site for either one hour, half hour, minute or second pulse, as per requirement. The equipment offered shall have six (6) output ports. Various combinations of output ports shall be selected by the customer, during detailed engineering, from the following:
19.2 19.3
19.4 19.5
19.6 19.7 19.8 19.9
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Voltage signal : Normally 0-5V with 50 milli Seconds minimum pulse duration. In case any other voltage signal required, it shall be decided during detailed engineering. Potential free contact (Minimum pulse duration of 50 milli Seconds.) IRIG-B RS232C
19.10 The equipment shall have a periodic time correction facility of one second periodicity. 19.11 Time synchronisation equipment shall be suitable to operate from 220V DC or 110V DC as available at Substation. 19.12 Equipment shall have real time digital display in hour, minute, second (24 hour mode) & have a separate time display unit to be mounted on the top of control panels having display size of approx. 100 mm height. 20.0 RELAY TEST KIT 20.1 One relay test kit shall comprise of the following equipment as detailed here under: 3 Sets 2 Nos. 1 No. 21.0 TYPE TESTS 21.1 The reports for following type tests shall be submitted by the bidder for the Protective relays, Fault locator, Disturbance recorder and Event Logger a) b) c) d) Insulation tests as per IEC: 60255-5 High frequency disturbance test as per IEC: 60255-4 (Appendix -E) -Class III (not applicable for electromechanical relays) Fast transient test as per IEC: 1000-4, Level III (not applicable for electromechanical relays) Relay characteristics, performance and accuracy test as per IEC: 60255 e) f) g) 21.2 Steady state Characteristics and operating time Dynamic Characteristics and operating time for distance protection relays and current differential protection relays For Disturbance recorder and Event logger only performance tests are intended under this item. Relay tools kits. Test plugs. Special type test plugs for use with modular type cases (if applicable).
Tests for thermal and mechanical requirements as per IEC: 60255-6 Tests for rated burden as per IEC: 60255-6 Contact performance test as per IEC: 60255-0-20 (not applicable for Event logger, Distance to fault locator and Disturbance recorder)
Steady state & Dynamic characteristics test reports on the distance protection relays, as type test, shall be based on test programme specified in Appendix-A on simulator/network analyser/PTL. Alternatively, the files generated using Electromagnetic transient Programme (EMTP) can also be used for carrying out the above tests. Single source dynamic tests on
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transformer differential relay shall be/ should have been conducted based on general guidelines specified in CIGRE committee 34 report on Evaluation of characteristics and performance of Power system protection relays and protective systems. 22.0 CONFIGURATION OF RELAY AND PROTECTION PANELS The following is the general criteria for the selection of the equipments to be provided in each type of panel. LINE PROTECTION PANEL The Line Protection panel for transmission lines shall consist of following relays and protection schemes:
Sr. No. 1. 2. 3. 4. 5. 6. 7. Description Main 1 Numerical distance Protection Scheme Distance to Fault Locator 3-Phase trip relays Flag relays, carrier receive relays, auxiliary relays timers etc. as per scheme requirements. Under voltage relay for isolator/earth switch Cutout wiring with TTB for standard energy meters. Directional back up over current relay and Earth fault Protection Scheme Quantity (132 kV) 1 Set 1 Set 1 No. Lot 2 Nos. 1 Set 1 Set
TRANSFORMER PROTECTION PANEL The protection panel for transformer shall consist of the following equipments:
Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Particulars Item Transformer Differential Protection Scheme Restricted Earth fault Protection Scheme Directional back up Over current and E/F Relay with non directional high set feature Over fluxing protection scheme Over load protection Scheme Three phase trip relays CVT selection relay as per scheme requirement Flag relays, auxiliary relays, timers etc. as per scheme requirements including transformer alarms and trip functions Cutout wiring with TTB for standard special energy meters. HV side 1 No. 1 No. 1 Set 1 No. 1 No. 2 No. Lot Lot 1 Set MV/LV side Nil 1 No. 1 Set Nil 2 No. Lot Lot 1 Set
BREAKER RELAY PANEL The breaker relay panel shall comprise of the following:
Sr. No. 1. 2. 3. 4. 5. Particulars Item Breaker Failure Protection Scheme DC supply supervision relay Trip circuit supervision relays Auto reclose scheme with check synchronising and dead line charging relay Flag relays, auxiliary relays, timers, trip relays etc. as per scheme requirements With A/R 1 No. 2 Nos. 2 Nos. 1 No. Lot Without A/R 1 No. 2 Nos. 2 Nos. Nil
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23.0 ERECTION AND MAINTENANCE TOOL EQUIPMENTS All special testing equipment required for the installation and maintenance of the apparatus, instruments devices shall be furnished in relevant schedule. 24.0 TROPICALISATION Control room will be normally air-cooled/air-conditioned. All equipments shall however be suitable for installation in a tropical monsoon area having hot, humid climate and dry and dusty seasons with ambient conditions specified in the specification. All control wiring, equipment and accessories shall be protected against fungus growth, condensation, vermin and other harmful effects due to tropical environment.
APPENDIX- A
Test programme for distance relays

General Comments: 1. These test cases are evolved from the report of working group 04 of study committee 34 (Protection) on evaluation of characteristics and performance of power system protection relays and protective systems. For any further guidelines required for carrying out the tests, reference may be made to the above document. The fault inception angles are referred to R- N voltage for all types of faults The fault inception angle is zero degree unless otherwise specified. Where not stated specifically, the fault resistance (Rf) shall be zero or minimum as possible in simulator. Single pole circuit breakers are to be used. The power flow in double source test is 500 MW
2. 3. 4. 5. 6.
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SWITCHYARD ERECTION
(SY)
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CHAPTER - SWITCHYARD ERECTION TECHNICAL SPECIFICATION FOR SWITCHYARD ERECTION
CONTENTS
Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 Description General ACSR MOOSE Conductor Galvanized Steel Earthwire Tubular Bus Conductors Earthing Conductors Spacers Bus Post Insulators Earthing Main Bus Bars Bay Equipment Lightning Protection Equipment Erection Details Storage Cabling Material Directly Buried Cables Installation of Cables Junction Box Testing and Commissioning Page No. 282 287 290 292 293 293 295 297 301 301 302 302 303 303 304 305 309 310 312 314 315
ANNEXURE-A ANNEXURE-B ANNEXURE-C
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CHAPTER - SE SECTION: SWITCHYARD ERECTION 1.0 GENERAL The detailed scope of work includes design, engineering, manufacture, testing at works, supply on FOR destination site basis, insurance, handling, storage, erection testing and commissioning of various items and works as detailed herein. This section covers the description of the following items. A. Supply of String insulators and hardware ACSR conductor Galvanised Steel Earthwire Aluminium Tubular Bus Bars Spacers Bus post insulators Earthing & earthing materials Lightning protection materials Cabling material Other items
B. Erection Of all items 1.1 String Insulators & Hardware The insulators for suspension and tension strings shall conform to IEC: 60383 and long rod insulators shall conform to IEC: 60433. Insulator hardware shall conform to IS: 2486. 1.1.1 Construction Features 1.1.1.1 Suspension and tension insulators shall be wet process porcelain with ball suitable for forming either suspension or tension strings. Each insulator shall have rated strength markings on porcelain printed and applied before firing. Porcelain used in insulator manufacture shall be homogeneous, free from laminations, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. Glazing of the porcelain shall be uniform brown colour, free from blisters, burrs and other similar defects. When operating at normal rated voltage there shall be no electric discharge between conductor and insulator which would cause corrosion or injury to conductors or insulators by the formation of substances due to chemical action. No radio interference shall be caused when operating at normal rated voltage. The design of the insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. All ferrous parts shall be hot dip
1.1.1.2
1.1.1.3 1.1.1.4
1.1.1.5
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galvanized in accordance with the latest edition of IS: 2629. The zinc used for galvanizing shall be of grade Zn-99.95 as per IS: 209. The zinc coating shall be uniform, adherent, smooth, reasonably bright, continuous and free from imperfections such as flux, ash, rust stains bulky white deposits and blisters. 1.1.1.6 Bidder shall make available data on all the essential features of design including the method of assembly of discs and metal parts, number of discs per insulator string insulators, the manner in which mechanical stresses are transmitted through discs to adjacent parts, provision for meeting expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions. Clamps for insulator strings and Corona Control rings shall be of aluminium alloy as stipulated for clamps and connectors. Insulator hardware shall be of forged steel. Malleable cast iron shall not be accepted except for insulator disc cap. The surface of hardware must be clean, smooth, without cuts, abrasion or projections. No part shall be subjected to excessive localized pressure. The metal parts shall not produce any noise generating corona under operating conditions. The tension Insulator hardware assembly shall be designed for 11500 kg tensile load. Earth wire tension clamp shall be designed for 1000 kg tensile load with a factor of safety of two (2).
1.1.1.7 1.1.1.8
1.1.1.9
1.1.1.10 The tension string assemblies shall be supplied along with suitable turn buckle. Sag compensation springs if required may also be provided. 1.1.1.11 All hardware shall be bolted type. 1.2 Long Rod Insulators 1.2.1 As an alternative to disc insulator, bidder can offer long rod insulators strings, with suitable hardware. The combination should be suitable for application specified and should offer the identical/equivalent parameters as would be available from insulator string comprising disc insulators and hardware combination. All constructional features specified at Clause 1.1.1 of this Section shall also apply to the long rod insulator string.
1.2.2 1.3 Tests
In accordance with the stipulations of the specification, the suspension and tension strings, insulator and hardware shall be subjected to the following type tests, acceptance tests and routine tests: 1.3.1 Type Tests on Insulator Strings: The test reports for following type tests shall be submitted for approval as per clause 9.2 of Section - GTR. a) Power frequency voltage withstand test with corona control rings under wet condition as per IEC: 60383. b) Switching surge voltage withstand test under wet condition as per IEC: 60383.
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c) Lightning Impulse voltage withstand test with corona control rings under dry condition as per IEC: 60383. d) Voltage distribution test (Dry). The voltage across each insulator unit shall be measured by sphere gap method. The result obtained shall be converted into percentage. The voltage across any disc shall not exceed 20% and 22% for 132 kV suspension and tension insulator strings respectively. e) Corona Extinction Voltage test (Dry) The sample assembly when subjected to power frequency voltage shall have be under dry condition shall be no evidence of Corona on any part of the sample. The atmospheric condition during testing shall be recorded and the test results shall be accordingly corrected with suitable correction factor as stipulated in IEC: 60383. f) RIV Test (Dry) Under the conditions as specified under (e) above the insulator string along with complete hardware fittings shall have a radio interference voltage level below 1000 micro volts at 1 MHz when subjected to 50 Hz AC line to ground voltage. The test procedure shall be in accordance with IS: 8263/IEC: 60437. g) Mechanical strength test. The complete insulator string along with its hardware fitting excluding arcing horn, corona control ring, grading ring, tension/suspension clamps shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string components shall not show any visual deformation and it shall be possible to dismantle them by hand. Hand tools may be used to remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded. 1.3.2 Type Tests on Insulators Type test report for Thermal Mechanical Performance tests as per IEC: 60575, Clause 3 shall be submitted for approval as per clause 9.2 of Section - GTR. 1.3.3 Acceptance Tests for Insulators: a) Visual examination as per IEC 60383 b) Verification of Dimensions as per IEC: 60383. c) Temperature cycle test as per IEC: 60383. d) Puncture Test as per IEC: 60383. e) Galvanizing Test as per IEC: 60383. f) Mechanical performance test as per IEC: 60575 Cl. 4.
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g) Test on locking device for ball and socket coupling as per IEC: 60372(2). h) Porosity test as per IEC: 60383. 1.3.4 Acceptance Test on Hardware Fitting a) Visual Examination as per Cl. 5.10 of IS: 2486 (Part-I). b) Verification of Dimensions as per Cl. 5.8 of IS: 2486 (Part-I) c) Galvanising/Electroplating tests as per Cl. 5.9 of IS: 2486 (Part-I). d) Slip strength test as per Cl. 5.4 of IS: 2486 (part-I) e) Shore hardness test for the Elastometer (if applicable as per the value guaranteed by the Bidder). f) Mechanical strength test for each component (including corona control rings and arcing horns). The load shall be so applied that the component is stressed in the same way as it would be in actual service and the procedure as given in 1.2.13.1 (g) above should be followed. g) Test on locking devices for ball and socket coupling as per IEC: 60372(2). 1.3.5 Routine Test on Insulator a) Visual Inspection as per IEC: 60383 b) Mechanical Routine Test as per IEC: 60383 c) Electrical Routine Test as per IEC: 60383 1.3.6 Routine Test on hardware Fittings a) Visual examination as per Cl. 5.10 of IS: 2486 (Part-I). b) Mechanical strength Test as per Cl. 5.11 of IS: 2486 (Part-I). 1.3.7 Test during manufacture on all Components as applicable on insulator a) Chemical analysis of zinc used for galvanising: Samples taken from the zinc ingot shall be chemically analyzed as per IS: 209. The purity of zinc shall not be less than 99.95%. b) Chemical Analysis, mechanical hardness tests and magnetic particle inspection for malleable casting: The chemical analysis, hardness tests and magnetic particle inspection for malleable casting will be as per the internationally recognized procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding tests will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance Program. 1.3.8 Test during manufacture on all components as applicable on hardware fittings: a) Chemical analysis of zinc used for galvanising: Samples taken from the zinc ingot shall be chemically analyzed as per IS: 209. The purity of zinc shall not be less than 99.95%
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b) Chemical analysis, hardness tests and magnetic particle for forgings: The chemical analysis, hardness tests and magnetic particle inspection for forgings will be as per the internationally recognized procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding tests will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance Programme. c) Chemical analysis and mechanical hardness tests and magnetic particle inspection for fabricated hardware: The chemical analysis, hardness tests and magnetic particle inspection for fabricated hardware will be as per the internationally recognized procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding tests will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance programme. 1.4 Parameters 1.4.1 Disc Insulators (132 kV) a) Type of insulators: b) Size of insulator units (mm): c) Electro mechanical strength: d) Creepage distance of: individual insulator units (minimum and as required to meet total creepage distance) e) Markings: f) Power frequency puncture: Fog type 255x145 120 kN 430 mm
Markings on porcelain shall be printed and applied before firing 1.3 times the actual wet withstand voltage flashover voltage.
*Long rod insulators should conform to equivalent electrical and mechanical parameters. 1.4.2 INSULATOR STRING (132 kV)
Sl. No. a) b) c) d) e) Description Power frequency withstand voltage of the complete string with Corona Control ring (wet)- kV rms. Lightning impulse withstand Voltage of string with corona control rings (dry)- kVp Switching surge withstand voltage of string with corona control rings (wet)- kVp Minimum corona extinction voltage level of string with Corona Control rings (dry)- kV rms. RIV level in micro volts of string with Corona Control rings at 320 kV (rms) for 400 kV string and 156 kV for 220 kV string across 300 Ohms resistor at 1 MHz Total creepage distance of the insulator string (mm) Total no. of discs per strings 275 650 NA NA NA
f) g)
3625 10
For tension application, double insulator strings and for suspension purpose single suspension insulator string shall be used for 132 kV systems.
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2.0
ACSR MOOSE CONDUCTOR 2.1 Details of Conductor 2.1.1 2.1.2 The Conductor shall conform to IS: 398 (Part V) - 1982 except where otherwise specified herein. The details of the conductor are tabulated below: a) Stranding and wire diameter: b) Number of Strands: Steel centre: 1st Steel Layer: 1st Aluminium Layer: 2nd Aluminium Layer: 3rd Aluminium Layer: c) Sectional area of aluminium: d) Total sectional area: e) Overall diameter: f) Approximate weight: g) Calculated d.c. resistance at 20 C: h) Minimum UTS:
o
54/3.53 mm Al+7/3.53mm Steel
1 6 12 18 24 528.5 mm2 597.00 mm2 31.77 mm 2004 kg/km 0.05552 ohm/km 161.2 kN
2.1.3 The details of aluminium strand are as follows: i) Minimum breaking load: of strand before stranding ii) Minimum breaking load: of strand after stranding iii) Maximum D.C. resistance: of strand at 20 C. 2.1.4 i) Minimum breaking load: of strand before stranding 1.57 kN 1.49 kN 2.921 Ohms/Km
The details of steel strand are as follows: 12.86 kN
ii) Minimum breaking load: of strand after stranding iii) Minimum number of: twist to be with stood in torsion test when tested on a gauge length of 100 times diameter of wire 2.2 Workmanship 2.2.1
12.22 kN 18 - before stranding 16 - after stranding
The finished conductor shall be smooth, compact, uniform and free from all imperfections including spills and splits, die marks, scratches, abrasions, scuff marks, kinks (protrusion of wires), dents, press marks, cut marks, wire cross over, over riding, looseness (wire being dislocated by finger/hand pressure and/or unusual bangle noise on tapping), material
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inclusions, white rust, powder formation or black spots (on account of reaction with trapped rain water etc.), dirt, grit etc. 2.2.2 All the aluminium and steel strands shall be smooth, uniform and free from all imperfections, such as spills and splits, die marks, scratches, abrasions and kinks after drawing. The steel strands shall be hot dip galvanised and shall have a minimum zinc coating of 260 gm/sq.m. after stranding of the uncoated wire surface. The zinc coating shall be smooth, continuous and of uniform thickness, free from imperfections and shall withstand minimum three dips after stranding in standard Preece test. The finished strands and the individual wires shall be of uniform quality and have the same properties and characteristics as prescribed in ASTM designation: B 498-74. The Steel strands shall be preformed and post formed in order to prevent spreading of strands in the event of cutting of composite core wire. Care shall be taken to avoid damage to galvanisation during performing and post-forming operation.
2.2.3
2.2.4
2.3 Joints in Wires 2.3.1 Aluminium Wires No joints shall, be permitted in the individual wires in the outermost layer of the finished conductor. However, joints in the 12 wire and 18 wire inner layers of the conductor shall be allowed but these joints shall be made by cold pressure butt welding and shall be such that no such joints are within 15 metres of each other in the complete stranded conductor. 2.3.2 Steel Wires There shall be no joint of any kind in the finished wire entering into the manufacture of the strand. There shall also be no strand splices in any length of the completed stranded steel core of the conductor. 2.4 Tolerances The manufacturing tolerances to the extent of the following limits only shall be permitted in the diameter of individual aluminium and steel strands and lay-ratio of the conductor. a) Diameter of aluminium and steel strands: Item Aluminium Steel Standard 3.53 mm 3.53 mm Maximum 3.55 mm 3.60 mm Minimum 3.51 mm 3.46 mm
b) Lay ratio of Conductor: Item Steel Aluminium Standard 6 wire layer 12 wire layer 18 wire layer 24 wire layer Maximum 18 14 13 12 16 12 11 10 Minimum
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2.5 Materials 2.5.1 Aluminium The aluminium strands shall be hard drawn from electrolytic aluminium rods having purity not less than 99.5% and a copper content not exceeding 0.04%. 2.5.2 Steel The steel wire strands shall be drawn from high carbon steel wire rods and shall conform to the following chemical composition: Element: Carbon: Manganese: Phosphorous: Sulphur: Silicon: 2.5.3 Zinc The Zinc used for galvanising shall be electrolytic High Grade Zinc of 99.95% purity. It shall conform to and satisfy all the requirements of IS: 209-1979. 2.6 Standard Length 2.6.1 2.7 Tests: 2.7.1 2.7.2 The following type, acceptance & routine tests and tests during manufacturing shall be carried out on the conductor. Type Tests In accordance with the stipulation of specification, the following type tests reports of the conductor shall be submitted for approval as per clause 9.2 of Section - GTR. a) b) c) d) 2.7.3 UTS test on stranded conductor. Corona extinction voltage test (dry) Radio Interference voltage test (dry) DC resistance test on stranded conductor The Conductor shall be supplied in standard length of 1500/1800 metres as required. No joint shall be allowed within a single span of stringing. % Composition 0.50 to 0.85 0.50 to 1.10 not more than 0.035 not more than 0.045 0.10 to 0.35
As per Annexure-A
Acceptance Tests
a) b) c) d) e) f) g) h) i)
Visual check for joints, scratches etc. and lengths of conductor Dimensional check on steel and aluminium strands Check for lay ratios of various layers Galvanising test on steel strands Torsion and Elongation test on steel strands Breaking load test on steel and aluminium strands Wrap test on steel and aluminium strands DC resistance test on aluminium strands UTS test on welded joint of aluminium strands
As per Annexure-A
IS: 398 (part-V) 1982 Clauses 12.5.2, 12.7 & 12.8 As per Annexure-A
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2.7.4
Routine Tests a) Check to ensure that the joints are as per specification. b) Check that there are no cuts, fins etc. on the strands. c) All acceptance tests as mentioned in Clause 2.7.3 above to be carried out on each coil.
2.7.5
Tests During Manufacture

a) b) c) Chemical analysis of zinc used for galvanizing Chemical analysis of aluminium used for making aluminium strands Chemical analysis of steel used for making steel strands
As per Annexure-A
2.7.6
Sample Batch for Type Testing The Contractor shall offer material for selection of samples for type testing, only after getting quality assurance plans approved from Owners Quality Assurance Department. The sample shall be manufactured strictly in accordance with the Quality Assurance Plan approved by Owner.
3.0 GALVANISED STEEL EARTHWIRE 3.1 Details of Earthwire 3.1.1 The galvanised steel earth wire shall generally conform to the specification of ACSR core wire as mentioned in IS: 398 (Part-II)-1976 except where otherwise specified herein. The details of the earth wire are tabulated below: a) Stranding and wire: diameter b) Number of strands Steel core: Outer Steel Layer: c) Total sectional area: d) Overall diameter: e) Approximate weight: f) Calculated d.c. resistance at 20oC: 7/3.66 mm steel
3.1.2
1 6 73.65 mm2 10.98 mm 583 kg/km 2.5 ohms/km
g) Minimum ultimate tensile strength: 68.4 kN h) Direction of lay of outer layer: 3.2 WORKMANSHIP 3.2.1 All steel strands shall be smooth, uniform and free from all imperfections, such as spills and splits, die marks, scratches, abrasions and kinks after drawing and also after stranding. The finished material shall have minimum brittleness as it will be subjected to appreciable vibration while in use. The steel strands shall be hot dip galvanised (and shall have a minimum zinc coating of 275 gms/sq.m.) after stranding of the uncoated wire
Right hand
3.2.2 3.2.3
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surface. The zinc coating shall be smooth, continuous, of uniform thickness, free from imperfections and shall withstand three and a half dips after stranding in standard Preece test. The steel wire rod shall be of such quality and purity that, when drawn to the size of the strands specified and coated with zinc, the finished strands shall be of uniform quality and have the same properties and characteristics in ASTM designation B498-74. 3.2.4 The steel strands shall be preformed and post formed in order to prevent spreading of strands while cutting of composite earth wire. Care shall be taken to avoid damage to galvanisation during performing and post forming operation. To avoid susceptibility towards wet storage stains (white rust), the finished material shall be provided with a protective coating of boiled linseed oil.
3.2.5
3.3
JOINTS IN WIRES There shall be no joint of any kind in the finished steel wire strand entering into the manufacture of the earth wire. There shall be no strand joints or strand splices in any length of the completed stranded earth wire.
3.4 TOLERANCES The manufacturing tolerances to the extent of the following limits only shall be permitted in the Diameter of the individual steel strands and lay length of the earth wire: Standard Maximum Minimum Diameter Lay length 3.5 MATERIALS 3.5.1 Steel The steel wire strands shall be drawn from high carbon steel rods and shall conform to the following requirements as to the chemical composition: Element Carbon Manganese Phosphorous Sulphur Silicon 3.5.2 Zinc The zinc used for galvanising shall be electrolytic High Grade Zinc of 99.95% purity. It shall conform to and satisfy all the requirements of IS: 209-1979. 3.6 STANDARD LENGTH 3.6.1 3.7.1 The earth wire shall be supplied in standard drum length of manufacturer. 3.7 TESTS The following type, routine & acceptance tests and tests during manufacturing shall be carried out on the earth wire.
3.66 mm 181 mm
3.75 mm 198 mm
3.57 mm 165 mm
% Composition Not more than 0.55 0.4 to 0.9 Not more than 0.04 Not more than 0.04 0.15 to 0.35
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3.7.2
TYPE TESTS In accordance with the stipulation of specification, the following type tests reports of the earth wire shall be submitted for approval as per clause 9.2 of Section - GTR. a) UTS test b) DC resistance test As per Annexure - B As per Annexure - B
3.7.3
ACCEPTANCE TESTS a) b) c) d) e) f) g) h) i) j) Visual check for joints, scratches etc. and length of earth wire Dimensional check Galvanizing test Lay length check Torsion test Elongation test Wrap test DC resistance test Breaking load test Chemical Analysis of steel
As per Annexure-B
IS: 398 (part-III) 1976
3.7.4
ROUTINE TESTS a) Check that there are no cuts, fins etc. on the strands. b) Check for correctness of stranding.
3.7.5
TESTS DURING MANUFACTURE a) Chemical analysis of zinc used for galvanishing b) Chemical analysis of steel As per Annexure - B As per Annexure - B
3.7.6
SAMPLE BATCH FOR TYPE TESTING The Contractor shall offer material for sample selection for type testing, only after getting quality assurance programme approved by the Owner. The samples for type testing shall be manufactured strictly in accordance with the Quality Assurance Programme approved by the Owner.
4.0 TUBULAR BUS CONDUCTORS 4.1 General Aluminium used shall be grade 63401 WP (range 2) conforming to IS: 5082. 4.2 Constructional Features 4.2.1 4.2.2 4.2.3 For outside diameter (OD) & thickness of the tube there shall be no minus tolerance, other requirements being as per IS: 2678 and IS: 2673. The aluminium tube shall be supplied in suitable cut length to minimize wastage. The welding of aluminium tube shall be done by the qualified welders duly approved by the owner.
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4.3 Tests In accordance with stipulations of the specification, Routine tests shall be conducted on tubular bus conductors as per IS: 5082. Also the wall thickness and ovality of the tube shall be measured by the ultrasonic method. In addition to the above tests, 0.2% proof tests on both parent metal and Aluminium tube after welding shall be conducted. 4.4 Parameters a) Size: b) Outer diameter (mm): c) Thickness (mm): d) Cross-sectional area (Sq. mm.) e) Weight (kg/m) 5.0 EARTHING CONDUCTORS 5.1 General All conductors buried in earth and concrete shall be of mild steel. All conductors above ground level and earthing leads shall be of galvanised steel, except for cable trench earthing. The minimum sizes of earthing conductor to be used are as indicated in clause 8.4 of this Section. 5.2 Constructional Features 5.2.1 Galvanised Steel a) Steel conductors above ground level shall be galvanised according to IS: 2629. b) The minimum weight of the zinc coating shall be 618 gm/sq. m. and minimum thickness shall be 85 microns. c) The galvanised surfaces shall consist of a continuous and uniformly thick coating of zinc, firmly adhering to the surfaces of steel. The finished surface shall be clean and smooth and shall be free from defects like discoloured patches, bare spots, unevenness of coating, spelter which is loosely attached to the steel globules, spiky deposits, blistered surfaces, flaking or peeling off etc. The presence of any of these defects noticed on visual or microscopic inspection shall render the material liable to rejection. 5.3 Tests In accordance with stipulations of the specifications galvanised steel shall be subjected to four one minute dips in copper sulphate solution as per IS: 2633. 6.0 SPACERS 6.1 General Spacers shall conform to IS: 10162. The spacers are to be located at a suitable spacing to limit the short circuit forces as per IEC: 865. 6.2 Constructional Features 6.2.1 No magnetic material shall be used in the fabrication of spacers except for GI bolts and nuts. 4"IPS (EH Type) 114.2 8.51 2825.61 7.7
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6.2.2 6.2.3 6.3 Tests
Spacer design shall be made to take care of fixing and removing during installation and maintenance. The design of the spacers shall be such that the conductor does not come in contact with any sharp edge.
Each type of spacers shall be subjected to the following type tests, acceptance tests and routine tests: 6.3.1 Type Tests: Following type test reports shall be submitted for approval as per clause 9.2 of Section - GTR. a) Clamp slip tests: The sample shall be installed on test span of twin conductor bundle string or quadruple conductor bundle string (as applicable) at a tension of 44.2 kN. One of the clamps of the sample when subjected to a longitudinal pull of 2.5 kN parallel to the axis of the conductor shall not slip on the conductor. The permanent displacement between the conductor and the clamp of sample measured after removal of the load shall not exceed 1.0 mm. Similar tests shall be performed on the other clamps of the same sample. b) Fault current test as per Cl. 5.14.2 of IS: 10162 c) Corona Extinction Voltage Test (Dry): This test shall be performed on equipment as per procedure mentioned at Annexure-C. d) RIV Test (Dry): This test shall be performed as per procedure mentioned at Annexure-C. e) Resilience test (if applicable) f) Tension Test g) Log decremant test (if applicable) h) Compression test i) Galvanising test 6.3.2 Acceptance Test (As per IS: 10162) a) Visual examination b) Dimensional verification c) Movement test d) Clamp slip test e) Clamp bolt torque test (if applicable) f) Assembly torque test g) Compression test h) Tension test i) Galvanising test j) Hardness test for neoprene (if applicable): The shore hardness of different points on the elastometer surface of cushion grip clamp shall be measured by shore hardness meter. It shall be between 65 to 80. k) Ultimate Tensile Strength Test: The UTS of the retaining rods shall be measured. It shall not be less than 35 kg/Sq. mm.
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6.3.3
Routine test a) Visual examination b) Dimensional verification
7.0
BUS POST INSULATORS The post insulators shall conform in general to latest IS: 2544, IEC: 168 and IEC: 815. 7.1 Constructional Features 7.1.1 Post type insulators shall consist of a porcelain part permanently secured in a metal base to be mounted on the supporting structures. They shall be capable of being mounted upright. They shall be designed to withstand any shocks to which they may be subjected to by the operation of the associated equipment. Only solid core insulators will be acceptable. Porcelain used shall be homogeneous, free from lamination, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. Glazing of the porcelain shall be of uniform brown in colour, free from blisters, burrs and other similar defects. The insulator shall have alternate long and short sheds with aerodynamic profile, the shed profile shall also meet the requirements of IEC: 815 for the specified pollution level. When operating at normal rated voltage there shall be no electric discharge between conductor and insulators which would cause corrosion or injury to conductors or insulators by the formation of substance produced by chemical action. The design of the insulators shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. All ferrous parts shall be hot dip galvanised in accordance with the latest edition of IS: 2633, & IS: 2629. The zinc used for galvanising shall be grade Zn 99.95 as per IS: 209. The zinc coating shall be uniform, adherent, smooth, reasonably bright, continuous and free from imperfections such as flux ash, rust stains, bulky white deposits and blisters. The metal parts shall not produce any noise generating corona under the operating conditions. a) Every bolt shall be provided with a steel washer under the nut so that part of the threaded portion of the bolts is within the thickness of the parts bolted together. b) Flat washer shall be circular of a diameter 2.5 times that of bolt and of suitable thickness. Where bolt heads/nuts bear upon the beveled surfaces they shall be provided with square tapered washers of suitable thickness to afford a seating square with the axis of the bolt. c) All bolts and nuts shall be of steel with well formed hexagonal heads forged from the solid and shall be hot dip galvanised. The nuts shall be good fit on the bolts and two clear threads shall show through the nut when it has been finally tightened up. 7.1.9 Bidder shall make available data on all the essential features of design including the method of assembly of shells and metals parts, number of
7.1.2
7.1.3 7.1.4
7.1.5
7.1.6 7.1.7
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shells per insulator, the manner in which mechanical stresses are transmitted through shells to adjacent parts, provision for meeting expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions. 7.2 Tests In accordance with the stipulations of the specification, the post insulators shall be subject to type, acceptance, sample and routine tests as per IS: 2544 and IEC:168. 7.2.1 In addition to acceptance/sample/routine tests as per IS: 2544 and IEC168, the following tests shall also be carried out. a) Ultrasonic test as an acceptance test b) Soundness test, metallurgical tests and magnetic test on MCI caps and pedestal tests as acceptance test. c) All hot dip galvanised components shall be subject to check for uniformity of thickness and weight of zinc coating on sample basis. d) The bending test shall be carried out at 50% minimum failing load in four directions as a routine test and at 100% minimum failing load in four directions as an acceptance test. e) Acceptance norms for visual defects allowed at site and also at works shall be agreed in the Quality plan. 7.2.2 In accordance with the stipulation of specification, the following type tests reports of the post insulators shall be submitted for approval as per clause 9.2 of Section - GTR. a) Power frequency withstand test (dry & wet) b) Lightning impulse test (dry) c) Switching impulse test (wet). d) Measurement of R.I.V (Dry): (As per Annexure C)
e) Corona extinction voltage test (Dry): (As per Annexure C) f) Test for deflection under load g) Test for mechanical strength. 7.3 Technical Parameters of Bus Post Insulators.
a) b) c) d) e) f) Type Voltage class (kV) Dry and wet one minute power frequency withstand voltage (kV rms) Dry lightning impulse withstand Voltage (kVp) Wet switching surge withstand voltage (kVp) Max. radio interference voltage (in micro volts) at voltage of 305 kV (rms) and 156 (rms) for 400 kV & 220 kV respectively between phase to ground. Corona extinction voltage (kV rms) Solid Core 420 680 1425 1050 500 Solid Core 245 460 1050 500 Solid Core 145 275 650 500
g)
320 (Min.)
156 (Min.)
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Total minimum cantilever strength (kG Minimum torsional moment) Minimum cantilever strength (kG) Total height of insulator (mm)
As per IEC: 273 3350 2300 (Minimum) Necessary substructure/stool required to match bys height using standard structure shall be provided by the Contractor 127 300 4 8 M16 18 Heavy (III) 10500 127 354 4 8 M16 18 Heavy (III) 6125
k)
l)
m)
P.C.D. Top (mm) Bottom (mm) No. of bolts Top Bottom Diameter of bolt/holes (mm) Top Bottom dia Pollution level as per IEC: 815 Minimum total creepage distance for Heavy Pollution (mm)
Heavy (III) 3165
n) o)
7.3.1
If corona extinction voltage is to be achieved with the help of corona ring or any other similar device, the same shall be deemed to be included in the scope of the Contractor.
8.0 EARTHING 8.1 The earthing shall be done in accordance with requirements given hereunder. The earth mat design shall be done by the Contractor as per IEEE: 80. The soil resistivity measurement shall also be done by the Contractor. The resistivity measurement of stone (to be used for stone spreading) shall also be done by the Contractor to confirm the resistivity value of stone considered in earth mat design. For measurement purpose, one sample of stones from each source (in case stones are supplied from more than one source) shall be used. The main earth mat shall be laid in the switchyard area in accordance with the approved design requirements. 8.2 Neutral points of systems of different voltages, metallic enclosures and frame works associated with all current carrying equipments and extraneous metal works associated with electric system shall be connected to a single earthing system unless stipulated otherwise. Earthing and lightning protection system installation shall be in strict accordance with the latest editions of Indian Electricity Rules, relevant Indian Standards and Codes of practice and Regulations existing in the locality where the system is installed. a) Code of practice for Earthing IS: 3043 b) Code of practice for the protection of Building and allied structures against lightning IS: 2309. c) Indian Electricity Rules 1956 with latest amendments. d) National Electricity Safety code IEEE-80.
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8.4 Details of Earthing System

Sl. Item No. a) Main earthing conductor to be buried in ground b) Conductor above ground & earthing leads (for equipment) c) Conductor above ground & earthing leads (for columns & aux. structure d) Earthing of indoor LT panels, Control panels and out door marshalling boxes, MOM boxes, junction boxes & lighting Panels etc. e) Rod Earth Electrode f) g) h) i) Size 40 mm dia 75 x 12 mm G.S. flat 75 x 12 mm G.S. flat 50 x 6 mm G.S. flat Material Mild Steel rod Galvanised Steel Galvanised Steel Galvanised Steel
40 mm dia 3000 mm long Pipe Earth Electrode (in treated earth 40 mm dia pit) as per IS. 3000 mm long Earthing for motors 25 x 3 mm G.S. flat Earthing conductor along outdoor 50 x 6 mm MS cable trenches flat Earthing of Lighting Poles 20 mm dia 3000 mm long
Mild Steel Galvanised Steel Galvanised steel Mild steel Mild steel rod
8.5
Earthing Conductor Layout 8.5.1 8.5.2 Earthing conductors in outdoor areas shall be buried at least 600 mm below finished ground level unless stated otherwise. Wherever earthing conductor crosses cable trenches, underground service ducts, pipes, tunnels, railway tracks etc., it shall be laid minimum 300 mm below them and shall be circumvented in case it fouls with equipment/structure foundations. Tap-connections from the earthing grid to the equipment/structure to be earthed, shall be terminated on the earthing terminals of the equipment/structure as per Earthing Details. (Drawing enclosed). Earthing conductors or leads along their run on cable trench, ladder, walls etc. shall be supported by suitable welding/cleating at intervals of 750 mm. Wherever it passes through walls, floors etc., galvanised iron sleeves shall be provided for the passage of the conductor and both ends of the sleeve shall be sealed to prevent the passage of water through the sleeves. Earthing conductor around the building shall be buried in earth at a minimum distance of 1500 mm from the outer boundary of the building. In case high temperature is encountered at some location, the earthing conductor shall be laid minimum 1500 mm away from such location. Earthing conductors crossing the road shall be laid 300 mm below road or at greater depth to suit the site conditions. Earthing conductors embedded in the concrete shall have approximately 50 mm concrete cover.
8.5.3
8.5.4
8.5.5
8.5.6 8.5.7
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8.6 Equipment and Structure Earthing 8.6.1 Earthing pads shall be provided for the apparatus/equipment at accessible position. The connection between earthing pads and the earthing grid shall be made by two short earthing leads (one direct and another through the support structure) free from kinks and splices. In case earthing pads are not provided on the item to be earthed, same shall be provided in consultation with Owner. Whether specifically shown in drawings or not, steel/RCC columns, metallic stairs etc. shall be connected to the nearby earthing grid conductor by two earthing leads. Electrical continuity shall be ensured by bonding different sections of hand-rails and metallic stairs. Metallic pipes, conduits and cable tray sections for cable installation shall be bonded to ensure electrical continuity and connected to earthing conductors at regular interval. Apart from intermediate connections, beginning points shall also be connected to earthing system. Metallic conduits shall not be used as earth continuity conductor. Wherever earthing conductor crosses or runs along metallic structures such as gas, water, steam conduits, etc. and steel reinforcement in concrete it shall be bonded to the same. Light poles, junction boxes on the poles, cable and cable boxes/glands, lockout switches etc. shall be connected to the earthing conductor running alongwith the supply cable which in turn shall be connected to earthing grid conductor at a minimum two points whether specifically shown or not. Railway tracks within switchyard area shall be earthed at a spacing of 30 m and also at both ends. Earthing conductor shall be buried 2000 mm outside the switchyard fence. All the gates and every alternate post of the fence shall be connected to earthing grid. The stone spreading shall also be done 2000 mm outside switchyard fence. The criteria for stone spreading shall be followed in line with requirement specified elsewhere in the specification 8.6.9 Flexible earthing connectors shall be provided for the moving parts.
8.6.2
8.6.3
8.6.4 8.6.5
8.6.6
8.6.7 8.6.8
8.6.10 All lighting panels, junction boxes, receptacles fixtures, conduits etc. shall be grounded in compliance with the provision of I.E. rules 8.6.11 A continuous ground conductor of 16 SWG GI wire shall be run all along each conduit run. The conductor shall be connected to each panel ground bus. All junction boxes, receptacles, switches, lighting fixtures etc. shall be connected to this 16 SWG ground conductor. 8.6.12 50x6 mm MS flat shall run on the top tier and all along the cable trenches and the same shall be welded to each of the racks. Further this flat shall be earthed at both ends and at an interval of 30 mtrs. The M.S. flat shall be finally painted with two coats of Red oxide primer and two coats of Post Office red enamel paint. 8.6.13 A 40 mm dia, 3000 mm long MS earth electrode with test link, CI frame and cover shall be provided to connect down conductor of lightning mast and towers with peak.
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8.7
Jointing 8.7.1 Earthing connections with equipment earthing pads shall be bolted type. Contact surfaces shall be free from scale, paint, enamel, grease, rust or dirt. Two bolts shall be provided for making each connection. Equipment bolted connections, after being checked and tested, shall be painted with anti corrosive paint/compound. 8.7.2 Connection between equipment earthing lead and main earthing conductors and between main earthing conductors shall be welded type. For rust protections, the welds should be treated with red lead and afterwards coated with two layers bitumen compound to prevent corrosion. Steel to copper connections shall be brazed type and shall be treated to prevent moisture ingression. Resistance of the joint shall not be more than the resistance of the equivalent length of the conductor. All ground connections shall be made by electric arc welding. All welded joints shall be allowed to cool down gradually to atmospheric temperature before putting any load on it. Artificial cooling shall not be allowed. Bending of earthing rod shall be done preferably by gas heating. All arc welding with large dia. conductors shall be done with low hydrogen content electrodes. The 75x12 mm GS flat shall be clamped with the equipment support structures at 1000mm interval.
8.7.3 8.7.4 8.7.5
8.7.6 8.7.7 8.7.8
8.8 Power Cable Earthing Metallic sheaths and armour of all multi core power cables shall be earthed at both equipment and switchgear end. Sheath and armour of single core power cables shall be earthed at switchgear end only. 8.9 Specific Requirement for Earthing Systems 8.9.1 Each earthing lead from the neutral of the power transformer/Reactor shall be directly connected to two pipe electrodes in treated earth pit (as per IS) which in turn, shall be buried in Cement Concrete pit with a cast iron cover hinged to a cast iron frame to have an access to the joints. All accessories associated with transformer like cooling banks, radiators etc. shall be connected to the earthing grid at minimum two points. Earthing terminal of each lightning arrester & capacitor voltage transformer shall be directly connected to rod earth electrode which in turn, shall be connected to station earthing grid. Auxiliary earthing mat comprising of 40 mm dia M.S. rods closely spaced (300x300 mm) conductors shall be provided at depth of 300 mm from ground level below the operating handles of the M.O.M. Box of the isolators. M.O.M. boxes shall be directly connected to the auxiliary earthing mat.
8.9.2
8.9.3
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9.0
Main Bus Bars The brief description of the bus switching scheme, bus bar layout and equipment connection to be adopted are indicated elsewhere in the specification. 9.1 The Contractor shall furnish supporting calculations for the bus bars/conductors to show adequacy of design parameters for: a) Fibre-stress b) Cantilever strength of post insulators c) Aeolian vibrations d) Vertical deflection of bus bars e) Short circuit forces in bundle conductor and spacer location for each span of ACSR conductor stringing as per layout drawings. 9.1.1 The welds in the aluminium tubes shall be kept to the minimum and there shall not be more than one weld per span. The procedure and details of welding shall be subject to Owners approval. Material for welding sleeve shall be same as that of aluminium tube. Welding sleeve shall be of 600 mm length. Corona bells shall be provided wherever the bus extends beyond the clamps and on free ends, for sealing the ends of the tubular conductor against rain and moisture and to reduce the electrostatic discharge loss at the end points. There shall be a small drain hole in the corona bell. The material of Corona bell shall be Aluminium alloy similar to that of clamps & connectors. To minimise the vibrations in the aluminium tubes, damping conductor shall be provided inside the aluminium tubes. For this purpose, the cut pieces of ACSR conductor which otherwise are considered wastages, shall be used as damping conductor. Details of past experience of the persons proposed to be employed for Aluminium tube welding and the test reports of the welded pieces to prove the electrical and mechanical characteristics shall also be furnished along with the bid. Welding at site shall be done by adopting a qualified procedure and employing qualified welders as per ASME-Section IX.
9.1.2
9.1.3
9.1.4
10.0 BAY EQUIPMENT 10.1 The disposition of various bay equipments shall be as per single line diagrams and layout drawings. 10.2 Bay Marshalling Kiosk:One number of bay marshalling kiosks shall be provided for each bay. In addition to the requirements specified elsewhere in the specification, the bay marshalling kiosk shall have three distinct compartments for the following purpose: (i) To receive two incoming 415 Volts, 3 phase, 63 Amps., AC supply with auto changeover and MCB unit and distribute minimum six (four in case of S/S having highest voltage 132 kV) outgoing 415V, 3 phase, 16 Amps AC supplies controlled by MCB. To distribute minimum ten (six in case of Sub-Station having highest voltage 132 kV) outgoing 240 Volts, 10 Amps. single phase supplies to be controlled by MCB to be drawn from above 3 phase incomers.
(ii)
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(iii) 200 (100 in case of S/S having highest voltage 132 kV) numbers terminal blocks in vertical formation for interlocking facilities. Additional marshalling kiosk shall be provided in case the existing marshalling kiosks in a diametre do not have adequate spare feeders. 11.0 LIGHTNING PROTECTION 11.1 Direct stroke lightning protection (DSLP) shall be provided in the EHV switchyard by lightning masts and shield wires. 11.2 The lightning protection system shall not be in direct contact with underground metallic service ducts and cab. 11.3 Conductors of the lightning protection system shall not be connected with the conductors of the safety earthing system above ground level. 11.4 Down conductors shall be cleated on the structures at 2000 mm interval. 11.5 Connection between each down conductor and rod electrodes shall be made via test joint (pad type compression clamp) located approximately 1500 mm above ground level. The rod electrode shall be further joined with the main earth mat. 11.6 Lightning conductors shall not pass through or run inside G.I. conduits. 12.0 EQUIPMENT ERECTION DETAILS 12.1 For equipment interconnection, the surfaces of equipment terminal pads, Aluminium tube, conductor & terminal clamps and connectors shall be properly cleaned. After cleaning, contact grease shall be applied on the contact surfaces of equipment terminal pad, Aluminium tube/conductor and terminal clamps to avoid any air gap in between. Subsequently bolts of the terminal pad/terminal connectors shall be tightened and the surfaces shall be cleaned properly after equipment interconnection. 12.2 Muslin or leather cloth shall be used for cleaning the inside and outside of hollow insulators. 12.3 All support insulators, circuit breaker interrupters and other fragile equipment shall preferably be handled with cranes having suitable booms and handling capacity. 12.4 Bending of Aluminium tube and compressed air piping if any should be done by a bending machine and through cold bending only. Bending shall be such that inner diameter of pipe is not reduced. 12.5 Cutting of the pipes wherever required shall be such as to avoid flaring of the ends. Hence only a proper pipe cutting tool shall be used. Hack saw shall not be used. 12.6 Handling of equipment shall be done strictly as per manufacturers/suppliers instructions/instruction manual. 12.7 Handling equipment, sling ropes etc. should be tested periodically before erection for strength. 12.8 The slings shall be of sufficient length to avoid any damage to insulator due to excessive swing, scratching by sling ropes etc.
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13.0 STORAGE 13.1 The Contractor shall provide and construct adequate storage shed for proper storage of equipments, where sensitive equipments shall be stored indoors. All equipments during storage shall be protected against damage due to acts of nature or accidents. The storage instructions of the equipment manufacturer/Owner shall be strictly adhered to. 14.0 CABLING MATERIAL 14.1 CABLE TAGS AND MARKERS 14.1.1 Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedule. 14.1.2 The tag shall be of aluminium with the number punched on it and securely attached to the cable conduit by not less than two turns of 20 SWG GI wire conforming to IS: 280. Cable tags shall be of rectangular shape for power cables and of circular shape for control cables. 14.1.3 Location of cables laid directly underground shall be clearly indicated with cable marker made of galvanised iron plate. 14.1.4 Location of underground cable joints shall be indicated with cable marker with an additional inscription Cable joints. 14.1.5 The marker shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at every change in direction. They shall be located on both sides of road and drain crossings. 14.1.6 Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit entry and at each end & turning point in cable tray/trench runs. Cable tags shall be provided inside the switchgear, motor control centres, control and relay panels etc., wherever required for cable identification, where a number of cables enter together through a gland plate. 14.2 Cable Supports and Cable Tray Mounting Arrangements 14.2.1 The Contractor shall provide embedded steel inserts on concrete floors/walls to secure supports by welding to these inserts or available building steel structures. 14.2.2 The supports shall be fabricated from standard structural steel members. 14.2.3 Insert plates will be provided at an interval of 750 mm wherever cables are to be supported without the use of cable trays, such as in trenches, while at all other places these will be at an interval of 2000 mm. 14.3 Cable Termination and Connections 14.3.1 The termination and connection of cables shall be done strictly in accordance with cable and termination kit manufacturers instructions, drawing and/or as directed by the Owner. The work shall include all clamping, fittings, fixing, plumbing, soldering, drilling, cutting, taping, heat shrinking (where applicable), connecting to cable terminal, shorting and grounding as required to complete the job. Supply of all consumable material shall be in the scope of Contractor.
14.3.2
14.3.3
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14.3.4
The equipment will be generally provided with unrolled gland plates for cables/conduit entry. The Contractor shall be responsible for drilling of gland plates, painting and touching up. Holes shall not be made by gas cutting. Control cable cores entering control panel/switch-gear/MCCB/MCC/ miscellaneous panels shall be neatly bunched, clamped and tied with nylon strap or PVC perforated strap to keep them in position. The Contractor shall tag/ferrule control cable cores at all terminations, as instructed by the Owner. In panels where a large number of cables are to be terminated and cable identification may be difficult, each core ferrule may include the complete cable number as well. Spare cores shall be similarly tagged with cable numbers and coiled up. All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively closed. Double compression type nickel plated (coating thickness not less than 10 microns) brass cable glands shall be provided by the Contractor for all power and control cables to provide dust and weather proof terminations.
14.3.5
14.3.6
14.3.7 14.3.8 14.3.9
14.3.10 The cable glands shall conform to BIS: 6121. They shall comprise of heavy duty brass casting, machine finished and nickel plated, to avoid corrosion and oxidation. Rubber components used in cable glands shall be neoprene and of tested quality. Cable glands shall be of approved make. 14.3.11 The cable glands shall also be suitable for dust proof and weather proof termination. The test procedure, if required, has to be discussed and agreed to between Owner and cable gland manufacturer. 14.3.12 If the cable-end box or terminal enclosure provided on the equipment is found unsuitable and requires modification, the same shall be carried out by the Contractor, as directed by the Owner. 14.3.13 Crimping tool used shall be of approved design and make. 14.3.14 Cable lugs shall be tinned copper solderless crimping type conforming to IS: 8309 & 8394. Bimetallic lugs shall be used depending upon type of cables used. 14.3.15 Solderless crimping of terminals shall be done by using corrosion inhibitory compound. The cable lugs shall suit the type of terminals provided. 14.4 Storage and handling of Cable Drums 14.4.1 Cable drums shall be unloaded, handled and stored in an approved manner and rolling of drums shall be avoided as far as possible. For short distances, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum.
15.0 DIRECTLY BURIED CABLES 15.1 The Contractor shall construct the cable trenches required for directly buried cables. The scope of work shall include excavation, preparation of sand bedding, soil cover, supply and installation of brick or concrete protective covers, back filling and ramming, supply and installation of route markers and
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joint markers. The Bidder shall ascertain the soil conditions prevailing at site, before submitting the bid. 15.2 The cable (power and control) between LT station, control room, DG set building and fire lighting pump house shall be laid in the buried cable trenches. In addition to the above, for lighting purpose also, buried cable trench can be used in outdoor area. Cable route and joint markers and RCC warning covers shall be provided wherever required. The voltage grade of cables shall be engraved on the marker.
15.3
16.0 INSTALLATION OF CABLES 16.1 16.2 Cabling in the control room shall be done on ladder type cable trays while cabling in switchyard area shall be done on angles in the trench. All cables from bay cable trench to equipments including and all interpole cables (both power and control) for all equipment, shall be laid in PVC pipes of minimum 50 mm nominal outside diameter of class 4 as per IS 4985 which shall be buried in the ground at a depth of 250mm below finish formation level. Separate PVC pipes shall be laid for control and power cables. Cables shall be generally located adjoining the electrical equipment through the pipe insert embedded in the floor. In the case of equipments located away from cable trench either pipe inserts shall be embedded in the floor connecting the cable trench and the equipment or in case the distance is small, notch/opening on the wall shall be provided. In all these cases necessary bending radius as recommended by the cable manufacturer shall be maintained. Cable racks and supports shall be painted after installation with two coats of metal primer (comprising of red oxide and zinc chromate in a synthetic medium) followed by two finishing coats of aluminium paint. The red oxide and zinc chromate shall conform to IS: 2074. Suitable arrangement should be used between fixed pipe/cable trays and equipment terminal boxes, where vibration is anticipated. Power and control cables in the cable trench shall be laid in separate tiers. The order of laying of various cables shall be as follows, for cables other than directly buried. a) Power cables on top tiers. b) Control instrumentation and other service cables in bottom tiers. 16.7 Single core cables in trefoil formation shall be laid with a distance of three times the diameter of cable between trefoil centre lines. All power cables shall be laid with a minimum centre to centre distance equal to twice the diameter of the cable of higher size of cables. Trefoil clamps for single core cables shall be of pressure die cast aluminium (LM-6), Nylon -6 or fibre glass and shall include necessary fixing GI nuts, bolts, washer etc. These are required at every 2 metre of cable runs. Power and control cables shall be securely fixed to the trays/supports with self locking type nylon ties with de-interlocking facility at every 5 metre interval for horizontal run. Vertical and inclined cable runs shall be secured with 25 mm wide and 2 mm thick aluminium strip clamps at every 2 meters.
16.3
16.4
16.5 16.6
16.8
16.9
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16.10 Cables shall not be bent below the minimum permissible limit. The permissible limits are as follows: Table of Cable and Minimum bending radius Power cable: 12 D Control cable: 10 D D is overall diameter of cable 16.11 Where cables cross roads, drains and rail tracks, these shall be laid in reinforced spun concrete or steel pipes buried at not less than one metre depth. 16.12 In each cable run some extra length shall be kept at a suitable point to enable one (for LT cables)/two (for H.T. cables) straight through joints to be made in case the cable develop fault at a later date. 16.13 Selection of cable drums for each run shall be so planned as to avoid using straight through joints. Cable splices will not be permitted except where called for by the drawings, unavoidable or where permitted by the Owner. If straight through joints are unavoidable, the Contractor shall use the straight through joints kit of reputed make. 16.14 Control cable terminations inside equipment enclosures shall have sufficient lengths so that changing of termination in terminal blocks can be done without requiring any splicing. 16.15 Metal screen and armour of the cable shall be bonded to the earthing system of the station, wherever required by the Owner. 16.16 Rollers shall be used at intervals of about two metres while pulling cables. 16.17 All due care shall be taken during unreeling, laying and termination of cable to avoid damage due to twist, kinks, sharp bends, etc. 16.18 Cable ends shall be kept sealed to prevent damage. In cable vault, fire resistant seal shall be provided underneath the panels. 16.19 Inspection on receipt, unloading and handling of cables shall generally be in accordance with IS: 1255 and other Indian Standard Codes of practices. 16.20 Wherever cable pass through floor or through wall openings or other partitions, GI/PVC wall sleeves with bushes having a smooth curved internal surface so as not to damage the cable, shall be supplied, installed and properly sealed by the Contractor at no extra charges. 16.21 Contractor shall remove the RCC/Steel trench covers before taking up the work and shall replace all the trench covers after the erection-work in that particular area is completed or when further work is not likely to be taken up for some time. 16.22 Contractor shall furnish three copies of the report on work carried out in a particular week, indicating cable numbers, date on which laid, actual length and route, testing carried out, terminations carried out, along with the marked up copy of the cable schedule and interconnection drawing wherever any modifications are made. 16.23 Contractor shall paint the tray identification number on each run of trays at an interval of 10 m. 16.24 In case the outer sheath of a cable is damaged during handling/installation, the Contractor shall repair it at his own cost to the satisfaction of the Owner. In case any other part of a cable is damaged, the same shall be replaced by a
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healthy cable at no extra cost to the Owner, i.e. the Contractor shall not be paid for installation and removal of the damaged cable. 16.25 All cable terminations shall be appropriately tightened to ensure secure and reliable connections. The Contractor shall cover the exposed part of all cable lugs whether supplied by him or not with insulating tape, sleeve or paint. 16.26 Cable trays i) ii) The cable trays shall be of G.S. sheet and minimum thickness of sheet shall be 2 mm. The Contractor shall perform all tests and inspection to ensure that material and workmanship are according to the relevant standards. Contractor shall have to demonstrate all tests as per specification and equipment shall comply with all requirements of the specification. a) Test for galvanising (Acceptance Test): The test shall be done as per approved standards. b) Deflection Test: (Type Test): A 2.5 metre straight section of 300 mm, 600 mm wide cable tray shall be simply supported at two ends. A uniform distributed load of 76 kg/m shall be applied along the length of the tray. The maximum deflection at the mid-span shall not exceed 7 mm. 16.27 Conduits, Pipes and Duct Installation 16.27.1 Contractor shall supply and install all rigid conduits, mild steel pipes, flexible conduits, hume pipes etc. including all necessary sundry materials such as tees, elbows, check nuts, bushing, reducers, enlargers, coupling cap, nipples, gland sealing fittings, pull boxes etc as specified and to be shown in detailed drawing. The size of the conduit/pipe shall be selected on the basis of 40% fill criterion. Contractor shall have his own facility for bending, cutting and threading the conduits at site. Cold bending should be used. All cuts & threaded ends shall be made smooth without leaving any sharp edges. Anticorrosive paint shall be applied at all field threaded portions. All conduit/pipes shall be extended on both sides of wall/floor openings. The fabrication and installation of supports and the clamping shall be included in the scope of work by Contractor. When two lengths of conduits are joined together through a coupling, running threads equal to twice the length of coupling shall be provided on each conduit to facilitate easy dismantling of two conduits. Conduit installation shall be permanently connected to earth by means of special approved type of earthing clamps. GI pull wire of adequate size shall be laid in all conduits before installation. Each conduit run shall be painted with its designation as indicated on the drawings such that it can be identified at each end. Embedded conduits shall have a minimum concrete cover of 50 mm. Conduit run sleeves shall be provided with the bushings at each end.
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16.27.9
Metallic conduit runs at termination shall have two locknuts and a bushing for connection. Flexible conduits shall also be suitably clamped at each end with the help of bushings. Bushings shall have rounded edges so as not to damage the cables.
16.27.10 Where embedded conduits turn upwards from a slab or fill, the termination dimensions shown on the drawings, if any, shall be taken to represent the position of the straight extension of the conduit external to and immediately following the bend. At least one half of the arc length of the bend shall be embedded. 16.27.11 All conduits/pipes shall have their ends closed by caps until cables are pulled. After cables are pulled, the ends of conduits/pipes shall be sealed in an approved manner to prevent damage to threaded portions and entrance of moisture and foreign material. 16.27.12 For underground runs, Contractor shall excavate and back fill as necessary. 16.27.13 Contractor shall supply, unload, store and install conduits required for the lighting installation as specified. All accessories/fittings required for making the installation complete, including but not limited to pull out boxes, ordinary and inspection tees and elbow, check nuts, male and female bushings (brass or galvanised steel), caps, square headed male plugs, nipples, gland sealing fittings, pull boxes, conduits terminal boxes, gaskets and box covers, saddle terminal boxes, and all steel supporting work shall be supplied by the Contractor. The conduit fittings shall be of the same material as conduits. 16.27.14 All unarmoured cables shall run within the conduits from lighting panels to lighting fixtures, receptacles etc. 16.27.15 Size of conduit for lighting shall be selected by the Contractor during detailed engineering. 16.27.16 Exposed conduits shall be run in straight lines parallel to building columns, beams and walls. Unnecessary bends and crossings shall be avoided to present a neat appearance. 16.27.17 Conduit supports shall be provided at an interval of 750 mm for horizontal runs and 1000 mm for vertical runs. 16.27.18 Conduit supports shall be clamped on the approved type spacer plates or brackets by saddles or U-bolts. The spacer plates or brackets in turn, shall be securely fixed to the building steel by welding and to concrete or brick work by grouting or by nylon rawl plugs. Wooden plug inserted in the masonry or concrete for conduit support is not acceptable. 16.27.19 Embedded conduits shall be securely fixed in position to preclude any movement. In fixing embedded conduit, if welding or brazing is used, extreme care should be taken to avoid any injury to the inner surface of the conduit. 16.27.20 Spacing of embedded conduits shall be such as to permit flow of concrete between them. 16.27.21 Where conduits are placed along with cable trays, they shall be clamped to supporting steel at an interval of 600 mm.
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16.27.22 For directly embedding in soil, the conduits shall be coated with an asphalt-base compound. Concrete pier or anchor shall be provided wherever necessary to support the conduit rigidly and to hold it in place. 16.27.23 Conduit shall be installed in such a way as to ensure against trouble from trapped condensation. 16.27.24 Conduits shall be kept, wherever possible, at least 300mm away from hot pipes, heating devices etc. when it is evident that such proximity may reduce the service life of cables. 16.27.25 Slip joints shall be provided when conduits cross structural expansion joints or where long run of exposed conduits are installed, so that temperature change will cause no distortion due to expansion or contraction of conduit run. 16.27.26 For long conduit run, pull boxes shall be provided at suitable intervals to facilitate wiring. 16.27.27 Conduit shall be securely fastened to junction boxes or cabinets, each with a lock nut inside and outside the box. 16.27.28 Conduits joints and connections shall be made thoroughly watertight and rust proof by application of a thread compound which insulates the joints. White lead is suitable for application on embedded conduit and red lead for exposed conduit. 16.27.29 Field bends shall have a minimum radius of four (4) times the conduit diameter. All bends shall be free of kinks, indentations of flattened surfaces. Heat shall not be applied in making any conduit bend. Separate bends may be used for this purpose. 16.27.30 The entire metallic conduit system, whether embedded or exposed, shall be electrically continuous and thoroughly grounded. Where slip joints are used, suitable bounding shall be provided around the joint to ensure a continuous ground circuit. 16.27.31 After installation, the conduits shall be thoroughly cleaned by compressed air before pulling in the wire. 16.27.32 Lighting fixtures shall not be suspended directly from the junction box in the main conduit run. 17.0 JUNCTION BOX a) The Contractor shall supply and install junction boxes complete with terminals as required. The brackets, bolts, nuts, screws etc required for erection are also included in the scope of the Contractor. b) Junction boxes having volume less than 1600 cubic centimeters may be installed without any support other than that resulting from connecting conduits where two or more rigid metallic conduits enter and accurately position the box. Boxes shall be installed so that they are level, plumb and properly aligned to present a pleasing appearance. c) Boxes with volumes equal to or greater than 1600 cubic cm, and smaller boxes terminating on less than two rigid metallic conduits or for other reasons not rigidly held, shall be adequately supported by auxiliary steel of standard steel shapes or plates to be fabricated and installed. The Contractor shall perform all drilling, cutting, welding, shimming and bolting required for attachment of supports.
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18.0 TESTING AND COMMISSIONING 18.1 An indicative list of tests for testing and commissioning is given below. Contractor shall perform any additional test based on specialties of the items as per the field Q.P./instructions of the equipment Contractor or Owner without any extra cost to the Owner. The Contractor shall arrange all equipments instruments and auxiliaries required for testing and commissioning of equipments along with calibration certificates and shall furnish the list of instrument s to the Owner for approval. 18.2 GENERAL CHECKS (a) Check for physical damage. (b) Visual examination of zinc coating/plating. (c) Check from name plate that all items are as per order/specification. (d) Check tightness of all bolts, clamps and connecting terminals using torque wrenches. (e) For oil filled equipment, check for oil leakage, if any. Also check oil level and top up wherever necessary. (f) Check ground connections for quality of weld and application of zinc rich paint over weld joint of galvanised surfaces. (g) Check cleanliness of insulator and bushings. (h) All checks and tests specified by the manufacturers in their drawings and manuals as well as all tests specified in the relevant code of erection. (i) Check for surface finish of grading rings (Corona control ring). (j) Pressure test on all pneumatic lines at 18.5 times the rated pressure shall be conducted. 18.3 STATION EARTHING a) Check soil resistivity b) Check continuity of grid wires c) Check earth resistance of the entire grid as well as various sections of the same. d) Check for weld joint and application of zinc rich paint on galvanised surfaces. e) Dip test on earth conductor prior to use. 18.4 MOOSE ACSR STRINGING WORK, TUBULAR BUS WORK AND POWER CONNECTORS a) Physical check for finish b) Electrical clearance check c) Testing of torque by torque wrenches on all bus bar power connectors and other accessories. d) Milli volt drop test on all power connectors. e) Sag and tension check on conductors. 18.5 ALUMINIUM TUBE WELDING a) Physical check
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b) Milli volt drop test on all joints. c) Dye penetration test & Radiography test on 10% sample basis on weld joints. c) Test check on 5% sample joints after cutting the weld piece to observe any voids etc.
18.6 INSULATOR Visual examination for finish, damage, creepage distance etc. 18.7 All pre/commissioning activities and works for substation equipment shall be carried out in accordance with owner's approved ''Pre-commissioning procedures and formats for substation bay equipments" to be submitted by the contractor.
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ANNEXURE-A (Testing Procedure for ACSR MOOSE Conductor) 1.0 UTS Test on Stranded Conductor Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor of minimum 5 m length suitably compressed with dead end clamps at either end. The load shall be increased at a steady rate up to 80 kN and held for one minute. The circles drawn shall not be distorted due to Relative movement of strands. Thereafter the load shall be increased at a steady rate to 161.2 kN and held for one minute. The applied load shall then be increased until the failing load is reached and the value recorded. Corona Extinction Voltage Test Two samples of conductor of 5m length shall be strung with a spacing of 450 mm between them at a height not exceeding 8.0 m above ground. This assembly shall be tested as per Annexure-C. Corona extinction voltage shall not be less than 320 KV (RMS) Line to ground. Radio Interference Voltage Test The sample assembly similar to that specified under (2.0) above shall be tested as per Annexure-C. Maximum RIV level (across 300 ohm resistor at 1 MHz) at 305 KV (RMS) line to ground voltage shall be 1000 micro volts. D.C Resistance Test on Stranded Conductor On a conductor sample of minimum 5 m length two contact clamps shall be fixed with a pre-determined bolt torque. The resistance shall be measured by a Kelvin double bridge by placing the clamps initially zero metre and subsequently one metre apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 20C as per clause no. 12.8 of IS: 398 (Part V)-1982. The resistance corrected at 20C shall conform to the requirements of this specification. Chemical Analysis of Zinc Samples taken from the zinc ingots shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this specification. Chemical Analysis of Aluminium and Steel Samples taken from the Aluminium ingots/coils/strands shall be chemically/ spectrographically analysed. The same shall be in conformity to the requirements stated in this specification. Visual Check for Joints, Scratches etc. Conductor drums shall be rewound in the presence of the inspector. The inspector shall visually check for scratches, joints, etc. and that the conductor generally conform to the requirements of this specification. The length of conductor wound on the drum shall be measured with the help of counter meter during rewinding. Dimensional Check for Steel and Aluminium Strands. The individual strands shall be dimensionally checked to ensure that they conform to the requirements of this specification. Check for Lay-ratios of various Layers. The lay-ratios of various layers shall be checked to ensure that they conform to the requirements of this specification and clause no. 9.4 and 9.5 of IS: 398 (Part - V) 1982.
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10.0 Galvanising Test The test procedure shall be as specified in IS: 4826-1968. The material shall conform to the requirements of this specification. 11.0 Torsion and Elongation Tests on Steel Strands The test procedures shall be as per relevant clause of IS: 398 (Part V), 1982. In torsion test, the number of complete twists before fracture shall not be less than 18 on a length equal to 100 times the standard diameter of the strand before stranding & 16 after stranding. In case test sample length of less or more than 100 times the standard diameter of the strand, the minimum number of twist will be proportionate to the length and if number comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the elongation of the strand shall not be less than 4% for a gauge length of 200 mm. 12.0 Breaking load test on welded Aluminium strand: Two Aluminium wires, shall be welded as per the approved quality plan and shall be subjected to tensile load. The welded point of the wire shall be able to withstand the minimum breaking load of the individual strand guaranteed by the bidder.
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ANNEXURE-B (Testing procedure for Galvanised Steel Earth wire) 1.0 UTS TEST Circles perpendicular to the axis of the earth wire shall be marked at two places on a sample of earth wire of minimum 5m length suitably compressed with dead end clamps at either end. The load shall be increased at steady rate up to 34 KN and held for one minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter, the load shall be increased at a steady rate of 68.4 KN and held for one minute. The earth wire sample shall not fail during this period. The applied load shall then be increased until the failing load is reached and value recorded. D.C. RESISTANCE TEST On an earth wire sample of minimum 5m length, two contact clamps shall be fixed with a predetermined Bolt torque. The resistance shall be measured by a Kelvin double-bridge by placing the clamps initially zero meter and subsequently one meter apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 20C shall conform to the requirements of this specification. VISUAL CHECK FOR JOINTS, SCRATCHES ETC. AND LENGTH OF EARTHWIRE Earth wire drums shall be rewound in the presence of the inspector. The inspector shall visually check for joints, scratches etc. and see that the earth wire generally conforms to the requirements of this specification. The length of earth wire wound on the drum shall be measured with the help of counter meter during rewinding. TORSION AND ELONGATION TESTS The test procedure shall be as per relevant clause of IS: 398 (Part-V). The minimum number of twists which a single steel strand shall withstand during torsion test shall be eighteen for a length equal to 100 times the standard diameter of the strand. In case the test sample length is less or more than 100 times the standard diameter of the strand, the minimum number of twists will be proportionate to the length and if number comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the elongation of the strand shall not be less than 64% or a gauge length of 200 mm. DIMENSIONAL CHECK The individual strands shall be dimensionally checked to ensure that they conform to the requirements of this specification. LAY LENGTH CHECK The lay length shall be checked to ensure that they conform to the requirements of this specification. GALVANISING TEST The test procedure shall as specified in IS: 4826-1968. The material shall conform to the requirements of this specification. CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING Samples taken from zinc ingots shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this specification. CHEMICAL ANALYSIS OF STEEL Samples taken from steel ingots/coils/strands shall be chemically/ spectrographically analysed. The same shall be in conformity to the requirements stated in this specification.
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ANNEXURE-C CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) TEST 1.0 General Unless otherwise stipulated, all equipment together with its associated connectors, where applicable, shall be tested for external corona both by observing the voltage level for the extinction of visible corona under falling power frequency voltage and by measurement of radio interference voltage (RIV). 2.0 Test Levels: The test voltage levels for measurement of external RIV and for corona extinction voltage are listed under the relevant clauses of the specification. Test Methods for RIV: 3.1 RIV tests shall be made according to measuring circuit as per International Special-Committee on Radio Interference (CISPR) Publication 16-1(1993) Part 1. The measuring circuit shall preferably be tuned to frequency with 10% of 0.5 MHz but other frequencies in the range of 0.5 MHz to 2 MHz may be used, the measuring frequency being recorded. The results shall be in microvolts. Alternatively, RIV tests shall be in accordance with NEMA standard Publication No. 107-1964, except otherwise noted herein. In measurement of, RIV, temporary additional external corona shielding may be provided. In measurements of RIV only standard fittings of identical type supplied with the equipment and a simulation of the connections as used in the actual installation will be permitted in the vicinity within 3.5 meters of terminals. Ambient noise shall be measured before and after each series of tests to ensure that there is no variation in ambient noise level. If variation is present, the lowest ambient noise level will form basis for the measurements. RIV levels shall be measured at increasing and decreasing voltages of 85%, 100%, 115% and 130% of the specified RIV test voltage for all equipment unless otherwise specified. The specified RIV test voltage for 400 kV, 220 KV is listed in the detailed specification together with maximum permissible RIV level in micro volts. The metering instruments shall be as per CISPR recommendation or equivalent device so long as it has been used by other testing authorities. The RIV measurement may be made with a noise meter. A calibration procedure of the frequency to which noise meter shall be tuned shall establish the ratio of voltage at the high voltage terminal to voltage read by noisel meter.
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Test Methods for Visible Corona The purpose of this test is to determine the corona extinction voltage of apparatus, connectors etc. The test shall be carried out in the same manner as RIV test described above with the exception that RIV measurements are not required during test and a search technique shall be used near the onset and extinction voltage, when the test voltage is raised and lowered to determine their precise values. The test voltage shall be raised to 130% of RIV test voltage and maintained there for five minutes. In case corona inception does not take place at 130%, test shall be stopped, otherwise test shall be continued and the voltage will then be decreased slowly until all visible corona disappears. The procedure shall be repeated at least 4 times with corona inception and extinction voltage recorded each time. The corona extinction voltage for purposes of determining compliance with the specification shall be the lowest of the four values at which visible corona (negative or positive polarity) disappears. Photographs with laboratory in complete darkness shall be taken under test conditions, at all voltage
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steps i.e. 85%, 100%, 115% and 130%. Additional photographs shall be taken at corona inception and extinction voltages. At least two views shall be photographed in each case using panchromatic film with an ASA daylight rating of 400 with an exposure of two minutes at a lens aperture of f/5.6 or equivalent. The photographic process shall be such that prints are available for inspection and comparison with conditions as determined from direct observation. Photographs shall be taken from above and below the level of connector so as to show corona on bushing, insulators and all parts of energised connectors. The photographs shall be framed such that test object essentially, fills the frame with no cut-off. In case corona inception does not take place at 130%, voltage shall not be increased further and corona extinction voltage shall be considered adequate. 4.1 The test shall be recorded on each photograph. Additional photograph shall be taken from each camera position with lights on to show the relative position of test object to facilitate precise corona location from the photographic evidence. 4.2 In addition to photographs of the test object preferably four photographs shall be taken of the complete test assembly showing relative positions of all the test equipment and test objects. These four photographs shall be taken from four points equally spaced around the test arrangement to show its features from all sides. Drawings of the laboratory and test set up locations shall be provided to indicate camera positions and angles. The precise location of camera shall be approved by Purchasers inspector, after determining the best camera locations by trial energisation of test object at a voltage which results in corona. 4.3 The test to determine the visible corona extinction voltage need not be carried out simultaneously with test to determine RIV levels. 4.4 However, both tests shall be carried out with the same test set up and as little time duration between tests as possible. No modification on treatment of the sample between tests will be allowed. Simultaneous RIV and visible corona extinction voltage testing may be permitted at the discretion of Purchasers inspector if, in his opinion, it will not prejudice other test. 5.0 Test Records: In addition to the information previously mentioned and the requirements specified as per CISPR or NEMA 107-1964 the following data shall be included in test report: a) Background noise before and after test. b) Detailed procedure of application of test voltage. c) Measurements of RIV levels expressed in micro volts at each level. d) Results and observations with regard to location and type of interference sources detected at each step. e) Test voltage shall be recorded when measured RIV passes through 100 micro volts in each direction. f) Onset and extinction of visual corona for each of the four tests required shall be recorded.
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POWER LINE CARRIER COMMUNICATION
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CHAPTER - PLCC TECHNICAL SPECIFICATION FOR POWER LINE CARRIER COMMUNICATION CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 Descrition General Standard and Drawing Location of Equipment Frequency Planning Proposed Arrangement Line Trap Coupling Device High Frequency Cable Power Line Carrier Terminal Speech Communication Mandatory Testing & Maintenance Equipment List of Commissioning Test Page No. 319 319 319 319 320 321 323 325 325 328 333 334
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CHAPTER - PLCC SECTION: POWER LINE CARRIER COMMUNICATION 1.0 GENERAL 1.1 All the PLCC equipment covered under the package shall conform to the requirements of the latest edition of the relevant IEC/IS Specifications or equivalent National Standards. 2.0 Standard and Drawing 2.1 The IEC/IS Specifications and international publication relevant to the equipment covered under this specification shall include but not be limited to the list given at Annexure - 'C' of Section GTR.
3.0 Location of Equipment 3.1 The PLCC Equipment and Line traps as specified shall be installed at the respective ends of the transmission lines. The Contractor shall be responsible for coordinating the equipment supplied by him with the already existing carrier equipment at the respective sub-stations. Contractor shall also be responsible for collecting all the necessary information/data from the respective substations/concerned Electricity Utilities for the installation of the equipment.
4.0 Frequency Planning 4.1 For planning frequency and output power of carrier terminals Bidders may plan for a minimum receive signal to noise ratio of 25 dB for the speech channels without companders. The noise power in 2.1 kHz band (300-2400 Hz) may be taken as -13 dB referred to the coupling point of the H.T. line. An additional minus two and a half dB may be assumed for psophometric factor. As far as coupling loss (phase to phase) is concerned the Bidders may assume the same as 6 dB at one coupling end for evaluating SNR. For protection channels the minimum SNR shall not be less than 15 dB under adverse weather. A safety margin of 9 dB shall be taken over and above these SNR values in order to cater for variations in line attenuation from the computed value as in hand reserve. Frequency and output power of PLC terminals for protection shall be planned such that the protection signal is received with full reliability even when one of the phases is earthed or is on open circuit on the line side causing an additional minimum loss of 6 dB. The Bidder shall indicate the noise power in the bandwidth used for protection signaling and shall submit the SNR calculations for speech as well as protection channels on all the line section given in at the proposed frequencies. Sample calculations for SNR requirement and power allocation over different channels must be furnished along with the bid. Maximum permissible line attenuation shall be clearly brought out in these calculations. Further, Bidder shall submit details of frequency planning done (including computer studies carried out and facilities available) for PLCC links on EHV lines in the past in the relevant schedule of DRS. Bidder must enclose one copy of computer study result done in the past along with the Bid. 4.2 Successful Bidder shall be fully responsible for the coordination required with concerned Electricity Utilities for finalising the frequency plan.
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4.3
The frequency plan will be referred to wireless Adviser/DOP Department for clearance and in case any change in the Contractors recommended carrier frequency and power output is proposed by these authorities, the Contractor shall have to modify his proposal accordingly. Change of power output shall, however, not involve repeater stations.
5.0 Proposed Arrangement 5.1 The power line carrier communication equipment required by the OWNER is to provide primarily efficient, secure and reliable information link for carrier aided distance protection and direct tripping of remote-end breaker and also for speech communication between sub-stations. It shall include separate carrier terminals of multipurpose type for speech and protection purposes. All carrier terminals including those for protection shall be suitable for point to point speech communication also. 5.2 For security reasons each transmission line shall be protected by Main-I and Main-II protections as given below: Main-I Main-II Numerical Distance protection with permissive inter-tripping. Distance protection of a different measuring technique than that of relay under Main I.
132 kV transmission lines shall have Main I protection same as above along with backup over current and earth fault protections. 5.3 The requirement of carrier information on each link covered under this specification is as below: a) One protection channel for Main-I and another for Main-II distance protection schemes. Speech and data channel can also be used for protection wherever possible. b) One speech channel with a facility to superimpose telex and data signals. c) One main and one back-up protection channel for direct circuit breaker intertripping for lines. 5.4 The equipment for protection signals shall have high degree of reliability and speed. It shall be guaranteed to function reliably in the presence of noise impulse caused by isolator or breaker operation. The equipment shall be suitable for direct tripping of remote end breaker for fault in un-switched Operation of Buchholz relays of reactor etc. It shall also be possible to effect direct tripping of breaker at one end when the other end breaker opens out either manually or by relays such as Bus fault relay etc. 5.5 The time intervals between receipt of a trip command on the transmit side, its transmission over the carrier link, reception at the far end and giving command to the trip relays at the distant end shall not exceed 20 mS. for permissive intertripping and 30 m sec. for direct inter-tripping even for the longest line section. The above timings are inclusive of operating time for auxiliary relays and interposing relays, if any, included in the PLCC equipment. 5.6 The requirement of protection signaling channel is such that security against incorrect signals being received shall be at least two to three orders higher than reliability against a signal not being received. 5.7 For reasons of security and reliability, inter-circuit coupling shall be used for D/C lines and phase to ground coupling shall be used for S/C lines. Double differential coupling shall also be considered for double circuit lines. Bidders
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must furnish detailed write-up on methods of coupling and recommend suitable coupling mode for double-circuit lines along-with the bids. Coupling mode shall, however, be fully confirmed by Contractor after conducting detailed computer study taking into account the transpositions of lines for optimum coupling mode over these line sections. The coupling arrangement shall be fully optimised by the Contractor after conducting detailed study of every line section individually, taking into account the temperature variations, transpositions, earth resistivity, conductor configuration, carrier channels requirements, security and reliability criteria and other relevant details. The line attenuation shall be calculated for complete range of frequencies. The earth resistivity data, existing frequency networks and other relevant details of each line will be furnished to the Contractor for carrying out the computer studies and frequency planning. The Contractor shall complete the computer studies wherever required and submit the frequency plan and optimum coupling details within a period of one month from the date of receipt of above data. 5.8 The transmission lines may be transposed. The transmission tower configuration and conductor details shall be forwarded after the award to enable the contractor to make his own computer study assessment of the carrier path based on wave propagation over transposed lines with each transposition point acting as Modal Converter. 5.9 The parameters of the equipment quoted shall be such that the mode of wave propagation on power line (with transpositions indicated) shall not impose any limitation on the efficient and reliable performance of information link from protection or communication point of view. 5.10 The Contractor shall have to check and prove through the results of his computer studies that attenuation due to transpositions in the EHV lines is within limits and the offered equipment will perform satisfactorily. 5.11 The Bidder shall submit curves illustrating incorrect tripping and Failure to trip probability plotted against corona noise level, in the presence of impulse noise due to switching of isolator and circuit breaker etc. Details of field tests and laboratory tests for successful operation of his equipment, under such adverse conditions shall be furnished by the Bidder. These are to be related to end-to-end signaling and shall take into account the type of communication link e.g. account shall be taken of transpositions in the phase to phase coupled H.T. line. Details of field tests and laboratory tests for successful operation of the equipment under the above circumstances shall be submitted by the Bidder illustrating the above parameters. 6.0 LINE TRAP 6.1 Line trap shall be broad band tuned for its entire carrier frequency range. Resistive component of impedance of the line trap within its carrier frequency blocking range shall not be less than 570 ohms. 6.2 Line trap shall be provided with a protective device in the form of surge arrestors which shall be designed and arranged such that neither significant alteration in its protective function nor physical damage shall result from either temperature rise or the magnetic field of the main coil at continuous rated current or rated short time current. The protective device shall neither enter into operation nor remain in operation, following transient actuation by the power frequency voltage developed across the line trap by the rated short time current.
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The lightning arrestor shall be station class current limiting active gap type. Its rated discharge current shall be 10 kA. Coordination, however, shall be done by taking 20 kA at 8/20 micro-sec. discharge current into account. Bidder has to furnish full justification in case the use of gap-less metal oxide arrestor is recommended by them. 6.3 The lightning arrestor provided with the line trap of each rating shall fully comply with the requirements of IS: 3070 Part-I/IEC-99-I Part-I. It shall conform to type tests as applicable and type test certificate for the same shall be submitted by the Bidder. 6.4 The lightning arrestor provided with the line trap shall be subject to routine and acceptance tests as per IEC-99-1 (Part-I). 6.5 The line trap on power lines shall show no visual corona discharge at power frequency falling voltage. Suitable corona rings may be incorporated in the line trap. Radio interference voltage for 420/245/132 kV shall not exceed 500 micro volts at 280/163/97 kV (rms) respectively. 6.6 Line trap shall be equipped with the bird barriers. 6.7 Line trap shall conform to IEC 353 (latest) fulfilling all the technical requirements. The rated short time current for 1 second shall be 40 kA and mH rating shall be 0.5 or 1.0 mH depending on frequency plan. 6.8 The Bidder shall indicate continuous current rating of the line trap at 65 C ambient. 6.9 Reports for the following type tests on each type of shall be submitted as per clause 9.2 of GTR. 1. Measurement of Inductance of the main coil. 2. Measurement of temperature rise. 3. Insulation test. 4. Short time current test. 5. Corona Extinction Voltage test (procedure for this shall be mutually agreed). 6. Radio Interference Voltage measurement test (procedure for this shall be mutually agreed). 6.10 The Bidder must enclose with his bid the reports of type and routine tests conducted on similar equipment earlier as per IEC-353. 6.11 Welding All the welding included in the manufacture of line traps shall be performed by personnel and procedure qualified in accordance with ASME-IX and all the critical welds shall be subject to NDT as applicable. 6.12 Line Trap Mounting 6.12.1 The Line Trap shall be suitable for outdoor pedestal or suspension mounting and shall be mechanically strong enough to withstand the stresses due to maximum wind pressure of 260 kg/square meter. For pedestal mounting, each line trap shall be mounted on a tripod structure formed by three insulator stacks arranged in a triangular form. All the accessories and hardware, mounting stool including bolts for fixing the line trap on insulators shall be of non-magnetic material and shall be supplied by the Contractor.
6.12.2
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6.12.3
For suspension mounting, Contractor shall be required to coordinate the mounting arrangement with the existing arrangement. Non-magnetic suspension hook/link of adequate length and tensile strength to provide necessary magnetic clearance between the line trap and suspension hardware shall be supplied by the Contractor.
6.13 Terminal Connectors 6.13.1 The line traps shall be suitable for connecting to 4" IPS aluminium tube or 3" IPS Al. tube or ACSR single/twin bundle conductor with horizontal or vertical take off. Necessary connector shall be supplied by the Contractor. Terminal Connectors shall conform to IS: 5561. No part of clamp or connector (including hardware) shall be of magnetic material. Clamps and connectors shall be designed corona controlled. All nuts and bolts shall be suitably shrouded. Radio interference Voltage for 420/245/132 kV shall not exceed 500 micro volts at 280/163/97 kV (rms) respectively. Clamps/connectors shall be designed for the same current ratings as line trap and temperature rise shall not exceed 35 C over 50 C ambient. No current carrying part shall be less than 10 mm thick. Clamps/connectors shall conform to type test as per IS: 5561. Type Test reports shall also be submitted for following additional type tests: a) Visual Corona Extinction Test b) Radio Interference Voltage Measurement 6.13.8 Bidders are required to submit along with their bid typical drawings clearly indicating the above mentioned features of the line traps, line trap mounting arrangement and terminal connectors. For suspension mounted line traps, Bidder shall submit drawings showing single point as well as multipoint (normally 3 point) suspension arrangements.
6.13.2 6.13.3 6.13.4 6.13.5 6.13.6
6.13.7
7.0 COUPLING DEVICE 7.1 The coupling devices shall be interposed between the capacitor voltage transformer and coaxial line to the PLC transmitter/receiver and in conjunction with the capacitor voltage transformer shall ensure: a) Efficient transmission of carrier frequency signals between the carrier frequency connection and the power line. b) Safety of personnel and protection of the low voltage parts and installation, against the effects of power frequency voltage and transient over voltages. 7.2 The coupling device, in conjunction with the CVT shall from an electric filter of band pass type: a) It shall match characteristic impedance of H.T. line to impedance of the carrier frequency connection. b) Galvanic isolation between primary and secondary terminals of the coupling device shall be performed by the above mentioned transformer.
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c) Power frequency currents derived by the CVT may be drained to the earth by a separate inductance termed drain coil of suitable rating. d) Voltage surges coming from the power line at the terminals of the coupling device shall be limited by a non-linear surge arrestor of suitable rating in the primary side. Requirement of a gas type voltage arrestor in secondary side of the coupling device shall have to be fully justified, but in any case the input circuit of PLC equipment shall have protective devices in the form of zener diodes and surge suppressers. The surge arrester shall have power frequency spark over voltage coordinated with the equipment ahead of it. e) For direct and efficient earthing of its primary terminals, the coupling device shall be equipped with an earthing switch. The Earth Switch shall be available for earthing of CVT-HT terminals, when the coupling filter units are removed from circuit for maintenance/ replacement. The design shall take due regard of requirements for safety in accordance with the Indian Electricity Rules. 7.3 Two numbers phase to earth type coupling filters shall be used to achieve phase to phase/ inter-circuit coupling. Connection between secondaries of the two phases to earth type coupling device shall be through a balancing transformer/hybrid such that reliable communication shall be ensured even when one of the coupled phase is earthed or open circuited on the line side. 7.4 Coupling device shall conform to IEC-481 and shall have the following carrier frequency characteristics as applicable to a phase to earth type coupling device: a) b) c) d) e) f) Nominal line side Nominal equipment Composite loss Return Loss Bandwidth Nominal peak 320 ohms for 400 kV line impedance 400 ohms for 220/132 kV line impedance 75 ohms (unbalanced) side impedance Not more than 2 dB Not less than 12 dB shall suit the frequency plan between 36 and 500 kHz not less than 650 W envelope power (for Inter-modulation product 80 dB down)
7.5 The coupling device shall be suitable for outdoor mounting. Temperature of metallic equipment mounted outdoor is expected to rise up to 65 C during the maximum ambient temperature of 50 C specified. The equipment offered by the Bidder shall operate satisfactorily under these conditions. 7.6 The H.T. Terminal of coupling device shall be connected to H.F. Terminal of the CVT by means of 6 mm sq. copper wire with suitable lugs & taped with 11 kV insulation by the contractor. 7.7 Coupling device shall have at least two terminals for carrier equipment connection. Bidder shall confirm that such a parallel connection to coupling device directly will not result in any additional attenuation. 7.8 The coupling device including the drainage coil, surge arrester and earthing switch shall conform to type tests and shall be subject to routine tests as per IEC481/IS: 8998. Routine tests shall include but not be limited to the following: i) Composite loss and return loss tests on coupling device.
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ii) Turns ratio test and insulation tests on the balancing transformer. iii) Milli volt drop test, power frequency voltage test and mechanical operation test on earthing switch. iv) Power frequency spark over test for lightning arrester as per relevant IS/IEC. 7.9 Reports for the following type tests on coupling device shall be submitted as per clause 9.2 of GTR. 1) Return loss test. 2) Composite loss test. 3) Distortion and inter modulation test. 4) Impulse voltage test. 5) Tests on Arrestors Bidder shall furnish, along with his bid copies of all type and routine test conducted earlier on similar coupling device in accordance with relevant standards. 8.0 High Frequency Cable 8.1 High frequency cable shall connect the coupling device installed in the switchyard to the PLC terminal installed indoor. 8.2 The cable shall be steel armoured and its outer covering shall be protected against attack by termites. Bidder shall offer his comments on method employed by him for earthing of screen and submit full justification for the same with due regard to safety requirements. Bidder must enclose in his bid a detailed construction drawing of the cable being offered, with mechanical and electrical parameters. 8.3 Impedance of the cable shall be such as to match the impedance of the PLC terminal on one side and to that of the coupling device on the other side over the entire carrier frequency range of 40-500 kHz. 8.4 Conductor resistance of cable shall not exceed 16 ohms per Km at 20C. 8.5 The cable shall be designed to withstand test voltage of 4 kV between conductor and outer sheath for one minute. 8.6 Bidder shall specify attenuation per Km of the cable at various carrier frequencies in the range of 40 to 500 kHz. The typical attenuation figures for H.F. cable shall be in the range of 1 to 5 dB/km in the frequency range of 40-500 kHz. 8.7 The H.F. cable shall conform to type tests and be subjected to routine tests as per IEC: 96-2/ BS: 2316/ IS: 5802. 8.8 All HF cables within the scope of this specification shall be laid and termination shall be carried out by the Contractor. 8.9 The cables shall be supplied wound on drums containing nominal length of 500 meters each. However, exact requirement of drum lengths shall be finalised during detailed engineering to avoid joint in HF cable and its wastage.
9.0 Power Line Carrier Terminal 9.1 As already indicated the information link shall be provided for speech, protection, telex and data services.
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9.2 PLC terminal shall use Amplitude Modulation and shall have single side band transmission mode. These shall be equipped for fixed frequency duplex working. Characteristic input and output parameters of the SSB PLC terminals shall be as per IEC-495, unless otherwise specified. 9.3 The salient features are detailed out below: a) Mode of transmission Amplitude Modulation single side band with suppressed carrier or reduced carrier. b) Carrier frequency c) Nominal carrier frequency band in either direction of transmission d) Power output (PEP) at HF terminal e) Frequency difference between a pair of PLC terminals 40 to 500 kHz range 4.0 kHz
20/40 Watt Frequency difference between VF signal at the transmitting and receiving ends will not exceed 2 Hz with suppressed carrier. With reduced carrier frequency difference shall be zero. This shall include permissible ambient temperature variation and supply frequency and voltage variation and supply frequency and voltage variation of (+) 15% (-) 10% For 40 dB change in carrier frequency signal level within the regulation range, change in VF receive levels of both speech and other signals shall be less than 1dB. 48 V DC + 15%, - 10%. (Positive pole earthed)
f) Automatic gain control
g) Supply voltage
9.4 All the PLC terminals shall be of multipurpose type. The Bidder shall confirm that the total transmission time for teleprotection shall not exceed 20 ms for permissive and 30 ms for direct tripping signals. Speech and teleprotection channels shall independently fulfill the SNR requirements out of the power allocated to its channel from the total power of the PLC terminals. Detailed calculation for SNR requirement and power allocation over different channels should be furnished along with the bid. 9.5 In the input circuit of the PLC terminal protective devices shall be provided in the form of zener diodes or surge suppressers in order to eliminate any surge transfer through the coupling device or the surge induced in the connecting path of H.F. cable. 9.6 To improve voice transmission characteristics for the system, compressors and expanders shall be provided. The companders shall have at least 2:1 compression ratio with a corresponding expansion ratio of 1:2. The operating range of compander shall be compatible with the audio power levels specified for 4 wire operation. The improvement gained by companders shall however not be taken into account for power allocation and shall be in-hand reserve. 9.7 Sudden changes in input level to the receiver shall not cause false tripping. The Bidder shall clearly indicate in his offer the methods adopted to ensure above phenomenon. The receiver design shall also provide protection against false tripping from random noise.
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9.8 Fail-safe devices shall be provided, so that a malfunction in one unit or subassembly cannot cause damage elsewhere in the system. All plug-in equipment shall be fitted with features to prevent improper insertion. The electrical cables shall not be routed across sharp edges or near sources of high temperature. The adjustments, which are susceptible to misadjustment from accidental contact/vibration, shall be equipped with suitable locking devices. 9.9 The PLC set shall be designed to give guaranteed performance from 0 C to 50 C ambient temperature. The thermal capability of the equipment shall be so designed that the equipment remains operational successfully up to 60 C ambient temperature. Any ventilation fans provided for circulation of air inside the cabinets shall conform to relevant Indian Standards. 9.10 The terminals shall be provided with built-in indicating instrument to facilitate checking of important voltages and current values and signal levels in different parts of the PLC Terminals. Protection fuses shall be provided in all important circuits and fuses shall be so mounted as allow their easy inspection and replacement. All test points shall be easily accessible. The carrier set shall be provided with suitable supervision and alarm facilities. Individual parts of the carrier set should be accessible from front, making it possible to place the carrier cabinets side-by-side. All components and parts of the carrier set shall be suitably tropicalised. 9.11 PLC terminals shall be housed in floor mounting sheet metal cabinets, suitable for mounting on concrete plinth as well as channel frame by means of nuts and bolts or welding. The cabinets shall be properly cleaned and spray painted with two coats of synthetic enamel paint. Exterior of the cabinets shall be painted with smoke-glossy finish. Interior of the cabinets shall be painted with white enamel paint with glossy finish. All the panels shall be properly earthed to the OWNERs earthing grid by the Contractor. Contractor shall submit detailed drawings for earthing connections. 9.12 All the panels shall be protected against moisture ingress and corrosion during storage. Panels shall be properly dried before they are installed and energized. Bidder shall indicate measures adopted to prevent ingress of moisture during operation. 9.13 All cabinets having PLC terminals shall be provided with lamps of sufficient wattage for interior illumination with switch. Each panel shall be provided with 240 V AC single phase socket with switch to accept 5 & 15A standard Indian plugs. 9.14 A name plate shall be provided on the front door of each cabinet indicating channel function, transmitter frequency and direction etc. 9.15 Reports for the following type tests for PLC Terminals shall be submitted as per clause 9.2 of GTR. Tests to determine various characteristics of PLC terminals as per IEC 495. a) Voltage variation b) Carrier frequency range & band. c) Frequency accuracy d) Transmit/Receive frequency difference. e) Automatic gain control f) Harmonic distortion
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g) Selectivity h) Output impedance, Return loss &Tapping loss i) Return loss, Af inputs/Outputs j) Balance to ground k) Limiter action l) Spurious emission m) Carrier frequency levels and levels n) Attenuation distortion o) Noise generated within terminal p) Near and far end cross talk q) Group delay distortion r) Conducted noise s) Telephone signaling channel t) Speech levels u) Voltage withstand test v) Insulation test 9.16 Heat Soaking of panels All the solid state equipment/system panels shall be subjected to the Heat Soaking as per the following procedure: All solid state equipment shall be burn-in for minimum of 120 hours continuously under operation condition. During the last 48 hours of testing, the ambient temperature of the test chamber shall be 50C. Each PLC panel shall be complete with all associated sub-systems and the same shall be in operation during the above test. During the last 48 hours of the above test, the temperature inside the panel shall be monitored with all the doors closed. The temperature of the panel interior shall not exceed 65C. 10.0 SPEECH COMMUNICATION 10.1 PLC equipment offered shall provide telephone communication between the stations where the transmission lines are terminating. The equipment shall be suitable for providing the following facilities: a) It shall be possible for subscriber at any of the stations to contact the subscriber at all other stations connected in the system as shown in the specification drawing by dialing his call number. To achieve this a 24 lines EPAX with 4 wire interface & remote subscriber units shall be provided/available at different stations. b) The equipment shall contain all normal facilities like ring back tone, dial tone, engage tone & priority tone, and suitable pulses to establish and disconnect communication between subscribers. c) The equipment shall be provided with necessary alarm circuits and fuses etc. d) The equipment shall be of 4 kHz bandwidth on either direction and be suitable for providing superimposed data and tele-printer facilities at a later date without major modifications and high cost. The Bidder shall clearly
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indicate in his bid the provision made in his proposal for future development and the extent to which such additional facilities can be added at a later date. e) The system shall be completely automatic with definite number allocated for each telephone. The numbering scheme for telephones, exchange and tie lines shall be developed by the Bidder and indicated in the bid. Final numbering scheme shall be fully coordinated with the existing/proposed future systems by the Contractor. f) Arrangement for over-riding facilities shall be provided by means of priority keys wherever specified. The over-riding facility shall enable cutting-in ongoing calls with the priority key and ask the concerned parties to finish their conversation. The wanted number should then get automatically connected without having to redial the number. g) All the carrier telephone conversations shall be secret and it should not be possible for anybody to over hear the conversation going on between any two parties excepting those provided with over-riding facilities. h) The necessary cables for connecting all the telephone instruments ordered for at each sub-station (including wiring and termination) shall be provided by the Contractor. These telephone instruments shall be located within control room building at respective sub-station. i) The cabinets housing the equipment for EPAX, four wire E/M interface & remote subscriber units (four wire) shall have mounting arrangement similar to that for PLC terminals. j) All the terminals for speech shall be supplied fully wired for addition of VFTs and transit filters in future. k) Equipment for speech communication must be fully compatible with OWNERs existing equipment. Any interfaces required for proper matching and connection with the OWNERs existing equipment shall be provided by the Contractor. l) Terminals for protection shall be suitable for speech between two ends of each transmission line or on tandem operation basis with back to back connection at the intermediate stations. n) Each PLC terminal for speech as well as protection purposes shall be provided with a plug-in type service telephone and buzzer. Further, 4 wire remote telephone instruments (parallel to service telephone) shall also be provided on one PLC terminal for protection for each link. These instruments shall be located in respective Switchyard control room to enable the operator to make emergency calls on point-to-point basis. Each such instrument shall be equipped with a buzzer and press-to-call key and shall not require any additional power supply units. 10.2 Electronic Private Automatic Exchange (EPAX) 10.2.1 The 24 line Electronic Private Automatic Exchange (EPAX) wherever specified shall be connected to minimum six trunk routes thorough PLCC channels (speech panel) with Four-wire E/M interface unit. This 4-wire interface unit either shall form an integral part of the EPAX system or be suitable for mounting/housing in the carrier panel. The exchange will have its own ringing current and tone generator etc. The exchange shall be suitable for working on 48 V DC Power Supply (positive pole earthed).
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The exchange shall be fully automatic, solid state, and of modular construction and shall have multiple switching routes (minimum 4routes). 10.2.2 EPAX shall also be provided with two (2) additional interface units and operate exclusively with OWNERs leased subscriber lines, of Department of Telecommunication (DOT) and compatible with 2 wire full duplex, voice grade mode of operation. The details of communication protocol, for interfacing of the DOT leased lines, shall be coordinated by the Contractor, with the licensing authority (DOT). 10.3 Remote End Four Wire E/M Interface & Subscriber Unit or Equivalent EPAX (4x4) 10.3.1 The remote end four wire E/M interface & subscriber units, wherever specified, shall be of electronic type and be suitable for working on fixed frequency power line carrier systems with E & M signaling. This shall be housed in the carrier set and be fully wired to the power line carrier terminal equipment. 10.3.2 This unit shall receive and register various signals, on PLCC Channels, from remote end exchanges or other remote end subscriber units and associated four wire interface unit. 10.3.3 The four wire interface unit shall be equipped for routing transit calls and shall be supplied pre-wired to handle calls for minimum eight directions, in a form suitable for transmission over PLCC. 10.3.4 The bidder shall also indicate the total number of trunk-line capacity, available with each four-wire interface unit. The unit shall be suitable for connecting two-wire telephone sets. Further, the associated telephone cables for locating two subscriber lines, within the control room is in the scope of this specification. 10.4 Network Protection Equipment (Protection Coupler) 10.4.1 The Bidder shall offer voice frequency transmission equipment which shall work on frequency shift or coded signal principle for transmission/reception of protection signals as single purpose channel. The equipment shall be suitable for connection to the power line carrier terminal. 10.4.2 The voice frequency transmission equipment shall not only be insensitive to corona noise but shall also remain unaffected by impulse type noise which are generated by electrical discharge and by the opening and closing of circuit breakers, isolators, earthing switches etc. The equipment shall also be made immune to field strength of 10V/m expected to be caused by portable radio transmitters in the range of 20-1000 MHz. In his offer, bidder shall clearly explain as to what measures have been taken to make the equipment insensitive to corona noise, white noise and to impulse noise of an amplitude larger than the wanted signal and submit full field test and laboratory test reports. The guarantee on design data shall not be acceptable. 10.4.3 The equipment shall be unaffected by spurious tripping signals. The Bidder shall submit proof as to how this is achieved satisfactorily.
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10.4.4 The equipment shall be suitable for transmission of direct and permissive trip signal as well as blocking signals for protective gear of power system. The equipment shall be operated in the audio frequency range in speech band or above speech band as superimposed channel in 4 kHz band of SSB carrier. The equipment shall operate with full duplex frequency shift mode of operation or by switching between two frequencies in case of coded signals. The protection signaling equipment shall be of solid state design, modular in construction and have a proven operating record in similar application over EHV systems. Details regarding application of the equipment shall be submitted along with the bid. Each protection signaling equipment shall provide: i) ii) Transmission facilities for minimum three protection signals. Reception facilities for minimum three protection signals.
10.4.5 The equipment shall be designed for remote tripping/ blocking on permissive basis and direct tripping for reactor fault and others. The overall time of PLC, VFT and transmission path for permissive trip/blocking shall be 20 m. Sec. or less and for direct tripping 30 m. Sec. or less even for the longest line section. Operating time lower than specified above may be preferred provided they fulfill the requirements of security and reliability as mentioned below: False - trip probability (Noise burst of any amplitude) Fail to trip probability for S/N 6 dB in 3.1 kHz Band (white Noise Measurement) 10-2 10-5
10.4.6 It may be emphasized that specified time, as mentioned above is composed of the following: a) Back-to-back signal delay in frequency shift or coded signals protection equipment. b) Back-to-back delay in PLC terminal. c) Delay in transmission line. d) Operation time of interposing relay, if any, in frequency shift or coding equipment. Reference is invited in this regard to the guide lines expressed in CIGRE Publication Teleprotection report by Committee 34 and 35. 10.4.7 The following transfer criteria shall be provided by the equipment: a) Transmit side One number potential free NO (normally open) contact of protective relays (To be supplied by the OWNER) of under noted rating for each of the following functions: i) Permissive trip command ii) Direct trip command Contact Rating: Maximum voltage:
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Maximum current rating: Maximum power rating: b) Receive Side
5 amps 1250 W/VA
Voice frequency transmission equipment for network protection shall be provided with one potential free NO (normally open) contact of the under noted rating for each of the following functions: i) Permissive trip command ii) Direct trip command Contact Rating: Rated voltage: Rated current: Other Parameters: c) Alarm In addition, the voice frequency protection terminal shall provide at least one number potential free change over contact of the following rating for alarm purposes. Rated voltage: Rated current: Other Parameters: 250 volts DC 0.1 A DC As per IEC-255-0-20 250 Volts DC 0.1 A DC As per IEC-255-0-20
10.4.8 The Contractor shall submit drawings showing inter-connection between PLCC and protection panels for approval by the OWNER. 10.4.9 It has to be ensured that under no circumstances protection channel should share the power. Each protection channel shall be able to transmit power for which system is designed. For example, a 40 W PLC terminal shall transmit 40 Watt (max.) for protection channel alone in the event of fault. Speech and super-imposed data channels, in the same protection terminal must get disconnected momentarily during the operation of protection channels. 10.4.10The equipment shall be constructed such that in permissive line protection system, operational reliability of the protection channel may be checked over the carrier link by means of a loop test. It shall be possible to carry out the above test from either end of the carrier link. During healthy condition of the transmission line, the loop test shall not initiate a tripping command. In the event of a system fault, while loop test is in progress, protection signal shall over-ride the test signal. 10.4.11The equipment shall be complete with built in counters for counting the number of trip commands sent and number of trip commands received. 10.4.12Reports for the following tests as per clause 9.2 of GTR shall be submitted for approval for protection coupler and the relays associated with PLCC equipment for network protection signaling equipment and interface unit with protective relay units if any: 1) Protection coupler (As per IEC 60834 -1) a) Power supply variation b) Power supply interruption
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c) Reflected noise d) Reverse polarity e) Interference by discrete frequency f) Transmission time g) Interference by frequency deviation. (Wherever applicable) h) Alarm functioned g) Security h) Dependability i) Voltage withstand test j) Insulation test. j) Electrical fast transient test (along with carrier terminal) k) HF disturbance test (along with carrier terminal) l) Electro static discharge test (along with carrier terminal) m) Radiated electromagnetic field susceptibility test (along with carrier terminal) n) Environment test (as per IS 9000) 2. Relays. a) Impulse voltage withstand test as per Clause 6.1 of IS: 8686 (for a test voltage appropriate to Clause III as per Clause 3.2 of IS: 8686). b) High Frequency Disturbance test as per Clause 5.2 of IS: 8686 (for a test voltage appropriate to Clause III as per Clause 3.2 of IS: 8686). 11.0 Mandatory Testing & Maintenance Equipment Print testing kit for PLCC terminal, E/M interface & subscriber unit, Protection coupler & EPAX-comprising of following items of reputed make in addition to any other special items required for testing and maintenance of this equipment packed in a carrying brief case: 1. 2. 3. 4. 5. 6. Screw driver set with multi up fixing feature Nose pliers Cutting pliers Ordinary Pliers Adjustable wrench Soldering iron with tip earthed a) 150 Wattsb) 35 Watts c) 10 watts 1 No. 1 No 1 No.
operated with isolated (step down) transformer having provision for interchangeable taps. 7. Desoldering pump
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8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Print extender Print puller Large selection of test leads Solder wire Large selection of plugs, jacks & pistol probes compatible with equipment supplied Dummy load Interface card/print for Tx to Rx loop-back Test oscillator/tone generator with indicating meters - either built in or separate ESD wrist band ESD conducting mat
12.0 LIST OF COMMISSIONING TESTS The following tests shall be carried out on complete system/subsystem during commissioning: 1. 2. 3. 4. Composite loss and return loss on coupling device using dummy load. Composite loss (Attenuation) for HF Cable coupling device. End to end attenuation measurement for verification of optimum coupling mode. Test shall be done for all combinations. End to end return loss for optimum coupling mode. a. open behind line trap. b. grounded behind line trap. 5. 6. 7. 8. 9. 10. 11. If end to end return loss for optimum coupling mode is not satisfactory, same shall be measured for other coupling modes also. Adjustment of Tx/Rx levels on PLCC equipment as per test schedule. AF frequency response (end to end) for the entire 4 kHz Bandwidth for speech and tele-operation channels. Measurement of noise in 2 kHz bandwidth with and without line energised. SNR (test-one) with line energised noting down weather conditions. Transmission time for tele-protection and other data channels. Observation of Tx/Rx levels (test-tone) for each channel at both ends by sequential switching on/off parallel channels using dummy load and also with the transmission line. Observation of end to end and trunk dialing performance. Observation of end-to-end protection signaling (command sent & received) in conjunction with protective relays, noting down transmission/receipt of unwanted commands under switching operations in the switchyard during protective relay testing.
12. 13.
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Notes: 1. All measurements for link attenuation, composite loss and return loss shall be carried out for the entire range of carrier frequencies with specific attention to the frequencies. i. ii. within coupling device bandwidth. within line trap bandwidth, and
iii. operating frequencies. 2. Following tests shall be carried out independently at each and i. ii. Composite loss & return loss for coupling device. Attenuation test for HF cable + coupling device.
iii. Levels and other local adjustments (on dummy load). Final adjustment shall be on end to end basis. iv. Test for loading by parallel channels with dummy load. This test can be done along with tests for coupling device. v. 3. Protection signaling under local loop test (dummy load).
Necessary test instruments required for all the above tests shall be brought by commissioning engineers of the contractor.
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LIGHTING SYSTEM
(LS)
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CHAPTER - LIGHTING SYSTEM TECHNICAL SPECIFICATION FOR LIGHTING SYSTEM CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 Description Lighting System Description of Items Lighting Fixtures and Accessories Receptacles Switch and Switchboard Conduit and Conduit Accessories Junction Boxes Terminal Blocks Pull Out Boxes Lighting Panels (LP) Emergency Portable Lighting Fixtures Lighting Poles Ceiling Fans and Regulators Lighting Wires Painting of Shop Made Items Lighting System Installation Works Page No. 338 340 343 345 346 346 346 347 347 347 349 350 350 350 351 352
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CHAPTER - LS SECTION: LIGHTING SYSTEM 1.0 LIGHTING SYSTEM 1.1 The scope of work comprises of design, engineering, testing, supply, installation, testing and commissioning of various lighting fixtures complete with lamps, supports and accessories, ceiling fans complete with electronic regulators, exhaust fans for toilets and pantry & accessories, lighting panels, lighting poles complete with distribution boxes, galvanised rigid steel conduits, lighting wires, G.I. earth wire, receptacles, tag block & telephone socket, switchboards, switches, junction boxes, pull out boxes complete with accessories, lighting transformer.
1.2 SYSTEM DESCRIPTION Standard sub-station lighting system arrangement shall be followed. The lighting system shall comprise of the following: 1.2.1 AC Normal Lighting AC lights will be connected to AC lighting panels. All the lights connected to the AC lighting system in different areas will be connected to the main lighting distribution boards. 1.2.2 AC Emergency Lighting This system will be available in control room building, Fire fighting pump house, DG Set building & switchyard. AC lighting load will be connected to this system which will be normally ON. The lighting panels of this system will be connected to the Emergency lighting board which is fed from diesel generator during the emergency. 50% of lighting fixtures shall be connected on AC emergency lighting. 1.2.3 D.C. Emergency lighting A few DC emergency lighting fixtures operated on the DC system will be provided in the strategic locations including staircase, corridors, electrical rooms, Battery charger room, LT switchgear room in control room building, Fire fighting pump house and DG Set building so that the operating personnel can safely find their way even during emergency of a total AC failure. These lights will be normally 'OFF' and will be switched 'ON' automatically when under voltage occurs in the AC main lighting distribution board. GLS lamp down lighters in false ceiling area and Bulkhead fixtures in non false ceiling area to be used. 1.2.4 Portable Fixtures Three numbers of battery operated, portable fixtures will be provided in the Control room building and one number shall be provided in DG Set Building Cum Fire fighting pump house. These fixtures will be provided at important locations in the above mentioned areas.
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1.3
The lighting layout for and around Control Room Cum Administrative Office Building & DG cum Fire fighting Pump House indicating the type & BOQ for items shall be submitted by the successful bidder for approval of the owner. The lux levels to be maintained in the switchyard shall be as per following:
Sl. No. 1) Area Switchyard Average Lux Level 50 lux on main Equipment (i.e., Transformer, Reactor ISO, CB, CT, CVT, SA) at first level (Equipment connections level). 20 lux on balance area of switchyard and street/Road at ground level.
The minimum lux level to average lux level ratio should not be less than 0.3 (i.e. Emin/Eav>0.3). The maintenance factor for outdoor illumination design shall be considered as 0.65. For achieving the specified lux levels in the switchyard, the contractor can provide luminaries of 1x400 W/1x250 W and 2x400 W/ 2x250 W flood light as per requirement. The contractor shall submit detailed calculation for reaching the above Lux level. Contractor shall confirm the Lux levels at different locations of the switch yard and street lighting by measurement. In addition to the normal lighting provided in the switchyard area to maintain the desired lux levels, few high beam fixtures on swivel support shall be provided in strategic locations near equipments which shall be kept normally OFF and these shall be switched ON in case of maintenance work. 1.4 Ceiling fans (1400 mm sweep, AC 230 volts) shall be provided in DG Set building, fire fighting pump house and non AC rooms in the control room building as shown in the enclosed drawings. Wall mounted fans shall be provided in the conference room, shift manager and sub-station in-charge rooms in control room building. Exhaust fans shall be provided in toilets and pantry. 1.5 One no. of aluminium ladder of each size shall be supplied by the contractor for maintenance purpose. 1.6 The following specific areas are included in the scope of lighting: (i) (ii) Switchyard Area. Switchyard Control Room cum Administrative Office Building.
(iii) DG Building cum Fire fighting pump house. (iv) Street lighting (peripheral) inside switchyard fencing (Street lighting shall be done using street lighting poles). v) Landscape Lighting around control room.
1.7 For Outdoor Illumination The switchyard and street lighting design, detailed drawings showing the lighting layout and Electrical distribution diagram shall be prepared by the Contractor and submitted for approval. The above layout drawings will include disposition and location of lighting fixtures, receptacles etc. For Indoor Illumination
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The conduit layout for substation buildings based on the tender drawings, Electrical distribution diagram for substation buildings & for landscape lighting cable schedule for substation yard etc. shall be prepared by the Contractor. All wiring including telephone wiring (tinned two pair copper) shall be in concealed conduit. Concealed MS junction boxes for sockets and light points shall be provided in all the rooms of Control Room cum Administrative Office Building and DG Building cum Fire Fighting pump house. 1.8 Each cable and conduit run shall be tagged with number that appears in the cable and conduit schedules. Cables and conduits shall be tagged at their entrance and/or exit from any piece of equipment, junction or pull box, floor opening etc. 1.9 The tag shall be made up of aluminium with the number punched on it and securely attached to the cable by not less than two turns of G.I. wire. Cable tags shall be rectangular in shape for power cables and circular shape for control cables. 1.10 Location of cables laid directly under ground shall be indicated clearly by cable marker made of galvanised iron plate embedded in concrete block. 1.11 The location of under ground cable joints, if any, shall be clearly indicated with cable marker with an additional inscription "cable joint". 1.12 The marker, which is a concrete block, shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at every change of direction. It shall also be located on both sides of the road or drain crossing. 2.0 DESCRIPTION OF ITEMS The Contractor shall supply and install the following equipment and accessories in accordance with the specification. 2.1 LIGHTING PANELS 2.1.1 OUTDOOR 415 AC lighting panel with 415V, 63A, 3 phase 4 wire bus and one number 63A, TPN, MCB with neutral unit as incomer and 20A, MCB as outgoing feeders, the details are as follows: Type Description ACP-2 Outdoor Details of outgoing feeders) 6 Nos. 20 A single pole MCB and 3 Nos. 32 A Triple pole MCB with Neutral and suitable timer and contractor for automatic switching. ACP-3 Outdoor street 3 Nos. 32 A Triple pole MCB with Neutral lighting panel with suitable timer and contractor for automatic switching
Note: The numbers of outgoing feeders indicated above are the minimum.
2.1.2 INDOOR 415 V indoor AC lighting panel, 63A 3 phase 4 wire bus and one number 63 amp TPN MCB with 300 ma 63 A RCCB. Flush mounted with per phase isolation and indication lamps din mounted. The DB will be flush mounted. ACP-1 Indoor 18 Nos. outgoing 16-32 Amps SPMCP
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2.2 220V DC indoor type change over board and 220V DC 32A two wire bus and one 32A contractor backed up by 32A double pole MCB as incomer. The panel shall have local push button controls. Following are the various types of panels required with control timer. Type DCP Description Indoor Details of outgoing feeders 6 Nos. 16 A DP MCB unit
2.3 Sub-Lighting Panels Type Description SLP SLP 4 pole 32A Isolator suitable for 415 V, 50 cycles AC supply, with LILO facility using 8 Nos. terminal blocks suitable for cable up to 16 mm sq cable Enclosure shall be suitable for outdoor use with IP-55 degree of protection as per IS: 13947 (Part-1). 2.4 Lighting Fixtures and Receptacles Lighting Fixtures
Type SC Description 150W SON-T Tubular Sodium Vapour lamp in street lighting luminaires. A special optical reflector clear acrylic cover, a single piece die cast aluminium housing made out of LM6 and corrosion resistance proof. Similar to Philips Cat No. SRX-51 and Bajaj Cat No. BJMSDT/150/Crompton Greaves Cat No. SSG 23151H. (Street Light Luminaire should be suitable for Bottom Entry/Side entry both for pipe mounting) 2x36W fluorescent lamps in industrial reflector type fixture, complete with accessories and suitable for pendent mounting, similar to Philips Cat. No. TKC 24/236/Bajaj Cat. No. BJIV-236/Crompton Greaves Cat No. 1VE 1224 HSB. Incandescent GLS lamp in recessed down light having high purity aluminium reflector electrochemically brightened and anodized. Stainless steel leaf springs and pressure die cast ceiling similar to Philips Cat. No. DN-622 Crompton Greaves cat DDLV 10-BC. Weather proof integral Floor Lighting with housing made of corrosion resistant die cast aluminium painted black. Grey powder coated outside suitable for 150W SON-T lamp complete with all accessories and suitable for termination with conduits/flexible Cat. No. F69045 (C). Similar to Philips Cat. No. SWF230/150/Bajaj Cat. No. BGEMF-150WSV Crompton Greaves Cat. No. FAD 11151H. 2x400/2x250W HP Sodium Vapour Lamps in high Flood Lighting fixture suitable for outdoor mounting with aluminium enclosure: similar to Philips Cat. No. SNT001/Bajaj Cat. No. BJEF-22CA/Crompton Greaves Cat. No. FHD1324. 1x250/1x400 HP Sodium Vapour lamps in high flood lighting fixture suitable for outdoor mounting with aluminium enclosure and integral control gear: similar to Phillips Cat. No. SWF 330/CGL Cat. No. FAD 1114/Bajaj Cat. No. BJEF T14CA. 1x11 W CFL Lamp emergency light with Battery operated portable fixture with built in chargeable batteries and battery charger suitable for a lighting period of six hours similar to ALPHA DELUX of M/s DELTA FLASH LITE/MICRO LITE OF M/s MICRO /BPL MAKE. 9W CFL lamp in bulkhead fixtures with cast aluminium alloy body, suitable for column, wall and ceiling mounting finished stove enameled silver grey outside white inside, to be supplied complete (with front cover, wire guard, tropicalised, gasket and lamp holder taped 3/4" E.T. for conduit entry) similar
FI
IF
SFI
SF2
SF3
PF
FB
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FF
FL
MP
IB
BL DLR DSM HL CL
to Philips Cat. No. FXC 101/Bajaj Cat. No. BJBE-19/Crompton Greaves. 2x36W fluorescent lamp with mirror optics in recessed mounting type decorative fluorescent fitting consisting of white stove enameled sheet steel housing with accessories and reflector of aluminium sheet steel duty electrochemically brightened and anodised fitted with aluminium lamellae painted white. Similar to Philips Cat. No. TBS-285/236 and Bajaj Cat. No. BJLM236/Crompton Greaves Cat. No. CRFA 24 HSB. 2x36W fluorescent lamps in decorative lighting fixture with widespread mirror optics suitable for pendent mounting with twin tube complete with all accessories: similar to Philips Cat. No. TCS-306/236 and Bajaj Cat. No. BJSM-236/Crompton Greaves Cat. No. CSB W 1124 HSB. 125 HP MV Lamp in weather proof post top lantern with case aluminium canopy, mounting piece, opal acrylic cover tropicated gasket and all other accessories for mounting on pole top similar to Philips Cat. No. HPC101/Bajaj/Crompton Greaves Cat No. MPT12IH/BC. 60/100W GLS lamp in bulkhead fixtures with cast aluminium alloy body, suitable for column, wall and ceiling mounting finished stove enameled silver grey outside white inside, to be supplied complete (with front glass, wire guard, tropicalised, gasket and E.S. Porcelain, lamp holder taped 3/4" E.T. for conduit entry) similar to Philips Cat. No. NXC 101/Crompton Greaves IBH1110. 2x9 or 1x18 W CFL bollard light for landscape lighting having FRP/LLDPE housing similar to Philips FGC202/Crompton Greaves Cat. No. CFBL1129. DLR 2x18 W CFL Down Light for recess mounting lighting having similar to Philips FBH225/2X18/Crompton Greaves Cat. No. DDLH218TG. DSM 1x13 W surface mounted CFL similar to Art Light Make Cat. No. RL 3146.
2x18 CFL Decorative hanging down light similar to Cat. No. Art Light RL 3166/HL
1x18 W Decorative ceiling mounted luminaire similar to Philips Dixie Cat. FL 343/118
2.5 RECEPTACLES RO R1 RP 15A, 240V, Outdoor Receptacle 2 pole, 3- pin type 5/15A, 240V, Indoor Receptacle 3-pin type. 63A, 415V, Interlocked switch socket, outdoor receptacle
2.6 SWITCH BOARDS Modular type switches, 5/15 Amp. Receptacles. 2.7 CONDUITS AND ACCESSORIES Galvanised Rigid Steel Conduits of 19mm/25mm/32mm/40mm dia. 2.8 JUNCTION BOXES with 5 Nos. of terminal blocks 2.9 LIGHTING POLES - (Type A1 poles & Type E1 poles) 2.10 CEILING FANS-1400 mm Sweep with Electronic regulator 2.11 MAINTENANCE EQUIPMENT i) ii) A type aluminium ladder of 3 mtr vertical height. Cartwheel mounted aluminium ladder vertical height 7.5 Mtrs. when extended.
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2.12 LIGHTING TRANSFORMER Supply, erection, testing and commissioning of 100 kVA or above (in case the capacity of transformer required is higher than 100 kVA as per approved calculations)/25KVA (in case of substations where highest voltage level is 132kV), 415/415 V, 3 phase, 50 Hz Dry type natural air cooled lighting transformers. The technical parameters of these lighting transformers are as follows: Technical Parameters of Lighting Transformer Type of transformer Rating Voltage ratio No. of phases Frequency Winding connection Class of insulation Impedance No. of taps & steps Ref. standard : : : : : : : : : : Dry type natural air cooled. 100 kVA or above 25 kVA (as applicable). 415/415 volts. Three. 50 Hz. Dyn-1. 'B' Class. 4% 10%. 5, 5% in steps of 2.5%. IS: 2026.
The enclosure for the above transformer shall have degree of protection not less than IP-42. The rating of lighting transformer should be suitable for lighting load. The contractor shall submit the supporting calculation for the rating of lighting transformer. 3.0 LIGHTING FIXTURES AND ACCESSORIES 3.1 General All lighting fixtures and accessories shall be designed for continuous operation under atmospheric conditions existing at site, without reduction in the life or without any deterioration of materials, internal wiring. 3.2 Temperature Rise All lighting fixtures and accessories shall be designed to have a low temperature rise according to the relevant Indian Standards. The design ambient temperature shall be taken as 50 C. 3 .3 Supply Voltage 3.3.1 Lighting fixtures and accessories meant for 240V A.C. operation shall be suitable for operation on 240V A.C. 50Hz, supply voltage variation of 10%, frequency variation of 5% and combined voltage and frequency variation of 10%. Lighting fixture and accessories meant for 220V DC operation shall be suitable for operation on 220V DC with variation between 190 to 240 Volts.
3.3.2
3.4 Lighting Fixtures The lighting fixtures shall be Philips or Bajaj or Crompton Greaves make only except for fixtures type DSM & HL for which make has been specified elsewhere in this section. The different types of lighting fixtures are also indicated elsewhere in this Section.
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3.4.1
All fixtures shall be designed for minimum glare. The finish of the fixtures shall be such that no bright spots are produced either by direct light source or by reflection. All lighting fixtures shall be complete with fluorescent tubes/incandescent lamps/mercury vapour/sodium vapour lamps as specified and shall be suitably wired up. All fluorescent lamp fixtures shall be complete with all accessories like ballasts, power factor improvement capacitors, lamps, starters, holders etc. High beam fixtures shall be suitable for pendant mounting and flood lights shall have suitable base plate/frame for mounting on steel structural member. Hook mounted high beam fixtures are not acceptable. Each lighting fixture shall be provided with an earthing terminal suitable for connection to 16 SWG GI earthing conductors.
3.4.2
3.4.3
3 4.4
3.4.5
3 .4 6 All light reflecting surfaces shall have optimum light reflecting coefficient such as to ensure the overall light output as specified by the manufacturer. 3.4.7 Height of fixtures should be such that it is easy to replace the lamps with normal ladder/stool. In case the ceiling height is very high, the fixtures may be placed on the walls for ground lighting.
3.5 ACCESSORIES 3.5.1 Reflectors The reflectors shall be manufactured from sheet steel or aluminium as applicable. They shall be securely fixed to the captive type. 3.5.2 Lamp holders and Starter Holders (a) Lamp holders/starter holders for fluorescent tubes shall be of the spring loaded, low contact resistance, bi-pin rotor type, resistant to wear and suitable for operation at the specified temperature, without deterioration in insulation value, contact resistance or retention of the lamp/starter. They shall hold the lamp/starter in position under normal condition o f shock and vibration. Lamp holders/starter for incandescent lamps and HPMV/HPSV lamps shall be of screwed type, manufactured in accordance with relevant standard and designed to give long and satisfactory service.
(b)
3.5.3
Ballasts a) The Ballasts shall be designed, manufactured and supplied in accordance with relevant standard and function satisfactorily under site condition specified. The ballasts shall be designed to have a long service life and low power loss. Ballasts shall be mounted using self locking anti-vibration fixing and shall be easy to remove without dismantling the fixtures. They shall be totally enclosed units. The ballasts shall be of the inductive, heavy duty type, filled with thermosetting insulating moisture repellent polyester compound filled under pressure or vacuum. The ballast wiring shall be of copper wire. They shall be free from hum. Ballasts which produce
b)
c)
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humming sound shall be replaced free of cost by the Contractor. Ballasts for high pressure mercury vapour/ HPSV lamps shall be provided with suitable tappings to set the voltage within the range specified. End connections and taps shall be brought out in a suitable terminal block, rigidly fixed to the ballast enclosure. d) 3.5.4 Separate ballast for each lamp shall be provided in case of multilamp fixtures.
Starters Starters shall have bimetal electrodes and high mechanical strength. Starters shall be replaceable without disturbing the reflector or lamps and without the use of any tool. Starters shall have brass contacts and radio interference suppressing capacitor.
3.5.5
Capacitors a) The capacitors shall have a constant value of capacitance and shall be connected across the supply of individual lamp circuits. b) The capacitors shall be suitable for operation at supply voltage as specified and shall have a value of capacitance so as to correct the power factors of its corresponding lamp circuit to the extent of 0.98 lag. c) The capacitors shall be hermetically sealed in a metal enclosure.
3.6
Lamps 3.6.1 3.6.2 General Lighting Services (GLS) lamps shall be provided with screwed caps and shall be of 'clear' type unless otherwise specified. The fluorescent lamps shall be 'Day-light-colour' type unless otherwise specified and shall also be provided with features to avoid blackening of lamps ends. The Bidder should clearly state these features in the bid. Mercury vapour lamps, sodium vapour lamps shall be colour corrected type, with screwed caps.
3.6.3
3.7 The Bidder shall furnish typical wiring diagram for Fluorescent, HPMV & HPSV fitting including all accessories. The diagram shall include technical details of accessories i.e. starters, chokes, capacitors etc. 3.8 Flexible conduits if required, for any fixture shall be deemed to be included in Contractors scope.
4.0 RECEPTACLES a) All receptacles shall be of cast steel/aluminium, heavy duty type, suitable for fixing on wall/column and complete with individual switch. b) In general the receptacles to be installed are of the following types: i) Type RO-15A, 240V, 2 pole, 3 pin type with third pin grounded, metal clad with gasket having cable gland entry suitable for 2Cx6 sq. mm. PVC/aluminium armoured cable and a metallic cover tied to it with a metallic chain and suitable for installation in moist location and or outdoor. The switch shall be of rotary type. Receptacles shall be housed in an enclosure made out of 2 mm thick Gl sheet with hinged doors with padlocking arrangements. Door shall be lined with good quality gasketing. This shall conform to IP-55.
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ii)
Type RI The 5/15 amp 6 pin receptacles with switches will be of Modular type with flush type switches and electroplated metal enclosures of approved make Type RP - 63A, 415V, 3 phase, 4 pin interlocked plug and switch with earthing contacts. Other requirements shall be same as type RO. The receptacle shall be suitable for 3.5C x 35/3.5Cx70 sq. mm. aluminium conductor cable entry and shall also be suitable for loop-in and loop out connection of cables of identical size. Receptacle shall be suitable for outdoor application. Receptacles shall be housed in a box made out of 2mm thick G.I. sheet, with hinged door with padlocking arrangement. Door shall be lined with good quality gasketing. This shall conform to IP-55.
iii)
5.0 SWITCH AND SWITCHBOARD (a) All Switch board/boxes, 5/15 Amp Receptacles and electronic fan regulators located in office/building areas shall be modular flush mounted type or brick wall with only the switch knob projecting outside. Switch boards/boxes shall have conduit knock outs on all the sides. Adequate provision shall be made for ventilation of these boxes. The exact number of switches including regulator for fans and layout of the same in the switchboard shall be to suit the requirement during installation. The maximum number of luminaires, controlled by one no 6 amp switch would 4 nos. For DC fixtures there will be no switch and the same shall be directly controlled from DC LP The luminaires shall be wired in such a fashion that luminaires on each phase are evenly distributed all over the room.
(b) (c) (d)
(e)
6.0
CONDUITS & CONDUIT ACCESSORIES 6.1 The conduits shall conform to IS: 9537. All conduits shall be seemed by welding, shall be of heavy gauge and shall be hot dip galvanised. 6.2 Flexible conduits wherever required shall be made with bright, cold rolled annealed and electro-galvanised mild steel strips. 6.3 All conduits accessories shall conform to relevant IS and shall be hot dip galvanised.
7.0 JUNCTION BOXES 7.1 The junction boxes shall be concealed type for indoor lighting and suitable for mounting on columns, lighting poles, structures etc., for outdoor lighting. 7.2 Junction boxes shall be of square/rectangular type of 1.6 mm sheet steel with minimum 6 mm thick pressure die cast aluminium material LM-6 and shall have bolted cover with good quality gasket lining. 7.3 The junction box and cover shall be hot dip galvanised. 7.4 The junction boxes shall be complete with conduit knockouts/threaded nuts and provided with terminal strips. The junction boxes shall be suitable for termination of conduit/glands of dia 20 mm, 25 mm, 32 mm, 40 mm on all sides. The junction boxes shall be provided with 4 way terminals suitable for two numbers 10 sq. mm. wire & for street lighting/switchyard lighting suitable for 2 numbers 4Cx16 sq. mm aluminium cable.
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7.5 The junction boxes shall have the following indelible markings (i) (ii) Circuit Nos. on the top. Circuit Nos. with ferrules (inside) as per drawings.
(iii) DANGER sign in case of 415 volt junction box. 7.6 The junction boxes shall be weather proof type with gaskets conforming to IP 55 as per IS: 13947 (Part I). The conduit connections shall also be properly sealed to prevent entry of water.
8.0 TERMINAL BLOCKS 8.1 Each terminal shall be suitable for terminating up to 2 Nos. 10 sq. mm. stranded aluminium Conductors without any damage to the conductors or any looseness of connections. Terminal strips provided in street - lighting poles shall be suitable for terminating up to 2 Nos. 4Cx16 sq. mm aluminium cables.
9.0 PULL OUT BOXES 9.1 The pull out boxes shall be concealed type for indoor lighting and suitable for mounting on column, structures etc., for outdoor lighting. The supply of bolts, nuts and screws required for the erection shall be included in the installation rates. 9.2 The pull out boxes shall be circular of cast iron or 16 SWG sheet steel and shall have cover with good quality gasket lining. 9.3 The pull out boxes and cover shall be hot dip galvanised. 9.4 The pull out boxes shall be completed with conduit knock outs/threaded hubs and provided at approximately 3 meters intervals in a conduit run.
10.0 LIGHTING PANELS (L.P.) 10.1 Each panel shall be provided with one incoming triple pole MCB with neutral link and outgoing miniature circuit breakers as per clause 2.0. The panels shall conform to IS-8623. Constructional Features 10.2.1 Panels shall be sheet steel enclosed and shall be dust, weather and vermin proof. Sheet steel used shall be of thickness not less than 2.00 mm (cold rolled) or 2.5 mm (hot rolled) smoothly finished, leveled and free from flaws. Stiffeners shall be provided wherever necessary. The indoor lighting panels will be ready made DB of minimum 20 SWG sheet thickness. 10.2.2 The panels shall be of single front construction, front hinged and front connected, suitable for either floor mounting on channels, sills or on walls/columns by suitable M.S. brackets. 10.2.3 Panels shall have a dead front assembly provided with hinged door(s) and out door panels will be with padlocking arrangement with single key supplied in duplicate. 10.2.4 All out door panels, removable covers, doors and plates shall be gasket all around with neoprene gaskets. 10.2.5 The panels shall be suitable for cable/conduit entry from the top and bottom. Suitable removable cable gland-plate shall be provided on the top and bottom o f panels. Necessary number of double compression
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cable gland shall be supplied, fitted on to this gland plate. The glands shall be screwed on top and made of tinned brass. 10.2.6 The panels shall be so constructed as to permit free access to connection of terminals and easy replacement of parts. 10.2.7 Each panel shall have a caution notice fixed on it. 10.2.8 Each panel will be provided with directory holder in which printed and laminated as built circuit directory would be kept. 10.2.9 Each outdoor lighting panel shall be provided with one No. ON indicating lamp for each phase along with fuses. For indoor lighting panels din mounted phase indication lamps will be provided, mounted along side of the MCB. 10.3 Main Bus Bars 10.3.1 Bus bars shall be of aluminium alloy conforming to IS: 5082 and shall have adequate cross-section to carry the rated continuous and withstand short circuit currents. Maximum operating temperature of the bus bars shall not exceed 85 C. The bus bars shall be able to withstand a fault level of 9 kA for 1 second for AC panels and 4 kA for 1 second for DC panels. The indoor lighting panels shall have copper bus bar. 10.4 Residual Current Circuit Breakers (RCCB) 10.4.1 For indoor panels 63A 4-pole 300 ma conforming IS: 12640 will be provided along with incomer. 10.5 Miniature Circuit Breaker (MCB) a) The miniature circuit breakers shall be suitable for manual closing, opening, automatic tripping under overload and short circuit. The MCBs shall also be trip free. b) Single pole as well as three pole versions shall be furnished as required in the Schedule of Lighting Panels. c) The MCBs and panel MCCB together shall be rated for full fault level. In case the MCB rating is less than the specified fault level the bidder shall coordinate these breaker characteristics with the back up MCCB in such a way that if fault current is higher than breaker rating, the MCCB should blow earlier than the breaker. If the fault current is less than MCB breaking capacity, MCB shall operate first and not the incomer MCCB. d) The MCBs shall be suitable for housing in the lighting panels and shall be suitable for connection with stranded copper wire connection at both the incoming and outgoing side by copper lugs or for bus bar connection on the incoming side. e) The terminals of the MCBs and the open close and trip conditions shall be clearly and indelibly marked. f) The tenderer shall check and co-ordinate the ratings of MCBs with respect to starting characteristics of discharge lamps. The vendor has to furnish overload and short circuit curve of MCB as well as starting characteristics curves of lamps for Employers approval. g) The MCB shall generally conform to IS: 8828.
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10.6
Contactors Contactors shall be of the full voltage, direct-on line air break, single throw, electro-magnetic type. They shall be provided with at least 2-NC and 2 NO auxiliary contacts. Contactor shall be provided with the three elements, positive acting, ambient temperature compensated time lagged, hand reset type thermal overload relay with adjustable settings to suit the rated current. Hand reset button shall be flush with the front of the cabinet and suitable for resetting with starter compartment door closed. The Contactor shall be suitable for switching on Tungsten filament lamp also. The bidder shall check the adequacy of the Contactors rating wire with respect to lighting load.
10.7
Push Buttons All push buttons shall be of push to actuate type having 2 NO and 2 NC self reset contacts. They shall be provided with integral escutcheon plates engraved with their functions. Push buttons shall be of reputed make.
10.8
Labels a) The lighting panels shall be provided on the front with panel designation labels on a 3 mm thick plastic plate of approved type. The letter shall be black engraved on white back ground. b) All incoming and outgoing circuits shall be provided with labels. Labels shall be made of non-rusting metal or 3 ply lamicold. Labels shall have white letters on black or dark blue background.
10.9
Earthing Terminals Panels shall be provided with two separate and distinct earthing terminals suitable to receive the earthing conductors of size 50x6 G.S. Flat.
10.10 Type test reports for following tests on all lighting panels shall be submitted for approval as per clause 9.2 of section: GTR. (i) (ii) Wiring continuity test. High voltage (2.5 kV for 1 minute) and insulation test.
(iii) Operational test. (iv) Degree of protection (Not less than IP-55 test on outdoor Lighting Panels and IP-52 test on indoor Lighting Panels as per IS: 13947 (Part-I)). (v) Heat run test.
10.11 Lighting Transformer. Lighting transformer shall be located in MCC room, in separate enclosure. Enclosure shall have degree of protection not less than IP-42 as per IS: 13947 (Part-I). 11.0 EMERGENCY PORTABLE LIGHTING FIXTURES 11.1 The portable fixtures shall have a built in battery rated for six hours, battery chargers and solid state inverters. These shall be of approved make. 11.2 The portable fixtures shall be of a single unit, completely tropicalised and suitable for prolonged use with no maintenance. 11.3 The portable fixtures shall be supplied and necessary supporting brackets of galvanised steel suitable for wall/column mounting shall also be supplied.
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11.4 The portable fixture shall come up automatically in the event of failure of normal supply. 12.0 LIGHTING POLES 12.1 The Contractor shall supply, store and install the following types of steel tubular lighting poles required for street lighting. a) Type A1 Street Lighting Pole - for one fixture b) Type E1 Post top lantern pole - for one fixture 12.2 Street/flood light poles shall conform to the enclosed drawings. In front of control room building, DG Set and Fire Fighting Buildings, decorative post top lantern (Type E1) poles and Bollards shall be installed as per the quantities given in the tender drawing. 12.3 Lighting poles shall be complete with fixing brackets and junction boxes. Junction boxes should be mounted one meter above ground level. 12.4 The lighting poles shall be coated with bituminous preservating paint on the inside as well as on the embedded outside surface. Exposed outside surface shall be coated with two coats of metal primer (comprising of red oxide and zinc chromate in a synthetic medium). 12.5 The galvanised sheet steel junction box for the street lighting poles shall be completely weather proof conforming to IP-55 and provided with a lockable door and HRC fuse mounted on a fuse carrier and fuse base assembly. The fuses & junction box shall be as specified in the specification. However, terminals shall be stud type and suitable for 2 Nos. 16 sq. mm. cable. 12.6 Wiring from junction box at the bottom of the pole to the fixture at the top of the pole shall be done through 2.5 sq. mm wire. 12.7 Distance of centre of pole from street edge should be approximately 1000 to 1200 mm. 12.8 Earthing of the poles should be connected to the switchyard main earth mat wherever it is available and the same should be earthed through 3 meter long, 20 mm dia, earth electrode. 13.0 CEILING & WALL MOUNTED FANS AND REGULATORS 13.1 The contractor shall supply and install 1400 mm sweep ceiling fans complete with electronic regulator and switch, suspension rod, canopy and accessories. The wall mounted fans shall be of 400 mm sweep 13.2 The contractor shall supply and install the switch, electronic regulator and board for mounting switch and electronic regulator for ceiling fans. 13.3 Winding of the fans and regulators shall be insulated with Class-E insulating material. Winding shall be of copper wire. 13.4 Electronic regulator with smooth control shall be provided. 13.5 Fans and electronic regulators shall be of Alstom/Crompton Greaves/Bajaj Electricals/Usha Electricals make. 14.0 LIGHTING WIRES 14.1 The wiring used for lighting shall be standard products of reputed manufacturers.
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14.2 The wires shall be of 1100 V grade, PVC insulated product of reputed manufacturers. 14.3 The conductor sizes for wires used for point wiring beyond lighting panels shall be single core 4 sq. mm, 6 sq. mm and 10 sq. mm stranded aluminium wires and 2.5 sq. mm, 4 sq. mm, 6 sq. mm and 1.5 sq. mm stranded copper wire. 14.4 The wires used for connection of a lighting fixture from a nearest junction box or for loop-in loop-out connection between two fluorescent fixtures shall be single core copper stranded conductor, 1100V grade flexible PVC insulated cords, unsheathed, conforming to IS: 694 with nominal conductor cross sectional areas of 2.5 sq. mm. 14.5 The wires shall be colour coded as follows: Red for R - Phase Yellow for Y - Phase Blue for B - Phase Black for Neutral White for DC (Positive) Grey for DC (Negative) 15.0 PAINTING OF SHOP MADE ITEMS 15.1 All sheet steel work shall be phosphated in accordance with the following procedure and in accordance with IS: 6005 'Code of Practice for Phosphating Iron and Steel'. Oil grease and dirt shall be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with dilute acid followed by washing with running water, rinsing with slightly alkaline hot water and drying. After phosphating through rinsing shall be carried out with clean water, followed by final rinsing with diluted dichromate solution and oven drying. The phosphate coating shall be sealed by the application of two coats of ready mixed stoving type metal primer (comprising of red oxide and Zinc chromate in a synthetic medium). The first coat may be 'flash dried' while the second coat shall be stoved. After application of the primer, two coats of finishing synthetic enamel paint shall be applied with each coat followed by stoving. The second finishing coat for the external of panels shall be applied after completion of tests. The panels can also be powder coated instead of painting after surface treatment as given above. Both outside and inside of lighting panel, sheet metal fabricated junction boxes etc. and outside of lighting fixtures shall be finished in light grey (IS-5 shade 631). Inside of lighting fixtures shall be finished in white. The colour of indoor lighting panels should match with colour of wall. Each coat of primer and finishing paint shall be of slightly different shade so as to enable inspection of the painting. The final finished thickness of paint film on steel shall not be less than 100 microns and shall not be more than 150 microns. The final thickness of powder coating will not be less than 50 microns. For indoor lighting panels the painting will be as per approved manufacturers, specification.
15.2 15.3 15.4 15.5
15.6
15.7
15.8 15.9
15.10 Finished painted appearance on equipment shall present on aesthetically pleasing appearance, free from dents and uneven surfaces.
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16.0 LIGHTING SYSTEM INSTALLATION WORKS 16.1 General 16.1.1 In accordance with the specified installation instructions as shown on manufacturers drawings or as directed by employer, contractor shall unload, erect, install, test and put into commercial use all the electrical equipment included in the contract. Equipment shall be installed in a neat, workmanship manner so that it is level, plumb square and properly aligned and oriented. Tolerances shall be as established in manufacturers drawing or as stipulated by purchaser. All apparatus, connections and cabling shall be designed so as to minimize risk of fire or any damage which will be caused in the event of fire.
16.1.2
16.2 Conduit System 16.2.1 Contractor shall supply, store and install conduits required for the lighting installation as specified. All accessories/fittings required for making the installation complete, including but not limited to pull out boxes (as specified in specification ordinary and inspection tees and elbow, check nuts, male and female bushings (brass or galvanised steel), caps, square headed make plugs, nipples, gland sealing fittings, pull boxes, conduits terminal boxes, glands, gaskets and box covers, saddle terminal boxes, and all steel supporting work shall be supplied by the Contractor. The conduit fittings shall be of the same material as conduits. The contractor shall also supply 19 mm PVC conduit and accessories for telephone wiring. All unarmoured cables shall run within the conduits from lighting panels to lighting fixtures, receptacles. etc. Size of conduit shall be suitably selected by the Contractor. Conduit support shall be provided at an interval of 750 mm for horizontal runs and 1000 mm for vertical runs. Conduit supports shall be clamped on the approved type spacer plates or brackets by saddles or U-bolts. The spacer plates or brackets in turn, shall be securely fixed to the building steel by welding and to concrete or brick work by grouting or by nylon rawl plugs. Wooden plug inserted in the masonry or concrete for conduit support is not acceptable. Where conduits are along with cable trays they shall be clamped to supporting steel at an interval of 600 mm. For directly embedding in soil, the conduits shall be coated with an asphalt-base compound. Concrete pier or anchor shall be provided wherever necessary to support the conduit rigidly and to hold it in place. For long conduit run, pull boxes shall be provided at suitable intervals to facilitate wiring. Conduit shall be securely fastened to junction boxes or cabinets, each with a lock nut inside and outside the box.
16.2.2 16.2.3 16.2.4 16.2.5
16.2.6 16.2.7
16.2.8 16.2.9
16.2.10 Conduits joints and connections shall be made through water-tight and rust proof by application of a thread compound which insulates the joints. White lead is suitable for application on embedded conduit and red lead for exposed conduit.
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16.2.11 The entire metallic conduit system shall be embedded, electrically continuous and thoroughly grounded. Where slip joints are used, suitable bounding shall be provided around the joint to ensure a continuous ground circuit. 16.2.12 Conduits and fittings shall be properly protected during construction period against mechanical injury. Conduit ends shall be plugged or capped to prevent entry of foreign material. 16.3 Wiring 16.3.1 Wiring shall be generally carried out by PVC insulated wires in conduits. All wires in a conduit shall be drawn simultaneously. No subsequent drawing of wires is permissible. Wires shall not be pulled through more than two equivalent 90 bends in a single conduit run. Where required, suitable junction boxes shall be used. Wiring shall be spliced only at junction boxes with approved type terminal strip. For lighting fixtures, connection shall be teed off through suitable round conduit or junction box, so that the connection can be attended without taking down the fixture. For vertical run of wires in conduit, wires shall be suitably supported by means of wooden/hard rubber plugs at each pull/junction box. Maximum two wires can be terminated to each way of terminal connections. Separate neutral wires are to be provided for each circuit. AC and DC wiring should not run through the same conduit.
16.3.2
16.3.3 16.3.4
16.3.5 16.3.6 16.3.7 16.3.8 16.4.1 16.4.2
16.4 Lighting Panels The lighting panels shall be erected at the locations to be finalised during detailed engineering. Suitable foundations/supporting structures for all outdoor type lighting panels shall be provided by the Contractor.
16.5 Foundation & civil works 16.5.1 16.5.2 Foundation for street lighting poles, panel foundation and transformer foundation shall be done by the contractor. All final adjustment of foundation levels, chipping and dressing of foundation surfaces, setting and grouting of anchor bolts, sills, inserts and fastening devices shall be carried out by the contractor including minor modification of civil works as may be required for erection. Any cutting of masonry/concrete work, which is necessary shall be done by the contractor at his own cost and shall be made good to match the original work.
16.5.3
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Notes: 1. All measurements for link attenuation, composite loss and return loss shall be carried out for the entire range of carrier frequencies with specific attention to the frequencies. i. ii. within coupling device bandwidth. within line trap bandwidth, and
iii. operating frequencies. 2. Following tests shall be carried out independently at each and i. ii. Composite loss & return loss for coupling device. Attenuation test for HF cable + coupling device.
iii. Levels and other local adjustments (on dummy load). Final adjustment shall be on end to end basis. iv. Test for loading by parallel channels with dummy load. This test can be done along with tests for coupling device. v. 3. Protection signaling under local loop test (dummy load).
Necessary test instruments required for all the above tests shall be brought by commissioning engineers of the contractor.
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FIRE PROTECTION SYSTEM
(FPS)
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CHAPTER - FIRE PROTECTION SYSTEM TECHINCAL SPECIFICAITON FOR FIRE PROTECTION SYSTEM CONTENTS Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 Description Intent of Specification Design and Construction Shop and Site Tests Spare Parts Horizontal Centrifugal Pumps Diesel Engines Piping, Valves and Specialties Air Vessels Heat Detectors/Fire Detectors and Spray Nozzles Portable and Wheel/Trolley Mounted Fire Extinguishers Instruments Electric Motors Battery & battery Chargers Control & Annunciation Panels Page No. 356 356 363 365 365 369 372 379 379 380 382 384 389 391
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CHAPTER - FPS SECTION: FIRE PROTECTION SYSTEM 1.0 INTENT OF SPECIFICATION This section covers the design and performance requirements of the following types of fire protection systems: a. b. c. d. e. Hydrant System. High Velocity Water (HVW) Spray System. Fire Detection System. Portable Fire Extinguishers. Wheel/Trolley mounted Fire Extinguishers.
1.1 It is not the intent to completely specify all details of design and construction. Nevertheless, the system design and equipment shall conform in all respects to high standard of engineering, design and workmanship and shall be capable of performing in continuous commercial operation in a manner acceptable to the Owner. The system design shall also conform to TAC/NFPA norms. 1.2 The scope of work include complete earthwork (i.e. excavation, back filling etc.) for the entire buried piping for the system, valve pits and pipe supports for buried, entrenched and over ground piping. 1.3 The equipment offered shall comply with the relevant Indian Standards. The equipment conforming to any other approved international standards shall meet the requirement called for in the latest revision of relevant Indian Standard or shall be superior. Ambient temperature for design of all equipment shall be considered as 50C. The successful bidder shall prepare detailed layout and piping drawing based on other layout drawing of the sub-station such as road, drainage, cable trench, etc. Various equipment under the fire protection system should be supplied from the suppliers approved by Department of Power.
1.4 1.5 1.6 2.0
DESIGN AND CONSTRUCTION 2.1 Hydrant System Hydrant system of fire protection essentially consists of a large network of pipe, both under ground and over ground which feeds pressurised water to a number of hydrant valves, indoor as well as outdoor. These hydrant valves are located at strategic locations near buildings, Transformers and Reactors. Hose pipes of suitable length and fitted with standard accessories like branch pipes, nozzles etc. are kept in hose boxes. In case of emergency, these hoses are coupled to the respective hydrant valves through instantaneous couplings and jet of water is directed on the equipment on fire. Hydrant protection shall be provided for the following in the sub-station. a) b) c) d) e) Control room building. D.G. set building. LT Transformer area. Fire Fighting pump House. Stores.
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f) Transformers. 2.1.1 A warning plate shall be placed near the hydrant points for the transformers and such other equipments and the pump in the sub-stations to clearly indicate that water shall be sprayed only after ensuring that the power to the transformer/equipments which is on fire is switched off and there are no live parts within 20 metres of distance from the personnel using the hydrant. 2.2. HIGH VELOCITY WATER (HVW) SPRAY SYSTEM HVW spray type fire protection essentially consists of a network of projectors and an array of heat detectors around the transformer/equipments to be protected. On operation of one or more of heat detectors, water under pressure is directed to the projector network through a Deluge valve from the pipe network laid for this system. This shall be provided for transformers and equipments in sub-stations. Wet detection initiation system shall be employed for automatic operation. The system shall be designed in such a way that the same can be extended to protect additional transformer/equipments to be installed in future. However, for the purpose of design it shall be assumed that only one transformer/equipment will be on fire. The system shall be designed to have a pressure of 5.5kg/cm2 at 350 m3/hr. at the farthest transformer/equipment location as identified in the tender drawings. 2.2.1 The Electrical clearance between the emulsifier system pipe work and live parts of the protected equipment shall not be less than the values given below: 1. 420 kV bushing 3500 mm 2. 245 kV bushing 2150 mm 3. 145 kV bushing 1300 mm 4. 52 kV bushing 630 mm 5. 36 kV bushing 320 mm Minimum water pressure available at the farthest and/or highest projector (HVW spray system) on the equipment protected shall be 3.5 kg/cm2 (g). However, water pressure available at any projector shall not exceed 5.00kg/ cm2 (g). Water shall be applied at a rate of 10.2 LPM/M2 of the surface area of the entire transformer/equipment including radiator, conservator etc. (including bottom surface for transformer). Deluge Valve Deluge Valve shall be water pressure operated manual reset type. The Deluge valve shall be closed water tight when water pressure in the heat detector pipe work is healthy and the entire pipe work shall be charged with water under pressure up to the inlet of the Deluge valve. On fall of water pressure due to opening of one or more heat detectors, the valve shall open and water shall rush to the spray water network through the open Deluge valve. The valves shall be manually reset to initial position after completion of operation. Each Deluge Valve shall be provided with a water motor gong which shall sound an alarm when water after passing through the Deluge valve, is tapped through the water motor. Each Deluge valve shall be provided with a local panel from which will enable manual electrical operation of the valve. In addition to this, each valve shall be provided with local operation latch. Test valves shall
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simulate the operation of Deluge valves and shall be of quick opening type. The general construction shall conform to requirements under clause No. 7.0 for piping, valves and specialties. 2.2.4 High Velocity Spray Nozzles (Projectors) High velocity spray system shall be designed and installed to discharge water in the form of a conical spray consisting of droplets of water traveling at high velocity, which shall strike the burning surface with sufficient impact to ensure the formation of an emulsion. At the same time the spray shall efficiently cut off oxygen supply and provide sufficient cooling. 2.2.5 Minimum set point of the heat detectors used in the HVW spray system shall be 79oC. The optimum rating shall, however, be selected by the Bidder, keeping in mind the maximum and minimum temperature attained at site.
2.3
Fire Detection System This system shall be provided for 400 kV substations. 2.3.1 Suitable fire detection system using smoke detectors and/or heat detectors shall be provided for the entire control room building, including corridor and toilets. Fire detectors shall be located at strategic locations in various rooms of the building. The operation of any of the fire detectors/manual call point should result in the following: 1. A visual signal exhibited in the annunciation panels indicating the area where the fire is detected. 2. An audible alarm sounded in the panel, and 3. An external audible alarm sounded in the building, location of which shall be decided during detailed engineering. 4. If the zone comprises of more than one room, a visual signal shall be exhibited on the outer wall of each room. 5. A signal shall be given to air conditioning system for its shut down. 2.3.2 2.3.3 Each zone shall be provided with two zone cards in the panel so that system will remain healthy even if one of the cards becomes defective. Fire detectors shall be provided on ceiling as well as on false ceiling in conference room, on false ceiling in control room and relay room and on ceiling in all other areas. Coverage area of each smoke detector shall not be more than 80 m2 and that of heat detectors shall not be more than 40 m2. Ionisation type smoke detectors shall be provided in all areas except AHU Room where heat detectors shall be provided. If a detector is concealed, a remote visual indication of its operation shall be provided. Manual call points (Break Glass Alarm Stations) shall be provided at strategic locations in the control room building. All cabling shall be done through concealed conduits.
2.4
Portable and Wheel/Trolley mounted Fire Extinguishers 2.4.1 Portable Fire Extinguishers Adequate number of portable fire extinguishers of pressurized water, dry chemical powder, and carbon dioxide type shall be provided in suitable locations in control room building and DG set & FF building. These extinguishers will be used during the early phases of fire to prevent its
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spread and costly damage. The design, construction & testing of pressurized water type, dry chemical powder type and carbon dioxide type portable fire extinguishers shall meet the requirements as per Clause 10.0. 2.4.2 Wheel/Trolley mounted Fire Extinguishers Wheel/Trolley mounted fire extinguishers shall be provided for the protection of transformers in 200 kV and 132 kV sub-stations. Dry chemical powder (DCP) type and Carbon dioxide (CO2) type of 22.5 kg capacity shall be provided. Each 220 kV or 132 kV transformer shall be provided with 2 Nos. of DCP type and 2 Nos. of CO2 type extinguishers. The design, construction & testing of Dry Chemical Powder (DCP) type and Carbon Dioxide (CO2) type of 22.5 kg capacity shall meet the requirements of relevant IS codes and Clause 10.0 of this specification. 2.5. Water Supply System 2.5.1 For 400 kV Sub-Stations. Water for hydrant & HVW system shall be supplied by one electrical motor driven pump with another pump, driven by diesel engine, shall be used as standby. Two Nos. water storage tanks of total capacity 420 cu. m. shall be provided. Pumps shall work under positive suction head. Annunciations of the hydrant & HVW spray systems shall be provided in fire water pump house and repeated in 400 kV control room. The outdoor piping for the system in general shall be laid above ground on concrete pedestals with proper clamping. However, at road/rail crossings, in front/access of buildings, places where movement of cranes/vehicles is expected and at any other place where above ground piping is not advisable, the pipes shall be laid underground as per Clause No. 7.4.5. Such locations shall be finalized during detailed engineering. The whole system will be kept pressurized by providing combination of air vessel and jockey pumps. The capacity of air vessel shall not be less than 3m3. Minor leakage will be met by Jockey Pump. One additional jockey pump shall be provided as standby. The pumps and air vessel with all auxiliary equipment will be located in firewater pump house. Operation of all the pumps shall be automatic and pumps shall be brought into operation at preset pressure. Fire pumps shall only be stopped manually. Manual start/stop provision shall be provided in local control panel. 2.5.2 For 220 kV and 132 kV Sub-Stations. Water for hydrant system shall be supplied by one Diesel engine driven pump of 96 m3/hr. capacity at 56 MWC discharge pressure. An RCC tank of 100 m3 size shall be provided for water storage. The tank shall be provided with all accessories such as drain, overflow and filling connection with float valve etc. The hydrants shall be provided for all buildings, store yard and each transformer/reactor. The pump shall work on positive suction and the operation will be manual. The pump shall be located in the DG set room. 2.5.3 The design and construction of horizontal centrifugal pumps along with drives and accessories shall be in line with the requirements of Tariff Advisory Committee of India.
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2.5.4
The technical specification of the diesel engine driven fire pump and electric motor driven fire pumps shall meet requirements as set in Data Sheet. The general design of the fire fighting pump sets shall meet the requirements under Clauses No. 5.0 for horizontal centrifugal pumps and 12.0 for electrical motors. Each pump shall be provided with a nameplate indicating suction lift/delivery head, capacity and number of revolutions per minute. Design, construction, erection, testing and trial operation of piping, valves, strainers, hydrant valves, hoses, nozzles, branch pipes, hose boxes, expansion joints etc. shall conform to the requirements of Clause No. 7.0.
2.5.5 2.5.6
2.6. Instrumentation and Control System 2.6.1 All instruments like pressure indicators, differential pressure indicators, pressure switches, level indicators, level switches, temperature indicators, alarms and all other instruments and panels as indicated in the specification and drawings and those needed for safe and efficient operation of the whole system shall be furnished according to the requirements of Clause No. 11.0. 2.6.2 Control Panel Power feeder for motors will be from switchgear board located in control building but control supply for all local control panels, annunciation panels, battery charger units, space heaters etc. shall be fed from the AC and DC distribution boards located in pump house. These AC & DC distribution boards will be fed from the switchgears and DCDBs located in control building. a) Panel for motor driven fire water Pump The panel shall be provided with: 1. 2. 3. 4. 5. 6. 7. TPN switch Auto/manual switch Start/Stop Push buttons with indication lamp DOL starter with thermal O/L relay Indicating lamp showing power ON Indication lamp with drive ON/OF Indication lamp showing Motor Trip 1 No. 1 No. 1 Set 1 Set 1 Set 1 Set 1 No.
Main power cable from breaker feeder of main switchboard shall be terminated in this panel and another cable shall emanate from this panel which shall be terminated at motor terminals. b) Panel for two Nos. Jockey Pump: 1 No.
The panel shall be provided with the following:

1. 2. 3. 4. 5.
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Fuse-switch unit for Jockey pumps: Auto/manual switch for Jockey Pumps: Selector switch for selecting either jockey pump: D.O.L. starter with overload relay self-resetting type, for all the drives: Start/stop push button for Jockey Pump with
1 Set for each pump 1 No. each 1 No. 1 No. each 1 Set for each
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6.
indication lamp with pad-locking arrangements in stop position: Indication lamp for trip indication:
jockey pump 1 No. each for all the drives.
c) Panel for 2 Nos. battery charger & Diesel Engine driven fire water pump: 1 No. The panel shall be provided with the following: 1. 2. 3. 4. 5. 6. 7. 8. Auto/Manual switch for Diesel Engine driven pump Start/Stop push buttons with indication lamp Indicating lamp showing drive ON/OFF D.C. Voltmeter/Ammeter in the battery charger circuit Battery charger will be as per specification described Selector switch for selecting either of battery chargers for the battery sets. Selector switch for selecting either set of batteries for Diesel engine starting. Selector switch for boost charging/Trickle charging of battery set. 1 No. 1 Set 1 Set
d) Individual local control panel is to be considered for each transformer/Reactor/equipments deluge system wherever this equipment is envisaged. This panel shall contain push buttons with indicating lamps for spray ON/OFF operation in the valve operation circuit. Push buttons shall be concealed behind glass covers, which shall be broken to operate the buttons. Provision shall be made in the panel for the field signal for the annunciations such as spray ON and fire in the Transformer/Reactor/equipments. A signal for spray ON shall also be provided in the control room fire alarm panel for employers event logger. 2.6.3 Annunciation Panels a) Location: Fire Water Pump House i) ii) Indicating lamps showing power supply ON" and status indication lamps for each motor. Annunciation windows complete with buttons. Details are as follows: Number 1 1 1 1 1
Sl. Description No. 1. Electric motor driven fire water pump running 2. Electric motor driven fire water pump fails to start 3. Diesel engine driven fire water pump running 4. Diesel engine driven water pump fails to start 5. Jockey pump-1 running
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6. 7. 8. 9. 10. 11. 12. 13. 14. 15. b)
Jockey pump-1 fails to start Jockey pump-2 running Jockey pump-2 fails to start Fire in Transformer/Reactor Deluge system operating for Transformer/ Reactor Fire fitting System in operation/Header pressure low Fire in smoke detection system zone Water storage tank water level low High speed diesel tank level low Spare
1 1 1 1 for each equipment 1 for each equipment 1 1 2 1 10
Location 400 kV Control Room i) ii) Indication lamp showing power supply 'ON' Provision shall be made in the panel for a signal for spray ON for each Transformer/Reactor/equipments for owner's use for event logger. Following annunciations shall be provided. Sl. Description No. 1. Fire in Transformer/Reactor 2. 3. 4. 5. Diesel engine driven fire water pump in operation Motor driven fire water pump in operation Fire fighting water storage tank level Low Fire/fault Number 1 for each equipment 1 1 2 1+1 (duplicate) for each zone as applicable 10
iii)
6. c) d)
Spares
Each annunciation panel shall be provided with a hooter. Indication for fault in respective areas shall also be provided. Each annunciation window shall exhibit FIRE and 'FAULT' conditions separately.
2.6.4
The control and interlock system for the fire protection system shall meet the following requirements: 1. Electric Motor Driven Fire water Pump Pump should start automatically under any of the following conditions: a) HVW spray or Hydrant system header pressure low. b) Operation of any deluge valve
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Pump should be stopped manually only. Pump should also be started manually if required from local control panel. 2. Diesel Engine Driven Standby Pump The pump should automatically start under any of the following conditions: a) Header pressure low. b) Electric motor operated fire water pump fails to start. 3. Pump should be stopped manually only. Pump should also be started manually if required from the local control panel. The battery set which is connected for starting of Diesel engine shall not be subjected to boost charge.
Jockey Pump Jockey pump shall start automatically when water pressure in header falls below the set value. Jockey pump shall stop automatically when the pressure is restored to its normal value. Manual starting/stopping shall be possible from the local control panel.
3.0
SHOP AND SITE TESTS 3.1 Shop Tests 3.1.1 Shop tests of all major equipment centrifugal pumps, diesel engines, electrical drive motors, piping, valves and specialties, pressure and storage vessels, MCC, electrical panels, controls, instrumentation etc. shall be conducted as specified in various clauses and as per applicable standards/codes. Shop tests shall include all tests to be carried out at Contractor's works, works of his sub-contractor and at works where raw materials supplied for manufacture of equipment are fabricated. The tests to be carried out shall include but not be limited to the tests described as follows: a) Materials analysis and testing. b) Hydrostatic pressure test of all pressure parts, piping, etc. c) Dimensional and visual check. d) Balancing test of rotating components. e) Determination of performance characteristics of pumps, compressors, diesel engines, electrical drive motors, etc. f) Response characteristics of heat/smoke detectors. g) Performance characteristics of HVW spray nozzles (projectors). h) Temperature rating test on heat detectors. i) Flow rate and operational test on flow control valves. j) Operational test of alarm valve (water-motor gang). k) Calibration tests on instruments and tests on control panel.
3.1.2
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l) Destruction/burst tests on 2% or minimum one (1) no. of hoses and portable type fire extinguishers for each type as applicable. Any fraction number shall be counted as next higher integer. m) Performance test on fire extinguishers as required in the code. 3.1.3 3.1.4 In the absence of any Code/Standard, equipment shall be tested as per mutually agreed procedure between the supplier and the Employer. A comprehensive visual and functional check for panels would be conducted and will include a thorough check-up of panel dimensions, material of construction, panel finish, compliance with tubing and wiring specifications, quality of workmanship, proper tagging & locations of instruments/accessories. The wiring check shall be complete point to point ring out and check for agreement with installation drawings and equipment vendor prints of the complete system and an inspection of all field connection terminals and leveling. All test certificates and reports shall be submitted to the employer for approval. The employers representative shall be given full access to all tests. The manufacturer shall inform the employer allowing adequate time so that, if the employer so desires, his representatives can witness the test.
3.1.5 3.1.6
3.2. Site Tests 3.2.1 General a) All piping and valves, after installation will be tested hydraulically at pressure of 1.5 times that of the maximum attainable pressure in the system to check against leak tightness. b) All manually operated valves/gates shall be operated throughout 100% of the travel and these should function without any trouble whatsoever, to the satisfaction of the Employer. c) All pumps shall be run with the specified fluid from shut off condition to valve wide open condition. Head developed will be checked from the discharge pressure gauge reading. During the test, the pumps and drives shall run smoothly without any undue vibration, leakage through gland, temperature rise in the bearing parts, noise, flow pulsation etc. d) All pressure vessels should be tested hydraulically at the specified test pressure, singly or in the system. e) Painting shall be checked by dry type thickness gauges. f) Visual check on all structural components, welding, painting etc. and if doubt arises, these will be tested again. g) All test instruments and equipment shall be furnished by the Contractor to the satisfaction of the Employer. h) Automatic starting of all the fire pumps by operating the test valves. i) Automatic operation of the Jockey pump j) Operation of the automatic flow control valve by operating the test valve and remote operating of the solenoid valve. k) Operation of entire annunciation system.
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3.2.2
After erection at site, the complete HVW spray protection and hydrant system shall be subject to tests to show satisfactory performance for which detailed procedure shall be submitted for Employer's approval. It shall be in line with standard Performance Guarantee Test procedure enclosed at Appendix-I. All the detectors installed shall be tested for actuation by bringing a suitable source of heat/smoke near the detector and creating a stream of hot air/smoke over the detector.
3.2.3
4.0
SPARE PARTS The Contractor shall indicate in his scope of supply all the mandatory spares in the relevant schedules. The list of mandatory spares is indicated in Section - Projects.
5.0
HORIZONTAL CENTRIFUGAL PUMPS This clause covers the design, performance, manufacturing, construction features and testing of horizontal centrifugal pumps used for the purpose of fire fighting. 5.1 The materials of the various components shall conform to the applicable IS/BS/ASTM/DIN Standards. 5.1.1 In case of any contradiction with the aforesaid standards and the stipulations as per the technical specification as specified hereinafter, the stipulations of the technical specification shall prevail. In case of contradiction between this specification and "horizontal centrifugal pump data specification sheets" enclosed, stipulations of the data specification sheets will prevail.
5.2. General Performance Requirements 5.2.1 5.2.2 The pump set shall be suitable for continuous operation at any point within the "Range of operation". Pumps shall have continuously rising head capacity characteristics from the specified duty point towards shut off point, the maximum being at shut off. Pumps shall be capable of furnishing not less than 150% of rated capacity at a head of not less than 65% of the rated head. The shut off head shall not exceed 120% of rated head. Range of operation shall be 20% of rated flow to 150% of rated flow. The pump-motor set shall be designed in such a way that there is no damage due to the reverse flow through the pump which may occur due to any mal-operation of the system. Drive Rating The drive rating shall not be less than the maximum power requirement at any point within the "Range of Operation specified where the supply frequency is 51.5 Hz (and the motor is running at 103% of its rated speed). During starting under reverse flow condition, the motor shall be capable of bringing the pump to rated speed at normal direction with 90% rated voltage at motor terminals.
5.2.3
5.2.4
5.2.5
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5.2.7
Pump set along with its drive shall run smooth without undue noise and vibration. Acceptable peak to peak vibration limits shall generally be guided by Hydraulic Institute Standards. The Contractor under this specification shall assume full responsibility in the operation of the pump and drive as one unit.
5.2.8
5.3. Design & Construction 5.3.1 Pump casing may be axially or radially split. The casing shall be designed to withstand the maximum pressure developed by the pump at the pumping temperature. 5.3.2 Pump casing shall be provided with adequate number of vent and priming connections with valves, unless the pump is made self-venting & priming. Casing drain, as required, shall be provided complete with drain valves. 5.3.3 Under certain conditions, the pump casing nozzles will be subjected to reactions from external piping. Pump design must ensure that the nozzles are capable of withstanding external reactions not less than those specified in API-610. 5.3.4 Pump shall preferably be of such construction that it is possible to service the internals of the pump without disturbing suction and discharge piping connections. 5.3.5 Impeller The impeller shall be secured to the shaft and shall be retained against circumferential movement by keying, pinning or lock rings. On pumps with overhung shaft impellers shall be secured to the shaft by an additional locknut or cap screw. All screwed fasteners shall tighten in the direction of normal rotation. 5.3.6 Wearing Rings Replaceable type wearing rings shall be furnished to prevent damage to impeller and casing. Suitable method of locking the wearing ring shall be used. 5.3.7 Shaft Shaft size selected shall take into consideration the critical speed, which shall be at least 20% away from the operating speed. The critical speed shall also be at least 10% away from runaway speed. 5.3.8 Shaft Sleeves Renewable type fine finished shaft sleeves shall be provided at the stuffing boxes/mechanical seals. Length of the shaft sleeves must extend beyond the outer faces of gland packing or seal and plate so as to distinguish between the leakage between shaft & shaft sleeve and that past the seals/gland. 5.3.9 Shaft sleeves shall be securely fastened to the shaft to prevent any leakage or loosening. Shaft and shaft sleeve assembly should ensure concentric rotation.
5.3.10 Bearings Bearings and hydraulic devices (if provided for balancing axial thrust) of adequate design shall be furnished for taking the entire pump load arising from all probable conditions of continuous operation throughout its
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"Range of Operation" and also at the shut-off condition. The bearing shall be designed on the basis of 20,000 working hours minimum for the load corresponding to the duty point. Bearings shall be easily accessible without disturbing the pump assembly. A drain plug shall be provided at the bottom of each bearing housing. 5.3.11 Stuffing Boxes Stuffing box design shall permit replacement of packing without removing any part other than the gland. Stuffing boxes shall be sealed/cooled by the fluid being pumped and necessary piping, fittings, valves, instruments, etc. shall form an integral part of the pump assembly. 5.3.12 Shaft Couplings All shafts shall be connected with adequately sized flexible couplings of suitable design. Necessary guards shall be provided for the couplings. 5.3.13 Base Plates & Sole Plate A common base plate mounting both for the pump and drive shall be furnished. The base plate shall be of rigid construction, suitably ribbed and reinforced. Base plate and pump supports shall be so constructed and the pumping unit so mounted as to minimize misalignment caused by mechanical forces such as normal piping strain, hydraulic piping thrust etc. Suitable drain taps and drip lip shall be provided. 5.3.14 Balancing All rotating components shall be statically and dynamically balanced at shop. 5.3.15 All the components of pumps of identical parameters supplied under this specification shall be interchangeable. 5.3.16 Prime Mover The design and construction of the electric drive motor shall be as specified in Clause 12. 5.4. Tests and Inspection 5.4.1 The manufacturer shall conduct all tests required to ensure that the equipment furnished conform to the requirements of this specification and are in compliance with the requirements of applicable Codes and Standards. The particulars of the proposed tests and the procedures for the tests shall be submitted to the Employer/Engineer for approval before conducting the tests. 5.4.2 Where stage inspection is to be witnessed by employer, in addition to above, the bidder shall submit to the employer/engineer at the beginning of the contract, the detailed PERT-Chart showing the manufacturing programme and indicating the period where employer or his authorized inspecting agency are required at the shop. Material of Construction All materials used for pump construction shall be of tested quality. Materials shall be tested as per the relevant standards and test certificates shall be made available to the employer/engineer.
5.4.3
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5.4.4
Where stage inspection is to be witnessed by employer, all material test certificates shall be correlated and verified with the actual material used for construction before starting fabrication, by employer's inspector who shall stamp the material. In case mill test certificates for the material are not available, the contractor shall carry out physical and chemical tests at his own cost from a testing agency approved by the employer, as per the requirements of specified material standard. The samples for physical and chemical tests shall be drawn up in presence of employers inspector who shall also witness the tests. Shaft shall be subjected to 100% ultrasonic test and machined portion of the impeller shall be subject to 100% DP test. On finished shaft DP test will also be carried out. Hydraulic test at shop All pressure parts shall be subjected to hydraulic testing at a pressure of 150% of maximum pressure generated by the pump at rated speed or 200% of total dynamic head whichever is higher, for a period not less than one (1) hour.
5.4.5
5.4.6
5.4.7
Performance test at shop Pumps shall be subjected to routine tests to determine the performance of the pumps. These tests shall be conducted in presence of employer/engineer's representative as per the requirements of the Hydraulic Institute Standards/ASME Power Test Code PTC 8.2/BS599/I.S.S., latest edition. Routine tests shall be done on all the pumps.
5.4.8
Performance tests shall be conducted to cover the entire range of operation of the pumps. These shall be carried out to span 150% of rated capacity up to pump shut-off condition. A minimum of five combinations of head and capacity are to be achieved during testing to establish the performance curves, including the design capacity point and the two extremities of the range of operation specified. Tests shall preferably be conducted along with the actual drives being supplied.
5.4.9
5.4.10 The Bidders shall submit in his proposal the facilities available at his works to conduct performance testing. If because of limitations of available facilities, a reduced speed test or model test has to be resorted to establish pump performance, the same has to be highlighted in the offer. 5.4.11 In case of model testing, the stipulations of latest edition of Hydraulic Institute Standards shall be binding. Prototype or model tests, however, shall be conducted with the suction condition identical to the field conditions i.e. sigma values of prototype and model is to be kept same. 5.4.12 Prior to conducting model testing, calculations establishing model parameters, sizes and test procedure will be submitted to Employer/Engineer for approval. 5.4.13 All rotating components of the pumps shall be subjected to static and dynamic balancing tests. 5.4.14 After installation, pumps offered may be subjected to testing at field also by Employer. If the performances at field are not found to meet the requirement, then the equipment shall be rectified by the contractor without any extra cost. Prior to performance testing, the procedure for
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such tests will be mutually agreed between employer and contractor. The Contractor shall furnish all necessary instruments, accessories and personnel for site testing. Prior to testing, the calibration curves of all instruments and permissible tolerance limit of instruments shall be mutually agreed upon. 5.4.15 If desired by the Employer, the Contractor shall conduct necessary model test for establishing optimum sump dimensions/flow correcting devices in existing sump, to suit the pump offered. 5.4.16 The employer or his authorized representative shall have full access to at least. Prior to performance tests, the contractor shall intimate the employer allowing adequate time so that if the employer so desires, his representative can witness the test. 5.4.17 Report and test certificates of the above tests shall be submitted to the employer/engineer for approval. 6.0 DIESEL ENGINES This Clause covers the design, performance, manufacturing construction features and testing of compression ignition diesel engines, used primarily for driving centrifugal pumps, used for the purpose of fire fighting. 6.1 Design and Construction General 6.1.1 6.1.2 The diesel engine shall be of multi-cylinder type four-stroke cycle with mechanical (airless) injection, cold starting type. The continuous engine brake horse power rating (after accounting for all auxiliary power consumption) at the site conditions shall be at least 20% greater than the requirement at the duty point of pump at rated RPM and in no case, less than the maximum power requirement at any condition of operation of pump. Reference conditions for rated output of engine shall be as per IS: 10000, Part-II or ISO: 3046, Part-I. The engine shall be designed with regard to ease of maintenance, repair, cleaning and inspection. All parts subjected to substantial temperature changes shall be designed and supported to permit free expansion and contraction without resulting in leakage, harmful distortion or misalignment. Starting The engine shall be capable of both automatic and manual start. The normal mode of starting is automatic but in the event of failure of automatic start or at the discretion of the operator, the engine can be started manually from the LCP. Since the fire pumping unit driven by the diesel engine is not required to run continuously for long periods and the operation will not be frequent, special features shall be built into the engine to allow it to start within a very short period against full load even if it has remained idle for a considerable period.
6.1.3 6.1.4 6.1.5
6.1.6
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6.1.7
If provision for manual start (cranking) is provided, all controls/mechanisms, which have to be operated during the starting process, shall be within easy reach of the operator. Automatic cranking shall be effected by a D.C. motor having high starting torque to overcome full engine compression. Starting power will be supplied from either of the two (2) sets of storage batters. The automatic starting arrangement shall include a 'Repeat Start' feature. The battery capacity shall be adequate for 10 (ten) consecutive starts without recharging with a cold engine under full compression. The batteries shall be used exclusively for starting the diesel engine and be kept fully charged all the time in position. Arrangement for both trickle and booster charge shall be provided. Diesel engine shall be provided with two (2) battery charger units of air cooled design. The charger unit shall be capable of charging one (1) set of battery at a time. Provision shall, however, be made so that any one of the charger units can be utilized for charging either of the two (2) batteries.
6.1.8
6.1.9
6.1.10 For detail design of battery and battery charger, sub-section Electrical may be referred to. 6.1.11 Governing System: The engine shall be fitted with a speed control device, which will control the speed under all conditions of load. 6.1.12 The governor shall offer following features: a) Engine should be provided with an adjustable governor capable of regulating engine speed within 5% of its rated speed under any condition of load between shut-off and maximum load conditions of the pumps. The governor shall be set to maintain rated pump speed at maximum pump load. b) Engine shall be provided with an over speed shut-down device. It shall be arranged to shut-down the engine at a speed approximately 20% above rated engine speed and for manual reset, such that the automatic engine controller will continue to show an over speed signal until the device is manually reset to normal operating position (Vol. II, NFPA, 1978). 6.1.13 The governor shall be suitable for operation without external power supply. 6.1.14 Fuel System The diesel engine will run on High Speed Diesel. 6.1.15 The engine shall be provided with fuel oil tank having adequate capacity to hold sufficient fuel oil for a minimum of six (6) hours of full load run. The fuel oil tank shall preferably be mounted near the engine. No fuel oil tank will be provided by the employer. 6.1.16 The fuel oil tank shall be of welded steel constructed to relevant standards for mild steel drums. The outlet of the tank shall be above the inlet of fuel injection pump of the diesel engine to ensure adequate pressure at suction of injection pump.
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6.1.17 The fuel oil tank shall be designed in such a way that the sludge and sediment settles down to the tank bottom and is not carried to the injection pump. A small sump shall be provided and fitted with drain plug to take out sludge/sediment and to drain oil. Adequate hand holes (greater than 80 mm size) shall be provided to facilitate maintenance. 6.1.18 Pipeline carrying fuel oil shall be gradually sloped from the tank to the injection pump. Any valve in the fuel feed pipe between the fuel tank and the engine shall be placed adjacent to the tank and it shall be locked in the open position. A filter shall be incorporated in this pipeline, in addition to other filters in the fuel oil system. Pipe joints shall not be soldered and plastic tubing shall not be used. Reinforced flexible pipes may also be used. 6.1.19 The complete fuel oil system shall be designed to avoid any air pocket in any part of the pipe work, fuel pump, sprayers/injectors, filter system etc. No air relief cock is permitted. However, where air relief is essential, plugs may be used. 6.1.20 A manual fuel pump shall be provided for priming and releasing of air from the fuel pipelines. 6.1.21 Lubricating Oil System Automatic pressure lubrication shall be provided by a pump driven by the crank shaft, taking suction from a sump and delivering pressurized oil through cooler and fine mesh filters to a main supply header fitted in the bed plate casing. High pressure oil shall be supplied to the main and big end bearings, cam-shaft bearings, cam-shaft chain and gear drives, governor, auxiliary drive gears etc. Valve gear shall be lubricated at reduced pressure through a reducing valve and the cams by an oil bath. 6.1.22 Cooling Water System Direct cooling or heat exchanger type cooling system shall be employed for the diesel engine. Water shall be tapped from the fire pump discharge. This water shall be led through duplex strainer, pressure breakdown orifice and then after passing through the engine, the water at the outlet shall be taken directly to the sump through an elevated funnel. 6.2 Testing & Inspection 6.2.1 The manufacturer shall conduct all tests required, to ensure that the equipment furnished conforms to the requirement of this sub-section and in compliance with requirements of applicable codes. The particulars of the proposed tests and the procedure for the tests shall be submitted to the employer for approval before conducting the tests. 6.2.2 At manufacturer's works, tests shall be carried out during and after completion of manufacture of different component/parts and the assembly as applicable. Following tests shall be conducted. 6.2.3 Material analysis and testing. 6.2.4 Hydrostatic pressure testing of all pressure parts. 6.2.5 Static and dynamic balance tests of rotating parts at applicable over-speed and determination of vibration level. 6.2.6 6.2.7
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6.2.8 6.2.9
Dimensional check of close tolerance components like piston, cylinder bore etc. Calibration tests of all fuel pumps, injectors, standard orifices, nozzles, instruments etc.
6.2.10 Over speed test of the assembly at 120% of rated speed. 6.2.11 Power run test. 6.2.12 Performance test of the diesel engine to determine its torque, power and specific fuel consumption as function of shaft speed. Performance test of the engine shall be carried for 12 hours out of which 1 Hour at full load and one hour at 110% overload. 6.2.13 Measurement of vibration & noise. (i) Measurement of vibration The vibration shall be measured during full load test as well as during the overload test and limit shall be 100 microns. (ii) Measurement of noise level The equivalent 'A' weighted sound level measured at a distance of 1.5 meter above floor level in elevation and 1.0 meter horizontally from the base of the equipment, expressed in dB to a reference of 0.0002 microbar shall not exceed 93 dBA. 6.2.14 Adjustment of speed governor as per BS: 5514. 6.2.15 Diesel engine shall be subjected to routine tests as per IS: 10000/BS: 5514. 7.0 PIPING, VALVES AND SPECIALITIES This clause covers the design, manufacture, shop testing, erection, testing and commissioning of piping, valves and specialties. 7.2 Scope The piping system which shall include but not be limited to the following: 7.2.1 Plain run of piping, bends, elbows, tees, branches, laterals, crosses, reducing unions, couplings, caps, expansion joints, flanges, blank flanges, thrust blocks, anchors, hangers, supports, saddles, shoes, vibration dampeners, sampling connections, hume pipes etc. 7.2.2 Gaskets, ring joints, backing rings, jointing material etc. as required. Also all welding electrodes and welding consumables including special ones, if any. 7.2.3 Instrument tapping connections, stubs etc. 7.2.4 7.2.5 7.2.6 Gate and globe valves to start/stop and regulate flow and swing check valves for one directional flow. Basket strainers and Y-type strainers Bolts, nuts, fasteners as required for interconnecting piping, valves and fittings as well as for terminal points. For pipe connections into Owner's R.C.C. works, Bidder will furnish all inserts. Painting, anti-corrosive coatings etc. inside and outside pipes and equipment.
7.2.7
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Adequate number of air release valves shall be provided at the highest points in the piping system to vent any trapped air in the system. 7.3 Design 7.3.1 Material of construction of various pipes shall be as follows: (a) Buried Pipes Mild steel black pipes as per IS: 1239, Part-I medium grade (for pipes of sizes 150 NB and below) or IS: 3589, Fe 410 grade (for pipes of sizes 200 NB and above) suitably lagged on the outside to prevent soil corrosion, as specified elsewhere. (b) Over ground pipes normally full of water mild steel black pipes as per IS: 1239, Part-I medium grade (for pipes for sizes 150 NB and below) or IS: 3589, Fe 410 grade (for pipes of sizes 200 NB and above). Over ground pipes normally empty, but periodic charge of water and for detector line for HVW System. Mild steel galvanized pipes as per IS: 1239, Part-I medium grade (for pipes of sizes 150 NB and below) or IS: 3589, Fe 410 grade (for pipes of sizes 200 NB and above).
(c)
7.3.2
All fittings to be used in connection with steel pipe lines up to a size of 80 mm shall be as per IS: 1239, Part-II mild steel tubular and other wrought steel pipe fittings, heavy grade. Fittings with sizes above 80 mm up to 150 mm shall be fabricated from IS: 1239 heavy grade pipes or steel plates having thickness not less than those of IS: 1239, Part-I heavy grade pipes. Fittings with sizes above 150 mm shall be fabricated from IS: 3589 Class-2 pipes. All fitting used in GI piping shall be threaded type. Welding shall not be permitted on GI piping. Pipelines carrying water, air etc. should be sized on the basis of following values of allowable velocities based on the rated capacity of the pumps: Velocity in M/Sec. Pipe Size Below 50-150 200 mm & 50 mm mm upwards 1.2-1.5 1.2-20 1.2-1.8 1.8-2.4 2.1-2.5 1.5-2.4 2.1-2.4 15-20 20-30 25-35 20-30 25-40 35-45
7.3.3
Service Description a) b) c) d) Pump suction Pump discharge Header Compressed air below 2 kG/cm2(g) e) Compressed air 2 kG/cm2g and above 7.3.4 7.3.6
For steel pipeline, welded construction should be adopted unless specified otherwise. All piping system shall be capable of withstanding the maximum pressure arising from any condition of operation and testing including water hammer effects. Gate/sluice valve will be used for isolation of flow in pipe lines and shall be as per IS: 778/BS-5150 (for size up to 40 mm), IS: 780 (for sizes above 40 mm and up to 300 mm) and IS: 2906 (for sizes above 300 mm).
7.3.9
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Valves shall be of rising spindle type. PN 1.6 class valves shall be provided. 7.3.10 Gate Valves shall be provided with the following: (a) (b) (c) (d) Hand wheel. Position indicator. Draining arrangement of valve seat. Locking facility (where necessary).
7.3.11 Gate valves shall be provided with back seating bush to facilitate gland removal during full open condition. 7.3.12 Globe valves shall be provided with contoured plug to facilitate regulation and control of flow. All other requirements should generally follow those of gate valve. 7.3.13 Non-return valves shall be swing check type. Valves will have a permanent "arrow" inscription on its body to indicate direction of flow of the fluid. These valves shall generally conform to IS: 5312. 7.3.14 Whenever any valve is found to be so located that it cannot be approached manually from the nearest floor/gallery/platform hand wheel with floor stand or chain operator shall be provided for the same. 7.3.15 Valves below 50 mm size shall have screwed ends while those of 50 mm and higher sizes shall have flanged connections. 7.3.16 Strainers Basket Strainer a) Basket strainers shall be of 30mesh and have the following materials of construction: Body Fabricated mild steel as per IS: 2062 (Tested Quality). Strainer Wires of stainless steel (AISI: 316), 30 SWG, suitably reinforced. b) c) d) e) Inside of basket body shall be protected by two (2) coats of heavy duty bitumastic paint. Strainers shall be Simplex design. Suitable vent and drain connections with valves shall be provided. Screen open area shall be at least 4 times pipe cross sectional area at inlet. Pressure drop across strainer in clean condition shall not exceed 1.5 MWC at 410 M3/Hr flow.
7.3.17 Y-type On-line Strainer Body shall be constructed of mild steel as per IS: 2062 (tested quality). Strainer wires shall be of stainless steel AISI: 316, 30 SWG, 30 mesh. Blowing arrangement shall be provided with removable plug at the outlet. Screen open area shall be at least 4 times pipe cross- sectional area at inlet. 7.3.18 Hydrant Valve (Outdoor) and Indoor Hydrant Valves (Internal Landing Valves).
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The general arrangement of outdoor stand post assembly, consisting of a column pipe and a hydrant valve with a quick coupling end shall be as per TAC requirement. Materials of construction shall be as follows: a) b) Column pipe M.S. IS: 1239 med. grade. Hydrant Valve i) ii) Gun metal Leaded tin bronze as per IS: 318, Grade-2 iii) Hand Wheel: Cast Iron as per IS: 210, Grade-20. iv) Washer, gasket etc.: Rubber as per IS: 638. v) Quick coupling Leaded tin bronze as per IS: 318, connection Grade-2. vi) Spring Phosphor Bronze as per IS: 7608. vii) Cap and chain Leaded tin bronze as per IS: 318, Grade-2. The general design of hydrant valve shall conform to IS: 5290. 7.3.19 Hoses, Nozzles, Branch pipes and Hose boxes (a) Hose pipes shall be of unlined flax canvas/reinforced rubber-lined canvas construction as per IS: 4927/type A of IS: 636 with nominal size of 63 MM (2") and lengths of 15 meter or 7.5 meter, as indicated elsewhere. All hoses shall be ISI marked. Hosepipes shall be capable of withstanding an internal water pressure of not less than 35 kg/cm without bursting. It must also withstand a working pressure of 8.5 kg/ cm without undue leakage or sweating. Each hose shall be fitted with instantaneous spring lock type couplings at both ends. Hose shall be fixed to the coupling ends by copper rivets and the joint shall be reinforced by 1.5 mm galvanized mild steel wires and leather bands. Branch pipes shall be constructed of copper and have rings of leaded tin bronze (as per IS: 318 Grade-2) at both ends. One end of the branch pipe will receive the quick coupling while the nozzles will be fixed to the other end. Nozzles shall be constructed of leaded tin bronze as per IS: 318, Grade-2. Suitable spanners of approved design shall be provided in adequate numbers for easy assembly and dismantling of various components like branch pipes, nozzles, quick coupling ends etc. Hose pipes fitted with quick coupling ends, branch pipes, nozzles spanner etc. will be kept in a hose box, which will be located near point of use. The furnished design must meet the approval of Tariff Advisory Committee. All instantaneous couplings, as mentioned under Clause Nos. 3.3.19, 3.3.20 and 3.3.21 above shall be of identical design (both male and female) so that any one can be interchanged with another. One
Body: Trim:
(b)
(c)
(d)
(e) (f)
(g)
(h)
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male, female combination shall get locked in by mere pushing of the two halves together but will provide leak tightness at a pressure of 8 kg/cm2 of water. Designs employing screwing or turning to have engagement shall not be accepted. 7.4 Fabrication & Erection 7.4.1 The contractor shall fabricate all the pipe work strictly in accordance with the related approved drawings. 7.4.2 End Preparation (a) (b) (c) 7.4.3 For steel pipes, end preparation for butt welding shall be done by machining. Socket weld end preparation shall be sawing/machining. For tees, laterals, miter bends, and other irregular details cutting templates shall be used for accurate cut.
Pipe Joints (a) In general, pipes having sizes over 25 mm shall be joined by butt welding. Pipes having 25 mm size or less shall be joined by socket welding/screwed connections. Galvanized pipes of all sizes shall have screwed joints. No welding shall be permitted on GI pipes. Screwed joints shall have tapered threads and shall be assured of leak tightness without using any sealing compound. Flanged joints shall be used for connections to vessels, equipment, flanged valves and also on suitable straight lengths of pipe line of strategic points to facilitate erection and subsequent maintenance work.
(b)
7.4.4
Over ground Piping (a) Piping to be laid over ground shall be supported on pipe rack/supports. Rack/supports details shall have to be approved by employer/engineer. Surface of over ground pipes shall be thoroughly cleaned of mill scale, rust etc. by wire brushing. Thereafter one (1) coat of red lead primer shall be applied. Finally two (2) coats of synthetic enamel paint of approved colour shall be applied.
(b)
7.4.5
Buried Pipe Lines (a) Pipes to be buried underground shall be provided with protection against soil corrosion by coating and wrapping with two coats of coal tar hot enamel paint and two wraps of reinforced fibre glass tissue. The total thickness of coating and wrapping shall not be less than 3 mm. Alternatively corrosion resistant tapes can also be used for protection of pipes against corrosion. Coating and wrapping shall be in line with IS: 10221. Buried pipelines shall be laid with the top of pipe one meter below ground level. At site, during erection, all coated and wrapped pipes shall be tested with approved Holiday detector equipment with a positive signaling device to indicate any fault hole breaks or conductive particle in the protective coating.
(b) (c) (d)
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7.5
General Instruction for Piping Design and Construction 7.5.1 While erecting field run pipes, the contractor shall check, the accessibility of valves, instrument tapping points, and maintain minimum headroom requirement and other necessary clearance from the adjoining work areas. 7.5.2 7.5.3 Modification of prefabricated pipes, if any, shall have to be carried out by the contractor at no extra charge to the Employer. Welding (i) (ii) Welding shall be done by qualified welders only. Before welding, the ends shall be cleaned by wire brushing, filing or machine grinding. Each weld-run shall be cleaned of slag before the next run is deposited.
(iii) Welding at any joint shall be completed uninterrupted. If this cannot be followed for some reason, the weld shall be insulated for slow and uniform cooling. (iv) Welding shall be done by manual oxyacetylene or manual shielded metal arc process. Automatic or semi-automatic welding processes may be done only with the specific approval of employer/consultant. (v) As far as possible welding shall be carried out in flat position. If not possible, welding shall be done in a position as close to flat position as possible.
(vi) No backing ring shall be used for circumferential butt welds. (vii) Welding carried out in ambient temperature of 5C or below shall be heat-treated. (viii) Tack welding for the alignment of pipe joints shall be done only by qualified welders. Since tack welds form part of final welding, they shall be executed carefully and shall be free from defects. Defective welds shall be removed prior to the welding of joints. Electrodes size for tack welding shall be selected depending upon the root opening. (ix) Tacks should be equally spaced as follows: For 65 NB and smaller pipes: For 80 NB to 300 NB pipes: For 350 NB and larger pipes: (x) 2 tacks 4 tacks 6 tacks
Root run shall be made with respective electrodes/filler wires. The size of the electrodes/filler wires. The size of the electrodes shall not be greater than 3.25 mm (10 SWG) and should preferably be 2.3 mm (12 SWG). Welding shall be done with direct current values recommended by the electrode manufacturers.
(xi) Upward technique shall be adopted for welding pipes in horizontally fixed position. For pipes with wall thickness less than 3 mm, oxyacetylene welding is recommended. (xii) The root run of butt joints shall be such as to achieve full penetration with the complete fusion of root edges. The weld projection shall not exceed 3 mm inside the pipe.
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(xiii) On completion of each run craters, weld irregularities, slag etc. shall be removed by grinding or chipping. (xiv) Fillet welds shall be made by shielded metal arc process regardless of thickness and class of piping. Electrode size shall not exceed 10 SWG (3.25 mm). At least two runs shall be made on socket weld joints. 7.6 Tests at Works 7.6.1 Pipes (i) (ii) Mechanical and chemical tests shall be performed as required in the codes/standards. All pipes shall be subjected to hydrostatic tests as required in the codes/standards.
(iii) 10% spot Radiography test on welds of buried pipes shall be carried out as per ASME VIII. 7.6.2 Valves (i) (ii) Mechanical and chemical tests shall be conducted on materials of the valve as required in the codes/standards. All valves shall be tested hydrostatically for the seat as well as required in the code/standards for a period of ten minutes.
(iii) Air test shall be conducted to detect seat leakage. (iv) Visual check on the valve and simple operational test in which the valve will be operated thrice from full open to full close condition. (v) 7.6.3 No repair work on CI valve body, bonnet or wedge shall be allowed.
Strainers (i) (ii) Mechanical and chemical tests shall be conducted on materials of the strainer. Strainers shall be subjected to a hydrostatic test pressure of 1.5 times the design pressure or 10 kg/cmg whichever is higher for a period of one hour.
(iii) Pressure drop test on one strainer of each size/type shall be conducted. 7.6.4 Hydrant valves and Indoor Hydrant Valves (Internal Landing Valves) (i) The stand post assembly along with the hydrant valve (valve being open and outlet closed) shall be pressure tested at a hydrostatic pressure of 21 kg/cm2g to detect any leakage through defects of casting. Flow test shall be conducted on the hydrant valves at a pressure of 7 kg/cm2g and the flow through the valve shall not be less than 900 liters/min.
(ii)
(iii) Leak tightness test of the valve seat shall be conducted at a hydrostatic test pressure of 14 kg/cmg. 7.6.5
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Unlined flax/reinforced rubber-lined canvas hoses shall be tested hydrostatically. Following tests shall be included as per IS: 4927/IS: 636. a) b) c) Percolation test Pressure test at 21 kg/cm2g Burst test at 32 kg/cm2g (minimum)
The branch pipe, coupling and nozzles shall be subjected to a hydro static test pressure of 21 kg/cm2g to detect any leakage through defects of casting. Dimensional checks shall be made on the hose boxes and nozzle spanners. 8.0 AIR VESSELS 8.1 8.2 8.3 Air vessels shall be designed and fabricated of mild steel as class-II vessels as per IS: 2825. Inside surface of the tank paints/coatings/linings as required. shall be protected by anti-corrosive
Outside surfaces of the vessels shall be provided with one (1) coat of red lead primer with two (2) coats of synthetic enamel paint of approved colour and characteristics. Tests & Inspection 8.4.1 Air vessels shall be hydraulically tested at 1.5 times design pressure or 2 times the working pressure, whichever is higher, for a period not less than one (1) hour. All materials used for fabrication shall be of tested quality and test certificates shall be made available to the Owner. Welding procedure and Welder's qualification tests will be carried out as per relevant IS Standard. NDE tests, which will include 100% Radiography on longitudinal seams and spot Radiography for circumferential seams, for pressure vessel will be carried out.
8.4
8.4.2 8.4.3 8.4.4
9.0
HEAT DETECTORS/FIRE DETECTORS AND SPRAY NOZZLES 9.1 Intent of Specification This specification lays down the requirements of the smoke detectors, heat detectors and spray nozzles for use in various sub-systems of the fire protection system. 9.2 Codes and Standards All equipment supplied shall conform to internationally accepted codes and standards. All equipment offered by Bidders should be TAC approved or have been in use in installations which have been approved by TAC. 9.3 Heat Detectors, Quartzoid bulb type. (Used in HVW spray system) a) b) Heat detectors shall be of any approved and tested type. Fusible chemical pellet type heat detectors are however not acceptable. Temperature rating of the heat detector shall be selected by the bidder taking into consideration the environment in which the detectors shall operate. Minimum set point shall, however, be 79oC.
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c) d) e)
Heat detectors shall be guaranteed to function properly without any maintenance work for a period of not less than twenty five (25) years. The heat detectors must be approved by the Tariff Advisory Committee, India or FOC, London or a reputed international authority. The heat detectors shall be mounted on a pipe network charged with water at suitable pressure. On receipt of heat from fire, the heat detector will release the water pressure from the network. This drop in water pressure will actuate the Deluge valve. The bidder may offer alternative method of heat detection and type of heat detectors, provided these are acceptable to the Tariff Advisory Committee and the employer.
f)
9.4
HVW Spray Nozzles (Projectors) High velocity water spray system shall be designed and installed to discharge water in the form of a conical spray consisting of droplets of water traveling at high velocity which shall strike the burning surface with sufficient impact to ensure the formation of an emulsion. At the same time the spray shall efficiently cut off oxygen supply and provide sufficient cooling. Integral non-ferrous strainers shall be provided in the projectors ahead of the orifice to arrest higher size particle, which are not allowed to pass through the projectors. Material of construction of projector shall be in line with TAC/NFPA requirement
9.5 Fire Detectors 9.5.1 9.5.2 9.5.3 Fire detectors shall be approved by FOC-London or similar international authorities and also by Tariff Advisory Committee of India. Both smoke and heat type fire detectors shall be used Bidder shall clearly indicate the mode of operation of detectors in his proposal. The set point shall be selected after giving due consideration for ventilating air velocity and cable insulation. The set point shall be adjustable. Fire detectors shall be equipped with an integral L.E.D. so that it shall be possible to know which of the detectors has been operated. The detectors which are to be placed in the space above the false ceiling or in the floor void shall not have the response indicators on the body but shall be provided with remote response indicators. Approval from Department of Atomic Energy (DAE), Government of India shall be made available for ionisation type smoke detectors. All accessories required to satisfy DAE shall also be included in the scope of supply. Fire detectors shall be guaranteed to function properly without any maintenance work for a period of not less than ten (10) years.
9.5.4
9.5.5
9.5.6
10.0 PORTABLE AND WHEEL/TROLLEY MOUNTED FIRE EXTINGUISHERS 10.1 Intent of Specification This specification lays down the requirement regarding fire extinguishers of following types: Portable fire extinguishers. a)
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b) c)
Dry chemical powder type Carbon Dioxide type
Wheel/Trolley mounted fire extinguishers. a) b) Dry chemical powder type Carbon Dioxide type
10.2 All the extinguishers offered by the Bidder shall be of reputed make and should have been approved by Tariff Advisory Committee of India or any other international authorities like FOC - London/NFPA-USA. Certificates to this effect shall be furnished by the Bidder. All extinguishers shall be ISI marked. 10.3 Design and Construction 10.3.1 10.3.2 10.3.3 10.3.4 10.3.5 10.3.6 All the portable extinguishers shall be of freestanding type and shall be capable of discharging freely and completely in upright position. Each extinguisher shall have the instructions for operating the extinguishers on its body itself. All extinguishers shall be supplied with initial charge and accessories as required. Portable type extinguishers shall be provided with suitable clamps for mounting on walls or columns. All extinguishers shall be painted with durable enamel paint of fire red colour conforming to relevant Indian Standards. Pressurization of water type fire extinguishers shall either be done by compressed air or by using gas cartridge. The constant air pressure type shall conform to IS: 6234 and the gas pressure type shall conform to IS: 940. Both these extinguishers shall be ISI marked. Dry chemical powder type extinguisher shall conform to IS: 2171. Carbon dioxide type extinguisher shall conform to IS: 2878. Wheel/trolley mounted fire extinguishers of Dry chemical powder type shall conform to IS: 10658
10.3.7 10.3.8 10.3.9
10.3.10 Wheel/trolley mounted fire extinguishers of carbon dioxide type shall conform to IS: 2878 10.4 Tests and Inspection 10.4.1 10.4.2 Particulars of shop tests and procedure shall be submitted to the Employer before hand for his approval. A performance demonstration test at site of five (5) percent or one (1) number whichever is higher, of the extinguishers shall be carried out by the Contractor. All consumable and replaceable items require for this test would be supplied by the contractor without any extra cost to employer. Performance testing of extinguisher shall be in line of applicable Indian Standards. In case where no Indian Standard is applicable for a particular type of extinguisher, the method of testing shall be mutually discussed and agreed to before placement of order for the extinguishers.
10.4.3
10.5 Performance Guarantee

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The contractor shall guarantee all equipment supplied by him against any defect due to faulty design, material and workmanship. The equipment shall be guaranteed to operate satisfactorily at the rated conditions at site. 10.6 Painting Each fire extinguisher shall be painted with durable enamel paint of fire red colour conforming to relevant Indian Standards. 11.0 INSTRUMENTS 11.0.1 Intent of Specification The requirements given in the sub-section shall be applicable to all the instruments being furnished under this specification. 11.0.2 All field mounted instruments shall be weather and dust tight, suitable for use under ambient conditions prevalent in the subject plant. All field mounted instruments shall be mounted in suitable locations where maximum accessibility for maintenance can be achieved. 11.1 Local Instruments Pressure/Combination/Differential Gauges & Switches. 11.1.1 11.1.2 The pressure sensing elements shall be continuous 'C' bourdon type. The sensing elements for all gauges/switches shall be properly aged and factory tested to remove all residual stresses. They shall be able to withstand at least twice the full scale pressure/vacuum without any damage or permanent deformation. For all instruments, connection between the pressure sensing element and socket shall be braced or hard soldered. Gauges shall be of 150 mm diameter dial with die-cast aluminium, staved enamel black finish case, aluminum screwed ring and clear plastic crystal cover glass. Upper range pointer limit stop for all gauges shall be provided. All gauges shall be with stainless steel bourdon having rotary geared stainless steel movements. Weatherproof type construction shall be provided for all gauges. This type of construction shall be fully dust tight, drip tight, weather resistant and splash proof with anti-corrosive painting conforming to NEMA- 4. All gauges shall have micrometer type zero adjuster. Neoprene safety diaphragm shall be provided on the back of the instruments casing for pressure gauges of ranges 0-10 Kg/cm and above. Scales shall be concentric, white with black lettering and shall be in metric units.
11.1.3 11.1.4
11.1.5 11.1.6
11.1.7 11.1.8
11.1.9
11.1.10 Accuracy shall be + 1.0 percent of full range or better. 11.1.11 Scale range shall be selected so that normal process pressure is approximately 75 percent of full scale reading.
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11.1.12 All gauges shall have 1/2 inch NPT bottom connection. 11.1.13 All instruments shall conform to IS: 3624 - 1966. 11.1.14 All instruments shall be provided with 3 way gauge isolation valve or cock. Union nut, nipple and tail pipe shall be provided wherever required. 11.1.15 Switch element contact shall have two (2) NO and two (2) NC contacts rated for 240 Volts, 10 Amperes A.C. or 220 Volts, 5 Amperes D.C. Actuation set point shall be adjustable throughout the range. ON-OFF differential (difference between switch actuation and de-actuation pressures) shall be adjustable. Adjustable range shall be suitable for switch application. 11.1.16 Switches shall be sealed diaphragm, piston actuated type with snap action switch element. Diaphragm shall be of 316 SS. 11.1.17 Necessary accessories shall be furnished. 11.2 Timers 11.2.1 11.2.2 The timers shall be electro-mechanical type with adjustable delay on pick-up or reset as required. Each timer shall have two pairs of contacts in required combination of NO and NC.
11.3 Level Gauges/Indicator/Switches 11.3.1 Level Gauges i) ii) Gauge glasses shall be used for local level indication wherever shown in the flow diagram. Gauge glasses, in general, shall be flag glass type with bolted cover. Body and cover material shall be of carbon steel with rubber lining. Level coverage shall be in accordance with operating requirements. Maximum length of a single gauge glass shall not exceed 1.4 M. Should a larger gauge glass be required, multiple gauges of preferably equal length shall be used with 50 mm overlap in visibility. Reflex type gauge glasses shall be used for colour less liquids and transparent type gauge glasses shall be used for all liquids having colour. Each gauge glass shall be complete with a pair of offset valves. Valves shall have union bonnet, female union level connection, flanged tank connection, and vent and drain plug. Offset valves shall have corrosion resistant ball-check to prevent fluid loss in the event of gauge glass breakage. Valve body shall have a working pressure of 200 percent of the maximum static pressure at the maximum process fluid temperature. Valve body materials shall be of carbon steel with rubber lining.
iii)
iv)
v)
vi)
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11.3.2
Level Indicators i) Float type mechanical level gauges with linear scale type indicator shall be offered for measuring level of tanks wherever shown in the flow diagram. AISI-316 stainless steel float, guide rope and tape shall be used. Housing shall be of mild steel painted with anti-corrosive painting. The scale indicator shall be provided at a suitable height for ease of reading. Accuracy shall be +1% of scale range or better.
ii) iii) iv) 11.3.3
Level Switches i) ii) iii) Level switches shall be of ball float operated magnetic type complete with cage. Materials of construction shall be suitable for process and ambient conditions. The float material shall be AISI-316 stainless steel. Actuating switches shall be either hermetically sealed mercury type or snap acting micro-switches. Actuation set point shall be adjustable. ON-OFF differential (difference between switch actuation and de-actuation levels) shall be adjustable. Adjustable range shall be suitable for switch application. All switches shall be repeatable within +1.0 percent of liquid level change required activating switch. Contacts shall be rated for 50 watts resistive at 240 V A.C. Number of contacts shall be two NO and two NC for each level switch.
11.4 Solenoid Valves 11.4.1 11.4.2 11.4.3 11.4.4 The body of the valves shall be Forged brass or stainless steel. The coil shall be continuous duty, epoxy moulded type Class-F, suitable for high temperature operation. The enclosure shall be watertight, dust-tight and shall conform to NEMA-4 Standard. The valves shall be suitable for mounting in any position.
11.5 Switches, Lamps, Meters Etc. All electrical components on the panel namely push buttons, switches, lamps, meters etc. shall meet the requirements of sub-section Electrical enclosed with the specification. 11.6 All local instruments shall be inspected by Employer/Consultant as per the agreed quality plan. 11.7 Makes of control panel and local instruments, accessories shall be as per Employer's approval. 12.0 ELECTRIC MOT ORS 12.1 General 12.1.1 12.1.2
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This clause covers the requirements of three phase squirrel cage induction motors and single-phase induction motors. The motors to be furnished, erected and commissioned as covered under this specification shall be engineered, designed, manufactured, erected,
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and tested as per the requirements specified herein. These requirements shall however be read along with the requirements of the respective driven equipment being supplied under the specification of which this specification forms a part. 12.1.3 12.1.4 12.1.5 The motor supplied under this specification shall conform to the standards specified in GTR. Terminal point for all motors supplied under this specification shall be at the respective terminal boxes. Materials and components not specifically stated in this specification but are necessary for satisfactory operation of the motor shall be deemed to be included in the scope of supply of this specification. Notwithstanding anything stated in this motor specification, the motor has to satisfy the requirement of the mechanical system during normal and abnormal conditions. For this the motor manufacturer has to coordinate with the mechanical equipment supplier and shall ensure that the motor being offered meets the requirements.
12.1.6
12.2 Codes & Standards 12.2.1 The design, manufacture, installation and performance of motors shall conform to the provisions of latest Indian Electricity Act and Indian Electricity Rules. Nothing in these specifications shall be construed to relieve the contractor of his responsibility. In case of contradiction between this specifications and IS or IEC, the stipulations of this specification shall be treated as applicable. National Electrical Code for hazardous location and relevant NEMA standard shall also be applicable for motors located in hazardous location.
12.2.2 12.2.3
12.3 Design Features 12.3.1 Rating and type (i) (ii) The induction motors shall be of squirrel cage type unless specified otherwise. The motors shall be suitable for continuous duty in the specified ambient temperature.
(iii) The MCR kW rating of the motors for 50 C ambient shall not be less than the power requirement imposed at the motor shaft by the driven equipment under the most onerous operation conditions as defined elsewhere, when the supply frequency is 51.5 Hz (and the motor is running at 103% of its rated speed). (iv) Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously in the system having the following particulars: a) Rated terminal voltage From 0.2 to 200 kW Below 0.2 kW Variation in voltage b) Frequency
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c) Any combination of (a) & (b) 12.3.2 Enclosure Motors to be installed outdoor and semi-outdoor shall have hose proof enclosure equivalent to IP-55 as per IS: 4691. For motors to be installed indoor, the enclosure shall be dust proof equivalent to IP-54 as per IS: 4691. For hazardous locations, the enclosures of the motor shall be of flameproof construction. 12.3.3 12.3.4 Cooling method Motors shall be TEFC (totally enclosed fan cooled) type. Starting requirements (i) Induction motor a) All induction motors shall be suitable for full voltage direction line starting. These shall be capable of starting and accelerating to the rated speed along with the driven equipment without exceeding the acceptable winding temperature even when the supply voltage drops down to 80% of the rated voltage. Motors shall be capable of withstanding the electro-dynamic stresses and heating imposed if it is started at a voltage of 110% of the rated value. The starting current of the motor at rated voltage shall not exceed six (6) times the rated full load current subject to tolerance as given in IS: 325. Motors when started with the driven equipment imposing full starting torque under the supply voltage condition specified under Clause 12.3.1 (iv) (a) shall be capable of withstanding at least two successive starts with coasting to rest between starts and motor initially at the rated load operating temperature. The motors shall also be suitable for three equally spread starts per hour, the motor initially at a temperature not exceeding the rated operating temperature. The locked rotor withstand time under hot condition at 110% of rated voltage shall be more than the starting time with the driven equipment at minimum permissible voltage (clause 12.3.4 (i) (a) by at least two seconds or 15% of the accelerating time whichever is greater. In case it is not possible to meet the above requirement the bidder shall offer centrifugal type speed switch mounted on the motor shaft which shall remain closed for speeds lower than 20% and open for speeds above 20% of the rated speed. The speed switch shall be capable of withstanding 120% of the rated speed in either direction of rotation.
b)
c)
d)
e)
12.3.5
Running requirements (i) When the motors are operating at extreme condition of voltage and frequency given under Clause No. 12.3.1 (iv) the maximum permissible temperature rise over the ambient temperature of 50 C shall be within the limits specified in IS: 325 (for 3-phase
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induction motors) and IS: 996 (for 1 phase motor) after adjustment due to increase ambient temperature specified herein. (ii) The double amplitude of motor vibration shall be within the limits specified in IS: 4729. Vibration shall also be within the limits specified by the relevant standard for the driven equipment when measured at the motor bearings.
(iii) All the induction motors shall be capable of running at 80% of rated voltage for a period of 5 minutes with rated load commencing from hot condition. (iv) Induction motors shall be so designed as to be capable of withstanding the voltage and torque stresses developed due to the difference between the motor residual voltage and incoming supply voltage during fast changeover of buses. The necessary feature incorporated in the design to comply with this requirement shall be clearly indicated in the proposal. (v) Motors shall be capable of developing the rated full load torque even when the supply voltage drops to 70% of rated voltage. Such operation is envisaged for a period of one second. The pull out torque of the induction motors to meet this requirement shall not be less than 205% of full load torque.
(vi) The motors shall be capable of withstanding for 10 seconds without stalling or abrupt change in speed (under gradual increase of torque) an excess torque of 60 percent of their rated torque, the voltage and frequency being maintained at their rated value. (viii) Guaranteed performance of the motors shall be met with tolerances specified in respective standards. 12.4 Construction Features 12.4.1 Stator (i) Stator frame The stator frames and all external parts of the motors shall be rigid fabricated steel or of casting. They shall be suitably annealed to eliminate any residual stresses introduced during the process of fabrication and machining. (ii) Stator core The stator laminations shall be made from suitable grade magnetic sheet steel varnished on both sides. They shall be pressed and clamped adequately to reduce the core and teeth vibration to minimum. (iii) Insulation and winding a) All insulated winding conductor shall be of copper. The overall motor winding insulation for all 415 volts motors shall be of epoxy thermosetting type i.e., class 'F' but limited to class-B operating from temperature rise consideration. Other motors may be of conventional class-B type. The windings shall be suitable for successful operation in hot, humid, tropical climate with the ambient temperature of 50oC.
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12.4.2
Rotor (i) Rotors shall be so designed as to keep the combined critical speed with the driven equipment away from the running speed by at least 20%. Rotors shall also be designed to withstand 120% of the rated speed for 2 minutes in either direction of rotation.
(ii) 12.4.3
Terminal box leads (i) For motors of 415 Volts and below a single terminal box may be provided for power and accessories leads.
(iii) Terminal boxes shall be of weatherproof construction designed for outdoor service. To eliminate entry of dust and water, gaskets of neoprene or approved equivalent shall be provided at cover joints and between box and motor frame. (iv) Terminal box shall be suitable for top and bottom entry of cables. (v) Unless otherwise approved, the terminal box shall be capable of being turned through 360o in steps in 90o.
(vi) The terminals shall be complete with all accessories for connecting external cables. They shall be designed for the current carrying capacity and shall ensure ample phase to phase to ground clearances. (vii) Suitable tinned brass compression type cable glands and cable lugs shall be supplied by the Contractor to match Employer's cable. (viii) Terminal box for single core cable shall be of nonmagnetic material. (ix) Marking of all terminals shall be in accordance with IS: 4728. 12.4.4 Rating Plates (i) Rating plates shall be provided for all motors giving the details as called for in the following standards. a) IS: 325 (for three phase squirrel cage induction motors). b) IS: 996 (for single phase A.C. and universal electric motors). (ii) In addition to above, the rating plate shall indicate the following: a) Temperature rise in oC under normal working conditions. b) Phase sequence corresponding to the direction of rotation for the application. c) Bearing identification number (in case of ball/roller bearing) and recommended lubricants. 12.4.5 Other Constructional Features (i) Two independent earthing points shall be provided on opposite sides of the motor for bolted connection of Employer's earthing conductor to be specified to the successful Bidder.
(iv) Motor weighing more than 25 kg. Shall be provided with eyebolts, lugs or other means to facilitate lifting.
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12.5. Paint and Finish 12.5.1 Motor external parts shall be finished and painted to produce a neat and durable surface, which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all sharp edges and scales removed and treated with one coat of primer and two coats of grey enamel paint. Motor fans shall also be painted to withstand corrosion. All fasteners used in the construction of the equipment shall be either of corrosion resistant material or heavy cadmium plated. Current carrying fasteners shall be either of stainless steel or high tensile brass.
12.5.2 12.5.3 12.5.4
12.6 Tests at Manufacturers Works 12.6.1 Motors shall be subject to routine tests in accordance with the following standards: a) For 3 phase induction motors: IS: 325 & IS: 4029
b) For single phase induction motors: IS: 996 12.6.2 In addition, the following tests shall also be carried out: a) 20% over speed test for 2 minutes on all rotors. b) Measurement of vibration. c) Measurement of noise level. d) Phase sequence and polarity checks relative to mechanical rotation. 12.6.3 Results of routine tests carried out on all motors in accordance with the standards indicated above shall be furnished to the Engineer in six (6) copies for his scrutiny and approval. Only on acceptance from his side, motors can be considered suitable for dispatch. 12.6.4 The Employer reserves the right to send his representative(s) to witness the tests. At least 3 weeks notice shall be given intimating the date of tests. 12.6.5 Tests after installation at site (i) After installation and commissioning at site, the motors along with the driven equipment shall be subject to tests to ascertain their conformity with the requirement of this specification and those of the driven equipment specification and the performance data quoted by the Bidder. In case of non-conformity of the motor with these specifications and performance requirement, the Engineer may at his discretion reject or ask for necessary rectification/replacement as detailed under Clauses 38 and 39 of General Terms and Conditions of Contract (GCC) in Volume-I of this Part.
(ii)
13.0 BATTERY & BATTERY CHARGERS This clause covers the design, performance, manufacturing, construction features and testing of Battery and Battery charger used primarily for starting the diesel engine driving the fire water pumps. 13.1 General Information
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13.1.1 13.1.2 13.1.3
The equipment specified hereinafter is required for starting the diesel engines and other operation of the plant as required. For each diesel engine there shall be two (2) sets of Battery and two (2) sets of Battery Charger. The D.C. voltage shall be obtained normally after necessary rectification by battery charger. The Battery Charging system shall be capable of meeting the following requirements: Float charging the Battery. Boost Charging the Battery. The battery shall be large enough to crank the engine 10 times without charging in between and without getting drained to an extent which will affect its life. The Bidder shall indicate the battery voltage and battery capacity in Ampere-Hour at ten (10) hour discharge rate. The battery voltage at any time during operation shall not be less than the minimum voltage required for operation of the D.C. loads.
13.1.4 13.1.5 13.1.6
13.1.7
13.2 General Design The Battery and Battery Charger shall be located indoor. The Battery Charger shall have suitable provision for mounting on column/wall. 13.2.1 Battery (i) (ii) The cells shall be lead-acid type. The Battery shall be automotive type. The cells shall be sealed in type with anti-splash type vent plug.
(iii) The cell terminal posts shall be provided with connector bolts and nuts effectively coated with lead to prevent corrosion. Lead or lead coated copper connectors shall be furnished to connect up cells of battery set. (iv) Positive and Negative terminal posts shall be clearly and indelibly marked for easy identification. (v) The electrolyte shall be of battery grade Sulphuric Acid conforming to IS: 226-2962. Water for storage batteries conforming to IS: 1069 shall be used in the preparation of the electrolyte.
13.2.2
Battery Charger i) The Bidder shall furnish the battery charging scheme complete with all necessary accessories such as transformers, switches, fuses, starters, contactors, diodes, ammeters, voltmeters and other devices as required for trouble free operation. All devices and equipment shall conform to relevant Indian Standard or shall be superior to it. The scheme of the battery charger shall be such that the battery can be charged automatically as well as manually.
(ii)
(iii) The boost charger shall have sufficient capacity to restore a fully discharged Battery to a state of full charge in eight (8) hours with some spare margin over maximum charging rate. Suitable
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provision shall be kept so that, for a particular engine, any of the two (2) charger units can be used for charging any of the two (2) batteries. (iv) The charging equipment shall be housed in a panel of sheet steel construction with hinged door on the front side. The minimum thickness of sheet steel shall be 2.5 mm. The panel shall have suitable provision for taking the cable from bottom/top. (v) The instruments, switches and lamps shall be flush/semi-flush mounted on the front panel. Name plate of approved type shall be provided for each of this equipment.
(vi) The panel shall be complete with internal wiring and input-output terminal block. Terminal blocks shall be clip on type of suitable rating. All equipment and wire terminals shall be identified by symbols corresponding to applicable schematic/wiring diagram. (vii) Space heaters of adequate capacity shall be provided to prevent moisture condensation in the panel. (viii) The panel shall be chemically cleaned, rinsed, bonderised, rinsed and air dried. Immediately after bonderising, the steel shall be sprayed with a coat of primer. The finish of the panel shall consist of two coats of sprayed-on pearl grey enamel or lacquers (IS: 631). 13.3 Testing 13.3.1 13.3.2 13.3.3 13.3.4 13.3.5 13.3.6 13.3.7 13.3.8 13.3.9 The Battery Charger shall also be subjected to the following tests at manufacturer's works as per IS - 4540 Insulation test. Connection checking. Measurement of voltage regulation. Auxiliary of devices. Alternating current measurement. Performance test. Temperature rise test. Following acceptance tests shall be carried out in batteries as per IS: 1651. a) Marking and packing b) Verification of dimensions c) Test for capacity d) Test for voltage during discharge 14.0 CONTROL & ANNUNCIATION PANELS 14.1 Intent of Specification The following requirement shall be applicable to the control and annunciation panels furnished under these specifications.
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14.2 General Information 14.2.1 14.2.2 The equipment specified herein is required for controlling, metering, monitoring and indication of electrical systems of the plant offered. The selection and design of all the equipment shall be so as to ensure reliable and safe operation of the plant and shall be subjected to approval by the employer. The reference ambient temperature outside the panel shall be taken as 50oC and relative humidity 100%.
14.2.3
14.3 Equipment to be furnished Control & annunciation panels shall be furnished complete with all accessories and wiring for safe and trouble free operation of the plant. Details are included in sub-section General. 14.4 Constructional Details 14.4.1 The panel frames shall be fabricated using suitable mild steel structural sections or pressed and shaped cold-rolled sheet steel of thickness not less than 2.5 mm. Frames shall be enclosed in cold-rolled sheet steel of thickness not less than 1.6 mm. Stiffeners shall be provided wherever necessary. Free standing type panels shall be provided with hinged door with locking arrangement. The access doors, cutest and covers shall be equipped with neoprene/synthetic rubber all around and the latches sufficiently strong to hold them in alignment when closed. The panels to be installed outdoor or semi outdoor shall have a degree of protection of IP: 55 and those installed indoor shall have a degree of protection of IP: 52 as per IS: 2147. If a panel consists of a number of panels, each panel should be mounted side by side and bolted together to form a compact unit, when two panels meet, the joints shall be smooth, close fittings and unobstructive. Removable eye bolt or lifting lugs shall be provided on all panels to facilitate easy lifting. The heights of all operating equipment on the panel shall be between 800 mm to 1600 mm from the finished floor level. If the control panel height is small then it should be mounted on a separate support so that the operating height of the equipment comes within the above limit. The proper supporting arrangement shall be provided by the contractor. Cable entries to the panel may be from bottom or top. The cable entry required will be intimated to the successful bidder. A suitable removable gland plate of 3 mm thick shall be mounted not less than 200 mm above the floor level. All equipment mounted on the front face of the panels shall be flush or semi-flush type. All equipment shall be so located that their terminal and adjustment are readily accessible for inspection or maintenance and their removal and replacement can be done without interruption of service to other equipment. The contractor shall submit the panel general arrangement drawings clearly bringing out internal mounting details, dimensions of equipment, clearance between the equipment and the edges of the panel, for approval.
14.4.2
14.4.3
14.4.4 14.4.5
14.4.6
14.4.7
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14.5 Name Plates and Labels 14.5.1 Each panel shall be provided with prominent, engraved identification plates for all front mounted equipment. Panel identification name plate shall be provided at front and rear as required. All name plates shall be of non-rusting metal or 3 ply lamicold, with white engraved lettering on black background. Inscription and lettering sizes shall be subjected to employer's approval. Suitable plastic sticker labels shall be provided for easy identification of all equipment located inside the panel. These labels shall be positioned so as to be clearly visible and shall give the device number, as mentioned in the wiring drawings.
14.5.2
14.5.3
14.6 AC/DC Power Supply 14.6.1 The Employer will provide one feeder each for AC and DC to the panel. The Contractor shall make for his own arrangements for providing these power supplies to different panels. The Contractor shall provide suitable isolating switch fuse unit in the control panel for receiving the above incoming AC and DC supplies. Fuse and link shall be provided for isolating of individual circuit without disturbing other circuits.
14.6.2
14.7 Wiring 14.7.1 All inter panel wiring and connections between panels (if there is group of panels) including all bus wiring for AC & DC supplies shall be provided by the contractor. All internal wiring shall be carried out with 1100 V grade, single core, 1.5 square mm or larger stranded copper wires having colour-coded PVC insulation. CT circuits shall be wired with 2.5 square mm copper wires, otherwise similar to the above. Extra-flexible wire shall be used for wiring to devices mounted on moving parts such as doors. Spare contacts of auxiliary relays, timers and switches shall be wired out to the terminal blocks as required by the employer/engineer at the time of detailed engineering.
14.7.2
14.7.3 14.7.4
14.8. Terminal Blocks 14.8.1 Terminal Blocks shall be of 650V grade, rated for 10 Amps and in onepiece moulding. It shall be complete with insulating barriers, clip-ontype terminals, and identification strips. Marking on terminal strip shall correspond to the terminal numbering on wiring diagrams. It shall be similar to 'Elmex-Standard' type terminals. Terminal blocks shall be arranged with at least 100 mm clearance between two sets of terminal block. The terminal blocks shall have at least 20% spare terminals.
14.8.2 14.8.3
14.9 Grounding A continuous copper bus 25 x 3 mm size shall be provided along the bottom of the panel structure. It shall run continuously throughout the length of the panel and shall have provision at both ends for connection to the station grounding grid (25 x 6 mm MS Flat).
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14.10 Space Heater and Lighting 14.10.1 Space heaters shall be provided in the panels for preventing harmful moisture condensation. 14.10.2 The space heaters shall be suitable for continuous operation on 240V AC, 50 Hz, and single phase supply and shall be automatically controlled by thermostat. Necessary isolating switches and fuses shall also be provided. 14.10.3 Free standing panel shall have a 240V AC, plug point and a fluorescent light operated by door switch. 14.11 Control and Selector Switches 14.11.1 Control and selector switches shall be of rotary type, with escutcheon plates clearly marked to show the function and positions. 14.11.2 Control/selector switches shall be spring return or stay put type as per the requirements. Handles of control/selector switches shall be black in colour. Shape and type of handles shall be to the approval of the employer. 14.11.3 The contact ratings shall be at least the following: i) ii) iii) 14.12 Push Buttons 14.12.1 Push buttons shall be spring return, push to actuate type and rated to continuously carry and break 10A at 240V AC and 0.5A (Inductive) at 220V DC. The push buttons shall have at least 1 NO and 1 NC contact. All contact faces shall be of silver or silver alloy. 14.12.2 All push buttons shall be provided with integral escutcheon plates marked with its function. 14.12.3 The colour of buttons shall be as follows: Green: Red: Black: For motor START, Breaker CLOSE, Valve/ damper OPEN. For motor TRIP, Breaker OPEN, Valve/ damper CLOSE. Make and carry continuously: Breaking current at 240V DC: Breaking current at 240V DC: 10 Amp. 1Amp. (Inductive) 5 Amp. at 0.3 p.f. lagging
For all annunciation functions, overload reset and miscellaneous. 14.12.4 Red push buttons shall always be located to the left of green push buttons. In case of clinker grinder etc. the push buttons would be blackred-green from left to right. 14.13 Indicating Lamps 14.13.1 Indicating lamps shall be of the panel mounting, filament type and of low-watt consumption. Lamps shall be provided with series resistors preferably built-in-the lamps assembly. The lamps shall have escutcheon plates marked with its function, wherever necessary. 14.13.2 Lamp shall have translucent lamp covers of the following colours: Red Green
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White: Blue:
for motor AUTO-TRIP. for all healthy conditions (e.g. control supply, lub oil pressure and also for spring charged).
Amber: for all ALARM conditions (e.g. pressure low, over load and also for 'service' and 'Test' position indication). 14.13.3 Bulbs and lamps covers shall be easily replaceable from the front of the panel. 14.13.4 Indicating lamps should be located directly above the associated push button/control switches. Red lamps shall variably be located to the right of the green lamp. In case a white lamp is also provided, it shall be placed between the red and green lamps. Blue and amber lamps should normally be located above the red and green lamps. 14.14 Fuses 14.14.1 All fuses shall be of HRC cartridge plug-in-type and shall be of suitable rating, depending upon circuit requirements. 14.14.2 All fuses shall be mounted on fuse carriers, which shall be mounted on fuse bases. 14.15 Contactors 14.15.1 Contactors shall be of air break, electromagnetic type rated as per requirement. These shall be of utilization category AC 3 as per IS: 2959. 14.15.2 Operating coils of AC contactors shall be of 240V AC or 220V DC as required. AC contactors shall operate satisfactorily between 85% to 110% of the rated voltage. The contactor shall not drop out at 70% of the rated voltage. 14.15.3 DC contactors shall have a coil voltage of 220V DC and shall be suitable for satisfactory continuous operation at 80% to 110% of the rated voltage. 14.16 Relays and Timers 14.16.1 All auxiliary relays & timers shall be of proven design and of reputed make. Contacts of relays and timers shall be of solid silver or silver cadmium oxide or solid silver faced. Timers shall have the provision to adjust the delay on pick-up or reset as required. 14.16.2 All relays and timers shall have at least two NO and two NC contacts. 14.16.3 All relays and timers shall be suitable for 240V AC and 220V DC as required. DC relays shall operate satisfactorily between 70% to 110% and AC relays shall be suitable for voltage variation between 80% to 110%. 14.17 Indication Instruments 14.17.1 All indicating and integrating meters shall be flush mounted on panel front. The instruments shall be of at least 96 mm square size with 90 degree scales and shall have an accuracy class of 2.0 or better. The covers and cases of instruments and meters shall provide a dust and vermin proof construction.
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14.17.2 All instruments shall be compensated for temperature errors and factory calibrated to directly read the primary quantities. Means shall be provided for zero adjustment removing or dismantling the instruments. 14.17.3 All instruments shall have white dials with black numerals and lettering. Black knife edge pointer with parallax free dials will be preferred. 14.17.4 Ammeters provided on motor feeders shall have a compressed scale at the upper current region to cover the starting current. 14.18 Annunciation System 14.18.1 The annunciation system shall be complete with all necessary relays, flashers and other accessories required for the proper operation of the equipment and shall be completely solid state. The control circuit shall be mounted on plug-in type glass epoxy printed circuit boards. Audible alarms for the system shall be mounted inside the panel. One set of acknowledge, test and reset push buttons shall be mounted on the panel. 14.18.2 Indications shall be engraved on Acrylic inscription plate window and shall be visible clearly when the indication lamp is lighted (black letters on white background). Each window shall be provided with two lamps. 14.18.3 Audible horn shall sound when a trouble contact operates and shall continue to sound until the acknowledge button is pressed. 14.18.4 Indication lamps shall flash when trouble contact operates and shall continue flashing until acknowledge button is pressed. 14.18.5 After acknowledge button is pressed, the horn and flashing shall stop but the indication lamp shall remain lighted. 14.18.6 After trouble is cleared indication lamps shall be ready and shall go off only when reset. 14.18.7 Silencing the horn in conjunction with one trouble contact shall not stop and horn sounding if another trouble contact operates. 14.18.8 When test button is pressed, all lamps shall flash and horn shall sound. 14.18.9 Annunciator systems shall operate on 220V DC Systems. 14.18.10 The annunciation system shall include alarm for AC control system failure (working on DC supply), DC supply failure (working on AC supply) and test facilities for these alarms. 14.18.11 List of annunciations required on the panels has been listed elsewhere. The contractor shall also provide additional annunciations if desired by the employer/engineer during Vendor drawing review stage and for such additional annunciations no extra charges shall be claimed by the contractor, if the number of such additions are within 10% of the number stipulated in this specification. 14.18.12 20% spare windows shall be provided on the panel. 14.19 Painting 14.19.1 All sheet steel work shall be pre-treated, in tanks, in accordance with IS: 6005, degreasing shall be done by alkaline cleaning. Dust and scale shall be removed by pickling; the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline hot water and dried. The phosphate coating shall be "Class-C" as specified in IS: 6005. The phosphated surfaces shall be rinsed and passivated prior to
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application of stoved lead oxide primer coating. After primer application, two coats of finishing synthetic enamel paint on panels shall be applied. Electrostatic painting shall also be acceptable. Finishing paint on panels shall be shade 692 (smoke grey) of IS: 5 unless required otherwise by the Employer. The inside of the panels shall be glossy white. Each coat of finishing shall be properly stoved. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peelable compound by spraying method to protect the finished surface from scratches, grease, dirt and oily spots during testing, transportation handling and erection. 14.20 Tests 14.20.1 Following tests/inspection shall be carried out by the Contractor in the presence of Employer's representative: (A) Factory Tests 1. Compliance with approved drawings, data and specification. 2. Visual check for workmanship. 3. Wiring continuity and functional checks. 4. Calibration of instruments relays and meters wherever required by inspector. 5. HV test 6. Insulation resistance measurement before and after HV test. 7. Testing to observe compliance to degree of protection as per IS -2147 (latest). (B) Inspection/Testing at site: 1. IR test before and after HV test 2. HV Test 3. Functional Testing. (C) 1. The Fire detection and annunciation panel shall be tested as per BS: 3116 Part-IV. 2. The Annunciation System shall be routine tested.
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APPENDIX -I STANDARD PERFORMANCE GUARANTEE TEST PROCEDURE 1.0 SCOPE, PURPOSE AND CODES 1.1 Scope This test procedure shall cover the performance guarantee tests for all the subsystems covered in the subject package. 1.2 Purpose The purpose of this test procedure is to describe the criteria of acceptance test for the subsystems of fire protection system. 1.3 Codes The following codes and standards shall be applicable for conducting test unless otherwise modified or supplemented by the enclosed procedure and mutually agreed to, between the employer and the contractor. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 2.0 NFPA-13: NFPA-15: Standard for the installation of sprinkler system. Standard for water spray fixed system for the fire protection.
NFPA-12A: Standard for Halogen 1301 Fire Extinguishing System NFPA-72E: Standard on Automatic Fire Detectors. Fire Protection Manual by TAC (Latest Edition). NFPA-12: IS: 3034: IS: 2878: IS: 2171: IS: 940: Standard on Carbon dioxide extinguisher systems. Fire safety of industrial building: Electrical generating and distributing stations code of practice. CO2 (Carbon Dioxide) Type Extinguisher DCP (Dry Chemical Powder) type Pressurized Water Type
CONDITIONS OF TEST 2.1 Conduct of Test Test shall be conducted by accredited representatives of the contractor and the Employer. The contractor shall be given permission to inspect the entire system in advance and make it ready for the test. Contractor's representatives shall witness all phases of the test and record and data jointly with the Employer's representatives. 2.1.1 a) The responsibility for conducting the test rests with the contractor. b) Any instruments required for the PG test will be provided by the contractor. Calibration of test instruments shall be the responsibility of the contractor. c) Calibration of instruments to be used in the test shall be carried out at a Government approved test lab. Calibration of instruments should be carried out previous to, but not more than six months before the
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commencement of test. The calibration certificate of the instruments should be valid for the period of test. d) Replacement of fused/damage parts, i.e. quartzoid bulb, thermoelectric sprinkler and liner heat sensing cable etc., during the test shall be responsibility of contractor. 2.1.2 The design performance of the equipments/systems shall be demonstrated by the contractor after evaluating the acceptance test. Should the results of the test deviate from the design values, the contractor shall be given opportunity to modify the equipments as required to enable it to meet the acceptance criteria. In such cases the acceptance test shall be repeated for retest and the cost of modifications, including labor, materials and cost of additional testing shall be borne by the contractor. The chance for repeat testing will be given only once during the contract period. All hand appliances and their accessories as well as components of hydrant, sprinkler and other protective equipments shall be of a type and make, as per norms of Tariff Advisory Committee/IS. All operating parts of the systems shall be fully tested to arrive that they are in operating condition. The operating tests shall include the tests of automatic detection equipment. Provision shall be made for the disposal of water is surging from outlets to avoid property damage. Contractor should furnish a written statement to the effect that the work covered in this contract has been completed and all specified flushing of underground, above ground piping has been successfully completed together with specified hydrostatic pressure tests. All the erection/commissioning protocols in respect of hydro test of hydrant mains, spray lines, vibration/noise level, data of pumps, holiday test results of pipe coatings, IR/conductor resistance values of LHS cables, alarm/annunciation/control systems, batteries, pipe line flushing laying of pipelines as per approved drawings, compliance of all hand appliances and their accessories as well as all components of hydrant/sprinkler/spray/other protective equipments to TAC, BIS ; all other systems/equipments shall be made available before conducting the PG test. Sample checking of all the above mentioned items shall be carried out during PG test.
2.1.3
2.1.4 2.1.5 2.1.6 2.1.7
2.1.8
3.0
HYDRANT SYSTEM 3.1 a) Sequential auto start of the electric and diesel engine pumps shall be checked by opening the test hydrants. b) The minimum running pressure of 3.5 kg/sq. cm at the highest/farthest (hydraulically most remote hydrant point) shall be available with Hydrant pump running at full capacity and 2 hydrants open simultaneously. This test shall be repeated every month during guarantee period. c) Vibration and noise level measurements for the pumps at 100% and 150% duty points should be below the specified value indicated in the approved data sheets.
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d) Auto operation of jockey pump, for pressurizing of system shall be checked for eight hours and reading of actuating/cut of pressures shall be recorded. e) Control panel/annunciation panel shall be checked for operation i.e. proper functioning and audiovisual indicators. f) Battery and battery charger shall be checked for auto charging and providing sufficient power for three consecutive starting kicks to diesel engine within five minutes with A.C. supply switched off. g) The hydrant mains shall be hydraulically tested and shall be capable withstanding for 30 minutes a pressure equivalent to 150% of the design pressure or 200% of maximum operating pressure, whichever is higher. In case this test have been conducted before commissioning, such test is not mandatory and shall be verified. h) All the hydrant valves, isolating valves and values of monitors shall be operated repeatedly for smooth operation and there shall be no leakage. i) For diesel engine test shall be carried out for two (2) hours out of which half hour at full load and on 10% overload for half hour. Performance of diesel engine shall be observed at the end of the above test. Following readings shall be taken after every half an hour and shall be compared with the specified values indicated in the approved data sheet. i) ii) iii) iv) v) Exhaust temp (with engine mounted calibrated temp. gauge). Closed circuit water temp. (With engine mounted calibrated temp. gauge). Lubricating oil pressure (with engine mounted calibrated temp. gauge). Lubricated oil pressure (with engine mounted calibrated pressure gauge). Speed (with digital non-contract RPM meter/techno-meter). Efficiency of combustion shall be verified from the colour of the exhaust. The colour of exhaust shall be haze clear and not black. Vibration and noise level measurement shall also be taken at full load and at overload run test. It shall be below the specified value indicated in approved data sheet.
3.2
HVW Spray Systems 1) Spray system shall be hydraulically tested and shall be capable of withstanding thirty minutes, a pressure equivalent to 150% of the design pressure. It the test has been done, protocols to be verified for its successful performance and accordingly it need not be repeated. 2) Full flow tests with water shall be done for the system piping as a means of checking the nozzle layout, discharge pattern and coverage, any obstructions and determination of relation between design criteria and actual performance, also to ensure against clogging of the smaller piping and the discharge devices by foreign matter carried by the water. 3) Rigidity of pipe supports shall also be checked during the water flow. 4) The maximum number of systems that may be expected to operate in case of fire shall be in full operation simultaneously in order to check the adequacy and condition of the water supply.
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5) The discharge pressure at the highest and most remote nozzle shall be at least 3.5 bars for which the system was designed. 6) Operation of deluge valve shall be checked by actuating detection system or opening the drain valve of deluge valves. 7) Resetting of deluge valve shall also be checked. 3.3 Sprinkler System Performance test of sprinkler system shall be done basically to test: 1) The adequacy of coverage and discharge of sprinkler in the hydraulically remote areas. The tests shall be conducted as per IS: 9972. 2) Automatic actuation of alarm valve due to opening of sprinklers. 3) Automatic operation of sprinkler pump. 4) Rigidity of pipe supports during the water flow. 5) Measurement of discharge pressure at most remote sprinkler by putting a pressure gauge. 6) Test certificate shall be submitted for quartzite bulb to check the bursting temperature. In case of certificate is not produced, the following method should be followed to check the bursting temperature of quartzoid bulb. "The fusible element sprinklers of glass bulbs for test shall be heated from ambient temperature to a temperature 20oC below their normal bursting temperature at a rate not exceeding 20oC per minute. The temperature is then to be held at 20oC +/- 2% below the normal rating for 10 minutes. The heating shall continue at a uniform rate of 0.4 to 0.7oC per minute until the sprinklers or bulb operates. The temperature at which the sprinklers or glass bulbs operate shall be noted with an accuracy of +/- 1.5%. The tests shall be carried out in portable water for rating up to and including 79oC and for higher rating in refined groundout oil". 7) I case of cable galleries, operation of alarm valve and thermoelectric sprinklers shall be checked by the actuation of the detection system. The actuation can be through a combination of ionisation and photoelectric type smoke detector or LHS cable or manually from control panel. 3.4 Fire Alarm System The entire installation shall be tested to ensure that it operates satisfactorily and that: 1) All detector and manual call points function properly. 2) The control and indicating equipment correctly registers and indicates the state of the installation. 3) All auxiliary equipment functions properly. 4) A restorable heat detector shall be tested with heat source, such as a hair dryer or shielded heat lamp, until it responds. After each heat test, the detector shall be reset. 5) The percent of all non-restorable detectors i.e. heat detector, QB and thermoelectric sprinkler shall be operated. These detectors shall be replaced by the contractor at his own cost.
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6) Smoke detector shall be tested with rapid developing fire source emitting visible or invisible smoke particles. Fire of this type included smoldering and fast burning fires of wood, paper, rubber, natural and synthetic fabrics, plastic and common liquid hydrocarbons. After each test smoky atmosphere near the detector should be cleared so that the detector shall reset. 3.5 Linear Heat Sensing Cable Type Heat Detection System 1) Conductor resistances and insulation resistances values of all LHS cables shall be measured. 2) A portion of a cable shall be heated by burning coal/blow lamp till the time it gets short. Check all the indications, alarms and actuating signals are in operation. 3) Location of LHS cable may be checked physically w.r.t. 3.6 Portable Fire Extinguishers a) All portable fire extinguishers of same type, shape, design and capacity produced by the same manufacturer from similar materials shall be grouped together to constitute a lot. b) Each lot shall be considered individually for the purpose of evaluation of quality. c) One number of sample, for testing, to be taken at random from a lot. c) The samples tested shall pass the tests, indicated in the relevant IS code, for the lot to be declared to conform the performance test requirements.
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AIR CONDITIONING SYSTEM
(AC)
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CHAPTER-AC SECTION: AIR CONDITIONING SYSTEM CONTENTS
Clause No. 1.0 2.0 3.0
Description General Scope Specification for Split AC Units
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CHAPTER AC SECTION: AIR CONDITIONING SYSTEM

1.0 GENERAL 1.1 This specification covers supply, installation, testing and commissioning and handing over to Department of Power of Air conditioning system for the control room building. Air conditioning units for control room building shall be set to maintain the following inside conditions. DBT 24.4 o C 2oC 1.2 The following rooms shall be air conditioned. i) ii) iv) v) 1.3 Control room. Conference room. Resident Engineers room. Battery room.
Air conditioning requirement of rooms indicated at Clause No. 1.2 shall be met using split AC units. High wall type split AC units of 2TR capacity each with high wall type indoor evaporator unit shall be used for all rooms.
2.0
Scope The scope of the equipment to be furnished and services to be provided under the contract are outlined hereinafter and the same is to be read in conjunction with the provision contained in other sections/clauses. The scope of the work under the contract shall be deemed to include all such items, which although are not specifically mentioned in the bid documents and/or in bidder's proposal, but are required to make the equipment/system complete for its safe, efficient, reliable and trouble free operation. 2.1 Five (5) Nos. of high wall type split AC units of 2TR capacity each complete with air cooled outdoor condensing unit having hermetically sealed compressor and high wall type indoor evaporator unit with cordless remote controller. Copper refrigerant piping complete with insulation between the indoor and remote outdoor condensers as required. PVC drain piping from the indoor units upto the nearest drain point. Power and control cabling between the indoor unit and outdoor unit and earthing. MS Brackets for outdoor condensing units, condensers as required.
2.2
2.3 2.4 2.5 3.0
Specification for Split AC units. 3.1 3.2 The split AC units will be complete with indoor evaporator unit, outdoor condensing units and cordless remote control units. Outdoor unit shall comprise of hermetically sealed reciprocating/rotary compressors mounted on vibration isolators, propeller type axial flow fans and copper tube aluminium finned coils all assembled in a sheet metal casing. The casing and the total unit shall be properly treated and shall be weatherproof type. They shall be compact in size and shall have horizontal discharge of air.
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3.3
The indoor units shall be high wall type. The indoor unit shall be compact and shall have elegant appearance. They shall have low noise centrifugal blowers driven by special motors and copper tube aluminium finned cooling coils. Removable and washable polypropylene filters shall be provided. They shall be complete with multi function cordless remote control unit with special features like programmable timer, sleep mode and soft dry mode etc. The Split AC units shall be of Carrier, Voltas, Blue Star, Hitachi, Daikin, LG, National, O General or Samsung make.
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STANDARD TECHNICAL SPECIFICATIONS SECTION-I GENERAL TECHNICAL SPECIFICATIONS 1.0 1.1 1.1.1 General Information and Scope Scope This Specification covers Designing, Manufacturing, fabrication, galvanizing and supplying of all type of 132 KV Single Circuit transmission line towers including bolts, nuts and washers, hanger, D-shackle and all type of tower accessories like phase plate, number plate, danger plate, bird guard, anticlimbing device etc., selecting type of foundation for different tower types and casting of foundation for tower footing, submission of design and drawings for towers, tower parts, foundations of various types of towers and erection of towers, tack welding of bolts and nuts including supply and application of zinc rich primer and two coats of enamel paint, tower ear thing, fixing of insulator string, stringing of conductors and earth wires along with all necessary line accessories and testing and commissioning of the erected transmission lines. Other items not specified above but required as per Bid Price Sheet (BPS). The contractor should submit foundation drawing, structural drawing, soft copies of all relevant drawings, bill of materials etc. to the DEPARTMENT OF POWER for approval within one month of the award of work. The scope of this specification also provides for development of Bolts and Nuts statement, Section wise steel requirement chart, fabrication & proto-assembly of towers and its inspection.
1.1.1.1
1.1.1.2 a) The provisional quantities of fabricated and galvanized steel, bolts and nuts as per specifications required for tower, concrete, excavation volume and reinforcement steel for foundation and other items are given in the schedule of BPS. However, the work shall be executed as per approved construction drawings. b) The various item of work is described very briefly in the schedule of quantities of bid proposal sheet (BPS). The various items of the schedule of quantities shall be read in conjuction with the corresponding sections in the technical specifications including amendments and, additions if any. The contractors rates shall be based on the description of activities in the schedule of BPS as well as necessary operations detailed in these Technical Specifications. c) The unit rates quoted shall include minor details which are obviously and fairly indented and which may not have been included these documents but are essential for the satisfactory completion of the various works. The unit rates quoted shall be inclusive of deployment of all plant equipment, men, material, skilled and unskilled labours etc. essential for satisfactory completion of various works. All measurements for payment shall be in S.I units. Lengths shall be measured in meters corrected to two decimal places. Areas shall be completed in sq. meters, volume in cubic meters and weight in kG and rounded of to two decimals. Provisional steel requirement of towers for the contract shall be furnished to successful Contractor at the time of placement of award as per the BPS. However, there may be variation in the steel requirement because of modification/change in tower requirement during execution otherwise.
Section-Technical Specifications
d)
e)
1.1.1.3
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1.1.1.4
The Contractor shall submit his offer taking into consideration that the tower and foundation shall be designed/developed and provided by the contractor for approval by the Department and approved design rights will be strictly reserved with the DEPARTMENT OF POWER. Further, the Contractor shall quote the unit rate for these items as per their units mentioned in the schedule of BPS for the contract. However, payment shall be made on per tower/foundation basis on completion of supply/erection as applicable. This Specification also includes the Designing, Manufacturing and supplying of hardware fitting for insulator string, earth wire and all type of accessories for conductor and earth wire as detailed in the specification. Contractor shall clearly indicate in their offer, the source from where they propose to procure these materials. The Technical description of these items is given in Section II & III of this section. All the raw materials such as steel, zinc for galvanizing, reinforcement steel and cement for tower foundation, coke and salt for tower earthing etc. bolts, nuts, washers D-shackles, hangers, links, danger plates, phase plate, number plate, bird guard, anti-climbing device etc. required for tower manufacture and erection shall be included in the Contractors scope of supply. Contractor shall clearly indicate in the offer, the sources from where he proposes to procure the raw materials and the components. The entire stringing work of conductor and earth wire shall be carried out by standard string technique. The Contractor having requisite experience has freedom to use Helicopter for stringing. The Contractor intending to use Helicopter shall furnish detail description of the procedure, type & number of Helicopter accessories etc. be deployed for stringing operation. Details of Transmission Line Routes and Terrain The above Single circuit line shall be laid in difficult hilly terrain mostly of Unclassified State Forest (USF) area and agricultural land of Tawang and West Kameng Districts of Arunachal Pradesh. It shall start from the existing 132 kV bay of NEEPCO Extension at Khuppi and shall terminate at the proposed 132/33 kV Sub-Station at Tawang via proposed 132/33 kV Sub-Station at Bomdila. Detailed surveys/Check survey of the line shall be carried out by the successful bidder and put up to the owner/department for approval of deviation whenever required. The details collected through surveys for the lines viz route, crossings, accessibility infrastructure details, and the location of all obligatory points shall be identified and submitted by the successful bidder to the Department of Power. The Contractors are advised to visit the proposed/likely routes of the lines to acquaint themselves about the topography of the line routes and other details before submitting the Bid. However for reference to the bidder a site sketches/Line route may be provided on request. Access to the Line and Right of Way Right of way and way leave clearance shall be arranged by the Department in accordance with work schedule. The Department will secure way leave and Right of way in the forest area.
1.1.2
1.1.3
1.1.4
1.2 1.2.1
1.2.2
1.2.3
1.3
1.4
Detailed Survey, Optimization of Tower Location

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1.4.1
The successful Bidder shall be provided with one set of the detailed survey report and route profile drawing for execution of the project. However, in addition to check survey; under certain circumstances, detailed survey for some stretches or locations including profiling and tower spotting may have to be carried out by the Contractor. The Provisional quantity for detailed survey, including profiling, tower optimization and spotting, shall be carried out by the successful bidder as stipulated herein. The contractor shall submit the proposal for detailed survey based on the shortest route alignment. The contractor shall finalize and submit results of detailed survey including any changes suggested within three (3) months from the date commencement of work at site. The soil investigation for the obligatory point are to be carried out by the contractor and report to be submitted within one month from the date of approval of profile. The bidder should note that the DEPARTMENT OF POWER will not furnish the topographical map prepared by Survey of India but will make available any assistance that may be required in obtaining the topographical maps. The detailed survey shall be made along the approved alignment. Soil resistivity, along the route alignment, shall be measured dry weather by four electrode method keeping inter-electrode spacing of 50 meters. For calculating soil resistivity, formula 2Plar (where a = 50meters, r = megger reading in ohms and Pl = 3.14) shall be adopted. Measurement shall be made at every 2 to 3 kms along the route of transmission lines, in case soil characteristics change within 2 to 3 kms the value shall also have to be measured at in intermediate locations. The megger reading and soil characteristics shall be indicated in the soil resistivity results. General Climatic Conditions Climatic conditions shall be of tropical nature having summer period for 8 months and winter period for 4 months in a year. Working season shall be approximately 6-8 months/year and balance four to six months shall be monsoon period. The maximum temperature during summer shall be of the order of 35 degree C and the minimum temperature in the winter shall be of the order of -10 degree C. Normal everyday temperature shall somewhere between 18 to 22 degree C.
1.4.2
1.4.3
1.4.4 1.4.5
1.5
1.6
Technical Data Contractors shall furnish all technical data as per relevant schedules in all copies of the Bid.
1.7 1.7.1
Statutory Regulations and Standards The Contractor is required to follow local statutory regulations along with The Electricity Act, 2003 as amended up to date and other local rules and regulations referred in this specifications. Reference Standards The codes and/or standards referred to in the specifications shall govern, in all cases wherever such references are made. In case of a conflict between such codes and/or standards and the specifications, latter shall govern. Such codes and/or standards, referred to shall mean the latest revisions, amendments/ changes adopted and published the relevant agencies unless otherwise indicated.
1.7.2 1.7.2.1
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1.7.2.2 1.8 1.8.1
Other internationally acceptable standards which ensure equal or better performance than those specified shall also be accepted. Quality Assurance, Inspection and Testing Quality Assurance To ensure that the supply and services under the scope of this Contract whether manufactured or performed within the Contractors works or his SubContractors premises or at Site or at any other place of work are in accordance with the specifications, the Contractor shall adopt suitable quality assurance programme to control such activities at all points necessary. Such programme shall be submitted by the Contractor in the bid. A quality assurance programme of the Contractor shall generally cover but not limited to the following: (a) (b) (c) (d) His organization structure for the management and implementation of the proposed quality assurance programme. Documentation control system. Qualification data for Contractors key personnel; The procedure for purchases of materials, part/components and selection of sub-Contractors services including vendor analysis, source inspection, incoming raw material inspection, verification of material purchases etc. System for shop manufacturing including process controls and fabrication and assembly controls. Control of non-conforming items and system for corrective action. Control of calibration and testing of measuring and testing equipments. Inspection and test procedure for manufacture. System for indication and appraisal of inspection status. System for quality audits. System for authorizing release of manufactured product to the Department. System for maintenance of records.
(e) (f) (g) (h) (i) (j) (k) (l)
(m) System for handling storage and delivery and (n) A quality plan detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of supply.
The Quality Plan excluding Standard Quality checks and assessment shall be mutually discussed and approved by the Department after incorporating necessary corrections by the Contractor as may be required. 1.8.2 1.8.2.1 1.8.3 1.8.3.1 Field Quality Plan All field activities shall be carried out in accordance with a prevailing norm of recognized institute. Quality Assurance Documents The Contractor shall be required to submit all the Quality Assurance Documents as stipulated in the Quality Plan at the time of the Departments inspection of material. The Department, through his duly authorized representatives, reserves the right to carry out Quality Audit and Quality Surveillance of the systems and
1.8.3.2
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procedures of the Contractors/his sub Contractors Quality Management and Control Activities. 1.9.0 Inspection, Testing and Inspection Certificates The provisions of the clause regarding Inspection, Testing and Inspection Certificates as described in General Contract Conditions (GCC) & Special Contract Conditions (SCC) shall be applicable to the supply and erection portion of the Works. The Department shall have the right to re-inspect at his expenses any material though previously inspected and approved by him at the Contractors works, before and after the same are erected at Site. If following the latter, material is found defective, than the Contractor shall bear the cost of this inspection and reinstated according to specifications. 1.10 Technical Parameters for 132 KV Lines Electrical System Data (a) Nominal voltage (b) Maximum system voltage (c) BIL (Impulse) 132 KV 145 KV 650 KV(Peak)
(d) Power frequency withstand voltage (wet) 275KV (rms) (e) Switching surge withstand voltage (Wet) 1050 KV (Peak) 2.0 2.1 Sl. No 1. Type Details of Line Materials Particulars of Conductor Particulars Conductor ACSR PANTHER Earth-wire Galvanised
Steel Earthwire
2.
Stranding and wire diameter (a) Aluminum (b) Steel Total sectional area Approximate overall diameter Approximate mass Calculated DC resistance At 20 deg C (max) Minimum ultimate Tensile Strength Modulus of elasticity Co-efficient of linear Expansion Mass of zinc coating Configuration of conductor sq mm mm Kg/Km Ohm/Km KGF Kg/sq mm
30/3.00 7/3.00 261.64 21 976 0.140 9127 8158
7/3.15 54.57 9.45 428 2.95 5710 193.3 0.0000115 275
3. 4. 5. 6. 7. 8. 9. 10. 11.
per deg Cen. 0.0000178 gm/sq m 260
(Ref. drawing enclosed)
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12.
Location of Earth-wire
one continuous earth wires to run Horizontal ly above the conductors
2.2
Particulars of Insulator Strings with disc Insulator

PARTICULARS SINGLE SUSPENSION STRING DOUBLE TENSION STRING SINGLE TENSION STRING
*This is subject to change to Polymer Composite Insulators during contract agreement.

Sl. No.
1. 2 3 4 5 6.
No of standard Insulator discs* Size of disc mm E&M strength of each Insulator disc KN Pollution Size and designation of pin ball shank mm Cree-page distance of each disc mm
1x10 255x145 90
2x10 255x145 90
1x10 255x145 90
Lightly polluted as per IEC publication 16 292 16 292 16 292
2.3
Insulator String Hardware a) b) c) d) e) f) g) h) i) j) Anchor Shackle Chain Link Ball clevis Arcing horn holding plate Yoke plate Socket horns Arcing horns Clevis Eye Free centre type/Armour grip suspension clamp for suspension strings Compression type dead end clamp
2.4
Accessories for conductor & Earth-wire a) b) c) d) e) f) g) Mid span compression joint Repair sleeves Flexible copper bonds Vibration dampers for conductor Vibration dampers for earth-wire Suspension clamp for earth-wire Tension clamp for earth-wire.
3. 3.1 3.1.1
Transmission Towers General Description of Tower The towers are of the A, B, C, D, CL & DL.
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3.1.2
The towers are of Single Circuit, self supporting lattice steel type, designed to carry the conductors with necessary insulators, earth-wires and all fittings under all loading conditions. The tower shall be fully galvanized using mild steel sections as specified. Bolts and nuts with spring washers are to the used for connection. Conductor and Earth-wire Configuration For single circuit towers type A, B C, D, CL & DL, the three phases shall be in Triangular formation (L shape). The Earth-wire shall run continuously above the phase wires.
3.1.3 3.2
3.3 3.3.1
Type of Towers The towers are classified as given below for 132 KV Transmission Lines. Deviation Limit 0 deg-2 deg. 2 deg-15 deg Typical Use a) To be used as tangent tower. a) Angle tower with tension insulator string. b) Also to be used for uplift forces resulting from an uplift span of 200 mts. under broken wire conditions. c) Also to be used for ant-cascading condition. d) To be used as section tower. C 15 deg -30deg a) Angle tower with tension insulator string. b) Also to be used for uplift forces resulting for an uplift span of 200 mts. under broken wire conditions. D 30 deg-45 deg a) Angle tower with tension insulator string. b) Also to be used for uplift forces resulting from an uplift span of 300 mts. under broken wire conditions. c) Complete dead end. DL 45 deg-60 deg a) Angle tower with tension insulator string. b) To be used for long Valley Crossings.
Type of Tower
A.
B.
3.3.2 Extensions 3.3.2.1 The towers are designed so as to be suitable for adding 3 M, 6M and 9M body extensions and unequal leg extensions for maintaining adequate ground clearances without reducing the specified factor of safety in any manner. Further provision of 15 M/25 M body Extension to tower type A and D is kept
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for power line crossing or any other obstacle, tower type A or D shall be used in with 15 M/25 M body extension depending upon the merit of the prevailing site conditions. 3.3.2.2 3.4 3.4.1 All above extension provision to normal towers shall be treated as part of normal tower only. Spans and Clearances Normal Span The normal ruling span of the line is 300 meters. However, the tension towers with reduced angle of deviation shall be used for longer spans and long valley crossings. 3.4.2 Wind Span The wind span is the sum of the two half spans adjacent to the support under consideration. For normal horizontal spans this equals to (300m) normal ruling span. 3.4.3 Weight Span The weight span is the horizontal distance between the lowest point of the conductors on the two spans adjacent to the tower. 3.4.4 In case at certain locations where actual spotting spans exceed the design spans and cross-arms and certain numbers of towers are required to be modified/reinforced, the modified/reinforced tower shall have factor of safety not less than of tested tower for the increased loadings. The price payable for additional weights on account of such modification/reinforcement shall be as per the unit price of normal towers in the Letter of Award. The tower with some modified members will be treated as part of normal towers only. Electrical Clearances Ground Clearance The min. ground clearance from the bottom conductor shall not be less than 6100 mm at the max. sag conditions (at 75 degree C and still air) for attitudes below 1000 mtrs. For altitudes of more than 1000 mtrs., the ground clearances shall be suitably increased as per IS-5613. a) An allowance of 150 mm shall be provided to account for errors in stringing. b) Conductor creep shall be compensated by over tensioning the conductor at a temperature of 26 degree C, lower than the stringing temperature for ACSR Panther. 3.4.5.2 3.4.5.2.1 Design and Drawings The relevant Design and drawings for all towers and their extensions shall be furnished to the Department for approval which shall include structural/erection drawings shop fabrication drawings, Bill of Materials, foundation working drawings etc. The structural/erection drawings, bills of materials and shop fabrication drawings for all the towers and their extensions shall be submitted for approval by the Contractor in two copies. The revised/corrected drawing/documents shall be submitted in four copies and will be finally approved by the Department. The tower members can be directly fabricated from the approved shop drawings. However, before taking up the mass
3.4.5 3.4.5.1
3.4.5.2.2
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fabrication, the contractor shall arrange for one number proto-assembly for each type of towers and extensions which shall be inspected by the Department. After successful proto-assembly inspection, the mass fabrication shall be taken up. The overall responsibility of fabrication tower members correctly lies with the Contractor only and the Contractor shall ensure that all the tower members can be fitted, while erecting without any undue strain on them. 3.4.5.2.3 Other than the drawings indicated above, some other drawings including shop drawings, if any, required for strengthening of towers, proper and effective execution of the project may also be required to be developed by the Contractor. However, no extra cost for the same shall be payable to the Contractor. The drawings submitted by the Contractor shall be approved/commented by the Department as the case may be within thirty (30) days of receipt of drawings in the Departments design office. If the designs/drawings are commented by the Department, the Contractor shall submit revised design/drawings duly incorporating all comments within fifteen (15) days of the date of issue of comments. The Bolts and Nuts statements, section wise Steel Requirement Sheet, the tower accessories drawings like name plate, danger plate, phase plate, number plate, anti-climbing device, step bolt, D-Shackle etc shall be prepared by the Contractor and submitted to the Department in three copies along with one reproduce-able for record. These drawings shall be prepared in A4 size only. All the drawings shall have a proper name plate clearly displaying the name and logo of the DEPARTMENT on right hand bottom corner. The exact format of the name plate shall be handed over to the successful Contractor for incorporation of the same on all the drawings. Also all the drawings shall carry the following statement and shall be displayed conspicuously on the drawing. WARNING: THIS IS PROPRIETORY ITEM AND DESIGN RIGHT IS STRICTLY RESERVED WITH THE DEPARTMENT. UNDER NO CIRCUMSTANCES THIS DRAWING SHALL BE USED BY ANYBODY WITHOUT PRIOR PERMISSION FROM THE DEPARTMENT IN WRITING. 3.4.5.2.7 While submitting the structural drawings, bill of materials (BOM) and any other drawings pertaining to the subject transmission line, the Contractor shall clearly indicate on each drawing, THE DEPARTMENT, Specification number, Name of the transmission line are made. The same practice is also to be followed while submitting distribution copies. The Contractor shall furnish the following in fifteen (15) copies to the Department for necessary distribution within fifteen (15) days after the receipt of the approval from the Department. a) Detailed working drawing for foundations. b) Detailed structural drawings indicating section size, length of members, sizes of plate along with hole to hole distance, joint details etc. c) Bill of materials, indicating cutting and bending detail against each member. d) Shop drawings showing all details relevant to fabrication. e) All the drawings for the tower accessories. f) One copy of reproducible for all drawings and BOM as above.
Part-III (Vol. 2/2) Section-Technical Specifications
3.4.5.2.4
3.4.5.2.5
3.4.5.2.6
3.4.5.2.8
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3.4.5.2.9
The Contractor is required to furnish the progress of submission and approvals of drawings on fifth day of every month till the completion of all the Design/Engineering activities. The details shall include description of drawing, schedule date of submission, actual date of submission schedule date of approval, actual date of submission of distribution copies and Remarks column. Provision of six additional columns shall be made in the above progress report to indicate date of comments issued the Department and details of submission of revised drawings. Materials Tower Steel Sections MS (Mild Steel) sections of tested quality in conformity with IS: 2062-1980 are used in design of towers, extensions and stub setting templates. The Contractor can use other equivalent grade of structural steel angle sections and plates conforming to latest International Standards. Steel plates below 6 mm size exclusively used for packing plates/packing washers produced as per IS: 1079-1994 (Grade-0) are also acceptable. However, if below 6mm size plates are used as load bearing plates viz. gusset plates, joint splices etc. the same shall conform to IS: 2062 or equivalent standard meeting mechanical strength/metallurgical properties corresponding to Fe 410 or above grade, depending upon the type of grade incorporated into design. The checkered plates shall conform to IS: 3502-1994. This list of Mild Steel Sections for this contract is as follows: 45x30x4 45x30x5 45x45x4 45x45x5 50x50x4 55x55x4 55x55x5 60x60x4 60x60x5 65x65x4 65x65x5 65x65x6 70x70x5 75x75x5 75x75x6 80x80x6 90x90x6 90x90x7 90x90x8 100x100x6 100x100x7 100x100x8 100x100x10 110x110x8 110x110x10 130x130x10 130x130x12
3.4.5.3.0
3.5 3.5.1
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3.5.2
For designing of towers, preferably rationalized steel section has been used. During execution of the project, if any particular section is not available, the same shall be substituted by higher section at no extra cost to the Department and the same shall be borne by the Contractor. However, design approval for such substitution shall be obtained from the Department before any substitution. Fasteners: Bolts, Nuts and Washers All bolts and nuts shall conform to IS: 6639-1972. All bolts and nuts shall be galvanized as per IS:1367(Part-13)/IS:2629 and shall have hexagonal head and nuts, the heads being forged out of the solid, truly concentric, and square with the shank, which must be perfectly straight. The bolt shall of 16mm. dia/24mm dia and of property class 5.6 as specified in IS: 1367(Part-III)-1979 and matching nut of property class 5.0 as specified in IS: 1367 (Part.VI)-1980. Bolts up to M16 and having length up to 10 times the diameter of the bolt should be manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. The shear strength of bolts for 5.6 grades should be 310 MPa minimum as per IS: 12427. Bolts should be provided with washer face in accordance with IS: 1363(Part-I) to ensure proper bearing. Nuts should be double chamfered as per the requirement of IS: 1363 Part-III, 1984. It should be ensured by the manufacturer that nuts should not be overlapped beyond 0.4MM oversize on effective diameter for size upto M16. Fully threaded bolts shall not be used. The length of bolts shall be such that the threaded portion will not extend into the place of contact of the members. All bolts shall be threaded to take the full depth of the nuts and threaded for enough to permit firm gripping of the members, but not further. It shall be ensured that the threaded portion of each bolt protrudes not less than 3mm and not more than 8mm when fully tightened. All nuts shall fit tight to the point where the shank of the bolt connects to the head. Flat and tapered washers shall be provided wherever necessary. Spring washers shall be provided for insertion under all nuts. These washers shall be of steel electro galvanized, positive lock type and 3.5mm in thickness for 16mm dia bolt and 4.5mm for 24mm bolt. The Contractor shall furnished bolt schedules giving thickness of members connected, the washer and the length of shank and the threaded portion of bolts and sizes of holes and any other special details of this nature. To obviate bending stress in bolts or to reduce to minimum, no bolt shall connect aggregate thickness of more than three (3) times its diameter. Bolt positions in assembled towers shall be as per IS: 5613 (Part-II-Section2)-1976. Bolts at the joints shall be so staggered that nuts may be tightened with spanners without fouling. To ensure effective in-process Quality Control it is essential that the manufacturer should have all the testing facilities for tests like weight of zinc coating, shear strength, other testing facilities etc. in-house. The manufacturer should also have proper Quality Assurance System which should be in line
3.5.3 3.5.3.1
3.5.3.2
3.5.3.3
3.5.3.4
3.5.3.5 3.5.3.6
3.5.3.7
3.5.3.8
3.5.3.9 3.5.3.10 3.5.3.11 3.5.3.12
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with the requirement of this specification and IS: 14000 series Quality System standard. 3.6 3.6.1 Tower Accessories Step Bolts & ladders Each tower shall be provided with step bolts conforming to IS: 10238 of not less than 16mm diameter and 175 mm long, spaced not more than 450mm apart and extending from about 3.5 metres above the ground level to the top of the tower. For single circuit tower the step bolt shall be fixed on one leg from 3.5m above ground upto top of the towers. Each step bolt shall be provided with two nuts on one end to fasten the bolt securely to the tower and button, head at the other end to prevent the feet from slipping away. The step bolts shall be capable of withstanding a vertical load not less than 1.5KN. For special structures, where the height of the super structure exceeds 50 meters, ladders along with protection rings as per the Department approved design shall be provided in continuation of the step bolts on one face of the tower from 30meters above ground level to the top of the special structure. From 3.5m to 30m height of super structure step bolts shall be provided. Suitable platform using 6mm thick perforated checkered plates along with suitable railing for access from step bolts to the ladder and from the ladder to each cross-arm tip and the ground wire support shall also to be provided. The platform shall be fixed on tower by using Counter-sunk bolts. 3.6.2 Insulator Strings and Earth wire Clamps Attachments a) I shaped suspension insulator string assemblies wherever required are to be supplied by the Contractor for which detail drawing shall be submitted by the contractor for the Departments approval shall be used for suspension towers. Each string shall be connected to the tower by a suitable strain plate of sufficient thickness for transferring load to the tower body. The supply of strain plate & D shackles etc. are also in the scope of the Contractor. b) Tension insulator string assemblies to be supplied by the contractor for which detail drawing shall be submitted by the contractor for the Departments approval (insulators to be supplied by the Department) shall be used for tension tower, the drawing of which is enclosed with specification. At tension towers strain plates of suitable dimensions under each cross-arm tip, shall be provided for taking the hooks of D-Shackle of the tension insulator strings. Full details of the attachments shall be provided to the successful Contractor. To achieve requisite clearances, if the design calls for providing extra D-shackle, link plate etc. before collecting the insulator string, the same shall be supplied by the contractor. 3.7.0 a) Earthwire Clamps Suspension Clamp Earthwire suspension clamps will be supplied by the Contractor, for which drawing shall be submitted by the contractor for the Departments approval. The Contractor shall also supply U-bolts/D-shackles, wherever required. b) Tension Clamps The Contractor shall supply earth wire tension clamps, for incorporation on the tower. Earth wire peak of tension towers shall be provided with suitable plates to accommodate the shackle of tension clamps. The Contractor shall
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also supply U-bolts wherever required and take the Departments approval for details of the attachment before the mass fabrication. 3.7.1 Anti-climbing Device Anti-climbing device, as per enclosed drawing shall be provided and installed by the Contractor for all towers. The height of the anti-climbing device shall be provided approximately 3m above ground level, and as per the drawing to be provided to the successful Contractor. 3.7.2 Danger, Number and Phase Plate Danger Plates, Number plates, circuit plates (for Single Circuit line only) and Phase Plates shall be provided and installed by the Contractor: a) Each tower shall be fitted with a number plate and danger plate. Each tension tower shall be provided with two sets of phase plates also. The arrangement for fixing these accessories shall not be more than 4.5m above the ground level. b) The letters, figures and the conventional skull and bones of danger plates shall conform to IS: 2552-1963 and shall be in a signal red on the front of the plate. c) The corners of the number and danger plate shall be rounded off to remove sharp edges. 3.7.3 Bird Guard To prevent birds perching immediately above the suspension insulator strings and fouling the same with droppings. Suitable Bird guards shall be provided as per IS: 5613 at cross-arms tips of all suspension towers. The bird guard arrangement shall be such that it shall either prevent bird from perching in position where they are liable the cause the damages or ensure that if birds do the perch, droppings will fall clear of the insulator string. 3.8 Tower Fabrication The fabrication of towers shall be in conformity with the following: 3.8.1 3.8.2 Except where hereinafter modified, details of fabrication shall conform to IS:802 (Part-II) 1978 or the relevant international standards. For splicing of members butt splices shall be used and the inside Angle and outside plate shall be designed to transmit the load and inside cleat Angle shall not be less than half the thickness of the heavier member connected plus 2mm. Lap splice may be used for connecting members of unequal size and the inside angle of lap splice shall be rounded at the heel to fit the fillet of the outside angle. All splices shall develop full stress in the member connected through bolts. Butt as well as lap splice shall be made as above and as close to the main panel point as possible. Joints shall be so designed as to avoid eccentricity as far as possible. The use of gusset plates for joining tower members shall be avoided as far as possible. However, where the connections are such that the elimination of the gusset plates would result in eccentric joints, gussets plates and spacer plates may be used in conformity with modern practices. The thickness of the gusset plates, required to transmit stress shall not be less than that of members connected. The use of filler in connection shall be avoided as far as possible. The diagonal web members in tension may be connected entirely to the gusset
3.8.3
3.8.4
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plate wherever necessary to avoid the use of filler and it shall be connected at the point of intersection by one or more bolts. 3.8.5 3.8.6 3.8.7 3.8.8 The tower structures shall be accurately fabricated to connect together easily at site without any undue strain on the bolts. No angle member shall have the two leg flanges brought together by closing the angle. The diameter of the hole shall be equal to the diameter of bolt plus 1.5mm. The structure shall be designed so that all parts shall be accessible for inspection and cleaning. Drain holes shall be provided at all points where pockets of depression are likely to hold water. All identical parts shall be made strictly inter-changeable. All steel sections before any work is done on them, shall be carefully leveled, straightened and made true to detailed drawings by methods which will not injure the materials so that when assembled, the adjacent matching surfaces are in close contact throughout. No rough edges shall be permitted in the entire structure. Drilling and Punching Before any cutting work is started, all steel sections shall be carefully straightened and trued by pressure and not by hammering. They shall again be trued after being punched and drilled. Holes for bolts shall be drilled or punched with a jig but drilled holes shall be preferred. The punching may be adopted for thickness upto 16mm. Tolerances regarding punch holes are as follows:a) Holes must be perfectly circular and to tolerance in this respect is permissible. b) The maximum allowable difference in diameter of the holes on the two sides of plates or angle is 0.8mm i.e the allowable taper in a punched holes not exceed 0.8mm on diameter. c) Holes must be square with the plates or angles and have their walls parallel. 3.8.10.3 All burrs left by drills or punch shall be removed completely. When the tower members are in position the holes shall be truly opposite to each other. Drilling or reaming to enlarge holes shall not be permitted. Erection mark Each individual member shall have erection mark conforming to the component number given to it in the fabrication drawings. This mark shall be marked with marking dies of 16 mm size before galvanizing and shall be legible after galvanizing. Erection Mark shall be A-BB-CC-DDD A BB CC DDD 3.8.12 = = = = The Departments code assigned to the Contractors- Alphabet Contractors Mark-Numerical Tower Type-Alphabet Number mark to be assigned by Contractor Numerical
3.8.9
3.8.10 3.8.10.1
3.8.10.2
3.8.11 3.8.11.1
3.8.11.2
Quantities and Weights
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3.8.12.1
The quantities of the following items have been envisaged in Metric Tone (MT) in the relevant Price Schedules for various types of towers: i) Tower body ii) Tower body extensions iii) Stubs and Cleats iv) Bolts and nuts including spring washers and step bolts etc. During detail engineering proto-assembly of each of the above items shall be inspected and approved by THE DEPARTMENT OF POWER and subsequently shall be released for fabrication and manufacturing as per the technical specification by the Contractor. The manufacturing of the above items shall be taken up in such a manner that the Equipment/Material offered for inspection to THE DEPARTMENT OF POWER are on completed Tower basis for each type of tower, completed Stubs & Cleats set basis so as to facilitate availability of erectable tower of each type and erectable stubs & cleats set for casting of foundation. After inspection of the offered Equipment/material by the DEPARTMENT OF PWOER representative(s), CIP shall be issued by the DEPARTMENT OF POWER for the material meeting the technical specification. However, MICC shall be issued only on completed tower basis for each type of tower (comprising the tower body, body extensions wherever applicable, bolts and nuts along with packing and spring washers) and on completed Stubs & Cleats basis suitable for each type of tower foundations (comprising a set of Stubs & Cleats, required bolts and nuts along with Spring Washers). Accordingly, the payment shall be reduced on completed tower basis of each type of tower (comprising tower body, body extensions wherever applicable, bolts and nuts along with spring washer and step bolts) and on completed set of stubs and cleats basis suitable for each type of foundations (comprising a set of Stubs & Cleats, required bolts and nuts along with spring washers) based on the weight of the items as calculated as per CI.3.9.12.3.
3.8.12.2
The provisional quantities required are mentioned in the respective Schedule of Prices. Final quantities shall be determined after completion and approval of the detailed route survey. The final quantities of tower shall be confirmed by the Department based on the requirement of quantities of various towers furnished by the Contractor after completion of detailed survey. Hence it will be responsibility of the Contractor to intimate the exact requirements of all towers and various line materials required immediately after the survey. The Department reserves the right to order the final quantities including some reasonable quantity of spares for which the rates quoted in the Bid shall be valid. Regarding quantity variation the provisions clause of SCC shall apply. The provisional quantities of total steel weight of tower, stub and its body extensions as well as bolts and nuts along with spring washers and step bolts are to be supplied by the Contractor under Package-A have been envisaged in the relevant price schedule. Fully galvanized tower parts are to be supplied. The estimated total weight of tower materials has been furnished in the BPS. The weight of tower shall mean the weight of tower calculated by using the black sectional (i.e ungalvanised ) weight of steel members of the size indicated in the approved fabrication drawings and bill of materials, without taking into consideration the reduction in weights due to holes, notches and bevel cuts etc. but taking into consideration the weight of the D-shackles, hangers, strain plates, pack
3.8.12.3
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plates, gusset plates, spring washers and pack washers etc. The rate quoted by the Contractor for tower material supply is deemed to be inclusive of galvanizing charges including the cost of zinc. For the payment purpose the round plane washer, forged hangers, D-shackles, U-bolts, step bolts, spring washers, bolts and nuts etc. shall be termed as fasteners. 3.9 Galvanising Fully galvanized towers and stub shall be-used for the lines. Galvanising of the member of the towers shall conform to IS: 2629-1985 and IS: 4759-1968. All galavanised members shall withstand tests as per IS: 2633-1986. For fasteners the galvanizing shall conform to IS:1367 (Part-13) The galvanizing shall be done after all fabrication work is completed, except that the nuts may be tapped or re-run after galvanising. Threads of bolts and nuts shall have a neat fit and shall be such that they can be turned with finger throughout the length of the threads of bolts and they shall be capable of developing full strength of the bolts. Spring washers shall be electro-galvanised as per clause 4 IS: 1573-1970. 3.10 Earthing The Contractor shall measure the tower footing resistance (TFR) of each tower after it has been erected and before the stringing of the earth wire during dry weather. Each tower shall be earthed, the tower footing resistance shall not exceed10 ohms. Plate type earthing wherein required shall be done in accordance with the latest additions and revisions of: IS: 3043 IS: 5613 3.10.1 3.10.2 Code of practice for Earthing Code of practice for Design, Installation and maintenance (Part-II/Section-2) of overhead power lines
The details for pipe earthing & Counter Poise earthing is given in the drawings enclosed with these specifications. The provisional quantities for pipe earthing are furnished in Schedule of Quantities as well as in Price Schedule. The Contractors are required to furnish unit rates also for adjustment purpose with actual quantities required during earthing. The quoted price shall include fabrication, supply and installation of earthing material including supply of coke, salt etc. Inspection and Tests General All standard tests, including quality control tests, in accordance with appropriate Indian/international standard, shall be carried out unless otherwise specified
3.11 3.11.1
3.11.2
Inspection In addition to the provision of Clause 4 of Section ECC, the following shall also apply:
3.11.2.1
a)
The Contractor shall keep the Department informed in advance about the time of starting and of the progress of manufacture and fabrication of various tower parts at various stages, so that arrangements could be made for inspection.
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b)
The acceptance of any part of items shall in no way relieve the Contractor of any part of his responsibility for meeting all the requirements of the Specification.
3.11.2.2
The Department or his representative shall have free access at all reasonable times to those parts of the Contractors works which are concerned with the fabrication of the Departments material for satisfying himself that the fabrication is being done in accordance with the provisions of the specifications. Unless specified otherwise, inspection shall be made at the place of manufacture prior to dispatch and shall be conducted so as not to interfere unnecessarily with the operation of the work. Should any member of the structure be found not to comply with the approved design, it shall be liable to rejection. No member once rejected shall be resubmitted for inspection, except in cases where the Department or his authorized representative considers that the defects can be rectified. Defect which may appear during fabrication shall be made good with the consent of, and according to the procedure proposed by the Contractor and approved by the Department. All gauges and templates necessary to satisfy the Department shall be supplied by the Contractor. The correct grade and quality of steel shall be used by the Contractor. To ascertain the quality of steel used, the inspector may at his discretion get the material tested at an approved laboratory. Packing Angle section shall be wire bundled. Cleat angles, gusset plates, brackets, fillet plate, hanger and similar loose pieces shall be tested and bolted together in multiples or securely wired through holes. Bolts, nuts, washers and other attachments shall be packed in double gunny bags accurately tagged in accordance with the contents. The packing shall be properly done to avoid losses and damages during transit. Each bundle or package shall be appropriately marked. Standards The manufacturing, fabrication, galvanising, testing, erection procedure and materials used for manufacture and erection of towers, construction of foundations shall conform to the following Indian Standards (IS)/International Standards which shall mean latest revisions, with amendments/changes adopted and published, unless specifically stated otherwise in the specification. In the event of supply of material conforming to Standards are equivalent to those specified. In case of award, salient features of comparison between the Standards proposed by the Contractor and those specified in this document will be provided by the Contractor to establish their equivalence. The material and services covered under these specifications shall be performed as per requirements of the relevant standard code referred hereinafter against each set of equipment and services. Other Internationally acceptable standards which ensure equal or higher performance than those specified shall also be accepted.
3.11.2.3
3.11.2.4
3.11.2.5
3.11.2.6 3.11.2.7
3.12 3.12.1 3.12.2
3.12.3 3.12.4 3.13 3.13.1
3.13.2
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Indian Standards (IS) 1. IS: 209-1992 2. IS: 800-1991
Title
Internationally recognized Standards/Guides ISO/R/752 ASTM B6 CSA S16.1 ASCE 52 IEC 826 BS 8100
Specification for Zinc Code of Practice for General Building Construction in Steel
3. (a) IS:802(Part-1) Code of Practice for Use of Structural Sec 1-1995 Steel in Overhead Transmission Line Sec 2-1992 Towers: Materials, loads and Permissible Stresses. Section 1 Materials and Loads. Section 2 Permissible Stresses. (b) IS: 802 (Part 2) Code of Practice for Use of Structural Steel in overhead Transmission Line: Fabrication, Galvanising, Inspection and Packing
ASCE 52
(C) IS:802-1978 Code of Practice for Use of Structural (Part 3) Steel in overload Transmission Line Towers & Testing 4. IS:808-1989 Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle Sections Code of Practice for Design Loads (Other than Earthquakes) for Building and Structures Hexagon Nuts (Size range M5 to M36) Technical Supply Conditions for Threaded Steel Fasteners Code of Practice for Painting of Ferrous Metals in Buildings: Part-I, Pretreatment; Part-II Painting. Electro-Plated Coating of Zinc on Iron and Steel Rolling and Cutting Tolerances of Hot Rolled Steel Products Criteria for Earthquake Resistant Design of Structures Plain Washers Steel for general structural purposes Ready Mixed Paint. Air Drying, Red Oxide, Zinc Chrome, Priming Specification
ASCE 52 IEC 652
5. IS:875-1992
6. IS:1363-1992 7. IS:1367-1992 10. IS:1477-1990
11. IS:1573-1991 12. IS:1852-1991 13. IS:1893-1991 14. IS:2016-1992 15. IS:2062-1992
16.
IEEE 693 ISO/R887 ANSI B18-22.1
IS:2074-1992
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17. IS:2551-1990 18. IS:2629-1990
Danger Notice Plates Recommended Practice for Hot Dip Galvanizing of Iron and Steel Method of Testing Uniformity of Coating of Zinc Coated Articles Code of Practice for Earthing Single Coil Rectangular section Spring Washers for Bolts, Nuts Screws High Strength Structural Bolts Specification, for Hot Dip Zinc Coatings on Structural Steel And Other Allied Products General Requirements for Plain Washers Code of Practice for Design. Installation and Maintenance of Overhead Power Lines Section-1 Design Part2, Section-2. Installation and Maintenance Specification for Heavy Washers For Steel Structures High Strength Structural Nuts Hexagon Bolts for Steel Structure Methods for Determination of Weight of Zinc Coated Iron and Steel Articles Specification for weldable structural Steel (Medium & High Strength Qualities) ASTM A394 CSA B33.4 ASTM A90 ASCE 52 DIN-127 ASTM A123 CSA G164 ASTM A123 CSA G164
19. IS:2633-1992 20. IS:3043-1991 21. IS:3063-1994
22. IS:3757-1992 23. IS:4759-1990
24. IS:5369-1991 25. IS:5613-1993
26. IS:6610-1991 27. IS:6623-1992 28. IS:6639-1990 29. IS:6745-1990
30. IS:8500-1992
31. IS:10238-1989 Step Bolts for Steel Structures 32. IS:12427-1988 Bolts for Transmission Line Towers 33. 34. Publication No. 19(N)/700 Indian Electricity Rules. Regulation for Electrical Crossing of Railway Tracks
3.13.3 The standards mentioned above are available from Reference/Abbreviation Name and address from which the Standards/guides are available IS Bureau of Indian Standards Manak Bhawan, 9, Bahadur Shah Zafar Marg New Delhi
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INDIA ISO International Organisation for Standardisation, Danish Board for Standardisation, Dansk Standardishing Sraat, Aurehoegvei-12 DK-2900 Helleprup DENMARK Canadian Standard Association 178, Rexadale Boulevard Rexdale (Ontario) CANADA M9W IR3 Deutsches Institute Fiir Normung Burggrafenstrassee 4-10 Post Fach 1107 D-1000, Berlin-30 GERMANY American Society for Testing and Material 1916 Race Street Philadelphia. PA 19103 1187 USA Kitab Mahal Baba Kharak Singh Marg New Delhi - 110001 INDIA American Society of Civil Engineers 345 East 47th Street New York, NY 10017 2398 USA
CSA
DIN
ASTM
Indian Electricity Rules Regulation for Electricity Crossing Of Railway Tracks ASCE
IEEE
Institute of Electrical and Electronics Engineers 445 Hoes Lane Piscataway, NJ 0885 1331 USA International Electrotechnical Commission Bureau Central de la commission 1 rue, de Varembe Geneva Switzerland Foundations Foundation includes supply of materials such as cement, sand, coarse aggregates and reinforcement steel etc.
IEC
4.0 4.1
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4.1.1
Foundation construction drawings will be supplied by the Department for all tower type & their extensions and for all foundations classification as described in Clause 4.2. Classifications of Foundations The foundation classification shall depend upon the type of soil, sub-soil water level and the presence of surface water which have been classified as follows
4.2
4.2.1
Normal dry To be used for locations where normal dry cohesive or non-choesive soils are met.
4.2.2
Sandy Dry Soil To be used for locations where cohesionless pure sand or negligible cohesion sand mixed with soil are met in dry condition.
4.2.3
Wet To be used for locations: a) Where sub-soil water is met at 1.5 meters or more below the ground level. b) Which are in surface water for long periods with water penetration not exceeding one meter below the ground level e.g. the paddy field.
4.2.4
Partially Submerged To be used at locations where sub-soil water table is met between 0.75 metres and 1.5 metres below the ground level.
4.2.5
Fully Submerged To be used at locations where sub-soil water table is met at less then 0.75 metres below the ground level.
4.2.6
Black Cotton Soil To be used at locations where soil is clayee type, not necessary black in colour, which shrinks when dry and swells when wet, resulting in differential movement. For designing foundations, for such locations, the soil is to be considered submerged in nature.
4.2.7
Fissured Rock To be used at locations where decomposed of fissured rock, hard gravel, kankar, limestone, laterite or any other soil of similar nature is met. Under cut type foundation is to be used for fissured rock locations. In case of fissured rock locations, where water table is met at less than 1.5 M below ground level, submerged fissured rock foundations shall be adopted. In case of dry locations dry fissured rock foundations shall be adopted. These foundations are listed in Schedule of Prices. If after soil investigation, water level is encountered at 1.5M or more below ground level, a separate foundation design shall be developed, payment for which shall be adjusted as explained in Cl. 4.6 of this section.
4.3
Hard Rock The locations where chiseling, drilling and blasting is required for excavation, Hard Rock type foundations are to be used. For these locations rock anchoring is to be provided to resist uplift forces. For quoting prices of Hard Rock
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Foundations, rock level shall be assumed at 1.5meters below the ground level. Due the change in rock level, no extra payment shall be made on account of increase in concrete volume, excavation volume and weight of reinforcement, also no recovery shall be made, if actual volume of concrete, excavations and weight of reinforcement are less than quoted in schedule of prices. Contractor has to quote the rate taking into account the above aspect. However for design purpose, rock level shall be considered at ground level and no overburden soil weight shall be considered for resisting the uplift. 4.3.1 In addition to the above depending on the site conditions other types of foundations shall also be provided to the Contractor suitable for Intermediate conditions under the above classifications of effect more economy. The proposal for these types of foundations shall be submitted by the Contractor based on the detailed soil investigation and approval for the same shall be obtained from the Department. Type of Foundations The open cast foundations i.e. slab and chimney type (max. depth of foundation 3.0meters) working drawing of all type of foundations for all type of towers shall be provided to successful Contractor. 4.4.1 The cement concrete used for the foundations shall be of grade M-15 corresponding to 1:2:4 nominal mix ratios with 20mm coarse aggregate for chimney portion and 40 mm aggregate for pyramid or slab portion. All the properties of concrete regarding its strength under compression tension, shear, punching and bend etc. as well as workmanship will conform to IS: 456-1978. a) The Portland Cement used in concrete shall conform to 33 grade (IS : 269) or 43 grade (IS: 8112) or 53 grade (IS:12269). b) The Puzzolena Cement used in concrete shall conform to IS: 1489- 1976. The curing time of Puzzolena cement will be decided at the time of execution of the work under the contract based on the certificate from a reputed laboratory which will be obtained and submitted by the contractor. Prior approval of the Department shall be required before use of Puszzolena cement. 4.4.4 4.4.5 Concrete aggregates shall conform to IS: 388-1970. The water used for mixing concrete shall be fresh, clean-and free from oil acids and alkalies, organic materials or other deleterious substances. Potable water is generally preferred. Reinforcement shall conform to IS: 432-1966 for M.S bars and hard drawn steel wires and to IS: 1139-1966 and IS: 1786-1966 for deformed and cold twisted bars respectively. All reinforcement shall be clean and free from loose mill scales, dust, loose rust and coats of paint, oil or other coatings, which may destroy or reduce bond, Contractor shall supply, fabricate and place reinforcement to shapes and dimensions as indicated or as required to carry out the intent of drawings and specifications. Design of Foundations Design of all type of foundations shall be developed by the Department & construction drawings will be provided to the successful Contractor. The provisional quantities of excavation, concreting and reinforcement steel required for the project are furnished in the schedule of prices in BPS. The indicative shapes of foundation are also enclosed in this specification.
4.3.2
4.4
4.4.3
4.4.6
4.5 4.5.1
429
4.6 4.6.1
Rates and Measurement for Foundation The Contractor is required to quote the unit rates for different foundation activity namely, excavation for different types of soil, concreting, supply and placement of reinforcement and stub setting in the relevant price schedule. The unit rates of excavation for each type of soil shall include excavation along with all associated activities like shoring, shuttering, dewatering till completion of foundation work stock piling, dressing, back filling of foundations after concreting with excavated/borrowed earth (irrespective of lead) and consolidation of earth, carriage of surplus earth to the suitable point of disposal as required by the Department or any other activity related to completion foundation work. The payment for this item shall be made on the basis of design excavation volume arrived at considering dimension of pit leading 150 mm gap around (except for under cut foundations) the base pad or actually excavated whichever is less and the unit rate of this item in indicated in Letter of Award. However, where soil is of composite in nature, classification of foundation shall be according the type of soil predominant in the footing. The payment for excavation shall be made as per actual type of soil in countered at the time of excavation, but the total payment for excavation portion shall not exceed the amount as payable for excavation considering the soil type same as that of foundation classification. The decision of the Department shall be final and binding with respect to classification of soil and foundations. Form boxes shall used for casting of foundations. The unit rate of concreting shall include the cost of supply, fabrication and placement of form boxes, cement, water, coarse and fine aggregates, mixing and placing concrete, curing of concrete and any other activities related to completion of concreting work of foundation. The payment for this item shall be made as per the actual volumes of concreting but limited to design volume based on unit rates for items indicated in letter of award.
4.6.2
4.6.3
The unit rate of reinforcement steel placement shall include supply and placement of reinforcement steel, stirrups, wire for winding the reinforcement chairs, bolsters and spacers etc. as required for completion the foundation work. The measurement of steel for payment shall be made on the calculated based on the calculated weight of reinforcement steel as per relevant Indian Standard actually used in Tones corrected to third place of decimal as calculated weight of steel as design/working drawing whichever is less. No allowance will be made for wastage. Construction of Tower Foundation, Stub Setting and Earthing General Design of tower foundations is treated in Clause 4.5.
4.7 4.7.1
4.7.2 4.7.2.1 4.7.2.2
Excavation Excavation work must not be started until the final tower schedule and profile has been approved by the Department. Except as specifically otherwise provided, all excavation for footing shall be made to the lines and grades of the foundations. For estimation purposes, the excavation wall shall be vertical and the pit dimensions shall be based on an assumed clearance of 150 mm on all sides of the foundation pad. For footings without undercut, this clearance will actually be established in practice for
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facilitating work. For footings with undercut, no such clearance will be allowed. All excavation shall be protected so as to maintain a clean sub grade and provide worker safety until the footing is placed, using timbering, shoring, dewatedng, etc., as approved by the DEPARTMENT OF POWER, Contractor shall especially avoid disturbing the bearing surface of the pad. Any sand, mud, silt or other undesirable materials which may accumulate in the excavated pit or borehole shall be removed by Contractor before placing concrete. 4.7.2.3 The soil to be excavated for tower foundations shall be classified as follows depending on the physical state of the soil at the time of excavation irrespective of the type of foundations to be installed. a) Normal Dry Soil: Soil removable by means of spades and shovels. Excavation done in dry soil for wet, partially submerged, fully submerged and wet black cotton type of foundations shall also be covered under this. b) Wet Soil: Where the subsoil water table is encountered or/and where pumping or bailing out of water is required. This type of excavation will also include excavation for wet soil in case of wet, partially submerged, fully submerged and wet black cotton type of foundations. The portion of the soil below the level of sub-soil water table up to the foundation depth shall only be treated as wet soil. The excavation done in wet soil for partially submerged, fully submerged and wet black cotton type of foundation shall also be covered under this. c) Dry Fissured Rock: Limestone, laterite, hard conglomerate or other soft or fissured rocks which can be quarried or split with crow bars, wedges or pickaxes. However, if required, light blasting may be resorted to for loosening the material, but this will not in any way entitile the material to be classified as hard rock. d) Wet Fissured Rock: Above fissured rock, when encountered with sub water or/ and where pumping or bailing out of water is required. Shall be treated as wet fissured rock. The portion of the fissured rock below the level of subsoil water table up to the foundation depth shall only be treated as wet fissured rock. e) Hard Rock Any rock excavation, other than specified under fissured rock above, for which blasting, drilling, chiseling are required. The unit rate quoted for hard rock excavation shall be inclusive of all costs for such drilling (including drilling required for anchoring), chiseling and basting etc. 4.7.2.4 Where soil is composite in nature, classification of foundation shall be according to the type of soil predominant in the footing and payment shall be made accordingly. No extra charge shall be admitted for the removal of fallen earth into a pit or borehole once excavated. Shoring and timbering as approved by Department shall be provided by the Contractor when the soil condition is so bad that there
4.7.2.5
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is likelihood of accident due to the failing of earth. Shoring and dimension shall be provided with no extra charge to the Department. 4.7.2.6 Where rock is encountered, the holes for tower footings shall preferably be drilled where blasting is restored to as an economy measure, it shall be done with the utmost care to minimize the use of concrete for filling the blasted area. Even in cases where unnecessary large quantities are excavated/ blasted, resulting in placement of large volume of concrete, payment to the contractor shall be limited to quantities as per foundation working drawing only. All necessary precautions for handling and use of blasting material shall be taken. In case where drilling is done the stub may be shortened suitably with the approval of the Department. 4.7.2.7 4.7.2.8 4.7.3 4.7.3.1 4.7.3.2 The Contractor shall supply requisite blasting material and be responsible for its storage and use. Indian Standard IS: 3764 shall be followed regarding safety of excavation work. Setting of Stubs For all towers the Contractor shall submit for approval the proposed method for setting of stubs. The stubs shall be set correctly and precisely in accordance with approved method at the exact location, alignment and levels with the help of stub setting templates and leveling instruments. Stubs shall be set-in the presence of Departments representative for which adequate advance intimation shall be given to the Department by Contractor. Setting of stub at each location shall be approved by Department. Stub Setting Templates Stub setting template shall be arranged by the contractor at his own cost for all types of towers with or without extension. Stub templates for standard towers and tower with extension up to +9M, separate adjustable type stub setting template shall be used. The stub templates shall be painted. The Contractor shall furnish sufficient number of templates for timely completion of the line without any extra cost of the Department. One set of each type of stub setting template shall be supplied to the Department, on completion of the project, at no extra cost to the Department. In case use of prop is permitted by the Department then also one set of each type of stub setting template shall be supplied to the Department, after completion of the work, at no extra cost to the Department. The following number / sets of stub setting templates/props shall be deployed by the Contractor: Templates/Props for tower type i) ii) For each type of B, C, D, CL & DL type For D+18/25 M Nos. to be deployed 4 each 1 each
4.7.3.3 4.7.4 4.7.4.1
4.7.4.2 4.7.4.3
4.7.4.4
However, if the Department feels that more templates/Props are required for timely completion of a particular line due to some urgency, the contractor shall have to deploy the same without any extra cost to the Department.
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4.7.4.5 4.7.4.5.1
Mixing, Placing and Compacting of Concrete The concrete shall be mixed in the mechanical mixer. However, in case of difficult terrain, hand mixing may be permitted at the discretion of the Department. The water for mixing concrete shall be fresh, clean and free from Oil, Acid and Alkali, Saltish or brackish water shall not be used. Mixing shall be continued until there is uniform distribution of material and the mix is uniform in colour and consistency. But in no case the mixing be carried out for less than two minutes. Normal mixing shall be done close to the foundation. But exceptionally the concrete may be mixed at the nearest convenient place of final deposit as rapidly as practicable by methods which shall prevent the segregation or loss of any ingredient. The concrete shall be placed and compacted before setting commences. To avoid the possibility of reinforcement rods being exposed due to unevenness of the bottom of the excavated pit, a pad of lean concrete 50 mm thick and corresponding to a 1:3:6 nominal mix shall be provide at the bottom of the pad. Form boxes shall be used for casting all types of foundations except of and undercut interface for which the adjoining subsurface material shall provide adequate support. The concrete shall be laid down in 150mm layers and consolidated well, so that the cement cream works, up to the top and no honey-combing occurs in the concrete. A mechanical vibrator shall be employed for compaction of the concrete. However, in case of difficult, terrain, manual compaction may be permitted at the discretion of the Department. Monolithic casting of foundations must be carried out. However, in case of unavoidable circumstances, a key construction joint can be provided at the chimney pad interface subject to approval of the Department. After concreting the chimney potion to the required height, the top surface should be finished smooth with a slight slope towards the edge for draining rain water. Wet locations shall be kept completely dewatered, both during and 24 hours after placing the concrete, without disturbance of the concrete. If the concrete surface is found to be defective after the form work has been removed, the damage shall be repaired with rich cement sand mortar to the satisfaction of the Department before the foundation is back filled. Backfilling and Removal of Stub Templates/props After opening of form work and removal of shoring, timbering, etc., backfilling shall be started after repairs, if any, to the foundation concrete. Backfilling shall normally be done with the excavated soil, unless it is a clay type or it consists of large boulders/stones, in which case the boulders shall be broken to a maximum size of 80 mm. At locations where borrowed earth is required for backfilling, Contractor shall bear the cost, irrespective of lead. The backfilling materials shall be clean and free organic or other foreign materials. A clay type soil with a grain size distribution of 500% or more passing the # 200 sieve as well as a black cotton soil are unacceptable for backfilling. The earth shall be deposited in maximum 200 mm layers, leveled, wetted if necessary and compacted properly before another layer, leveled, wetted if necessary and compacted properly before another layer is deposited. The moisture content for compaction shall be based on the Proctor compaction test results given in the Geotechnical Report, Clause 4.1. The
4.7.4.5.2
4.7.4.5.3
4.7.4.5.4
4.7.4.5.5
4.7.4.5.6 4.7.4.5.7
4.7.5 4.7.5.1
4.7.5.2
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density of the compacted backfill material may further be verified to the satisfaction of the Department based on the sand-cone method described in the ASTM D1556-82 standard. 4.7.5.3 The backfilling and grading shall be carried to an elevation of about 75 mm above the finished ground level to drain out water. After backfilling 50mm high, earthen embankment (band) will be made along the sides of excavation pits and sufficient water will be poured in the backfilling earth for at least 24 hours. After the pits have been backfilled to full depth, the stub template/props, as the case may be, can be removed. Curing The concrete shall be cured by maintaining the concrete wet for a period of at least 10 days after placing. Once the concrete has set for 24 hours the pit may be backfilled with selected moistened soil and well consolidated in layers not exceeding 200 mm thickness and thereafter both the backfill earth and exposed chimney shall be kept wet for the remainder of the prescribed 10 days. The exposed concrete chimney shall also be kept wet by wrapping empty cement bags around it and wetting the bags continuously during the critical 10 days period. 4.7.7 Benching When the line passes through hilly/undulated terrain, leveling the ground may be required for casting of tower footings. All such activities shall be termed benching and shall include cutting of excess earth and removing the same to a suitable point of disposal as required by the Department. Benching shall be resorted to only after approval from the Department. Volume of the earth to be cut shall be measured before cutting and approved by the Department for payment purposes. Further, to minimize benching, unequal leg extensions shall be considered and provided if economical. 4.7.8 4.7.8.1 4.7.8.2 Protection of Tower Footing Tower spotting shall endeavour to minimize the quantity of revetment required. The work shall include all necessary stone revetments, concreting and earth filling above ground level, the clearing from site of all surplus excavated soil, special measures for protection of foundation close to or in nalas, river bed undulated terrain, etc., including suitable galvanized wire netting and meshing packed with boulders. The top cover of stone revetment shall be sealed with M-15 concrete (1:2:4 mix) Contractor shall recommend protection at such locations wherever required. Details of protection of tower footing are given in drawing enclosed with these specifications for reference purpose only. Tower footings shall generally be backfilled using soil excavated at site unless deemed unsuitable for backfilling. In the latter case backfilling shall be done with borrowed earth of suitable quality irrespective of lead, as per the rate provided in the letter of award. The consolidation of earth after backfilling shall however be done free of cost. The provisional quantities for protection work of foundations are furnished in schedule of Quantities at well as in Price Schedule. The unit rate shall also be applicable for adjusting with the actual quantities of protection works done. The unit rates for revetment quoted in B.P.S shall also include excavation, (1:5) random masonry, lean concreting and sealing of top with M-15 concrete.
4.7.6
4.7.8.3
4.7.8.4
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4.6.8.5
For payment purposes the volume of random rubble massonary revetment shall be measured from bottom lean concrete to top sealing coat and paid at the quoted rates indicated in BPS. No extra rates shall be paid for allied work such as excavation, packed stone at head of weep holes etc. However, no deduction shall be made for the volume enclosed by weep holes. TOWER ERECTION, STRINGING AND INSTALLATION OF LINE MATERIALS General The scope of erection work shall include the cost of all labour, tools and plants such as stringing equipment and all other incidental expenses in connection with erection and stringing work shall indicate in the offer the sets of stringing equipment he would deploy exclusively for each transmission line package. The Contractor shall be responsible for transportation to site of all the materials to be provided by the Contractor as well as proper storage and preservation of the same at his own cost, till such time the erected line is taken over by the Department Similarly, the Contractor shall be responsible for transportation, proper storage, safe custody, and loss or damage of all the Departments supplied items, if any, for incorporation in the lines and shall maintain and render proper account of all such materials at all times. The Contractor shall replace all the materials lost or damaged during such storage, carriage and erection at his cost with same quality and specifications in such reasonable time without causing any delay in the execution of the work. Contractor shall set up required number of stores along the line and the exact location of such stores shall be discussed and agreed upon with the Department. The Department supplied items shall issued from its central store at specified locations and receipt, loading, unloading and transportation to such stores set up by the Contractor shall be the entire responsibility of the Contractor. Treatment of Minor Galvanization Damage Minor defects in hot-dip galvanized members shall be repaired by applying zinc enriched protection paint having at least 90% zinc content to the satisfaction of the Department before erection.
5.0 5.1 5.1.1
5.1.2
5.1.3
5.2
5.3
Assembly The contractor shall give complete details of the erection procedures he proposes to follow.
5.3.1
The method for the erection of towers shall ensure the following a) Straining of the members shall not be permitted for positioning. It may, however, be necessary to match holes positions at joints using tommy bars not more than 450mm in length; b) Prior to erection of an upper section, the lower section shall be completely braced, and all bolts provided tightened adequately in accordance with approved drawings to prevent any mishap during tower erection; c) All plan diagrams of relevant section of tower shall be in place prior to assembly of an upper section; d) The bolt positions in assembled towers shall be as per IS-5613 (PartII/Section-2);
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e) Tower shall be fitted with number, danger and phase plates as well as anticlimbing devices as described; f) After complete erection of the tower, all blank holes, if any, are to be filled by bolts and nuts of correct size. 5.4 5.4.1 Tightening to Bolts and Nuts All nuts shall be tightened properly using correct size spanner and torque wrench. Before tightening, it will be verified that filler washers and Plates are placed in relevant gap between members, bolts of proper size and length are inserted, and one spring washer is inserted under each nut. In case of step bolts, spring washers shall be placed under the outer nuts. The tightening shall progressively be carried out from the top downwards, care being taken that all bolts at every level are tightened simultaneously. The threads of bolts projecting outside the nuts shall be punched at their position on the diameter to ensure that the nuts are not loosened in course of time. If during tightening a nut is found to be slipping or running over the bolt threads. The bolt together with the nut shall be replaced. The threads of all the bolts projected outside the nuts shall be welded at two diametrically opposite places, the circular length of each welding shall be at least 10 mm. The welding shall be provided from ground level to waist level for single circuit towers. However, for river crossing towers, the welding shall be provided from ground level to 30 m height from stub level. After welding, one coat of zinc rich primer and two coats of enamel paint shall be applied to the welded portion to the satisfaction of the Department. Before application of zinc rich primer the welded portion shall be cleaned properly with steel wire brush. The cost of welding and paint, including application of paint shall be deemed to be included in the erection price. In addition to the tack welding of nuts with bolts, as described above, the Contractor can also propose some alternative arrangements, like use of epoxy resin adhesive which can serve the purpose of locking the nut permanently with the bolt and nuts preventing pilferage of the tower members. Insulator Hoisting I suspension insulator strings shall be used on Suspension towers and tension insulator strings on angle and dead end towers. These shall be fixed on all the towers just prior to the stringing. Damaged insulators and finings, if any, shall not be employed in the assemblies. Prior to hoisting, all insulators shall be cleaned in a manner that will not spoil, injure or scratch the surface of the insulator, but in no case shall any oil be used for that purpose, Corona control rings/arcing horn shall be fitted in an approved manner. Torque wrench shall be used for fixing various line materials and components such as suspension clamp for conductor and earthwire, etc., whenever recommended by the manufacturer of the same. 5.6 5.6.1 5.6.1.1 5.6.1.2 Handling of Conductor and Earthwire Running out of the Conductors The conductors shall be run out of the drums from the top in order to avoid damage. A suitable braking device shall be provided to avoid damaging, loose running out and kinking of the conductors. Care shall be taken that the conductors do
5.4.2
5.4.3
5.5
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not touch and rub against the ground or objects which could scratch or damage the strands. 5.6.1.3 The sequence of running out shall be from the top down. i.e. the earthwire shall be run out first followed in succession by the conductors. Unbalanced loads on towers shall be avoided as far as possible. Inner phase of line conductors shall be strung before the stringing of the outer phases is taken up. Towers not designed for one sided stringing shall be well guyed and steps taken by the Contractor to avoid damage. Guying proposal along with necessary calculations shall be submitted by the Contractor to the Department for approval. All expenditure related to this work is deemed to be included in the bid price and no extra payment shall be made for the same. When the 132 KV transmission line runs parallel to existing energized power lines, the Contractor shall take adequate safety precautions to protect personnel from the potentially dangerous voltage build up due to electromagnetic and electrostatic coupling in the pulling wire, conductors and earthwires during stringing operations. The Contractor shall also take adequate safety precautions to protect personnel from potentially dangerous voltage build up due to distant electrical storms. Running Blocks The groove of the running blocks shall be of such a design that the seat is semicircular and larger then the diameter of the conductor/ earthwire and it does not slip over or rub against the slides. The grooves shall be lined with hard rubber or neoprene to avoid damage to conductor and shall be mounted on properly lubricated bearings. The running blocks shall be suspended in a manner to suit the design of the cross-arm. All running blocks, especially those at the tensioning end, will be fitted, on the cross-arms with jute cloth wrapped over the steel work and under the slings to avoid damage to the slings as well as to the protective surface finish of the steel work. Repairs to Conductors. The conductor shall be continuously observed for loose or broken strands or any other damage during the running out operations. Repairs to conductors, if necessary, shall be carried out with repair sleeves. Repairing of the conductor surface shall be carried out only in case of minor damage, scuff marks, etc. The final conductor surface shall be clean, smooth and free from projections, sharp points, cuts, abrasions, etc. The Contractor shall be entirely responsible for any damage to the towers during stringing. Crossings Derricks or other equivalent methods ensuring that normal services need not be interrupted nor damage caused to property shall be used during stringing operations where roads, channels, telecommunication lines, powerlines and railway lines have to be crossed. However, shut down shall be obtained when working at crossings of overhead powerlines. The Contractor shall be entirely responsible for the proper handling of the conductor, earth wire and accessories in the field. 5.7
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5.6.1.5
5.6.1.6 5.6.2 5.6.2.1
5.6.2.2
5.6.3 5.6.3.1 5.6.3.2 5.6.3.3
5.6.3.4 5.6.4
Stringing of Conductor and Earth wire

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5.7.1. 5.7.2
The stringing of the conductor shall be done by the standard stringing method. The Contractor shall give complete details of the stringing methods he proposes to follow. Prior to stringing the Contractor shall submit the stringing charts for the conductor and earth wire showing the initial and final sages and tension for various temperatures and spans, along with equivalent spans in the lines for the approval of the Department. Conductors or earth wire shall not be allowed to hang in the stringing blocks for more than 96 hours before being pulled to the specified sag. Conductor creep are to be compensated by over tensioning the conductor at a temperature of 26 C lower than the ambient temperature or by using the initial sag and tensions indicated in the tables.
5.7.3
5.8 5.8.1
Jointing When approaching the end of a drum length at least three coils shall be left in place when the stringing operations are stopped. These coils are to be removed carefully, and if another length is required to be run out, a joint shall be made as per as the recommendations of the accessories manufacture. Conductor splices shall not crack or otherwise be susceptible to damage in the stringing operation. The contractor shall use only such equipment/methods during conductor stringing which ensures complete compliance in this regard. All the joints on the conductor and earthwire shall be the compression type, in accordance with the recommendations of the manufacturer, for which all necessary tools and equipment like compressors, dies, etc., shall be obtained by the Contractor. Each part of the joint shall be cleaned by wire brush till it is free of rust or dirt. Etc., and be properly greased with anti-corrosive compound. If required and as recommended by the manufacturer, before the final compression is carried out with the compressors. All the joints or splices shall be made at least 30 meters away from the tower structures. No joints or splices shall be made in spans crossing over main roads, and small river tension spans. Not more than one joint per sub conductor per span shall be allowed. The compression type fittings shall be of the self centering type or care shall be taken to mark the conductors to indicate when the fitting is centered properly. During compression or splicing operation; the conductor shall be handled in such a manner as to prevent lateral or vertical bearing against the dies. After compressing the joint the aluminum sleeve shall have all corners rounded, burrs and sharp edges removed and smoothened. During stringing of conductor, to avoid any damage to the joint, the contractor shall use a suitable protector for mid span compression joints in case they are to be passed over pulley blocks/aerial rollers. The pulley groove size shall be such that the joint along with protection can be passed over it smoothly. Tensioning and Sagging Operations The tensioning and sagging shall be done in accordance with the approved stringing charts or sag tables. The initial stringing chart shall be used for the conductor and final stringing chart for the earth wire. The conductors shall be pulled up to the desired sag and left in running blocks for at least one hour after which the sag shall be rechecked and adjusted, if necessary, before transferring the conductors from the running blocks to the suspension clamps. The conductor shall be clamped within 96 hours of sagging in.
5.8.2
5.8.3
5.8.4
5.8.5
5.9 5.9.1
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5.9.2
The sag will be checked in the first and the last section span for sections up to eight spans, and in one additional intermediate span for sections with more than eight spans. The sag shall also be checked when the conductors have been drawn up and transferred from running blocks to the insulator damps. The running blocks, when suspended from the transmission structure for sagging, shall be so adjusted that the conductors on running blocks will be a the same height as the suspension clamp to which it is to be secured. At sharp vertical angles, conductor and earth wire sags and tensions shall be checked for equality on both sides of the angle and running block. The suspension insulator assemblies will normally assume vertically when the conductor is clamped. Tensioning and sagging operations shall be carried out in calm weather when rapid changes in temperature are not likely to occur. Clipping In Clipping of the conductors into position shall be done in accordance with the manufactures recommendations. Jumpers at section and angle towers shall be secured in position. The security clip shall be properly opened and sprung into position. Fasteners in all fittings and accessories shall be secured in position. The security clip shall be properly opened and sprung into position. Fixing of Conductors and Earth wire Accessories Conductor and earth wire accessories including spaces, spacer dampers and vibration dampers supplied by the contractor shall be installed by the Contractor as per the design requirements and manufactures instruction within 24 hours of the conductor/ earth wire clamping. While installing the conductor and earth wire accessories, proper care shall be taken to ensure that the surfaces are clean and smooth and that no damage occurs to any part of the accessories or of the conductors.
5.9.3
5.9.4
5.9.5 5.10 5.10.1 5.10.2 5.10.3 5.11
5.12
Replacement If any replacement are to be effected after stringing and tensioning or during maintenance, leg members and bracing shall not be removed without first reducing the tension on the tower by proper guying techniques or releasing of the conductor. For replacement of cross arms, the conductor shall be suitably tied to the tower at tension points or transferred to suitable roller pulleys at suspension points.
5.13 5.13.1
Permitted Extra Consumption of Department Supplied Materials The Contractor shall be supplied conductor as per the following norms: Quantity of conductor = line length as per detailed survey x 3 phase x 1 (for single circuit line in plain terrain)
Note :
However for hilly terrain, where the level difference between two locations are there additional consumption shall be allowed equal to the increase in Conductor length due to slope effect. Contractor shall prepare detailed consumption statement for such locations for the approval of Engr - In charge. The Contractor shall make every effort to minimize breakage, losses and wastage of the line materials during erection. However , the Contractor shall be permitted an extra consumption of materials up to the limits specified in
5.13.2
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Table 5.1 and shall be permitted to dispose of the scrap, if any, at the end. However in case of full rate contract where supply and erection are to be carried out by the same contractor extra consumption of items due breakage or damage shall not be permitted. Table 5.1: Permitted extra consumption of materials Item Conductor Insulators 5.13.3 5.13.4 5.13.5 % of permitted extra consumption 1 1
In case of conductor the permitted extra consumption limit of one percent is inclusive of sag. Jump erring, damage, loss and wastage etc. The Contractor shall not be required to return to the Department empty wooden/steel conductor drums and shall dispose off the same at his cost. Any conductor drum which has been opened by the Contractor shall not be taken back by the Department and the unused conductor in such drums may be treated as waste permissible within the overall limits specified in Table 5.1 The quantities of tower parts, earth wire, hardware fittings, conductor & earth wire accessories indicated herein are tentative and actual quantity depend upon final survey (check survey). Payment for contractor supplied line materials shall be made for the quantities incorporated in the works plus permitted extra quantities as mentioned below: however the quantity of earthwire incorporated in the works are calculated as under: Quantity of earth wire = line length as per detailed survey x 1
5.14
5.14.1
Contractor shall make every effort to minimize the breakage, losses and wastage of the line material during erection. However the contractor shall be permitted the extra consumption upto the limit as specified in the table below and shall be permitted to dispose of the scrap if any of their end. However in case of full rate contract where supply and erection are to be carried out by the same contractor extra consumption of items due breakage or damage shall not be permitted. Item % of permitted extra consumption for contractor supplied Material 1 1
1. Earth wire 2. Hardware fittings 3. Conductor/Earth wire Accessories
Note: In case of earth wire the permitted extra consumption limit of 1% is inclusive of sag, jumpering damages, losses & wastage. 5.15 Final Checking, Testing and Commissioning After completion of the works, final checking of the line shall be carried out by the Contractor to ensure that all foundation works, tower erection and stringing have been done strictly according to the specifications and as approved by the Department. All the works shall be thoroughly inspected in order to ensure that: a) Sufficient backfilled earth covers each foundation pit and is adequately compacted;
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b) c) d) e)
Concrete chimneys and their copings are in good condition and finely shaped; All tower members are used strictly according to final approved drawing and are free of any defect or damage whatsoever; All bolts are properly tightened, punched, tack welded and painted with zinc rich paint; The stringing of the conductors and earth wire has been done as per the approved sag and tension charts and desired clearances are clearly available; All conductor and earth wire accessories are properly installed; All other requirements for completion of works such as fixing of danger plate. Phase plate, number plate, anti-climbing device, aviation signal have been fulfilled. Wherever required, that proper revetment (erosion protection) is provided; The original tracing profile and route alignment as well as tower design, structural drawings, bill of material and shop drawings of all towers are submitted to the Department for reference and record; the insulation of the as a whole is tested by the contractor through provision of his own equipment, labour, etc., to the satisfaction of the Department; All towers are properly grounded; The line is tested satisfactorily for commissioning purpose.
f) g)
h) i)
j)
k) l)
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SECTION II TECHNICAL SPECIFICATIONS 1. 1.1 1.1.1 TECHNICAL DESCRIPTION OF EARTH WIRE Details of Earth wire The galvanized steel earth wire shall generally conform to the specification of ACSR core wire as mentioned in IS: 398 (Part-II)-1976 except where otherwise specified herein. The details of the earth wire to be used on transmission line are tabulated below: a) b) Stranding and wire diameter Number of stands Steel core Outer steel/layer c) d) e) f) g) h) 1.2 1.2.1 Total sectional area Over all diameters Approximate weight Calculated D.C. resistance at 20 deg. Centigrade Minimum ultimate tensile strength Direction of lay of outer layer : : : : : : : : 1 6 54.55 sqmm. 9.45 mm 428 Kg/Km 3.375 Ohms/km 56 KN Right hand : 7/3.15 mm steel
1.1.2
Workmanship All steel strands shall be smooth, uniform and free from all imperfections, such as spills and splits, die marks, scratches, abrasions and kinks after drawing and also after stranding. The finished material shall have minimum brittleness as it will be subjected to appreciable vibration while in use. The steel strands shall be hot dip galvanized and shall have minimum, Zinc coating of 240 gm/sqmm, after stranding. The zinc coating shall be smooth continuous, of uniform thickness, free form imperfections and shall withstand three and a half dips after stranding in standard Preece test. The steel wire rod shall be of such quality and purity that, when drawn to the size of the strands specified and coated with zinc, the finished strands shall be of uniform quality and have the same properties and characteristics as prescribed in ASTM designation B498-74. The steel strands shall be preformed and post formed in order to prevent spreading of strands while cutting of composite earth wire. Care shall be taken to avoid damage to galvanization during performing and post forming operation. To avoid susceptibility towards wet storage stains (white rust), the finished material shall be provided with a protective coating of boiled linseed oil.
1.2.2 1.2.3
1.2.4
1.2.5
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1.3
Joints in Wires There shall be no joins of any kind in the finished steel wire strand entering into the manufacture of the earth wire. There shall be no strand joints or strand splices in any length of the completed stranded earth wire.
1.4
Tolerances The manufacturing tolerance to the extent of the following limits only shall be permitted in the diameter of the individual steel strands and lay length of the earth wire: Standard Diameter Lay length 3.15 mm 160 mm Maximum. 3.20 mm 175 mm Minimum 3.10 mm 145 mm
1.5 1.5.1
Materials Steel The steel wire stands shall be drawn from high carbon steel rods and shall conform to the following requirements as to the chemical composition Element Carbon Manganese Phosphorous Sulphur Silicon % Composition Not more than 0.55 0.4 to 0.9 Not more than 0.04 Not more than 0.04 0.15 to 0.35
1.5.2
Zinc The zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity. It shall conform to and satisfy all the requirements of IS: 209
1.6 1.6.1 1.6.2
Standard Length The standard length of the earth wire shall be 2000 meters. The tolerance on length shall be 5% on the standard length. Random length will be accepted provided no length is less than 70% of standard length and the total quantity of random lengths is not more than ten (10) percent of the total quantity in each shipment. Tests and Standards Tests The following type, acceptance and routine tests during manufacture shall be carried-out on the earth wire. For the purpose of this clause
2. 2.1
2.1.1
Type Tests shall mean those tests which are to be carried out to prove the process of manufacture and general conformity of the material to this Specification. These tests shall be carried out on samples prior to commencement of commercial production against the order. The Contractor shall indicate his schedule for carrying out these tests. Acceptance Tests shall mean those tests which are to be carried out on samples taken from each lot offered for pre-dispatch inspection, for the purposes of acceptance of that lot.
2.1.2
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2.1.3
Routine Tests shall mean those tests, which are to be carried out on each strand/spool/length of the conductor and earth wire to check requirements which are likely to vary during production. Tests During Manufacture shall mean those tests, which are to be carried out during the process of manufacture and end inspection by the Contractor to ensure the desired quality of the end product to be supplied by him. The norms and procedure of sampling for these tests will be as per the Quality Assurance Programme to be mutually agreed to by the Contractor and the Owner. The standards and norms to which these tests will be carried out are listed against them. Where a particular test is a specific requirement of this Specification, the norms and procedure of the test shall be as specified in Annexure-A or as mutually agreed to between the Contractor and the Owner in a Quality Assurance Programme. For all type and acceptance tests, the acceptance values shall be the values specified in this Specification, and/or guaranteed by the Contractor, whichever is applicable. Type Tests Type Tests on Earth wire The following tests shall be conducted once on sample/samples of earth wire for every 500 Km of production from each manufacturing facility: (a) (b) UTS test DC resistance test Annexure-A
2.1.4
2.1.5
2.1.6
2.1.7
2.2
2.3.2
Acceptance Tests on Earth wire (a) (b) (c) (d) (e) (f) (g) Visual and dimensional check on drum Visual check for joints scratches etc. and lengths of earth wire Dimensional Check Lay length check Galvanizing test Torsion test Elongation test Annexure-A
(h) (I) (j) (k) 2.4 2.4.1
Wrap test DC resistance test Breaking load test Chemical Analysis of steel Annexure-A IS: 398 (Part-III)-1976
Routine Tests Routine Tests on Earth wire (a) (b) Check for correctness of stranding Check that there are no cuts, fins etc. on the strands.
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(c) 2.4.2
Check that drums are as per Specification.
Tests During Manufacture on Earth wire (a) (b) Chemical analysis of Zinc used For galvanizing Chemical analysis of steel Annexure-A
2.5 2.5.1 2.5.2
Testing Expenses The break-up of the testing charges for the type tests specified shall be indicated separately. Contractors shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that the tests can be completed in these laboratories within the time schedule guaranteed by them. In case of failure in any type test, the Contractor is either required to manufacture fresh sample lot and repeat all the test successfully once or repeat that particular type test three times successfully on the sample selected from the already manufactured lot at his own expenses. In case fresh lot is manufactured by testing then the lot already manufactured shall be rejected. The decision of the purchaser in this regard shall be final and binding on Contractor. The entire cost to testing for the acceptance and routine tests and tests during manufacture specified herein shall be treated as included in the quoted unit price except for the expenses of the inspector/Owners representative. In case of failure in any type test, repeat type tests are required to be conducted, then all the expenses for deputation of Inspector/Owners representative shall be deducted from the contract price. Also if on receipt of the Contracts notice of testing, the Owners representative/inspector does not find plant to be ready for testing, the expenses incurred by the owner for redeputation shall be deducted from the contract price. Additional Tests The owner reserves the right of having at his own expenses any other test of reasonable nature carried out at Contractors premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine test satisfy himself that the materials 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 Contractors premises or at any other test centre. In case of evidence of non compliance, it shall be binding on the part of Contractor to prove the compliance of the items to the technical specifications by repeat tests or correction of deficiencies, or replacement of defective item all without any extra cost to the Owner. Sample Batch for Type Testing & Destructive Test The Contractor shall offer material for selection of samples for type testing and destructive testing only getting Quality Assurance Plan approved from Owners Quality Assurance Deptt. The sample shall be manufactured strictly in accordance with the Quality Assurance Plan approved by Owner. The Contractor shall offer at least three drums for selection of sample required for conducting all the type test.
2.5.3
2.5.4
2.5.5
2.6 2.6.1
2.6.2
2.7 2.7.1
2.7.2
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2.7.3 2.8 2.8.1
The Contractor is required to carry out all the Acceptance tests successfully in presence of Owners representative before sample selection. Test Reports Copies of type test reports shall be furnished in at least six copies along with one copy will be returned duly certified by the Owner only after which the commercial production of the material shall start. Record of routine test reports shall be maintained by the Contractor at his work for periodic inspection by the Owners representative. Test Certificates of tests during manufacture shall be maintained by the Contractor. These shall be produced for verification as and when desired by the Owner. Inspection The Owners representative shall at all times be entitled to have access to the works and all places of manufacture, where earth wire shall be manufactured and representative shall have full facilities for unrestricted inspection of the Contractors works, raw materials and process of manufacture for conducting necessary tests as detailed herein. The Contractor shall keep the Owner informed in advance of the time of starting and of the progress of manufacture of earth wire in its various stages so that arrangements can 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 earth wire shall be dispatched only after satisfactory testing for all tests specified herein have been completed. The acceptance of any quantity of material shall in no way relieve the Contractor of any of his responsibilities for meeting all requirements of the Specification, and shall not prevent subsequent rejection if such material is later found to be defective. Test Facilities The following additional test shall be available at the Contractors works: (a) Calibration of various testing and measuring equipment including tensile testing machine, resistance measurement facilities, burette thermometer, barometer etc. Standard resistance for calibration of resistance bridges. Finishing Earth wire shall be checked for length verification and surface finish on separate rewinding machine at reduced speed (variable from 8 to 16 meters per minute). The rewinding facilities shall have appropriate clutch system and free of vibrations, jerks etc., with traverse laying facilities.
2.8.2 2.8.3
2.9 2.9.1
2.9.2
2.9.3
2.9.4
2.10 2.10.1
(b) (c)
2.11 2.11.1
Packing for Earth wire The Earth wire shall be supplied in non-returnable, strong, wooden drums and provided with lagging of adequate strength, constructed to protect the Earth wire against all damage and displacement during transit, storage and subsequent handling and stringing operations in the field. The Contractor shall be responsible for any loss or damage during transportation handling
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and storage due to improper packing. The drums shall generally conform to IS: 1778-1980, except as otherwise specified herein after. 2.11.2 2.11.3 The drums shall be suitable for wheel mounting and for letting off the earth wire under a minimum controlled tension of the order of 5 KN. The general outline of the drum for Earth wire shall be as per annexed drawing. The Contractor should submit their proposed drum drawings along with the bid. For Earth wire two standard length shall be wound on each drum. For Earth wire, each strand shall be individually welded to prevent parting of two lengths at a tension less than 15 KN. The two ends where the first length finishes and the second length starts, shall be clearly marked with adhesive tape and no weld should be present outside these marks. The length between the two marks shall be treated as scrap and will not be taken into account for measurement purposes. All wooden components shall be manufactured out of seasoned softwood free from defects that may materially weaken the component parts of the drums. Preservative treatment shall be applied to the entire drum with preservatives of a quality which is not harmful to the earth wire. The flanges shall be of two ply construction with each ply at right angles to the adjacent ply and nailed together. The nails shall be driven from the inside face flange, punched and then clenched on the outer face. The thickness of each ply shall not vary by more than 3mm from that indicated in the figure. There shall be at least 3 nails per plank of ply with maximum nail spacing of 75mm. Where a slot is cut in the flange to receive the inner end of the earth wire the entrance shall be in line with the periphery of the barrel. The wooden battens used for making the barrel of the earth wire shall be of segmental type. These shall be nailed to the barrel supports with at least two nails. The battens shall be closely butted and shall provide a round barrel with smooth external surface. The edges of the battens shall be rounded or chamfered to avoid damage to the earth wire. Barrel studs shall be used for the construction of drums. The flanges shall be holed and the barrel studs shaft be threaded over a length on either end, sufficient to accommodate washers, spindle plates and nuts for fixing flanges at the required spacing. Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used on the inner surface of the flanges and the drum barrel shall be counter sunk. The ends of barrel shall generally be flushed with the top of the nuts. The inner cheek of the flanges and drum barrel surface shall be painted with a bitumen based paint. Before reeling, card board or double corrugated or thick bituminized waterproof bamboo paper shall be secured to the drum barrel and inside of flanges of the drum by means of a suitable commercial adhesive material. After reeling the earth wire, and exposed surface of the outer layer of earth wire shall be wrapped with water proof thick bituminized bamboo paper to preserve the earth wire from dirt, grit and damage during transport and handling.
2.11.4 2.11.5
2.11.6
2.11.7
2.11.8
2.11.9
2.11.10
2.11.11 2.11.12
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Medium grade craft/crepe/polythene paper shall be used in between the layers. 2.11.13 2.11.14 A minimum space of 50 mm shall be provided between the inner surface of the external protective lagging and outer layer of the earth wire. Each batten shall be securely nailed across grains as far as possible to the flange, edges with at least 2 nails per end. The length of the nails shall not be less than twice the thickness of the battens. The nails shall not protrude above the general surface and shall not have exposed sharp edges or allow the battens to be released due to corrosion. The nuts on the barrel studs shall be tack welded on the one side in order to fully secure them. On the second end, a spring washer shall be used. Out side the protective lagging there shall be minimum of two binder consisting of hoop iron/galvanized steel wire. Each protective lagging shall have tow recesses to accommodate the binders. The earth wire ends shall be properly sealed and secured on the side of one of the flanges to avoid loosening of the earth wire layers during transit and handling. Marking. Each drum shall have the following information stenciled on it in indelible ink along with other essential data. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Contractor/Award letter number. Name and address of consignee. Manufacturers name and address. Drum number Size of earth wire Length of earth wire in meters Gross weight of drum with earth wire & without lagging Weight of empty drum with lagging Arrow marking for unwinding Position of the earth wire ends
2.11.15 2.11.16
2.11.17
2.12
Number of turns in the outer most layer Distance between outer most layer of Earth wire and the inner surface of lagging (m) Barrel diameter at three locations and an arrow marking at the location of measurement 2.13 Verification of Earth wire Length The Owner reserves the right to verify the length of earth wire after unreeling at least ten (10) percent of the drums in a lot offered for inspection.
2.14
Standards
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The earth wire shall conform to the following Indian/International Standards, which shall man latest revisions, amendments/changes adopted and published, unless otherwise in the Specification. In the event of the supply of earth wire conforming to standards other than specified, the Contractor shall confirm in his bid that these standards are equivalent to those specified. In case of award salient features of comparison between the standards proposed by the Contractor and those specified in this document will be provided by the Contractor to establish their equivalence. Sl. No. 1 2 Indian Standards IS: 209-1979 IS: 398-1982 Title Specification for Zinc Specification for Aluminum Conductors for Overhead Transmission Purposes Aluminum Conductor Galvanized Steel Reinforced Aluminum Alloy Stranded Conductor Aluminumconductor Galvanized Steel Reinforced for Extra High Voltage (400KV) and above Reels and Drums for Bare Conductors Method of Tensile Testing of Steel Wire Recommended Practice for Hot Dip Galvanizing of Iron and Steel 9 IS: 2633-1986 Method of Testing Uniformity of Coating on Zinc Coated Articles 10 IS: 4826-1979 Galvanized coating on Round Steel Wires Methods of Determination of Weight of Zinc Coating of Zinc Coated Iron and Steel Articles Method of Radio Interference Tests on High Voltage Insulators IEC 888-1987 BS:443-1969 BS: 443-1969 ISO: 14601973 IEC: 437-1973 NEMA: 1071964 CISPR IEC: 104-1987 IEC: 888-1987 IEC: 889-1987 International Standards BS: 3436-1986 IEC: 209-1991 BS: 215-1970 BS-215-1970 IEC: 1089-1991 BS-3242-1970 IEC: 1089-1991 ASTM-8399 M86 IEC: 1089-1991 BS: 215-1970 BS: 1559-1949 IS06892-1984
3 4
IS: 398-1982 Part-II IS: 398-1979 Part-IV IS:398-1982 Part-V
6 7 8
IS: 1778-1980 IS: 1521-1972 IS: 2629-1985
11
IS: 6745-1972
12
IS: 8263-1976
13 14 15
IS: 9997-1988
Aluminum Alloy Redraw Rods Zinc Coated steel wires for stranded Conductors Hard drawn aluminum wire for
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overhead line conductors.
The standards mentioned above are available from Reference Abbreviation BS British Standards, British Standards Institution 101, Pentonvile Road, N-19-ND UK International Electro technical Commission, Electro Technique International, 1 Rule de Verembe Geneva SWITZERLAND Beureau of Indian Standards, Manak Bhavan, 9, Bahadur Shah Zafar Marg, New Delhi-110001 INDIA International Organization for Standardization, Danish Standardardising Sraat, Aurehoegvej-12 DENMARK National Electric Manufacture Association, 1 55, East 44th Street, New York, NY 10017 U.S.A Name and Address
IEC/CISPR
BIS
ISO
NEMA
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ANNEXURE-A 1. 1.1 Tests on Earth wire UTS Test Circles perpendicular to the axis of the earth wire shall be marked at two places on a sample of earth wire of minimum 5 m length suitably compressed with dead end clamps at either end. The load shall be increased at a steady rate up to 50% of UTS and held for one minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter the load shall be increased at steady rate to 100% of UTS and held for one minute. The earth wire sample shall not fail during this period. The applied load shall then be increased until the failing load is reached and the value recorded. 1.2 D.C. Resistance Test On a earth wire sample of minimum 5m length two contact clamps shall be fixed with a predetermined bolt torque. The resistance shall be measured by a Kelvin double bridge by placing the clamps initially at Zero meter and subsequently one meter apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 20C. The resistance corrected at 20 C shall conform to the requirements of this Specification. 1.3 Chemical Analysis of Zinc Samples taken from the zinc ingots shall be chemically/spectrographically analyzed. The same shall be in conformity to the requirements stated in the Specification. 1.4 Chemical Analysis of Steel Samples taken from the steel ingots/coils/strands shall be chemically,/ spectrographically analyzed. The same shall be in conformity to the requirements stated in this Specification. 1.5 Visual and Dimensional Check on Drums and its barrel strength test. The drums shall be visually and dimensionally checked to ensure that they conform to the requirements of this Specification. The details regarding barrel strength test will be discussed and mutually agreed to by Contractor and Owner in the quality assurance programme. 1.6 Visual Check for Joints, Scratches etc. and Length of Earth wire Ten percent drums from each lot shall be rewound in the presence of the Owner. The Owner shall visually check for scratches, joints etc. and that the earth wire generally conforms to the requirements of this Specification. The length of earth wire wound on the drum shall be measured with the help of counter meter during rewinding. 1.7 Dimensional Check The individual strands shall be dimensionally checked to ensure that they conform to the requirement of this Specification. 1.8 Lay Length Check
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The lay length shall be checked to ensure that they conform to the requirements of this Specification.
1.9
Galvanizing Test The test procedure shall be as specified in IS: 4826-1979. The material shall conform to the requirements of this Specification. The adherence of zinc shall be checked by wrapping around a mandrel four times the diameter of steel wire.
1.10
Torsion Test The minimum number of twists which a single steel strand shall withstand during torsion test shall be eighteen for a length equal to 100 times the standard diameter of the stand. In case test sample length is less or more than 100 times the stranded diameter of the strand the minimum number of twists will be proportioned to the length and if number comes in the fraction then it will be rounded off to next higher whole number.
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TECHNICAL SPECIFICATION SECTION-III 1. 1.1 1.1.1 TECHNICAL DESCRIPTION OF HARDWARE FITTINGS Details of Hardware Fittings The hardware fittings shall be as per the specification drawings enclosed with this specification. Single suspension, single tension, double suspension and double tension hardware fittings shall be supplied suitable for attaching to hanger/strain plate fixed to tower. Each hardware fitting shall be supplied complete in all respects and shall include the following hardware parts. Suitable arcing horn as specified in clause 1.8 here in after. Suitable yoke plates complying with the specifications given here in after. Suspension and dead end assembly to suit conductor size as detailed in clause 1.10 and 1.11 herein after. Without other necessary fittings as eye links, ball clevis, socket clevis, clevis eye, U clevis and chain link etc, the hardware fittings shall not be complete. 2.5% extra fasteners. Dimensions of Insulator String along with Hardware Fitting The various limiting dimensions of the single Suspension and single/double tension insulator strings along with hardware fittings shall be as per the specification drawings enclosed with this part of the specification. 1.3 1.3.1 Interchangeability The hardware fittings for insulator strings with disc insulators together with ball and socket fittings shall be of standard design, so that these hardware fittings are interchangeable with each other and suitable for use with disc insulators of any make conforming to relevant Indian/International Standard. Corona and RI Performance Sharp edges and scratches on all the hardware fittings shall be avoided. All surfaces must be clean, smooth, without cuts and abrasions or projections. The Contractor must give suitable assurance about the satisfactory corona and radio interference performance of the materials offered by him. 1.5 1.5.1 Maintenance The hardware fittings offered shall be suitable for employment of hot line maintenance technique so that usual hot line operations cab be carried out with ease, speed and safety. T he technique adopted for hot line maintenance shall be generally bare hand method & hot stick method. The Contractor should clearly establish in the bid, the suitability of his fittings for hot line maintenance. Designation Ball and Socket Designation The dimensions of the ball and socket shall be of 16 mm designation wherever 70/90 KN disc Insulators are used. The designation should be in accordance with the standard dimensions stated in IS: 2486-(Part-II)/IEC: 120. The dimensions shall be checked by the appropriate gauge after galvanizing only.
1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.2
1.4
1.6 1.6.1
453
1.7 1.7.1
Security Clips and Split Pins Security clips for use with ball and socket coupling shall be R-shaped, hump type which provides positive locking of the coupling as per IS:2486-(PartIII)/IEC:372.The legs of the security clips shall be spread after assembly in the works to prevent complete withdrawal from the socket. The locking device should be resilient, corrosion resistant and of suitable mechanical strength. There shall be no risk of the locking device being displaced accidentally or being rotated when in position. Under no circumstances shall the locking devices allow separation of fittings. The hole for the security clip shall be countersunk and the clip should be of such design that the eye of clip may be engaged by a hot line clip puller to provide for disengagement under energized conditions. The force required to pull the security clip into its unlocked position shall not be less than 50N (5kg) or more than 500N (50kg) Split pins shall be used with bolts & nuts. Arcing Horn The arcing horn shall be either ball ended rod type or tubular type. For insulator strings with disc insulators, the arcing horn shall be provided shown in the drawings of hardware fittings in these specifications. The sprat gap shall be so adjusted to ensure effective operation and arc actual field conditions. Yoke Plates The strength of yoke plated shall be adequate to with stand the minimum ultimate tensile strength as specified in the bid drawings. The plates shall be either triangular or rectangular in shape as may be necessary. The design of yoke plate shall take into account the most unfavorable loading conditions likely to be experienced as a result of dimensional tolerances for disc insulators as well as components of hardware fittings within the specified range. The Plates shall have suitable holes for fixing corona control rings/grading ring/arcing horn. All the corners and edges should be rounded off with a radius of attest 3mm. Design calculations i.e. for bearing & tensile strength, for deciding the dimensions of yoke plate shall be furnished by the Contractor. The holes provided for bolts in the yoke plate should satisfy shear edge condition as per Clause No.8.10 of IS: 8001984.
1.7.2
1.7.3 1.8 1.8.1 1.8.2 1.8.3 1.9
1.10 1.10.1 1.10.2
Suspension Assembly The suspension assembly shall be suitable for ACSR PANTHER (30/7/3.00) Conductor. The suspension assembly shall include either free centre type suspension clamp along with standard preformed armor rods or armor grip suspension clamp. The suspension clamp along with standard preformed armour rods set shall be designed to have maximum mobility in any direction and minimum moment of inertia so as to have minimum stress on the conductor in the case of oscillation of the same. The suspension clamp along with standard preformed armour rods/armour grip suspension clamp set shall have slip strength between 11 to 16 KN.
1.10.3
1.10.4
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1.10.5
The suspension assembly/shall be designed, manufactured and finished to give it a suitable shape, so as to avoid any possibility of hammering between suspension assembly and conductor due to vibration. The suspension assembly shall be smooth without any cuts, grooves, abrasions, projections, ridges or excrescence which might damage the conductor. The suspension assembly/clamp shall be designed so that is shall minimize the static & dynamic stress developed in the conductor under various loading conditions as well as during wind induced conductor vibrations. It shall also with stand power arcs & have required level of corona/RIV performance. Free Centre Type Suspension Clamp For the free Centre Suspension Clamp seat shall be smoothly rounded and curved into a bell mouth at the ends. The lip edges shall have rounded bead. There shall be at least two U-bolts for tightening of clamp body and keeper pieces together.
1.10.6
1.10.7
1.10.8 1.10.9
Standard Preformed Armour Rod Set The Preformed Armour Rods Set suitable for ACSR PANTHER Conductor shall be used to minimize the stress developed in the sub-conductor due to different static and dynamic loads because of vibration due to wind, slipping of conductor from the suspension clamp as a result of unbalanced conductor tension in adjacent spans and broken wire condition. It shall also withstand power arcs, chafing and abrasion from suspension clamp and localized heating effect due to magnetic power losses from suspension clamps as well as resistance losses of the conductor. The preformed armour rods set shall have right hand lay and the inside diameter of the helices shall be less than the outside diameter of the conductor to have gentle but permanent grip on the conductor. The surface of the armour rod when fitted on the conductor shall be smooth and free from projections, cuts and abrasions etc. The pitch length of the rods shall b determined by the Conductor but shall be less than that of the outer layer of conductor and the same shall be accurately controlled to maintain uniformity and consistently reproducible characteristic wholly independent of the skill of linemen. The length of each rod shall be 1930 16 mm and diameter shall be 6.35 0.10 mm. The tolerance in length of the rods in complete set should be within 13mm between the longest and shortest rod. The ends armour rod shall be parrot billed. The number of armour rods in each set shall be twelve. Each rod shall be marked in the middle with paint for easy application on the line. The armored rod shall not loose their resilience even after five applications. The conductivity of each rod of the set shall not be less than 40% of the conductivity of the International Annealed Copper Standard (IACS). Armour Grip Suspension Clamp The armour grip suspension clamp shall comprise of retaining strap, support housing, elastomer inserts with aluminum reinforcements and AGS prefored rod set. Elastomer insert shall be resistant to the effects of temperature up to 75C, Ozone, ultraviolet radiations and other atmospheric contaminants likely to be
1.10.10.
1.10.10.1
1.10.10.2
1.10.10.3 1.10.10.4 1.10.10.5 1.10.11 1.13.11.1
1.10.11.2
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encountered in service. The physical properties of the elastomer shall be of approved standard. It shall be electrically shielded by a cage of AGS performed rod set. The elastomer insert shall be so designed that the curvature of the AGS rod shall follow the contour of the neoprene insert. 1.10.11.3 1.10.11.4 The AGS preformed rod set shall be as detailed in clause 1.10.10.2 to 1.10.10.5 in general except for the following. The length of the AGS preformed rods shall be such that it shall ensure sufficient slipping strength as detailed under clause 1.10.4 and shall not introduce unfavorable stress on the conductor under all operating conditions. Dead end Assembly The dead end assembly shall be suitable for ACSR PANTHER (30/7/3.00) Conductor. The dead end assembly shall be compression type with provision for comprising jumper terminal at one end. The angle of jumper terminal to be mounted should be 30 with respect to the vertical line. The area of bearing surface on all the connections shall be sufficient to ensure positive electrical and mechanical contact and avoid local heating due to R losses. The resistance of the clamp when compressed on Conductor shall not be more than 75% of the resistance of equivalent length of Conductor. Die compression areas shall be clearly marked on each dead-end assembly designed for continuous die compressions and shall bear the words COM PRESS FIRST suitably inscribed near the point on each assembly where the compression begins. It the dead end assembly is designed for intermittent die compressions it shall bear identification marks COMPRESSION ZONE AND NON-COMPRESSION ZONE distinctly with arrow marks showing the direction of compressions and knurling marks showing the end of the zones. Tapered aluminum filler plugs shall also be provided at the line of demarcation between compression & non-compression zone. The letters, number and other markings on the finished clamp shall be distinct and legible. The dimensional tolerances of the cross section of aluminum and steel dead end; for dead end assembly for ACSR Wolf shall be as per the table given below: Item Dimension before Compression Inner Dia (mm) For ACSR PANTHER 1 2 Aluminum Dead-end Steel Dead-end 230.5 381 180.5 370.5 15.20.5 320.5 17.40.5 Outer dia (mm) Dimension after Compression Corner to corner width (mm) Face to face width (mm)
1.11 1.11.1 1.11.2
1.11.3
Sl. No.
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1.11.4
The assembly shall not permit slipping of, damage to, or failure of the complete conductor or any part there of at a load less than 95% of the ultimate tensile strength of the conductor. Fasteners: Bolts, Nuts and Washers All bolts and nuts shall conform to IS: 6639-1972 ISO-R-272-1968 & IS1363-1989. All bolts and nuts shall be galvanized as per IS-1367-(Part13)/IS2629. All bolts and nuts shall have hexagonal heads, the heads being forged out of solid truly concentric, and square with the shank, which must be perfectly straight. Bolts up to M16 and having length up to 10 times the diameter of the bolt should be manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. The shear strength of bolt for 5.6grade should be 310 MPa minimum as per IS-12427. Bolts should be provided with washer face in accordance with IS: 1363 Part-1 ISO-4016-1979 to ensure proper bearing. Nuts should be double chamfered as per the requirement of IS:1363 Part-III 1984 ISO-4034-1979. It should be ensured by the manufacturer that nuts should not be over tapped beyond 0.4mm over size on effective diameter for size up to M16. Fully threaded bolts shall not be used. The length of the bolt shall be such that the threaded portion shall not extend into the place of contact of the component parts. All bolts shall be threaded to take the full depth of the nuts and threaded enough to permit the firm gripping of the component parts but no further. It shall be ensured that the threaded portion of the bolt protrudes not less than 3 mm and not more than 8mm when fully tightened. All nuts shall fit and tight to the point where shank of the bolt connects to the head. Flat washers and spring washers shall be provided wherever necessary and shall be of positive lock type. Spring washers shall be electro-galvanized. The thickness of washers shall conform to IS: 2016-1967, ISO-R-887-1968. The Contractor shall furnish bolt schedules giving thickness of components connected the nut and the washer and the length of shank and the threaded portion of bolts and size of holes and any other special details of this nature. To obviate bending stress in bolt, it shall not connect aggregate thickness more than three time its diameter. Bolts at the joints shall be so staggered that nuts may be tightened with spanners without fouling. To ensure effective in-process Quality control it is essential that the manufacturer should have all the testing facilities for tests like weight of zinc coating, shear strength, other testing facilities etc, in house. The manufacturer should also have proper Quality Assurance system which should be in line with the requirement of this specification and IS-14000 services Quality System standard. Fasteners of grade higher than 8.8 are not to be used and minimum grade for bolt shall be 5.6.
1.12 1.12.1
1.12.2
1.12.3
1.12.4
1.12.5
1.12.6
1.12.7
1.12.8 1.12.9 1.12.10
1.12.11
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1.13
Materials The materials of the various components shall be as specified here under. The Contractor shall indicate the material proposed to be used for each and every component of hardware fitting stating clearly the class, grade or alloy designation of the material, manufacturing process & heat treatment details and the reference standards.
1.13.1 1.14 1.14.1
The details of materials for different component are listed as in Table No1 Workmanship All the equipment shall be of the latest design and conform to the best modern practices adopted in the Extra High Voltage field. The Contractor shall offer only such equipment as guaranteed by him to be satisfactory and suitable for 132 KV transmission lines and will give continued good performance. The design, manufacturing process and quality control of all the materials shall be such as to give the specified mechanical rating, highest mobility, elimination of sharp edges and corners to limit corona and radio-interference, best resistance to corrosion and a good finish. All ferrous parts including fasteners shall be not dip galvanized, after all machining has been completed. Nuts may, however, be tapped (threaded) after galvanized. The bolt threads shall be undercut to take care of the increase in diameter due to galvanizing. Galvanizing shall be done in accordance with IS: 2629-1985/IS-1367 (partv13) and shall satisfy the tests mentioned in IS:2633-1986. Fasteners shall withstand four dips while spring washers shall with stand three dips of one minute duration in the standard Price test. Other galvanized materials shall be guaranteed to withstand at least six successive dips each lasting one(1) minute under the standard price test for galvanizing. Before ball fittings are galvanized all die flashing on the shank and on the bearing surface of the ball shall be carefully removed without reducing the dimensions below the design requirements. The zinc coating shall be perfectly adherent and of uniform thickness, smooth, reasonably bright, continuous and free from imperfections such as flux, ash rust, stains, bulky white deposits and blisters. The zinc used for galvanizing shall be of grade Zn 99.95 as per IS: 209-1979. Pin balls shall be checked with the applicable GO gauges in at least two directions, one of which shall be across the line of die flashing and the other 90 to this line. NO GO gauges shall not pass in any direction. Socket ends, before galvanizing, shall be of uniform contractor. The bearing surface of socket ends shall be uniform about the entire circumference without depressions of high spots. The internal contours of socket ends shall be concentric with the axis of the fitting as per IS: 2486/IEC: 120. The axis of the bearing surfaces of socket ends shall be coaxial with the axis of the fittings. There shall be no noticeable tilting of the bearing surfaces with the axis of the fittings.
1.14.2
1.14.3
1.14.4
1.14.5
1.14.6
1.14.7
1.14.8
In case of casting, the same shall be free from all internal defects like shrinkage, inclusion, blow holes, cracks etc. Pressure die casting shall not be used for casting of components with thickness more than 5mm.
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1.14.9 1.14.10
All current carrying parts shall be so designed and manufactured that contact resistance is reduced to minimum. No equipment shall have sharp ends or edges, abrasions or projections and cause any damage to the conductor in any way during erection or during continuous operation which would produce high electrical and mechanical stresses in normal working. The design of adjacent metal parts and mating surfaces shall be such as to prevent corrosion of the contact surface and to maintain good electrical contact under service conditions. All the holes shall be cylindrical, clean cut and perpendicular to the plane of the material. The periphery of the holes shall be free from burrs. All fasteners shall have suitable corona free locking arrangement to guard against vibration loosening. Welding of aluminum shall be by inert gas shielded tungsten arc or inert gas shielded metal arc process. Welds shall be clean, sound, smooth, uniform without overlaps, properly fused and completely sealed. There shall be no cracks, voids incomplete penetration, incomplete fusion, under-cutting or inclusions. Porosity shall be minimized so that mechanical properties of the aluminum alloys are not affected. All welds shall be properly finished as per good engineering practices. Bid Drawings The Contractor shall furnish full description and illustrations of materials offered. Fully dimensioned drawings of the complete insulator string hard wares and there component parts showing clearly the following arrangements shall be furnished in five (5) copies along with the bid. Weight, material and fabrication details all the components should be included in the drawings. i) ii) iii) iv) v) vi) Attachment of the hanger or strain plate. Suspension or dead end assembly. Arcing horn attachment to the string as specified in clause 1.8 of the technical Specification. Yoke plates Hardware fittings of ball and socket type for inter connecting units to the top and bottom Yoke plates. Links with suitable fittings.
1.14.11 1.14.12 1.14.13
1.15 1.15.1 1.15.2
1.15.3
All drawings shall be identified by a drawings number and contract number drawings shall be neatly arranged. All drafting & lettering shall be legible minimum size of lettering shall be 3mm. All dimensions & dimension tolerances shall be mentioned in mm. The drawings shall include: i) Dimensions and dimensional tolerance. ii) Material, fabrication details including any weld details & any source finishes & coatings. Regarding material designation & reference standards are to be indicated. Catalogue No. Marking
iii) iv)
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v) vi)
Weight of assembly Installation instructions
vii) Design installation torque for the bolt or cap screw viii) Withstand torque that may be applied to the bolt or cap screw without failure of component parts. ix) x) 1.15.4 The compression die number with recommended compression pressure. All other relevant terminal details.
After placement of award, the Contractor shall submit fully dimensioned drawing including all the components in four (4) copies to the Owner for approval. After getting approval from the Owner and successful completion of all the type tests, the Contractor shall submit thirty (30) more copies of the same drawings to the Owner for further distribution and field use at Owners end. TABLE-1 Details of Material
Sl. No. 1
Name of Item Security Clips
Material Stainless Steel/ Phos Pher Bronze Mild Steel Rod/Tube Type
Process of Treatment
Reference Standard AISI 302 or 304-L/ IS- 1385-1968
Remarks
Arcing Horn
Hot dip galvanized Drop forged & normalized Hot dip Galvanized Hot dip Galvanized
As per IS-2261975 or IS2062-1992 As per IS: 2004-1978
Ball Fittings. Class-IV Socket, All Steel Shackles links cleves,
4.
Yoke Plate
Mild Steel
As per IS: 226-1975/ IS-2062-1992
Free Centre Clamp/Envelope Type Clamp a) Clamp Body/ keeper piece
High strength gth Al.Alloy 4600/LM-6 Or 6061/ 65032 Mild Steel
Casted or forged & Heat treated Hot dip galvanized
IS:617 or ASTM-B429
b) Cotter bolts, Hangers, Shackles, Brackets c) U.Bolts
IS-226-1975/ IS-2062-1992
Stainless Forged & Steel or heat treated High Strength
AISI 302 or 304-L ASTM-B429

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Al.alloy 6061/6063 or 65032/63400 6. P.A. Rod High Strength Heat Al.alloy type treatment 6061/65032 during Manufacturing High Strength Corrosion resistant Al. Alloy LM6, 4600 or 6061/65032 Cast/ forged Heat treated ASTM-B429 Min tensile Strength of 35 kg/ mm IS: 617 or ASTM-B429
7.
AGS Clamp a) Supporting House
b) Al. Insert & Retaining Strap c) Elastomer Cushion 11. Dead end Assembly a) Outer Sleeve of dead end.
High Strength forged & Al. Alloy of Heat treated type 6061/ 65032 Moulded on Al. reinforcement
ASTM-B429 or as per IS: 617
EC grade Aluminium
Note: Alternate materials conforming to other national standards of other countries also may be offered provided the properties and compositions of these are equal or superior to the properties and compositions of material specified. Contractor should furnish the details of comparison of material offered viz a viz specified in the bid or else the bids are liable to be rejected. 2.0 2.1 2.1.1 2.1.2 2.2 2.2.1 Accessories for ACSR Panther Conductor General This portion (under clause 2.) details the technical particulars of the accessories for ACSR Panther Conductor. 2.5% extra fasteners, filler plugs and retaining rods shall be provided. Mid Span Compression Joint Mid Span Compression Joint shall be used for joining two length of conductor. The joint shall have a resistively less than 75% of the resistively of equivalent length of conductor. The joint hall not permit slipping off, damage to or failure of the complete conductor or any part there of at a load less than 95% of the ultimate tensile strength of the conductor. The joint shall be made of aluminum or aluminum alloy for joining the conductor sleeves for the aluminum sleeve shall have aluminum of purity not less than 99.5%. If whole of the sleeve is not to be compressed then tapered aluminum filler plugs shall be provided on the line of demarcation between compression and non compression zone. The dimensions and dimensional tolerances of mid span compression joint shall be as per Table-II.
2.2.2
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2.3
Repair Sleeve Repair Sleeve of compression type shall be used to repair conductor with not more than two strands broken in the outer layer. The sleeve shall be manufactured 99.5% pure aluminum and shall have a smooth surface. The repair sleeve shall comprise of two pieces with a provision of seat for sliding of the keeper piece. The edges of the seat as well as the keeper piece shall be as rounded that the conductor strands are not damaged during installation. The dimensions and dimensional tolerances of repair sleeve shall be as per Table-II
2.4 2.4.1
Vibration Damper Vibration dampers of 4R-stockbridge type with four (4) different resonances spread within the specified Aeolian frequency band width corresponding to wind speed of 1m/s to 7m/s shall be used at suspension and tension points on each conductor in each span along with bundle spacers to damp out Aeolian vibration as mentioned hereinafter. Alternate damping systems or Dog bone dampers offering equivalent or better performance also shall be accepted provided the manufacturer meets the qualifying requirements stipulated in the Specifications. Relevant technical documents to establish the technical suitability of alternate systems shall be furnished by the Contractor along with the bid. One damper minimum on each side per sub-conductor for suspension point and two dampers minimum on each side per sub-conductor for tension points shall be used for ruling design span of 350 meters. The Contractor may offer damping system involving more number of dampers per ruling design span than the specified. However suitable price compensate shall be considered for evaluation. For the purpose of price compensation of the towers as suspension locations and 20% of the towers as tension locations and all the spans shall be assumed to be ruling design spans. The clamp of the vibration damper shall be made of high strength aluminum alloy of type LM-6. It shall be capable of supporting the damper and previous damage or chafing of the conductor during erection or continued operation clamp shall have smooth and permanent grip to keep the damper in position the conductor without damaging the strands or causing premature fatigue of the conductor under the clamp. The clamp groove shall be in uniform contact with the conductor over the entire clamping surface except for the rout edges. The groove of the clamp body and clamp cap shall be smooth, from projections, grit or other materials which could cause damage to the conductor when the clamp is installed. Clamping bolts shall be provided with selling nuts and designed to prevent corrosion of threads or loosening in service. The messenger cable shall be made of high strength galvanized steel/stain steel with a minimum strength of 135 Kg/ sqmm. It shall be of performed post formed quality in order to prevent subsequent droop of weigh maintain consistent flexural stiffness of the cable in service. The number of strands in the messenger cable shall be 19. The messenger cable, other than stainless steel shall be hot dip galvanized in accordance with the recommendations of IS: 4826-1979 for heavily coated wires. The damper mass shall be made of hot dip galvanized mild steel/cast iron or a permanent mould cast zinc alloy. All castings shall be tree from defects such
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
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as cracks, shrinkage, inclusions and blowholes etc. The surface of the damper masses shall be smooth. 2.4.8 The damper clamp shall be casted over the messenger cable and offer sufficient and permanent grip on it. The messenger cable shall not slip out of the grip at a load less than the mass pull-off value of the damper. The damper masses made of material other-than zinc alloy shall be fixed to the messenger cable in a suitable manner in order to avoid excessive stress concentration on the messenger cables which shall cause premature fatigue failure of the same. The messenger cable ends shall be suitably and effectively sealed to prevent corrosion. The damper mass made of zinc alloy shall be casted over the messenger cable and have sufficient and permanent grip on the messenger cable under all service conditions. The damper assembly shall be so designed that it shall not introduce radio interference beyond acceptable limits. Vibration dampers shall be capable of being installed and removed from energized line by means of hot line technique. In addition, the clamp shall be capable of being removed and reinstalled on the conductor at the designated torque without shearing or damaging of fasteners. Conductor must indicate the clamp bolt tightening torque to ensure that the slip strength of the clamp is maintained between 2.5 KN and 5 KN. The clamp when installed on the conductor shall not cause excessive stress concentration on the conductor leading to permanent deformation of the conductor strands and premature fatigue failure in operation. Vibration damper shall not have magnetic power loss more than 1 watt at 350 Amps. 50 HZ alternating current per sub-conductor when installed on a twin bundle system. Vibration analysis of the system, with and without damper and dynamic characteristics of the damper shall have to be submitted. The technical particulars for vibration analysis and damping design of the system are as follows: Sl No. 1 Configuration ACSR (3/7/3.00) Single circuit Single ACSR conductor. Description Technical Particulars
2.4.9 2.4.10
2.4.11
2.4.12
2.4.13
Span length in meters i) Ruling design span ii) Maximum span iii) Minimum span 300 meters 1100 meters 100 meters Shall be supplied by the owner
4 5
Tensile load in conductor at Various temperature and wind Condition Armour rods used Maximum permissible dynamic Strain
Standard preformed armour rods/AGS +/- 150 micro strains
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2.4.14.
The damper placement chart for spans ranging from 100m to 1100 m shall be submitted by the Contractor. Placement charts should be duly supported with relevant technical documents and sample calculations. The damper placement charts shall include the following 1) Location of the dampers for various combinations of spans and line tensions clearly indicating the number of dampers to be installed per conductor per span. Placement distances clearly identifying the extremities between when the distances are to be measured. Placement recommendation depending upon type of suspension clamp (viz free centre type/Armour grip type etc.) The influence of mid span compression joints, repair sleeves and armour rods (standard and AGS) in the placement of dampers.
2.4.15.
2) 3) 4) 2.6 2.6.1
Material and Workmanship All the equipment shall be of the latest proven design and conform to the best modern practice adopted in the extra high voltage field. The Contractor shall offer only such equipment as guaranteed by him to be satisfactory and suitable for 132 KV transmission line application with bundle conductors and will give continued good performance. The design, manufacturing process and quality control of all the materials shall be such as to achieve requisite factor of safety for maximum working load, highest mobility, elimination of sharp edges and corners, best resistance to corrosion and a good finish. All ferrous parts shall be hot dip galvanized, after all machining has been completed. Nuts may, however, be tapped (threaded) after galvanizing and the threads oiled. Spring washers shall be electro galvanized as per grade 4 of IS-1573-1970. The bolt threads shall be undercut to take care of increase in diameter due to galvanizing. Galvanizing shall be done in accordance with IS: 2629-1985/IS-1367(Part-13) and satisfy the tests mentioned in IS-2633-1986. Fasteners shall withstand four dips white spring washers shall withstand three dips. Other galvanized materials shall have a minimum over range coating of Zinc equivalent to 600 gm/sq.m and shall be guaranteed to withstand at least six dips each lasting one minute under the standard price test for galvanizing unless otherwise specified. The zinc coating shall be perfectly adherent, of uniform thickness, smooth, reasonably right, continuous and free from imperfections such as flux, ash, rust stains, bulky white deposits and blisters. The zinc used for galvanizing shall be of grade Zn.99.95 as per IS: 209-1979. In case of castings, the same shall be free from all internal defects like shrinkage, inclusion, blow holes, cracks etc. All current carrying parts shall be so designed and manufactured that contact resistance is reduced to minimum and localized heating phenomenon is averted. No equipment shall have sharp ends or edges, abrasions or projections and shall not cause any damage to the conductor in any way during erection or during continuous operation which would produce high electrical and mechanical stresses in normal working. The design of adjacent metal parts
2.6.2
2.6.3
2.6.4
2.6.5 2.6.6
2.6.7
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and mating surfaces shall be such as to prevent corrosion of the contact surface and to maintain good electrical contact under all service conditions. 2.6.8 2.6.9 Particular care shall be taken during manufacture and subsequent handling to ensure smooth surface free from abrasion or cuts. The fasteners shall conform to the requirements of IS: 6639-1972. All fasteners and clamps shall have corona free locking arrangement to guard against vibration loosening. Compression Markings Die compression areas shall be clearly marked on equipment designed for continuous die compressions and shall bear the words COMPRESS FIRST suitably inscribed on equipment where the compression begins. If the equipment is designed for intermittent die compressions. It shall bear the identification marks COMPRESSION ZONE and NON-COMPRESSION ZONE distinctly with arrow marks showing the direction of compression and knurling marks showing the end of the zones. The letters, number and other markings on finished equipment shall be distinct and legible. 2.8 2.8.1 Bid Drawings The Contractor shall furnish detailed dimensioned drawings of the equipments and all component parts. Each drawing shall be identified by a drawing number and Contractor number. All drawings shall be neatly arranged. All drafting and lettering shall be legible. The minimum size of lettering shall be 3mm. All dimensions and dimensional tolerances shall be mentioned in mm. The drawings shall include i) ii) Dimensions and dimensional tolerances Material, fabrication details including any weld details and any specified finishes and coatings. Regarding material, designations and reference of standards are to be indicated. Catalogue No. Marking Weight of assembly Installation instructions Design installation torque for the bolt or cap screw Withstand torque that may be applied to the bolt or cap screw without failure of component parts. The compression die number with recommended compression pressure. All other relevant technical details
2.7
2.8.2
iii) iv) v) vi) vii) (viii) ix) x) 2.8.3 2.8.4.1
Placement charts for spacer/spacer damper and damper The above drawings shall be submitted in five copies with all the details as stated above along with the bid document. After the placement of award the Contractor shall again submit the drawings in four copies to the Owner for approval. After Owners approval and successful completion of all type tests, 30(thirty) more sets of drawings shall be submitted to Owner for further distribution and filed use at Owners end.
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Table II Dimensions & Dimensional Tolerances for Mid Span Compression Joint, TConnector and Repair Sleeve Sl No. Item Dimensions before compression Inner Dia (mm) 1.
i)
Outer Dia (mm)
Length
(mm)
Dimensions after Compression Corner to Face to Corner Face width width (mm) (mm)
Mid Span Compression Joint Aluminum 230.5 11.10.2 Repair Sleeve 230.5
* Indicative only.
381 180.5 381
6105* 2035* 2415
370.5 17.40.5 370.5
320.5 5.10.5 320.5
ii) Steel 2.
3. 3.1
G.S Earth wire Accessories General
3.1.1 This portion (under clause 3) details the technical particulars of the accessories for Galvanized Steel Earth wire. 3.1.2 2.5% extra fasteners shall be supplied. 3.2 Mid Span Compression Joint Mid Span Compression joint shall be used for joining two lengths of earth wire. The joint shall be made of mild steel with aluminum encasing. The Brinnel Hardness of stainless steel should not exceed 200. The steel sleeve shall be hot of galvanized. The aluminum sleeve shall have aluminum of purity not less that 99.5%. Filler aluminum sleeve shall also be provided at the both ends. The joints shall not be permit slipping off, damage to or failure of the complete earth wire or Sl Item No. Dimensions before compression Inner Dia (mm) 1) Aluminum Sleeve Steel Sleeve Filler Aluminum Sleeve Outer Dia (mm) Length Dimensions after Compression Comer to Face to Comer Face width width (mm) (mm)
(mm)
220.5 100.2
300.5 210.5
3155 2305
29.40.5 20.20.5
250.5 17.50.5
2)
3).
11.50.2 210.5
252
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3.3
Vibration Damper
3.3.1 Vibration dampers of 4R-Stockbridge type with four(4) different frequencies spread within the specified Aeolian frequency band-width corresponding to wind speed of M/s to 7m/s shall be used for suspension and tension points on each earth wire in each span to damp out Aeolian vibration as mentioned herein after. 3.3.2 Alternate damping systems or Dog bone dampers offering equivalent or better performance also shall be acceptable provided the manufacturer meets the qualifying requirements stipulated in the Specifications. Relevant technical documents to establish the technical suitability of alternate systems shall be furnished by the Contractor along with the bid. 3.3.3 One damper minimum on each side per earth wire at suspension points and two dampers on each side pe earth wire at tension points shall be used for ruling design span of 350 meters. 3.3.4 The Contractor may offer damping system involving more number of dampers per ruling design span than the specified. However suitable price compensation shall be considered for evaluation. For the purpose of price compensation 80% of towers as suspension locations and 20% of the towers as tension locations and all the spans assumed to be ruling design spans. 3.3.5 The clamp of the vibration damper shall be made of aluminum alloy. It shall be capable of supporting the damper during installation and prevent damage or chafing of the earth wire during erection or continued operation. The clamp shall have smooth and permanent grip to keep the damper in position on the earth wire without damaging the strands or causing premature fatigue failure of the earth wire under the clamp. The clamp groove shall be in uniform contact with the earth wire over the entire clamping surface except for the rounded edges. The groove of the clamp body and clamp cap shall be smooth, free from projections, grit or materials which could cause damage to the earth wire when the clamp is installed. Clamping bolts shall be provided with self locking nuts designed to prevent corrosion of the threads or loosening during service. 3.3.6 The messenger cable shall be made of high strength galvanized steel/stainless steel with a minimum strength of 135 Kg/sqmm. It shall be of preformed and post formed quality in order to prevent subsequent droop of weights and to maintain consistent flexural stiffness of the cable in service. The number of standards in the messenger cable shall be 19. The messenger cable ends shall be suitably and effectively sealed to prevent corrosion. 3.3.7 The damper mass shall be made of hot dip galvanized mild steel/cast iron or a permanent mould cast zinc alloy. All castings shall be free from defects such as cracks, shrinkages, inclusions and blow holes etc. The inside and outside surfaces of the damper masses shall be smooth. 3.3.8 The vibration analysis of the system, with and without damper, dynamic characteristic of the damper shall have to be submitted by the Contractor along with his bid. The technical particulars for vibration analysis and damping design of the system are as follows.
Sl. No. Description 1. Span length in meters i) ii) Ruling design span Maximum span : : 300 meters 1100 meters
Technical Particulars
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iii) 2.
Minimum span
100 meters
Tensile load in Each earth wire at temperature of 0 deg.C and Still air. Maximum permissible Dynamic strain
1340 kgf +/- 150 micro strains
3.
3.3.9.
The damper placement chart for spans ranging from 100 m to 1100m shall be submitted by the Contractor. All the placement charts should be duly supported by relevant technical documents. The damper placement charts shall include the following: 1) Locations of the dampers for various combinations of spans and line tensions clearly indicating number of dampers to be installed per earth wire per span. Placement distances clearly identifying the extremities between which the distances are to be measured. Placement recommendation depending upon type of suspension clamp (viz, free centre type/trunion type etc.) The influence of mid span compression joints in the placement of dampers.
3.3.10.
2) 3) 4) 3.4
Flexible Copper Bond The flexible copper bond shall be circuit in cross-section of minimum 34 sq.mm equivalent copper area and not less than 500 mm in length. It shall consist of 259 wires of 0.417 mm dia. Tinned copper conductor. It shall be laid up as 7 stranded ropes, each of 37 bunched wires. The tinning shall be as per relevant Indian Standard. Two tinned copper connection lugs shall be press jointed to either ends of the flexible copper cable. One lug shall be suitable for 12 mm, dia bolt and the other for 16 mm dia. bolt. The complete assembly shall also include one 16 mm dia. 40mm long HRH MS bolt hot dip galvanized with nut and lock washer.
3.5 3.5.1
Suspension Clamp Standard twisted shackle for earth wire suspension clamp shall be supplied for attaching to the hanger plate of tower having minimum thickness of 12mm with hole of 21.5 mm diameter. At all suspension towers, suspension clamps shall be used to support the earth wire of 7/3.15mm size. The clamps shall be of either free centre type or trunion type and shall provide adequate area of support to the earth wire. The groove of the clamp shall be smooth, finished in an uniform circular or oval shape and shall slope down wards in a smooth curve to avoid edge support and hence to reduce the intensity of bending moment on earth wire. There shall be no sharp point in the clamps coming in contact with earth wire. There shall not be any displacement in the configuration of the earth wire strands nor shall the strands be unduly stressed in final assembly during working conditions. The clamping piece and the clamp body shall be clamped by at least two Ubolts of size not less than 1.0 mm diameter having one nut and one 3mm thick
3.5.2
3.5.3
3.5.4
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lock nut with washer on each of its limbs. Suspension clamps shall be provided with inverted type U-bolts. One limb of the U-bolt shall be long enough to accommodate the lug of the flexible copper bond. 3.5.5 The Contractor shall supply all the components of the suspension assembly including shackles, bolts, nuts, washers, split pin etc. The total drop of the suspension assembly from the centre point of the attachment to the centre point of the earth wire shall not exceed 150 mm. the design of the assembly shall be such that the direction of run of the earth wire shall be same as that of the conductor. The complete assembly shall be guaranteed for slip strength of not less than 9 KN and not more than 14 KN. The breaking strength of the assembly shall not be less than 25 KN. Tension Clamp At all tension towers suitable compression type tension clamps shall be used to hold 7/3.15 mm galvanized steel earth wire. Anchor shackle shall be supplied which shall be suitable for attaching the tension clamp to strain plates. The clamps shall have adequate area of bearing surface to ensure positive electrical and mechanical contact and shall not permit any slip to the earth wire under working tension and vibration conditions. The angle of jumper terminal to be mounted should be 30 deg. with respect to the vertical line. The clamps shall be made of mild steel with aluminum encasing. The steel should not crack or fail during compression. The Brinnel hardness of steel sleeve shall not exceed 200. The steel sleeve shall be hot dip galvanized. The aluminum encasing shall have aluminum of purity not less than 99.5%. Filler aluminum sleeve shall also be provided at the end. The complete assembly shall be so designed as to avoid undue bending in any part of the clamp and shall not produce any hindrance to the movements of the clamps in horizontal or vertical directions. The slip strength of the assembly shall not be less than 95% of the ultimate strength of the earth wire. The clamps shall be complete with all the components including anchor shackle, bolts, nuts, washers, split pin, jumper arrangement etc. Material and workmanship Same as Clause 2.6 of this section
3.5.6
3.6 3.6.1
3.6.2
3.6.3
3.6.4
3.6.5 3.6.6 3.7
3.8
3.9 4. 4.1 4.2
Compression Marking Same as Clause 2.7 of this section Bid Drawings Same as Clause 2.8 of this section Tests and Standards Tests Type Tests
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4.2.1
On the complete Disc Insulator String with Hardware Fittings (a) Power frequency voltage withstand Test with corona control rings/grading Ring and arcing horns under wet Condition. Impulse voltage flashover test under dry condition Impulse voltage flashover test under wet condition. Voltage distribution test Mechanical Strength test Vibration test IEC: 383-1993
IEC: 383-1993
b) c) d) e) f)
4.2.2
On Suspension Hardware Fitting only a) b) c) d) Magnetic power loss test for suspension assembly Clamp slip strength Vs torque test for suspension clamp Mechanical strength Test OZONE Test on elastomer
4.2.3
On Tension Hardware fittings only a) b) c) d) Electrical resistances test for dead end Assembly Heating cycle test for dead end Assembly Slip strength test for dead-end assembly Mechanical strength test
IS: 2486- (Part-I): 1971, Clause 5.4 & 5.6
4.2.4
Mid Span Compression Joint for Conductor and Earth wire a) b) c) d) Chemical analysis of materials Electrical resistance test Heating cycle test Slip strength test
IS: 121- Part-II), 1981 Clause 6.5 & 6.6
Note: Test mentioned at (c) & are not applicable to mid span compression joints for earth wire. 4.2.5 Repair Sleeve for Conductor a) 4.2.6 Chemical analysis of materials
Flexible Copper Bond a) Slip, Strength Test
4.2.7
Vibration Damper for Conductor and Earth wire a) b) c) Chemical analysis of materials Dynamic characteristics test Vibration analysis
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d) e) f) g) Note: 4.2.8
Clamp slip test Fatigue tests Magnetic power loss test Damper efficiency test IS: 9708-1980
Tests mentioned at (f) & are not applicable to dampers for earth wire.
Earth wire Suspension Clamp Assembly a) b) c) 4.2.9 a) b) c) d) Chemical analysis of materials Mechanical strength test Clamp slip strength Vs Torque test for suspension assembly Earth wire Tension Clamp Assembly Chemical analysis of materials Mechanical strength test (excluding clamp) Slip strength test on tension assembly Electrical resistance test on tension clamp All the type tests given under clause no. 4.2.1 above shall be conducted on Single suspension and Single tension insulator string along with hardware fittings. The tests specified under Clause No.4.2.1 (a) to (f) shall be conducted on Double tension Insulator string and double v suspension string along with hardware fittings.
4.3 4.3.1
Acceptance Tests On Both Suspension and Tension Hardware Fittings a) b) c) d) e) f) g) Visual Examination Verification of dimensions Galvanizing/Electroplating test Mechanical strength test of each component Mechanical Strength test of welded joint Test on locking device for ball and socket coupling Chemical analysis, hardness tests, grain size, inclusion rating & magnetic particle inspection for forgings/castings
IS: 2486 (Part-I)-1971 Clause 5.8 & 5.9
IEC: 372 (2)-1984
4.3.2
On Suspension Hardware Fitting only a) b) c) d) Clamp Slip strength Vs Torque test for suspension clamp Shore hardness test of elastomer cushion for AG suspension clamp Bend test for armour rod set Resilience test for armour rod set
IS: 2121 (Part-I) Clause 7.5, 7.10, 7.11
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e) 4.3.3
Conductivity test for armour rods set
On Tension Hardware Fittings Only a) Slip strength test for dead end assembly, IS: 2486 (Part-I) 1971, Clause 5.4
4.3.4
Mid Span Compression Joint for Conductor and Earth wire a) b) c) Visual examination and dimensional verification Galvanizing test Hardness test
IS: 2121 (Part-II)-1981 Clause 6.2, 6.3 & 6.7
4.3.5
Repair Sleeve for Conductor a) Visual examination and dimensional verification IS: 2121-(Part-II)1981 Clause 6.2,6.3
4.3.6
Flexible Copper Bond a) b) Visual examination and dimensional verification Slip strength test
IS: 2121 (Part-II)-1981 Clause 6.2, 6.3
4.3.7
Vibration Damper for Conductor and Earth wire a) b) Visual examination and dimensional verification Galvanizing test i) On damper masses
ii) On messenger cable c) d) e) f) g) h) 4.3.8 Verification of resonance frequencies Clamp slip Clamp bolt torque test Strength of the messenger cable Mass pull off test Dynamic Characteristics test
IS: 2121 (Part-II)-1981 Clause 6.2, 6.3 & 6.7
Earth wire Suspension Clamp Assembly a) b) c) d) Visual examination and dimensional verification Galvanizing test Clamp slip strength test Mechanical strength test on each component
IS: 2121 (Part-II)-1981
4.3.9
Earth wire Tension Clamp Assembly a) b) c) d) Visual examination and dimensional verification Galvanizing test Slip strength test for tension clamp Mechanical strength test on each component (excluding clamp)
IS: 2121 (Part-II)-1981
IS: 2121 (Part-II)-1981

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e)
Hardness test
4.4 4.4.1
Routine Tests For Hardware Fittings a) b) Visual examination Proof Load Test IS: 2486-(Part-0 1971
4.4.2
For Conductor and Earth wire Accessories a) Visual examination and dimensional verification IS: 2121-(Part-II) 1981 Clause 6.2 & 6.3
4.5
Tests During Manufacture On all components as applicable a) b) Chemical analysis of Zinc used for galvanizing Chemical analysis mechanical metallographic test and magnetic particle inspection for malleable castings. Chemical analysis, hardness tests and magnetic particle inspection for forgins
c) 5.0 5.1 5.2
Testing Expenses Testing charges for the type test specified shall be indicated separately in the prescribed schedule. Contractor shall indicate charges for all type tests covered under Clause No. 4.2.1 to 4.2.9 separately. The charges for each type test shall be separately indicated. Testing charges for all type tests specified under clause no. 4.2.1 shall be indicated only by insulator Contractors, as the charges for these tests shall be paid to them duly by the Owner to avoid duplication and shall not be indicated by the hardware Contractor. For type tests which involves the test on the complete insulator string with hardware fittings, the contractor of hardware fittings shall supply the necessary number of sets of hardware fittings at the place of testing free of cost. In case of failure in any type test the Contractor whose material has failed is either required to modify the design of the material & successfully carryout all the type tests as has been detailed out in Clause 4.1 of this specification or to repeat that particular type test at least three times successfully at his own expenses. In case of failure of the complete string in any type test, the manufacturer whose product has failed in the test shall get the test repeated at his cost. The supplier whose materials has not failed in the test shall be required to supply the requisite quantity of material has not failed in the test shall be required to supply the requisite quantity of material (that is, insulator discs or hardware fittings as the case may be) required for repeat testing at the place of testing and the cost of supply shall be borne by the Contractor whose material has failed in testing.
5.3
5.4
5.5
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5.6
Contractor shall indicate the laboratories in which they proposes to conduct the type tests. They shall ensure that adequate facilities for conducting the tests are available in the laboratory and the tests can be completed in these laboratories within the time schedule guaranteed by them in the appropriate schedule. The entire cost of testing for acceptance and routine tests and tests during manufacture specified herein shall be treated as included in the quoted Exworks/CIF Price. In case of failure in any type test, repeat type tests are required to be conducted then all the expenses for deputation of Inspector/Owners representative shall be deducted from the contract price. Also if on receipt of the Contractors notice of testing, the owners representative/Inspector does not find plant to be ready for testing the expenses incurred by the Owner for redeputation shall be deducted from contract price. The Contractor shall intimate the Owner about carrying out of the type tests along with detailed testing programme at least 3 weeks in advance (in case of Domestic Contractor and at least 6 weeks advance in case of Foreign Contractor) of the scheduled date of testing during which the Owner will arrange to depute his representative to be present at the time of carrying out the tests. Sample Batch for Type Testing The Contractor shall offer material for sample selection for type testing only after getting Quality Assurance Programme approved by the Owner. The Contractor shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. The sample for type testing will be manufactured strictly in accordance with the Quality Assurance Programme approved by the Owner. Before sample selection for type testing the Contractor shall be required to conduct all the acceptance tests successfully in presence of Owners representative. Schedule of Testing and Additional Tests The contractor has to indicate the schedule of following activities in their bids a) b) c) d) Submission of drawing for approval. Submission of Quality Assurance programme for approval. Offering of material for sample selection for type tests. Type testing.
5.7
5.8
5.9
6.0 6.1
6.2
7.0 7.1
7.2
The Owner reserves the right of having at his owner expense any other test(s) of reasonable nature carried out at Contractors premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the material comply with the specifications. 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 Contractors premises or at any other test centre. In case of evidence of non compliance, if shall be binding on the part of Contractor to prove the compliance of the items to the technical specifications by repeat tests, or correction of deficiencies, or replacement of defective, all without any extra cost to the Owner.
7.3
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8.0
Co-ordination for testing The Contractors shall have to co-ordinate testing of their hardware fittings with insulators to be supplied by other Contractors to the Owner and shall have to also guarantee overall satisfactory performance of the hardware fittings with the insulators.
9.0 9.1
Tests Reports Copies of type reports shall be furnished in at least six copies along with one original. One copy shall be returned duly certified by the Owner, only after which the commercial production of the concerned material shall start. Copies of acceptance test reports shall be furnished in at least six copies. One copy shall be returned, duly certified by the owner, only after which the materials will be dispatched. Record of routine test report shall be maintained by the Contractor at his works for periodic inspection by the Owners representative. Test certificates of tests during manufacture shall be maintained by the Contractor. These shall be produced for verification as and when desired by the Owner.
9.2
9.3 9.4
10.0 Inspection 10.1 The Owners representative shall at all times be entitled to have access to the works and all places of manufacture, where the material and/or its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection of the Contractors, Sub-Contractors works raw materials, manufacturers of all the material and for conducting necessary tests as detailed herein. The material for inspection shall be offered by the Contractor only under packed condition as detailed in clause 11.0 of this part of the Specification. The engineer shall select samples at random from the packed lot for carrying out acceptance tests. The Contractor shall keep Owner informed in advance of the time of starting and of the progress of manufacture of material in its various stages so that arrangements could be made for inspection. Material shall not 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 all tests specified herein have been satisfactorily completed. The acceptance of any quantity of material shall in 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 is later found to be defective. Packing and Marking All material shall be packed in strong and weather resistant wooden cases/ creates. The gross weight of the packing shall not normally exceed 200 Kg to avoid handling problems. The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and subsequent handling in the field.
10.2
10.3
10.4
10.5
11.0 11.1
11.2
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11.3 11.4
Suitable cushioning, protective padding, Dunn age or spacers shall be provided to prevent damage of deformation during transit and handling. Bolts, nuts washers, cotter pins, security clips and split pins etc. shall be packed duly installed and assembled with the respective parts and suitable measures shall be used to prevent their loss. Each component part shall be legibly and indelibly marked with trade mark of the manufacturer and year of manufacture. All the packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible marking. Each wooden ease/crate shall have all the markings stenciled on it in indelible ink.
11.5 11.6
Standards: Sl. No. 1. 2. Indian Standard IS: 6639-1990 IS: 9708-1993 Title Hexagonal Bolts for Steel Structures Specification for Stock Bridge Vibration Dampers for Overhead Power Lines Specification for Spacers Dampers for Twin Horizontal Bundle Conductors International Standards ISO/R 272-1968
3.
IS: 10162-1982
The Standards mentioned above are available from Reference Abbreviation BS Name and Address British Standards, British Standards Institution 101 Pentonvile Road N. 19-ND UK International Electro technical commission, Bureau Central de la Commission, Electro Technique International, 1 Rue de verembe Geneva SWITZERLAND Beureau of Indian Standards, Manak Bhavan, 9, Bahadur Shah Zafar Marg, New Delhi-110001 INDIA. International Organization for Standardization Danish Board Standardization Danish Standardizing Sratt. Aurehoegvej-12 DK-2900 Heeleprup DENMARK.
IEC/CISPR
BIS/IS
ISO
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NEMA
National Electric Manufacture Association, 155, East 44th Street, New York, NY 10017 USA.
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SECTION IV TECHNICAL SPECIFICATIONS 1. 1.1 1.1.1 TECHNICAL DESCRIPTION OF ACSR (PANTHER) Details of Conductors The ACSR Conductors shall generally conform of IEC: 1089 or IS: 398 (Part-II-1996) except where otherwise specified herein. ACSR PANTHER CONDUCTOR a) Code name b) Stranding and wire : : PANTHER ACSR 30 / 3.00mm Al dia 7 / 3.00mm steel dia c) Number of Strands Steel core
1st st
1.2
: : : : : : : : : : : : : : : : : : : 1.17 kN 1.11 kN 4.079 Ohms/km 19.11 kg/km 1 6 12 18 212.1 sqmm. 261.5 sqmm 21.00 mm 974 kg/km 0.139 ohm/km 89.67 kN Right hand 8158 Kg/sqmm 17.8 x 106
Steel layer
1 Aluminium layer 2nd Aluminium layer d) Sectional area of aluminium e) Total sectional area f) Overall diameter g) Approximate mass h) Calculated D.C resistance at 20 deg. Centigrade i) Minimum UTS j) Direction of lay of outer layer k) Modulus of Elasticity l) Co-efficient of Linear Expansion (Per C) m) Details of aluminium strand i) ii) Minimum breaking load of strand before stranding Minimum breaking load of strand after stranding
iii) Maximum D.C resistance of Stand at 20 deg. Centigrade iv) Weight
n) Details of steel strand: i) i)

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of strand after stranding iii) iv) Weight
: :
8.83 kN 55.13 kg/km
Minimum number of twists : to be withstood in torsion test when tested on a guage length of 100 times diameter of wire a) Before stranding b) After stranding : : 18 16
1.1.2 1.2.1
Workmanship All the aluminium and steel strands shall be smooth, uniform and free from all imperfections, such as spills and splits, die marks, scratches, abrasions, etc, after drawing and also after stranding. The finished conductor shall be smooth, compact, uniform and free from all imperfections including kinks (protrusion of wires), scuff marks, dents, pressmarks, cut-marks, wire cross over, over riding, looseness (wire being dislocated by finger/hand pressure and/or unusual bangle noise on tapping0, material inclusions, white rust, powder formation or black spot (on account of reaction with trapped rain water etc.), dirt, grit etc. The steel strands shall be hot dip galvanized and shall have a minimum zinc coating of 250 gms/sq.m. after stranding. The zinc coating shall be smooth, continuous, of uniform thickness, free from imperfections and shall withstand minimum two and half dips in standard Preece test. The steel wire rods shall be of such quality and purity that, when drawn to the size of the strands specified and coated with zinc, the finished strands and the individual wires shall be of uniform quality and have the same properties and characteristics as required in the specification. The steel strands shall be preformed and post formed in order to prevent spreading of strands in the event of cutting of cutting of composite core wire. Care shall be taken to avoid, damages to galvanization during pre-forming and post-forming operation. Joints in Wires Aluminium Wires During stranding, on aluminium wire welds shall be made for the purpose of achieving the required conductor length. No joints shall be permitted in the outer layer of the finished conductor. However joints are permitted in the 12 wire and 18 wire inner layer of the conductor unavoidably broken during stranding, provided such breaks are not associated with either inherently defective wire or with the use of short lengths of aluminium wires. Such joints shall not be more than four (4) per conductor length and shall not be closer than 15 meters from joint in the same wire or in any other aluminium wire of the completed conductor. Joints shall be made by cold pressure butt welding and shall withstand a stress of not less than the breaking strength of individual strand guaranteed.
1.2.2
1.2.3
1.2.4
1.3 1.3.1 1.3.1.1 1.3.1.2
1.3.1.3
1.3.2
Steel Wires
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There shall be no joint of any kind in the finished wire entering into the manufacture of the strand. There shall also be no strand joints or strand splices in any length of the completed stranded steel core of the conductor. 1.4 Creep in Conductor Creep in conductor is attributed partly to settlement of strands and partly due to non-elastic elongation of metal when subjected to load. The manufacturer of conductor shall furnish the amount of creep which will take place in 10, 20, 30, 40 and 50 years along with the supporting calculations. The calculations should be based on everyday temperature of 32 and everyday tension of 25% of UTS of conductor of 11/33kV lines. 1.5 Stranding In all constructions, the successive layers shall be stranded in opposite directions. The wires in each layer shall be evenly and closely stranded round the underlying wire or wires. The outer most layer of wires shall have a right hand lay. The ratio of the different layers shall be within the limits given in IS: 328 (Part-II) 1.6 Tolerances The manufacturing tolerances to the extent of the following limits only shall be permitted in the diameter of individual aluminium and steel strands and lay-ratio of the conductor. 1.6.1
,
For ACSR PANTHER Conductor a) Diameter of Aluminium and Steel Strands Standard Aluminium Steel b) 3.00 mm 3.00 mm Maximum 3.03 mm 3.06 mm Minimum 2.97 mm 2.94 mm
Lay ratio of Conductor Maximum Steel Aluminium 6 wire layer 6 wire layer 18 wire layer 28 14 16 Minimum 13 10 10
1.7 1.7.1
Materials Aluminium The aluminium strands shall be hard drawn from electrolytic aluminium rods of EC grade having purity not less than 99.5% and a copper content not exceeding 0.04%. They shall have the same properties and characteristics as prescribed in IEC: 889-1987.
1.7.2
Steel The steel wire strands shall be drawn from high carbon steel wire rods produced by either the acid or the basic open-hearth process, or the electric furnace process, or the basic oxygen process and shall conform to the following requirements as to the chemical composition.
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Element Carbon Manganese Phosphorous Sulphur Silicon
-----
% Composition 0.50 to 0.85 0.50 to 1.10
-------
Not more than 0.035 Not more than 0.045 0.10 to 0.35
The Steel wire strands shall have the same properties and characteristics as prescribed for regular strength steel wire in IEC: 888 1987. 1.7.3 Zinc The zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity. It shall conform to and satisfy all the requirements of IS: 209 1979. 1.8 1.8.1 Standard Length The standard length of the conductor shall be 2000meters. Conductor shall indicate the standard length of the conductor to be offered by them. A tolerance of +/-5% on the standard length offered by the Bidder shall be permitted. All lengths outside this limit of tolerance shall be treated as random lengths. Random lengths will be accepted provided no length is less than 70% of the standard length and the total quantity of such random lengths shall not be more than 10% of the total quantity ordered. Bidder shall also indicate the maximum single length, above the standard length, he can manufacture in the guaranteed technical particulars of offer. This is required for special stretches like river crossing etc. The owner reserves the right to place orders for the above lengths on the same terms and conditions applicable for the standard lengths during the pendency of the Contract. TESTS AND STANDARDS Type Tests The followings tests shall be conducted once on a sample/samples of conductor for every 750 Kms of production from each manufacturing facility: (a) (b) UTS test on stranded conductor DC resistance test on stranded conductor
1.8.2
1.8.3
2.0 2.1
Annexure - A
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2.2
Acceptance Tests (a) (b) Visual and dimensional Check on drum Visual check for joints scratches etc. and length measurement of conductor by rewinding Dimensional check on Steel and aluminium strands Check for lay-ratio Galvanising test on steel strands Torsion and Elongation tests on steel strands Breaking load test on Steel and Aluminium strands Wrap test on steel & Aluminium strands DC resistance test on Aluminium strands Procedure qualification test on welded joint of Aluminium strands Annexure-A
(c) (d) (e) (f) (g) (h)
IS: 398
IS: 398
Annexure-A
Note: All the above tests except (j) shall be carried out on aluminium and steel strands after stranding only. 2.3 Routine Test (a)
(b)
Check to ensure that joints are as per Specification. Check that there are no cuts, fins etc. on the strands. Check that drums are as per Specification. All acceptance test as mentioned above to be carried out on each coil.
(c) (d) 2.4
Tests During Manufacture (a) Chemical analysis of zinc used for galvanizing Chemical analysis of Aluminium used for making Aluminium strands Chemical analysis of steel used for making steel strands
(b)
Annexure A
(c)
2.5 2.5.1
Testing Expenses The testing charges for the type tests specified shall be included in the bid price.
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2.5.2
Contractor shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that adequate facilities are available in the laboratories and the tests can be completed in these laboratories within the time schedule guaranteed by them. In case of failure in any type test, the Contractor is either required to manufacture fresh sample lot and repeat all the tests successfully once or repeat that particular type test three times successfully on the sample selected from the already manufactured lot at his own expenses. In case a fresh lot is manufactured for testing, then lot already manufactured shall be rejected. The entire cost of testing for the acceptance and routine tests and Tests during manufacture specified herein shall be treated as included in the quoted unit price of conductor, except for the expenses of the inspector/Owners representative. In case of failure in any type test, if repeat type tests are required to be conducted, then all the expenses for deputation to Inspector/Owners representative shall be deducted from the contract price. Also if on receipt of the Contractors notice of testing, the Owners representative does not find PLANT to be ready for testing the expenses incurred by the Owner for-re-deputation shall be deducted from contract price. Additional Tests The Owner reserves the right of having at his own expenses any other test(s) of reasonable nature carried out at Contractors premises, at site or in any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the materials comply with the Specifications. The Owner also reserve the right to conduct all the tests mentioned in this specification at his own expense on the sample drawn from the site at Contractors premises or at any other test centre. In case of evidence of noncompliance, it shall be binding on the part of 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. Sample Batch for Type Testing The Contractor shall offer materials for selection of sample for type testing only after getting Quality Assurance Plan approved from Owners Quality Assurance Department. The sample shall be manufactured strictly in accordance with the Quality Assurance Plan approved by Owner. The Contractor shall offer at least three drums for selection of sample required for conducting all the type tests. The Contractor is required to carry out all the acceptance tests successfully in presence of Owners representative before sample selection. Test Reports Copies of type test reports shall be furnished in at least six copies along with the one original. One copy will be returned dully certified by the Owner only after which the commercial production of the material shall start. Record of routine test reports shall be maintained by the Supplier at his works for periodic inspection by the Owners representative.
2.5.3
2.5.4
2.5.5
2.6 2.6.1
2.6.2
2.7 2.7.1
2.7.2 2.7.3 2.8 2.8.1
2.8.2
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2.8.3
Test Certificates of tests during manufacture shall be maintained by the Contractor. These shall be produced for verification as and when desired by the Owner. Inspection The Owners representative shall at all times be entitled to have access to the works and all places of manufacture, where conductor shall be manufactured and representative shall have full facilities for unrestricted inspection of the Contractors works, raw materials and process of manufacture for conducting necessary tests as detailed herein. The Contractor shall keep the owner informed in advance of the time of starting and of the progress of manufacture of conductor in its various stages so that arrangements can 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 conductor shall be dispatched only after satisfactory testing for all tests specified herein have been completed. The acceptance of any quantity of material shall in no way relieve the Contractor of any of his responsibilities for meeting all requirements of the Specification, and shall not prevent subsequent rejection if such material is later found to be defective. Test Facilities The following additional test facilities shall be available at the Contractors works: a) Calibration of various testing and measuring equipment including tensile testing machine resistance measurement facilities, burette, thermometer, barometer etc. b) Standard resistance for calibration of resistance bridges. c) Finished conductor shall be check for length verification and surface finished on separate rewinding machine at reduced speed (variable from 8 to 16 meters per minute). The rewinding facilities shall have appropriate clutch system and free of vibrations, jerks etc, with traverse laying facilities.
2.9 2.9.1
2.9.2
2.9.3
2.9.4
2.10 2.10.1
2.10 2.11.1
Packing The conductor shall be supplied in non-returned, strong, wooden drums provided with lagging of adequate strength, constructed to protect the conductor against any damage and displacement during transit, storage and subsequent handling and stringing operations in the field. The contractor shall be responsible for any loss or damage during transportation handling and storage due to improper packing. The drums shall generally conform to IS: 1778 1980, except as otherwise specified hereinafter. The drums shall be suitable for wheel mounting and for letting off the conductor under a minimum controlled tension of the order of 5 KN. The Contractor should submit their proposed drum drawings along with the bid. The Contractor may offer more than one length of the conductor in a single drum. All wooden components shall be manufactured out of seasoned soft wood free from defects that may materially weaken the component parts of the drums.
2.11.2 2.11.3 2.11.4 2.11.5
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Preservative treatment shall be applied to the entire drum with preservatives of a quality, which is not harmful to the conductor. 2.11.6 The flanges shall be of two ply construction with 64mm thickness with each ply at right angles to the adjacent ply and nailed together. The nails shall be driven from the inside face flange, punched and then clenched on the outer face. Flange boards shall not be less than the nominal thickness by more than 2mm. There shall not be less than 2 nails per board in each circle. Where a slot is cut in the flange to receive the inner end of the conductor the entrance shall be in line with the periphery of the barrel. The wooden battens used for making the barrel of the conductor shall be of segmental type. These shall be nailed to the barrel supports with at least two nails. The battens shall be closely butted and shall provide a round barrel with smooth external surface. The edges of the battens shall be rounded or chamfered to avoid damage to the conductor. Barrel studs shall be used for the construction of drums. The flanges shall be holed and the barrel supports slotted to receive them. The barrel studs shall be threaded over a length on either end, sufficient to accommodate washers, spindle plates and nuts for fixing flanges at the required spacing. Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used on the inner surface of the flanges and the drum barrel shall be counter sunk. The ends of barrel shall generally be flushed with the top of the nuts. The inner check of the flanges and drum barrel surface shall be painted with a bitumen based paint. Before reeling, card board or double corrugated or thick bituminized water-proof bamboo paper shall be secured to the drum barrel and inside of flanges of the drum by means of a suitable commercial adhesive material. The paper should be dried before use. Medium grade Kraft paper shall be used in between the layers of the conductor. After reeling the conductor, the exposed surface of the outer layer of conductor shall be wrapped with water proof thick bituminized bamboo paper to preserve the conductor from dirt, grit and damage during transport and handling. A minimum space of 75 mm for conductor shall be provided between the inner surface of the external protective tagging and outer layer of the conductor. Outside the protective lagging, there shall be minimum of two binders consisting of hoop iron/galvanized steel wire. Each protective lagging shall have two recesses to accommodate the binders. Each batten shall be securely nailed across grains as far as possible to the flange, edges with at least 2 nails per end. The length of the nails shall not be less than twice the thickness of the battens. The nails shall not protrude above the general surface and shall not have exposed sharp, edges or allow the battens to be released due to corrosion. The nuts on the barrel studs shall be tack welded on the one side in order to fully secure them. On the second end, a spring washer shall be used. A steel collar shall be used to secure all barrel studs. This collar shall be located between the washers and the steal drum and secured to the central steel plate by welding.
2.11.7
2.11.8
2.11.9
2.11.10 2.11.11
2.11.12
2.11.13
2.11.14 2.11.15
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2.11.16
Outside the protective lagging, there shall be minimum of two binder consisting of hoop iron/ galvanized steel wire. Each protective lagging shall have two recesses to accommodate the binders. The conductor ends shall be properly sealed and secured with the help of U-nail on the side of one of the flanges to avoid loosening of the conductor layers during transit and handling. As an alternative to wooden drum Contractor may be also supply the conductors in non-returnable painted steel drums. After preparation of steel surface according to IS: 9954, synthetic enamel paint shall be applied after application of one coat of primer. Wooden / Steel drum will be treated at per for evaluation purpose and accordingly the Contractor should quote in the package. Marking Each drum shall have the following information stenciled on it in indelible ink along with other essential data: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Contract/ Award letter number. Name and address of consignee. Manufacturers name and address. Drum and lot number Size and type of conductor Length of conductor in meters Arrow marking for unwinding Position of the conductor ends Number of turns in the outer most layer. Gross weight of drum after putting lagging. Average weight of the drum without lagging Net weight of the conductor in the drum.
2.11.17
2.11.18
2.12
(m) Month and year of manufacture of conductor. The above should be indicated in the packing list also. 2.13 Verification of Conductor Length The Owner reserves the right to verity the length of conductor after unreeling at least ten (10) percent of the drums in a lot offered for inspection. 2.14 2.14.1 Standards The conductor shall conform to the following Indian/International Standards, which shall mean latest revisions, with amendments/ changes adopted and published, unless specifically stated otherwise in the Specification. In the event of the supply of conductor conforming to standards other than specified, the Bidder shall confirm in his bid that these standards are equivalent to those specified. In case of award, salient features of comparison between the standards proposed by the Contractor and those specified in this document will be provided by the Contractor to establish their equivalence.
2.14.2
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Sl. No. 1. 2.
Indian Standard IS : 209-1992 IS : 398-1982
Title
International Standards
Specification for zinc Specification for, Aluminium Conductors For Overhead Transmission Purposes Aluminum Conductor Galvanised Steel Reinforced Reels and Drums for Bare Conductors Method of Tensile Testing of Steel Wire Recommended Practice For Hot Dip Galvanizing of iron and Steel Method of Testing Uniformity of Coating On Zinc Coated Articles Galvanised Coating on Round Steel Wires Methods of Determination of Weight of Zinc Coating of Zinc Coated Iron and Steel Articles. Aluminium Alloy Redraw Rods
BS: 3436-1986 IEC:1089-1991 BS:215-1970
3.
IS: 398-1990 Part-II
BS-215-1970 IEC:1089-1991 BS: 1559-1949 ISO 6892-1984
4. 5. 6.
IS: 1778-1980 IS : 1521-1991 IS : 2629-1990
7.
IS: 2633-1992
8. 9.
IS: 4826-1992 IS : 6745-1990
IEC: 888-1987 BS : 443-1969 BS : 433-1969 ISO 1460-1973
10.
IS : 9997-1988
IEC 104-1987 101
11. 12.
IS : 1841-1978
13. 14.
15.
EC Grade Aluminium Rods Produced by rolling IS : 5484-1978 EC Grade Aluminium Rods produced by continuous casting and rolling Zinc Coated steel wires for stranded Conductors Hard drawn aluminium wire for overhead line conductors IS:398 (Part-IV) Aluminium Alloy stranded conductor
IEC : 888-1987 IEC : 889-1987
IEC : 208-1966 BS-3242-1970
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ANNEXURE-A 1.0 1.1 TESTS ON ACSR CONDUCTORS UTS Test on Stranded Conductor Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor of minimum 5 m length between fixing arrangement suitably fixed on a tensile testing machine. The load shall be increased at a steady rate upto 50% of minimum specified UTS and held for one minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter the load shall be increased at steady rate to minimum UTS and held for one minute. The Conductor sample shall not fail during this period. The applied load shall then be increased until the failing load is reached and the value recorded. 1.2 D.C Resistance Test on Stranded Conductor On a conductor sample of minimum 5m length two contact-clamps shall be fixed with a predetermined bolt torque. The resistance shall be measured by a Kelvin double bridge by placing the clamps initially zero meter and sub-sequently one meter apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 20C as per IS: 398-(Part-V)-1982. The resistance corrected at 20C shall conform to the requirements of this Specification. 1.3 Chemical Analysis of Aluminium and Steel Samples taken from the Aluminium and steel ingots/coils/ strands shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this Specification. 1.4 Visual and Dimensional Check on Drums The drums shall be visually and dimensionally checked to ensure that they conform to the requirements of this Specification. 1.5 Visual Check for Joints, Scratches etc. Conductor drums shall be rewound in the presence of the Owner. The Owner shall visually check for scratches, joints etc. and that the conductor generally conforms to the requirements of this Specification. Ten percent (10%) drums from each lot shall be rewound in the presence of the Owners representative. 1.6 Dimensional Check on Steel and Aluminium Strands The individual strands shall be dimensionally checked to ensure that they conform to the requirement of this Specification. 1.7 Check for Lay-ratios of Various Layers The lay-ratios of various layers shall be checked to ensure that they conform to the requirements of this Specification. 1.8 Procedure Qualification test on wield Aluminium strands. Two Aluminium wire shall be welded as per the approved quality plan and shall be subjected to tensile load. The breaking strength of the welded joint of the wire shall not be less than the guaranteed breaking strength of individual strands. 1.9 Chemical Analysis of Zinc Samples taken from the zinc ingots shall be chemically/ spectrographically analysed. The same shall be in conformity to the requirements stated in the Specification.
488
1.10
Galvanising Test The test procedure shall be as specified in IEC: 888. The material shall conform to the requirements of this Specification. The adherence of zinc shall be checked by wrapping around a mandrel four times the diameter of steel wire.
1.11
Torsion and Elongation Tests on Steel Strands The test procedures shall be as per clause No. 10.3 of IEC: 888. In torsion test, the number of complete twists before fracture shall not be less than 18 on a length equal to 100 times the standard diameter of the strand. In case test sample length is less or more than 100 times the stranded diameter of the strand, the minimum number of twists will be proportioned to the length and if number comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the elongation of the strand shall not be less than 4% for a gauge length of 250mm.
1.12
Check on Barrel Batten strength of Drums The details regarding barrel batten strength test will be discussed and mutually agreed to by the Contractor & Owner in the Quality Assurance Programme.
1.13
Break load test on individual Aluminium and Galvanized steel wires The test shall be conducted on both Aluminium and Galvanized steel wires. The breaking load of one speciment cut from each of the samples taken shall be determined by means of suitable tensile testing machine. The load shall be applied gradually and the rate of separation of the jaws of the testing machine shall be not less 25 mm/min. and not greater than 100mm/min. The ultimate breaking load of the specimens shall be not less than the values specification.
1.14
Resistance test on Aluminium wire The test shall be conducted on aluminium wires only, conforming to procedure as per IEC : 889. The electrical resistance of one specimen of aluminium wire cut from each of the samples taken shall be measured at ambient temperature. The measured resistance shall be corrected to the value corresponding to 20 degree C. by means of following formula. 1 R20 = RT -------------------1+alpha x (T-20) Where R20 RT = Resistance corrected at 20 degree C. = Resistance measured at T degree C
Alpha = Constant mass temperature coefficient of resistance 0.004.
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SECTION-V TECHNICAL SPECIFICATION 1.0 1.1 TECHNICAL DESCRIPTION FOR INSULATOR. General Requirements
1.1.1 All insulators shall conform to Type B of latest version of IS : 731. 2.0 DISC INSULATORS
2.1.1 Pin and Caps shall be made of drop forged steel and malleable cast iron/spheroidal graphite iron/drop forged steel respectively, duly hot dip galvanized and shall not be made by jointing, welding, shrink fitting or any other process from more than one piece of material. 2.1.2 Pin and Cap shall be designed to transmit the mechanical stresses to the shell by compression and develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric, of such design that it will not yield or distort under load conditions. 2.1.3 The pin ball shall move freely in the cap socket but without danger of accidental uncoupling during erection or in position. The design of the disc should be such that stresses due to expansion or contraction in any part of the insulator shall not lead to deterioration. 2.2 Security clip
2.2.1 Security clip for use with ball and socket coupling shall be of R-shaped hump type which shall provide positive locking of the coupling as per IS : 2486-(Part III)/ IEC:372. The legs of the security clips shall be spread after installation to prevent complete withdrawal from the socket. The locking device should be resilient, corrosion resistant and of suitable mechanical strength. There shall be no risk of the locking device being displaced accidentally or being rotated when in position- under no circumstances shall locking device allow separation of insulator units or fittings. 2.2.2 Security clips shall be made of good quality stainless steel or phosphor bronze as per IS : 1385-1968, 2.5% extra Security clip shall be provided. 2.3 Ball and Socket Designation The dimensions of the balls and sockets shall be of 16 mm designation in accordance with the standard dimensions stated in IS: 2486 (Part II). 3.0 INTERCHANGEABILITY The disc insulators inclusive of fittings shall be of standard design suitable for use with the hardware fittings of any make conforming to relevant Indian/International Standards. 4.0 4.1 MAINTENANCE The insulators offered shall be suitable for employment of hot line maintenance techniques so that the usual hot line operations can be carried out with ease, speed and safety. WORKMANSHIP All the material shall be of the latest design and conform to the best modern practices adopted in the distribution voltage field. Contractors shall offer only such insulators as are guaranteed by him to be satisfactory and suitable for specified voltage level lines and will give continued good service.
5.0 5.1
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5.2
The design, manufacturing process and material control at various stages shall be such as to give maximum working load, highest mobility, best resistance to corrosion, good finish and elimination of sharp edges and corners. The design of the insulators shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. In disc insulators, metal caps shall be free from cracks, seams, shrinks, air holes, burrs and rough edges. All surfaces of the metal parts shall be perfectly smooth with no projecting points or irregularities. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly. All ferrous parts shall be hot dip galvanized to give a minimum average coating of Zinc equivalent to 660 gm/sq.m and shall be in accordance with the requirement of IS : 2629-1985 and shall satisfy the tests mentioned in IS:2633 1986. The zinc used for galvanizing shall be of Grade Zn 99.95 as per IS:209-1979. The zinc coating shall be uniform, adherent, smooth, reasonably bright, continuous and free from imperfections such as flux, ash, rust stains, bulky white deposits and blisters. The galvanized metal parts shall be guaranteed to withstand at least six successive dips each lasting for one (1) minute duration under the standard preece test. Before ball fittings are galvanized, all die flashing on the shank surface of the ball shall be carefully removed without reducing the dimensions below the design requirements. In disc insulators, the design of the insulators shall be such that the shell shall not engage directly with hard metal. The design shall also be such that when units are coupled together there is no contact between the shell of one unit and metal of the next adjacent unit. The design of the shell ribs shall be such that the security clip of the insulator can be engaged and disengaged easily with hot stick without damaging the shell ribs. Insulator units after assembly shall be concentric and co-axial within limits as permitted by the relevant Indian Standards. EQUIPMENT MARKING Each insulator shall be legibly and indelibly marked with the trade mark of the manufacturer and year of manufacture. The guaranteed combined mechanical and electrical strength shall be indicated in Kilo Newton followed by the word KN to facilitate easy identification and to ensure proper use. The marking shall be on porcelain and shall be printed, not impressed and shall be applied before firing. Bid Drawings The Bidder shall furnish full description and illustration of the material offered. The Bidder shall furnish along with the bid the outline drawing (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) (b) (c) (d) Dimensions with manufacturing tolerances Minimum Creepage distance with positive tolerance Protected creepage distance Eccentricity of the disc (i) Axial run out
5.3 5.4
5.5
5.6
5.7
5.8 6.0 6.1
6.2 7.0 7.1 7.2
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(ii) Radial run out (e) (f) (g) (h) (i) (j) 7.3 Unit mechanical and electrical characteristics Size and weight of Pin Ball Shank / ball and socket parts Weight of unit insulator disc Materials Identification mark Manufacturers catalogue number
After placement of award, the Contractor shall submit fully dimensioned insulator drawings containing all the details as given in Clauses No. 1.12.2 above, 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 Owners end. TESTS AND STANDARDS Tests General The following type, acceptance, routing tests and tests during manufacture shall be carried out on the insulator individually and along with hardware fitting. For the purpose of this clause.
8.0 8.1
8.1.1 Type tests shall those tests which are to be carried out to prove the design process of manufacture and general conformity of the material to this specification. These tests shall be carried out on samples prior to commencement of commercial production against the specification. The Bidder shall indicate this schedule for carrying out these tests in the activity schedule. 8.1.2 Acceptance tests shall mean those tests which are to be carried out on samples taken from each lot offered for pre-despatch inspection for the purpose of acceptance of that lot. 10.1.3 Routine tests shall mean those tests, which are to be carried out on each insulator/hardware fitting to check requirements which are likely to vary during production. 10.1.4 Tests during manufacture shall mean those tests which are to be carried out during the process of manufacture and end inspection by the Supplier to ensure the desired quality of the end product to be supplied by him. 10.1.5 The norms and procedure of sampling for these tests will be as per the Quality Assurance Programme to be mutually agreed to by the Supplier and Owner. 10.1.6 The standards and norms to which these tests will be carried out are listed against them. Where a particular test is a specific requirement of this specification, the norms and procedure of these shall be as specified in Annuxure-A of this Section or as mutually agreed to between the Supplier and the Owner in the Quality Assurance Programme. 10.1.7 For all type and acceptance tests, the acceptance values shall be the values guaranteed by the Bidder in the Guaranteed Technical Particulars of this proposal or the acceptance value specified in this specification whichever is more stringent for that particular test. 10.1.8 For all type and acceptance tests, the Bidder shall guarantee only minimum values in the Guaranteed Technical Particulars. Bidder shall be required to achieve the same or higher values, as guaranteed, during testing for all type and acceptance tests.
492
10.2
Type Tests The following type tests shall be conducted on a suitable number of individual insulator unit, components, materials or complete stings: (a) (b) (c) Verification of dimensions Thermal mechanical performance test Power frequency voltage withstand and flashover test (i) dry (d) (e) (f) (g) (h) (ii) wet
Impulse voltage withstand and flashover test (dry) Visible Discharge test (dry) RIV test (dry) Mechanical failing Load Test (for pin insulator only) 24 hr mechanical strength test (for strain / string insulator only) Testing Expenses Testing charges for the type test specified shall be included in the bid price and no separate payment shall be made for the same.
10.2.1
10.3
Acceptance Tests (a) (b) (c) (d) (e) (f) (g) (h) Visual examination Verification of dimensions Temperature cycle test Galvanising test Mechanical performance test Test on locking device for ball and socket coupling Eccentricity test Metallurgical Test (i) (ii) (iii) (iv) (i) (j) (k) (l) Grain size Inclusion rating Chemical analysis Microstructure For Metal fitting only (in Black condition)
Mechanical Failing Load test (for Pin insulator only) Electro-mechanical strength test (for Strain Insulator only) Porosity test Puncture test (for Strain Insulator only)
10.4
Routine Tests (a) (b) (c) Visual Inspection Mechanical routine text (for Strain Insulator only) Electrical routine test (for strain insulator only)
10.5
Tests During Manufacture On all components as applicable
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(a) (b)
Chemical analysis of zinc used for Galvanizing Chemical analysis, mechanical, metallographic test and magnetic particle inspection for malleable castings. Chemical analysis hardness tests and magnetic particle inspection for forgings Hydraulic Internal Pressure tests on disc insulator shells
Annexure - A Annexure - A
(c)
Annexure - A
(d) 10.6 10.6.1
Annexure - A
Test Voltages The test voltages of insulators shall be as under. Highest system Voltage KV (rms) 415/240V (for pin 7 shackle type) 12 Visible Discharge Test KV (rms) Wet Power Frequency Withstand Test KV (rms) 10 Power Frequency Puncture withstand test Pin Strain/ string insulator Insulators KV (rms) KV (rms) 60 Impulse Voltage Withstand Test KV (rms)
35
105
36
27
75
180
1.3 times the actual dry flash over voltage of the insulator the actual dry flash over voltage of the insulator
75
10.6.2
For guy strain insulator, test voltages shall be Designation of Insulator Dry one min power freq withstand voltage KV (rms) A C 18 27 Wet one min power frequency withstand voltage KV (rms0 8 13
10.6.3 10.7 10.7.1
The withstand and flashover voltages are referred to the Reference Atmospheric Conditions as per Indian Standards. Failing Load Mechanical Failing Load (For Pin Insulators only) The insulators shall be suitable for a minimum failing load of 10KN (for 33KV), 5 KN (for 11KV) and 3.5 KN (for LT) applied in transverse direction. Shackle insulators shall be suitable for a minimum failing load of 11.5 KN for type 1 insulator and 16.0KN for type 2 insulator.
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Guy strain insulator type A shall be suitable for a minimum failing load of 44KN whereas, type C shall be suitable for a minimum failing load of 88KN. 10.7.2 Electro-Mechanical Failing Load String Insulator Units) (For Strain Insulators/
The insulators shall be suitable for a minimum failing load of 45KN (for 11KV lines) applied axially. 10.8 10.8.1 Additional Tests The Owner reserves the right of having at his own expense any other test(s) of reasonable nature carried out at Contractors premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the material comply with the Specifications. 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 Contractors premises or at any other test centre. In case of evidence of non compliance, 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. Co-ordination for testing The Contractor shall have to co-ordinate testing of insulators with hardware fittings to be supplied by other Contractor and shall have to also guarantee overall satisfactory performance of the insulators with the hardware fittings. 10.10 Guarantee The Contractor of insulators shall guarantee overall satisfactory performance of the insulators with the hardware fittings. 10.11 10.11.1 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 material 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 dispatched. Record of routine test reports shall be maintained by the Contractor at his works for periodic inspection by the Owners 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 The Owners representative 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 Contractors and sub-Contractors works, raw materials, manufacture of the material and for conducting necessary test as detailed herein.
10.8.2
10.9
10.11.2
10.11.3 10.11.4
10.12 10.12.1
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10.12.2
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 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. Packing and Marking All insulators shall be packed in strong seasoned wooden crates. The gross weight of the crates along with the material shall not normally exceed 200 Kg to avoid handling problem. For marine transportation, crates shall be paletted. The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and subsequent handling in the field. Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent damage or deformation during transit and handling. All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings. Each wooden case/crate shall have all the markings stenciled on it in indelible ink. Annexure-A
10.12.3
10.12.4
10.12.5
10.13 10.13.1
10.13.2 10.13.3 10.13.4
1.0
Hydraulic Internal Pressure Test on Shells ( if applicable) The test shall be carried out on 100% shells before assembly. The details regarding test will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance Programme.
2.0
Thermal Mechanical Performance Test (if applicable) Thermal Mechanical Performance Test shall be performed in accordance with IEC383-1-1993 Clause 20 with the following modifications. (1) (2) (a) Where X Mean value of the individual mechanical failing load.
The applied mechanical load during this test shall be 70% of the rated electromechanical or mechanical value. The acceptance criteria shall be X greater than or equal to R + 3S.
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R S (b) (c) 3.0
Rated electro-mechanical / mechanical failing load. Standard deviation The minimum sample size shall be taken as 20 for disc insulator units The individual electromechanical failing load shall be at least equal to the rated value. Also puncture shall not occur before the ultimate fracture.
Electromechanical / Mechanical Failing Load Test. This test shall be performed in accordance with clause 18 and 19 of IEC 383 with the following acceptance (i) X greater than or equal to R + 3S Where X: R: S: (ii) (ii) Mean value of the electro-mechanical/mechanical failing load. Rated electro-mechanical/mechanical failing load. Standard deviation
The minimum sample size shall be taken as 20 for disc insulators units. However, for larger lot size, IEC 591 shall be applicable. The individual electro-mechanical failing load shall be at least equal to the rated value. Also electrical puncture shall not occur before the ultimate fracture.
4.0
Chemical Analysis of Zinc used for Galvanizing Sample taken from the zinc ingot shall be chemically analysed as per IS: 2091979. The purity of zinc shall not be less than 99.95%
5.0
Tests for Forgings The chemical analysis hardness tests and magnetic particle inspection for forgings, will be as per the internationally recognized procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance Programme.
6.0
Tests on Castings The chemical analysis, mechanical and metallographic tests and magnetic, particle inspection for castings will be as per the internationally recognized procedures for these tests. The samplings will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance Programme.
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Part-III (Vol. 2/2)
497
Part-III (Vol. 2/2)
498
Part-III (Vol. 2/2)

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against their tender specification No.

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