MP Vidyut Vitaran Nd08adb Vol2 11feb11

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MADHYA PRADESH MADHYA KSHETRA VIDYUT VITARAN COMPANY LTD., BHOPAL

ASIAN DEVELOPMENT BANK LOAN NO.:-MFF: IND
FOR
Madhya Pradesh Energy Efficiency Improvement Investment Program
BID IDENTIFICATION NO.MPMKVVCL/ADB/II/D/08
VOLUME:-II
TABLE OF CONTENTS
1
(i) (ii) 2 3
QUESTIONAIRE COMMERCIAL QUESTIONAIRE TECHNICAL QUESTIONAIRE SCHEDULES & ANNEXURE (FOR SUPPLY, ERECTION & CIVIL WORK) TECHNICAL SPECIFICATION 01-08 09-13 01-16 01-16
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CHIEF GENERAL MANAGER (ADB) CELL

OFFICE OF THE CHAIRMAN AND MANGING DIRECTOR M.P. MADHYA KSHETRA VIDYUT VITARAN COMPANY LIMITED NISHTA PARISAR, GOVINDPURA BHOPAL 462 023
TELEPHONE NO. FASCIMILE E-MAIL ADDRESS
0755-2602033, 0755-2602034 ext-138 0755-2589821/2586636 seadbcell@mpmkvvc.com
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SCHEDULE I COMMERCIAL QUESTIONNAIRE

Bidders may please note the following: a. All points mentioned below should be confirmed/replied here only to avoid the risk of non-conformity of Bid as per Bid Document requirement. b. It may be noted by the Bidders that all replies should be clear and affirmative without any ambiguity. clarify, the details furnished in this Schedule should be clear and complete in itself. c. Bidders may note that no column should be left blank. To
d. In case of conflict between the Commercial questionnaire and the Instructions to Bidders or the Conditions of Contract, the clauses in the Instructions to Bidders and the Conditions of Contract shall prevail; and in case of conflict between the Bidders answers in the Commercial questionnaire and the Bidding Forms, the ones in the Bidding Forms shall prevail.
POINTS TO BE CONFIRMED IN RESPECT OF CLAUSES UNDER
Section 1 (ITB)
1 Please refer Clause 5 Eligible Plant and Services of Section 1, (Instructions to Bidders), and confirm that you qualify to participate for Plants and Services as per conditions mentioned therein. Please confirm that necessary undertaking/ document to this effect has been furnished with the bid.
Section-2 (Volume-I) Bid Data Sheet (BDS)

Please confirm that the quantum of bid security to be furnished for each lot as given in Section 2, the Bid Data Sheet Clause ITB 21.1 has been noted and bid security for correct amount has been furnished. Please indicate name of lot and bid security furnished for the lot against this column. Please confirm that unconditional BG, submitted towards bid security has been issued by a reputable Bank as per Clause 21.2 of Section I, Instructions to Bidders. 3. (a) Please refer Section 2 Bid Data Sheet Clause ITB 4.1 and confirm whether the bidder has participated as individual or as a joint venture. Please confirm that In case of joint venture, all parties shall be jointly and severely liable.
(b)
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(c) In case of joint venture, supporting legal documents and power of attorney and forms with the Bid have been enclosed as per prescribed formats. If the bidder has included goods manufactured by some other agency, please confirm that authorization from the manufacturer as per proforma in Section 4 has been enclosed. Have you noted that the bids to be submitted will also include additional documents as per ITB 11.1 (i) as per Section 2 bid data sheet and confirm that all documents have been furnished? Please confirm that in compliance to ITB 13.1, Section 2, Bid Data Sheet no alternative bid has been submitted. Please refer Section 2, Bid Data Sheet, ITB 18.4 (d) and confirm that the condition mentioned therein is acceptable to you and your bid is based on this requirement. Please refer Clause ITB 18.6 Section 2 Bid Data Sheet and confirm that offered prices are fixed. Please indicate currency of bid for supply. Please confirm that for following services, been offered included in rates:the prices have
6 7
8 9 10
Cost of inland freight, inland insurance and cost of Indian Agents commission, if any. Charges for survey and erection which include unloading at final destination, storage handling, insurance, erection, testing, commissioning & associated civil works. Costs of leftover items are included in the offered price. 11 12 13 Please confirm that bid is single stage One envelop, as per Section 2 Bid Data Sheet clause no. ITB 23.2. You have noted that no alternative time schedule is permitted in accordance with ITB 13.2 Section-2. Please confirm that you have noted that design services are not covered under the scope of this Bid Identification as per ITB 18.4 (c) Section-2. Please confirm that you have noted that no spare parts are required as per ITB 18.4 (e) Section-2.
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Points to be confirmed in respect of Clauses under Section 3 (Volume-I) Evaluation and Qualification Criteria
15 16
Please confirm that you have noted the stipulation that no margin of preference will apply. Please refer Clause 1.2.1 of Section 3 & confirm that
The conditions mentioned therein have been noted in regard to loading for minor omissions or missing items and The conditions mentioned therein have been noted in regard to loading for inland freight charges. 17 Please confirm you have noted that the technical criteria shall be evaluated on pass fail system as per Clause 1.1 of Section 3. Please confirm that following conditions for non responsiveness of bids stipulated in Vol. 1 & 2 of bidding document have been noted. otherwise your bid would be treated as non-responsive. Whether bid security furnished is for adequate amount and in proper form. Please indicate here lot No, bid security amount and mode of security. Please confirm that validity of your bids is 180 days from the date of bid opening otherwise your offer will be rejected. Please confirm that validity of bid security is 208 (180+28) days from the date of bid opening. In case validity is found to be short, bid will be rejected. Please confirm Letter of Bid has been submitted. Please confirm you are an eligible bidder under Clause 4 Section 1 and necessary documentation to this effect has been submitted. Please confirm you have noted that late bids will be returned. Please confirm you have carefully noted qualification criteria as brought out in Section 3 and necessary certificates/ supporting documents have been annexed with your bid in support of your claim for meeting the criteria.
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18.1
18.2 18.3
18.4 18.5
18.6 18.7
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18.8 18.9 18.10 Please confirm you have noted that conditional bid of any nature is not acceptable. Please confirm that you have noted that bid for part quantity for any lot will be treated as non- responsive. Time Schedule shall be the essence of the contract. Please confirm you have noted that contract performance Schedule in excess of specified Time Schedule will make your offer non-responsive. Please confirm you have noted that no deviation from terms and procedure of payment as per Appendix1, Section9 shall be permitted. Please confirm you have furnished required notarized power of attorney for authorized signatory or similar legal instrument in line with Clause ITB 22.2 of Section 2 Bid Data Sheet. Please confirm you have noted that incase of violation of condition regarding Corrupt Practice, the bid will be treated as non-responsive. Please confirm that Defect Liability Period for the Facility shall be Three years and is acceptable Please confirm liquidated damages Clause @ 0.5% per week up to a maximum of 5% of contract price are acceptable to you. Please confirm that in the event of the award of contract to you, performance security, 10% of the contract price as per Section 8 shall be furnished. Please confirm that all technical details as per Vol. II to make your offer complete in all respect has been submitted. Please confirm that the required technical questionnaire enclosed with technical bid has been submitted duly filled-in. Please confirm that you have a minimum experience as per Clause 2.4.1 of Section 3 and duly filled. Please confirm condition of Pending Litigation as per Clause 2.2 of Section 3 has been noted by you and necessary certificate has been given. Please confirm for the purpose of offering prices, you have followed the formats furnished under Section 4 without any deviation. Please confirm you have noted that no modification in the proforma is to be done(except for requisite modification in the Bidding Forms).
18.11
18.12
18.13
18.14 18.15
18.16
18.17 18.18 18.19 19
20
Page | Points to be replied in respect of Clauses under Section 8 (Volume-I) Special Conditions of Contract.
21 22 23 Please confirm that Installation work on the facilities will commence within 7 days as per GCC 8.1. Please confirm that you have noted no interest will be payable for delay in payment as per GCC 12.3. Please confirm that you have noted that Project Managers approvals/ disapproval shall be communicated within 14 days as per GCC 20.3.2 Section-8. Indian bidders have to note the requirement of deemed export benefit very carefully as brought out under GCC 14.3 of SCC Section 8. Please confirm you have noted this requirement and no condition have been incorporated in this regard in your Bid. Please refer Clause GCC 24; Section-8 and confirm that requirement of completion of the Facilities is acceptable to you. Please refer Clause GCC 25; Section-8 and confirm that requirement of commissioning and operational acceptance is acceptable to you. Please refer Clause GCC 39 Section-8 and confirm that conditions regarding Change in Facility are acceptable to you. Please refer Clause GCC 42 Section-8 and confirm that stipulations regarding termination of contract are acceptable to you. Please confirm you have noted that the Governing Law shall be Indian law (Indian Arbitration Act of 1996) as stipulated under Clause 45.5 GCC. Please note that you will be eligible to participate against Employers bid invitation only if bid document is procured by you from the Employer or downloaded from prescribed website. In support of proof of purchase of bid document from us photocopy of money receipt or covering letter vide which Bid document was forwarded by us should be enclosed with the bid security furnished by you. Please confirmed that technical & financial bid is placed in separate envelope. Please note that you will be eligible for participation only, if bid document is purchased in your name. Please confirm this requirement. Please confirm if:
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25
26
27
28
29
30
31
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(i) Your bid price is fixed, you cannot claim any price adjustment later 32 Please confirm terms of payment as per Appendix 1, Section 9 without any deviation is acceptable to you. Please note in case of any deviation, your offer will be treated as nonresponsive. Please confirm you have noted all conditions mentioned under Clause GCC 14.3. Please also confirm that you will claim only concessional rate of sales tax and indicate the rate here. Please confirm that the excise duty is not included on EXWork price. Please confirm that performance security shall be furnished as per condition stipulated under Clause GCC 13.3.2. Please confirm whether you have offered any discount on offered bid price and if so(a) Whether discount is conditional or unconditional. If discount is conditional, please state the condition here. Please confirm discount offered if any, is furnished separately for each lot.
33
34 35 36
(b)
SIGNATURE AND SEAL OF BIDDER
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SCHEDULE II
TECHNICAL QUESTIONAIRE
Bidders may please note the following: -
a. b. c.
Submission of this technical questionnaire with the bid document for each lot separately is a must. Non-submission of this document duly filled in will make the bid non-responsive. It may be noted by the bidders that all replies should be clear and affirmative without any confusion and without mentioning that the cross reference may be made to the bid document submitted by the bidder. To clarify, the details furnished in this questionnaire should be clear and complete in itself. Bidders have to be careful in furnishing all details clearly in this questionnaire. It may be noted that no column should be left blank. In case of conflict between the technical questionnaire and technical specification mention in volume two of bid, the clause in technical specification mention in volume two shall prevail; Name of Bidder and Address Country of origin. Have you furnished according to sub-clause 17.1 of the ITB, a statement of work method, equipment, personnel, schedules and other information as stipulated in sufficient details. Have you read sub-clause 36.2 of ITB and 1.1 of Section 3 regarding Technical evaluation and noted the criteria? Have you noted that alternative technical solution have not been allowed in accordance with. Have you noticed the requirement of detailed supply and construction schedules as given in Section 9 of the Bid Forms? The supply and construction schedule has to be completed within 18(eighteen) months of the contract period. Have you carefully gone through the scope of supply of Plant and Services as given in of Section 6 Employers Requirements. Please confirm that plants to be supplied shall comply with the technical specification given in Volume II of the Bid documents.
1 2 3
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Please indicate the ISS to which the following major materials will conform to (a) Power transformer 33/11KV 5 MVA (b) Distribution transformer 100 KVA, 11/0.4 KV Aluminum wound. (c) AAA Conductor Dog 100 sq. mm (d) AAA Conductor Rabbit 55 sq.mm (e) 350 KG PCC Pole 7 mtr. Long (e) 280 KG PCC Pole 9 mtr. Long (f) 140 KG PCC Pole 8 mtr. Long (g) 33 KV AB switches (h) 11 KV AB switches (i) 33 KV Lightning Arrestors (j) 11 KV Lightning Arrestors (k) 11 KV DO fuses (l) 33 KV disc insulators Porcelin (m) 11 KV disc insulators Porcelin (n) 33 KV pin Insulator (o) 11 KV pin insulators Porcelin (p) 33 KV G.S. pins (q) 33 KV strain hardware (r) 11 KV strain hardware (s) All Type Cables
10
Have you noticed the requirement of GPS based survey of Proposed 33 KV feeders, 11KV Feeders and Location of 33/11 KV Sub Station, as brought in sub-clause and preparation of single line diagram through Auto Cad system (Section 6) Have you noted that the power Transformer, VCB & other equipment supplied by you is as per technical Specification. Any deviation T.S. is not permited
11
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12 Have you noted that earthing of Substation is carried out as per T.S. and any site requirement in Earthing is excepted by you for maintaining the earth resistance value according to Indian Electricity Rules. Have you noted that all the Disc or Strain Insulators used in line or substation are Polymer Insulator excluding 33KV and 11 kv Pin Insulator.
13
14
Have you noted that back filling of pole is done by appropriate sized bolder and filling of bolder with muram including ramming and watering.
15
Have you noted that Muffing of substation structure and steel support of 33 KV and 11KV Line is done in round/square shape after completing of work. Curring of Concreting is also required. Have you noted that all the arrangement of light, water & residing of Labour is made by you during the construction at your cost .
16
17
Have you noted that all the jumper of sub station is made by wedge connector. Have you noted that the Employer reserves the right to get any plant tested in any NABL Accredited Laboratory in this country and that its result will be applied on pass fail basis. Failure of any equipment in test the testing charges will be recovered from you. Have you noted that steel sections to be used on 33 KV Lines, 11 KV lines, Power Transformers & structures of 33/11 KV Sub station shall be painted as per details given in schedule . Have you noted that the Contractor shall have to make its own arrangement to carry out precommissioning and Guarantee tests? The Employer will not supply and make available any raw materials. (GCC Clause 10.5 Section 8)
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19
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21 The Employer shall only render assistance in carrying out the tests (sub-clause GCC 25.1.2 of SCC Section 8). Have you noted the Clause GCC 27.10 of SCC Section 8 regarding period of Defect Liability.
22
23
Have your noted that new 33Kv and 11 KV Lines are to be errected on single pole/double pole tangent location/angle location/cut point location?
24
Have you noted that Bus bar of 33/11 Kv Sub station 33 Kv substation & 33 KV Line String with Dog Conductor & 11 KV Line string with Rabbit Conductor. Have you noted that manufacturer/contractor has to supply and install Meters with GPRS enabled Modem for Energy Auditing. The meters having open protocol and compatibility with our existing system
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26
Have you noted that safety appliance, T&P, Substation furniture are supplied as per annexure no. 6-1A, 6-2A, 6-3A.
27
Have you noted that yard leveling and metaling is done as per site requirement.
28
Have you noted that the tube well is digging after resistivity survey upto Sufficient depth of 200 mm dia. telescopic bore confirmation of 1 inch. yield of water and fitted with submersible pump.
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29 Power & Distribution Transformer specifications: i) Have you noted the condition of no load and full load losses in the specification of distribution transformer and that the transformer shall be rejected if it exceeds the value given therein. Have you noted that you are required to submit type test certificate which should not be more than 5 year old on the date of opening of bid. Have you noted the condition of inspection, testing and stage inspection as also routine/acceptance and type test. Have you noted that the garuntee provided by the manufacturer should be submitted to the employer. Have you noted that Distribution transformer of 100 KVA capacity shall be Aluminium wound
ii)
iii) iv) v)
30
Have you noted that steel fabricated material to be used in sub station & Line shall be galvanized and galvanized as per ISS standards.
GENERAL INSTRUCTIONS :31 (i) Any assert material for execution is left over, it is presume that the same should be provided by you at your cost. If any material dismantled during execution of proposed work, it should be returned to concern area store in same condition at your cost. Extension piece are to be provided to maintain clearances as per IE rules Items included in schedule may vary as per actual requirement of the area.
(ii)
(iii) (iv)
Signature & Seal of Bidder
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S.No .
PARTICULARS
Unit
Lot I
Lot II
Lot III
Lot IV
SUPPLY AND ERRECTION OF MATERIAL FOR 1K.M. 33 KV LINE ON PCC POLE WITH MAXIMUM SPAN OF 70 METER USING DOG CONDUCTOR SUPPLY AND ERRECTION OF MATERIAL FOR 1No. 33 KV Double Pole structure ON PCC POLE FOR EVERY 1.6 KMS.OF 33 KV LINE SUPPLY AND ERRECTION OF MATERIAL FOR 1No. 33 KV Triple Pole structure ON PCC POLE R SUPPLY AND ERRECTION OF MATERIAL FOR 1No. 33 KV FOUR Pole structure ON PCC POLE SUPPLY AND ERRECTION OF MATERIAL FOR 1No. 33 KV SINGLE POLE CUTPOINT POLE STRUCTURE SUPPLY AND ERRECTION OF MATERIAL FOR 1No. 33/11 KV 5MVA SUBSTATION SCHEDULE FOR SUPPLY AND ERRECTION AND ERRECTION OF MATERIAL FOR 1K.M. 11 KV LINE ON PCC POLE WITH MAXIMUM SPAN OF 70 METER USING RABBIT CONDUCTOR SUPPLY AND ERRECTION OF MATERIAL FOR 1No. 11 KV Double Pole structure ON PCC POLE FOR EVERY 1.6 KMS.OF 11 KV LINE SUPPLY AND ERRECTION OF MATERIAL FOR 1No. 11 KV Triple Pole structure ON PCC POLE SUPPLY AND ERRECTION OF MATERIAL FOR 1No. 11 KV FOUR Pole structure ON PCC POLE SUPPLY AND ERRECTION OF MATERIAL FOR 1No. 11 KV SINGLE POLE CUTPOINT POLE STRUCTURE SUPPLY AND ERRECTION OF MATERIAL FOR 1No. A.B. Switch for 33 KV SUPPLY AND ERRECTION OF MATERIAL FOR 1No. A.B. Switch for 11 KV SUPPLY AND ERRECTION OF MATERIAL FOR 1No. Gaurding
Km
310
470
420
577
No.
220
315
285
380
3 4 5 6
No. No. No. No.
31 7 12 21
49 8 17 27
28 6 16 22
20 2 21 30
Km
160
195
135
210
No.
160
195
135
210
No. No. No. No. No. No.
10 3 12 21 16 78
27 7 35 19 24 40
17 6 33 18 23 58
15 5 40 19 22 49
10 11 12 13 14
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ONLY FOR EXECUTION PURPOSE SHEDULE FOR SUPPLY OF PLANT - 1A

SCHEDULE FOR SUPPLY OF MATERIAL FOR 1K.M. 33 KV LINE ON PCC POLE WITH MAXIMUM SPAN OF 70 METER USING DOG CONDUCTOR Sl.No. 1 1 Particulars 2 Line supports-280 Kg/9.1 m long PCC pole 33 KV Galvanized 'V' cross-arms with two back clamps 75x75x6 mm Galvanized angle (14N0@24.6Kg/V-x arm) 33 KV Galvanized Top clamps 75x75x6 mm Galvanized Angle (14N0@3.575kG/V-x arm) Earthing Set (Coil earth as per Drg.No.G/007) 33 KV Pin Insulator with Galvanized Pins Dog AAAC Conductor (100 Sq.mm. Al.Eq.) with 3 % Sag Jointing Sleeves suitable for 80Sq.mm.Al. Eq. AAAC conductor Galvanized Stay set 20 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/4.0 mm. @8.5 kg.stay wire per stay set Anti climbing devices (1.7kg/no)(14no) Danger Boards Binding wire and tape Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Total Unit 3 Nos. Qty. 4 14
Kg
344.40(14No.)
Kg
49.98(14No.)
4 5 6 7 8 9 10 11 12 13 14 15 16
Nos. Nos. Kms. Nos. Sets Kg. kg. Nos. Kgs. Kgs. Kg Kg Kg
14 42 3.1 6 3 25 23.8 14 4 42 2 21 21
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ONLY FOR EXECUTION PURPOSE SHEDULE FOR SUPPLY OF PLANT - 2A SCHEDULE FOR SUPPLY OF MATERIAL FOR 1No. 33 KV Double Pole structure ON PCC POLE FOR EVERY 1.6 KMS.OF 33 KV LINE
Sl. No. 1 1 2 Particulars 2 280 Kg.,9.1 Mtrs. long PCC Poles G.S. crossarm of 100 X 50 X 6 mm. channel suitable for 5' centre DP (1SET@65.09Kg) Unit 3 No Kg. Qty. 4 2 65.09(1SET)
33 KV Strain set(polymer)
No.
4 5
33 KV Hard ware 33 KV Pin Insulator (polymer) Galvanized Horizontal and cross bracing 5' centre with set of four back clamps (1SET@51.670Kg) Galvanized Stay set 20 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/4.0 mm. @ 8.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices (1.7kg/no)(2no) Danger Boards Galvanized Nuts and Bolts Galvanized washer Barbed Wire GI Wire 8 SWG for Earthing Dog AAAC Conductor (100 Sq.mm. Al.Eq.) PG Clamp Dog to Dog Total
No. No.
6 2
Kg.
51.670(1SET)
7 8 9 10 11 12 13 14 15 16 17
Set Kg. No. Kg. No. Kg. Kg Kg Kg Kms. No.
6 51 2 3.4 1 7 1 3 3 0.01 3
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SCHEDULE FOR SUPPLY OF MATERIAL FOR 1No. 33 KV Triple Pole structure ON PCC POLE Sl. Particulars Unit Qty. No. 1 1 2 2 280 Kg.,9.1 Mtrs. long PCC Poles G.S.crossarm of 100 X 50 X 6 mm. channel suitable for 5' centre DP (1SET@65.090Kg/V-x arm) 3 No Kg. 4 3 130.18(2SET)
No.
4 5
33 KV Hard ware 33 KV Pin Insulator (polymer) Galvanized Horizontal and cross bracing 5' centre with set of four back clamps (1SET@51.670Kg) Galvanized Stay set 20 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/4.0 mm. @ 8.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices (1.7kg/no)(3no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Dog AAAC Conductor (100 Sq.mm. Al.Eq.) P G clamp Dog to Dog Total
No. No.
6 6
Kg.
103.34(2SET)
7 8 9 10 11 12 13 14 15 16 17
Set Kg. No. Kg. No. Kg. Kg. Kg Kg Kms. No.
6 51 3 5.1 2 14 2 5 3 0.15 3
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SCHEDULE FOR SUPPLY OF MATERIAL FOR 1No. 33 KV FOUR Pole structure ON PCC POLE Sl. No. 1 1 2 Particulars 2 280 Kg.,9.1 Mtrs. long PCC Poles Glavnised Steel DC crossarm of 100 X 50 X 6 mm. channel suitable for 5' centre DP (1SET@65.090Kg/V-x arm) 33 KV Strain set(polymer) Unit 3 No Kg. Qty 4 4 260.36(4SET)
No.
4 5
33 KV Hard ware 33 KV Pin Insulator (polymer) Glavnized Steel Horizontal and cross bracing 5' centre with set of four back clamps (1SET@51.670Kg) Glavnized Steel Stay set 20 mm. complete with back clamps, and turn buckles Glavnized Steel Stay wire 7/4.0 mm. @ 8.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices (1.7kg/no)(4no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Dog AAAC Conductor (100 Sq.mm. Al.Eq.) P G clamp Dog to Dog Total
No. No.
6 6
Kg.
206.68(4SET)
7 8 9 10 11 12 13 14 15 16 17
8 68 4 6.8 4 30 4 6 6 0.025 3
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SCHEDULE FOR SUPPLY OF MATERIAL FOR 1No. 33 KV CUT POINT ON H-Beams Sl. No. 1 1 Particulars 2 H-Beams 152 X 152 mm., 37.1 Kg./mtr 13 Mtr. Long Glavenised Steel crossarm of 100 X 50 X 6 mm. channel suitable for cut point-5feet (1SET@30Kg/x arm) Unit 3 Kg. 482.3 Qty 4
Kg.
30(1SET)
No.
4 5 6 7 8 9 10 11 12 13 14 15 16
33 KV Hard ware 33 KV Pin Insulator (polymer) Galvanized Stay set 20 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/4.0 mm. @ 8.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices(1.7kg/no)(1no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Dog AAAC Conductor (100 Sq.mm. Al.Eq.) P G clamp / T Clamp Dog to Dog Total
No. No. Set Kg. No. Kg. No. Kg. Kg Kg Kg Kms. No.
6 2 3 25 1 1.7 1 7 1 0 2 0.01 3
Page | ONLY FOR EXECUTION PURPOSE SHEDULE FOR SUPPLY OF PLANT - 6A

SCHEDULE FOR SUPPLY OF MATERIAL FOR 33/11 KV, 5 MVA SUBSTATION WITH TWO OUTGOING FEEDERS, A T NEW SITE (WITH SPACE RESERVED FOR UPGRADING TO TRANSFER BUS & TRANSFER BREAKER) Sl. No. 1 1. Particulars 2 CIVIL WORKS : i) Yard fencing with chain link mesh over brick wall (As per Anexure ''C'') ii) Galvanized main and wicket gate on RCC column (As per Anexure ''C'') iii) Galvanized Sheet Shine Board, bay indication board & RYB phase indication board (As per Anexure ''C'') iv) Cost of Control room & Internal electrification work for control room (As per Anexure ''C'') v) Yard leveling and metalling (As per Anexure ''C'') vi) 60 Mtr. deep 150 mm Dia Tube well (As per Anexure ''C'') vii)1000 Liter P/F Sintex overhead tank & GI pipe fitting for water supply including providing water tap near transformer neutral earthing (As per Anexure ''C'') viii) Providing and fixing 3HP submersible pump (As per Anexure ''C'') (ix) Fire Fighting Equipment (x) Single Line Diagram Board EQUIPMENTS : i) 33/11 KV Transformers (5.00 MVA) ii)11 KV VCB for X'mer & feeder protection iii) 33 KV VCB v) 11 KV VCB Control Panel having 2 Nos. feeders Protection facility vi) VCB Control Panel having 2 Nos. x'mer Protection facility for 33 KV & 11 KV side of Transformer. vii) 33 KV CT 100/50/5,200/100/5, 300/150/5 Amp. viii) 33 KV CT 600/300/5,200/100/5, 300/150/5 Amp. ix) 30V-100AH Lead Acid Battery with Battery Charger x) 11/0.4 KV Station Transformer (100 KVA) Schedule C-3(B) xi) 33 KV A B Switch Unit 3 Job Job Job Qty. 4 1 1 1
Job Job Job
1 1 1
Job
Job No No No No No No No No No Set No Set
1 1 1 1 3 1 1 1 3 9 1 1 4
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xii) 11 KV A B Switch xiii) 11 KV DO fuse unit xiv) 33 KV L.A.Station Type xv) 11 KV L.A. Station Type xvi) 33 KV Oil Immersed 3 Phase 4 wire CTPT Units xvii) 11 KV Oil Immersed 3 Phase 4 wire CTPT Units xviii) 110 V.,5 A. KWH electronic meter for 11KV xix) 110 V.,5 A. KWH electronic meter for 33KV xx) LTcT operated 3 Phase 4 wire Meter with CT & Modem xxi) DC Distribution box with MCB xxii) AC Distribution box with MCB xxiii) Sodium Vapour Lamp(250 Watts) xxiv) Control cable a. 2.5 Sq mm 8 Core b. 2.5 Sq mm 4 Core c. 2.5 Sq mm 2 Core xxv) P G clamp Dog to Dog conductor STRUCTURES AND BUS-BAR ARRANGEMENTS : i) PCC Pole 300 Kg. 8 Mtr Long for S/s structure of 33 KV & 11 KV ii) PCC Pole 280 Kg. 9.1 Mtr Long for 33 KV DP Structure iii) PCC Pole 140 Kg. 8 Mtr Long for 11 KV DP Structure, S/s X'mer & yard Lightining iv) Galvanized DC cross arm 100X50 mm, of all Lengh. v) AAAC Dog Conductor vi) 33 KV pin insulators & GI pins vii)11 KV pin insulators &GI pins viii) Strain Insulator Polymer for 33 KV side For Dog ix) Hardware set for 33 KV side For Dog x) Strain Insulator for 11 KV side Polymer insulator) xi) Hardware for 11 KV side suitable for Dog OTHER MISCELLANEOUS ITEMS : i) Concreting of structures & foundation(1:3:6) ii) 70 sq.mm Single core XLPE cable iii50 sq.mm Single core XLPE cable iv) 2.5 sq.mm. 2 core PVC Cable v) 16 sq.mm. PVC Cable Set Set No. No. No. No. No. No. No. No. No. No. Mtr. Mtr. Mtr. No. 10 4 9 18 1 3 3 1 1 1 1 3 300 200 200 100
Nos. Nos. Nos. Kg,. Km. No. No. No. No. No. No.
12 4 9 2800 0.8 12 25 33 33 114 114
Cmt. Mtr. Mtr. Mtr. Mtr.
70 24 80 100 100
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Distribution Box for S/s X'mer vi) Earthing of Sub station as per circular No.Discom/EZ/WS/1516 Dt.17.3.08 vii) Earthing of Poles (Coil) for DP viii) Earthing of transformer neutral with two numbers 50X5 mm copper strips, 3 nos. 11 KV pin insulators mounted on 50X6 mm Galvanized flat support and Al. pad Clamp with two bimetallic strips for twin panther conductor and AAAC/ACSR conductor for connection to two neutral earth pits. ix) Painting of structures x)Cable trench xi) Galvanized Nut & Bolts xii) Galvanized Washer xiii) Supply of T&P for Control Room as per Schdules 6 -III- A xiv) Supply of Safty Appliances for Control Room as per Schdules 6 -III- A xv) Supply of Furniture for Control Room as per Schdules 6 -III- A no. No. No. 1 1 10
LS
LS
LS LS Kg,. Kg,. LS LS LS
LS LS 275 27
Page |
SHEDULE FOR SUPPLY OF PLANT - 6-I A SCHEDULE FOR SUPPLY OF T&P FOR 33/11 KV, 5 MVA SUB-STATION
S.No. 1 2 3 4 5 6 7 8 9 10 11 12 Particulars D.E. Spanner set Tubler Spanner set Hack saw frame File 14", 10" & 10" half round Phawara Pick axe Ghamla Hammer (1Kg) Crow bars GI Bucket (14") Allumn. Ladder Cell Tester Qty. 1 1 1 3 1 1 2 1 2 2 1 1 Unit Set Set No No No No No No No No No No
Page | SHEDULE FOR SUPPLY OF PLANT - 6-II A SCHEDULE FOR SUPPLY OF Safety Appliances FOR 33/11 KV, 5 MVA SUB-STATION
S.No. 1 2 3 4 5 6 7 8 Particulars Tourch 3 Cells Insulated Screw Driver (12", 10'',8'',6'',4'') Insulated cutting pliers Neon Tester Rubber Ganuttes Earth discharge rod Shock treatment chart Rubber Mate as per ISI Qty. 1 1 1 1 2 8 1 2 Unit no set no no Pair no no no
Page |
SHEDULE FOR SUPPLY OF PLANT - 6-III A SCHEDULE FOR SUPPLY OF FURNITURE FOR S/s CONTROL ROOM FOR 33/11 KV, 5 MVA SUB-STATION
S.No. 1 2 3 4 5 6 7 8 9 10 11 Particulars Steel Table T-9 Steel Table CH-7 Steel Visitor Chair CH- 7 Steel Almirah Store well major Steel Square Stool ST-2 Wall Clock for control room Chain pully block 5 Ton Capacity Turfer 3 ton capacity Earth tester digital Megger 1000 Volt digital PP rope 20/25 sq. Cm. Qty. 1 1 4 1 1 1 1 1 1 1 100 Unit no. no. no. no. no. no. no. no. no. no. Kg.
Page |
ONLY FOR EXECUTION PURPOSE

SHEDULE FOR SUPPLY OF PLANT - 7A SCHEDULE FOR SUPPLY OF MATERIAL FOR 1K.M. 11 KV LINE ON PCC POLE WITH MAXIMUM SPAN OF 80 METER USING RABBIT CONDUCTOR Sl.No. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Particulars 2 140 Kg., 8.0 Mtrs. long PCC Poles 11 KV 'V' cross-arms with back clamps angle type 65x65x6 mm (12N0@12.340Kg/V-x arm) 11 KV Top clamps angle type 65x65x6 mm (12N0@3.00Kg/V-x arm) Earthing Set (Coil earth as per Drg. No. G/007 ) 11 KV Pin insulator porcelin AAAC Conductor rabbit with 3 % Sag Jointing Sleeves suitable for 80/100 Sq. mm.Al. Eq. AAAC conductor Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Anti climbing devices (1.7 kg/no)(12no) Danger Boards Binding wire and tape Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Total Unit 3 No. Kg. Kg. No. No. Km. No. Set Kg. kg. No. Kg. Kg. Kg Kg Kg Qty 4 12 148.08(12NO) 36(12NO) 12 36 3.1 6 4 22 20.4 12 3 14 2 18 18
Page | ONLY FOR EXECUTION PURPOSE

SHEDULE FOR SUPPLY OF PLANT - 8A SCHEDULE FOR SUPPLY OF MATERIAL FOR 1No. 11 KV Double Pole structure ON PCC POLE FOR EVERY 1.6 KMS.OF 11 KV LINE Sl. No. 1 1 2 Particulars 2 140 Kg., 8.0 Mtrs. long PCC poles Galvanized crossarm of channel of 100 X 50 X 6 mm. suitable for 4' centre DP(1SET@53.381Kg) 11 KV Strain set(polymer) 11 KV Hard ware 11 KV Pin insulator porcelain Galvanized Horizontal and cross bracing 4' centre with set of four back clamps(1SET@45.020Kg) Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) Anti climbing devices (1.7kg/no)(2no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire AAAC Conductor rabbit P G clamp / T Clamp Rabbit to Rabbit Total Unit 3 No. Kg. Qty 4 2 53.381(1SET)
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
No. No. No. Kg. Set Kg. No. Kg. No. Kg. Kg Kg Kg Km. No.
6 6 2 45.020(1SET) 6 33 2 3.4 2 6 1 3 3 0.01 3

SHEDULE FOR SUPPLY OF PLANT - 9A SCHEDULE FOR SUPPLY OF MATERIAL FOR 1No. 11 KV TRIPLE Pole structure ON PCC POLE Sl. No. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Particulars 2 140 Kg., 8.0 Mtrs. long PCC poles Galvanized crossarm of channel of 100 X 50 X 6 mm. suitable for 4' centre DP(1SET@53.381Kg) 11 KV Strain set(polymer) 11 KV Hard ware 11 KV Pin insulator porcelain Galvanized Horizontal and cross bracing 4' centre with set of four back clamps (1SET@45.020Kg) Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) Anti climbing devices (1.7kg/no)(3no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire AAAC Conductor rabbit P G clamp Rabbit to Rabbit Total Unit 3 No. Kg. No. No. No. Set Set Kg. No. Kg. No. Kg. Kg Kg Kg Km. No. Qty 4 3 106.76(2SET) 6 6 6 90.04(2SET) 6 33 3 5.1 3 10 1 5 5 0.015 3

SHEDULE FOR SUPPLY OF PLANT -10A SCHEDULE FOR SUPPLY OF MATERIAL FOR 1No. 11 KV FOUR Pole structure ON PCC POLE Sl. No. 1 1 2 Particulars 2 140 Kg., 8.0 Mtrs. long PCC poles Galvanized crossarm of channel of 100 X 50 X 6 mm. suitable for 4' centre DP (1SET@53.381Kg) 11 KV Strain set(polymer) 11 KV Hard ware 11 KV Pin insulator porcelain Galvanized Horizontal and cross bracing 4' centre with set of four back clamps (1SET@45.020Kg) Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) Anti climbing devices (1.7kg/no)(4no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire AAAC Conductor rabbit P G clamp / T Clamp Rabbit to Rabbit Total Unit 3 No. Kg. Qty 4 4 213.52(4SET)
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
No. No. No. Set Set Kg. No. Kg. No. Kg. Kg Kg Kg Km. No.
6 6 6 180.08(4SET) 8 44 4 6.8 4 15 1 6 6 0.025 3
Page |

SHEDULE FOR SUPPLY OF PLANT - 11A SCHEDULE FOR SUPPLY OF MATERIAL FOR 1No. 11 KV CUT POINT ON H-Beams Sl. No. 1 1 Particulars 2 H-Beams 152 X 152 mm., 37.1 Kg./mtr 11 Mtr. Long Galvanized crossarm of 100 X 50 X 6 mm.x1.2Mtr.channel suitable for cut point-5feet (1SET@27Kg) 11 KV Strain set(polymer) 11 KV Hard ware 11 KV Pin insulator porcelain Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/3.0 mm. @ 5.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices (1.7kg/no)(1no) Danger Boards Galvanized Nuts and Bolts Galvanized washer Barbed Wire AAAC Conductor rabbit P G clamp / T Clamp Rabbit to Rabbit Total Unit 3 Kg. Qty 4 408.1
Set
27Kg.(1SET)
3 4 5 6 7 8 9 10 11 12 13 14 15
No. No. No. Set Kg. No. Kg. No. Kg. Kg Kg Km. No.
6 6 2 3 17 1 1.7 1 7 1 2 0.01 3
Page | ONLY FOR EXECUTION PURPOSE Schedule for supply of plant-12A

SCHEDULE FOR SUPPLY OF MATERIAL FOR 1SET OF 33kV AB SWITCH ON EXISTING STRUCTURE. Sl. No. 1 1 Particulars 2 33 KV AB switch complete fitting Galvanized Angle 50x50x6 mm, 300 mm long for tightening AB switch (1.375 Kg/no.) Galvanized D.C.crossarm of channel of 100 X 50 X 6 mm. suitable for fixing of AB SWITCH ON 5' centre DP (65.090 Kg/set) Unit 3 Set Qty. 4 1
kg
4.125
kg
65.09
Galvanized D.C.crossarm of channel of 100 X 50 X 6 mm. suitable for fixing of AB Switch handle (32.5 Kg/set)
kg
32.5
Galvanized Angle 50x50x6 mm, 200 mm long for fixing of handle channel.(0.9166 Kg/per no.) Galvanized Angle 50x50x6 mm, 600 mm long for operating stand.(2.75 Kg/per no.) Galvanized Angle 50x50x6 mm, 250 mm long for operating stand.(1.1458 Kg/per no.) Galvanized Steel nuts & bolts (assorted size) Galvanized Steel washer AAA conductor (Dog) P G clamp / T Clamp Dog to Dog Total
kg
1.833
kg
5.5
kg
2.29
8 9 10 11
Kg Kg Mtr No.
7 1 12 3
Page |

SHEDULE FOR SUPPLY OF PLANT -14A SCHEDULE FOR SUPPLY OF MATERIAL FOR 1No. GAURDING Sl. No. 1 Particulars 2 Extension cross arm made by R.S. Jois 150X75 mm X1.5 mtr long duly drilled holes for top clamp & V-X Arm .(28.25kg /no) Gaurding crossarm made of 75 X 40 X 6 mm Galvanized Channel (2.25M LONG)37.57KG/SET Back Cleat for tighting of gaurding crossarm made of 50 X 50 X 6 mm G I .angle (200 M M LONG) I bolt of round Bar 16MM dia rod fully threaded 380mm long with Galvanised Nut 2 No in each bolt Galvanized Stay set 16 mm. complete with back clamps and turn buckles Galvanized Stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Galvanized Wire 8 SW G Galvanized Wire 10 SW G Galvanized Wire 24 SW G Galvanized Nuts and Bolts Galvanized washer P G clamp / T Clamp Dog to Dog Total Unit 3 Qty. 4
Kg.
28.25
Kg.
75.14(2SET)
No.
4 5 6 7 8 9 10 11 12
No. Set Kg. Kg. Kg. Kg. Kg. Kg No.
2 2 11 17 16 2 5 1 3

SHEDULE FOR ERRECTION OF PLANT - 1B SCHEDULE FOR WORK OF ERRECTION OF MATERIAL FOR 1K.M. 33 KV LINE ON PCC POLE WITH MAXIMUM SPAN OF 70 METER USING DOG CONDUCTOR 1 1 2 Line supports-280 Kg/9.1 m long PCC pole 33 KV Galvanized 'V' cross-arms with two back clamps 75x75x6 mm Galvanized angle (14N0@24.6Kg/V-x arm) 33 KV Galvanized Top clamps 75x75x6 mm Galvanized Angle (14N0@3.575kG/V-x arm) Earthing Set (Coil earth as per Drg.No.G/007) 33 KV Pin Insulator with Galvanized Pins Dog AAAC Conductor (100 Sq.mm. Al.Eq.) with 3 % Sag Jointing Sleeves suitable for 80Sq.mm.Al. Eq. AAAC conductor Galvanized Stay set 20 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/4.0 mm. @8.5 kg.stay wire per stay set Anti climbing devices (1.7kg/no)(14no) Danger Boards Binding wire and tape Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Total 3 Nos. 4 14
Kg
344.40(14No.)
Kg
49.98(14No.)
4 5 6 7 8 9 10 11 12 13 14 15 16
Nos. Nos. Kms. Nos. Sets Kg. kg. Nos. Kgs. Kgs. Kg Kg Kg
14 42 3.1 6 3 25 23.8 14 4 42 2 21 21
Page |

SHEDULE FOR RERRECTION OF PLANT - 2B SCHEDULE FOR WORK OF ERRECTION OF MATERIAL FOR 1No. 33 KV Double Pole structure ON PCC POLE FOR EVERY 1.6 KMS.OF 33 KV LINE Sl. Particulars Unit Qty. No. 1 2 3 4 1 280 Kg.,9.1 Mtrs. long PCC Poles No 2 2 G.S. crossarm of 100 X 50 X 6 mm. channel suitable for 5' centre DP (1SET@65.09Kg) Kg. 65.09(1SET)
No.
4 5
33 KV Hard ware 33 KV Pin Insulator (polymer) Galvanized Horizontal and cross bracing 5' centre with set of four back clamps (1SET@51.670Kg) Galvanized Stay set 20 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/4.0 mm. @ 8.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices (1.7kg/no)(2no) Danger Boards Galvanized Nuts and Bolts Galvanized washer Barbed Wire GI Wire 8 SWG for Earthing Dog AAAC Conductor (100 Sq.mm. Al.Eq.) P.G /T clamp Total
No. No.
6 2
Kg.
51.670(1SET)
7 8 9 10 11 12 13 14 15 16 17
6 51 2 3.4 1 7 1 3 3 0.01 3

SHEDULE FOR ERRECTION OF PLANT - 3B SCHEDULE FOR WORK OF ERRECTION OF MATERIAL FOR 1No. 33 KV Triple Pole structure ON PCC POLE Sl. Particulars Unit Qty. No. 1 1 2 2 280 Kg.,9.1 Mtrs. long PCC Poles G.S.crossarm of 100 X 50 X 6 mm. channel suitable for 5' centre DP (1SET@65.090Kg/V-x arm) 3 No Kg. 4 3 130.18(2SET)
No.
4 5
33 KV Hard ware 33 KV Pin Insulator (polymer) Galvanized Horizontal and cross bracing 5' centre with set of four back clamps (1SET@51.670Kg) Galvanized Stay set 20 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/4.0 mm. @ 8.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices (1.7kg/no)(3no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Dog AAAC Conductor (100 Sq.mm. Al.Eq.) P.G / T Clamp Dog to Dog. Total
No. No.
6 6
Kg.
103.34(2SET)
7 8 9 10 11 12 13 14 15 16 17
Set Kg. No. Kg. No. Kg. Kg. Kg Kg Kms. No.
6 51 3 5.1 2 14 2 5 3 0.15 3
Page |

SHEDULE FOR ERRECTION OF PLANT - 4B SCHEDULE FOR WORK OF ERRECTION MATERIAL FOR 1No. 33 KV FOUR Pole structure ON PCC POLE Sl. No. 1 1 2 Particulars 2 280 Kg.,9.1 Mtrs. long PCC Poles Glavnised Steel DC crossarm of 100 X 50 X 6 mm. channel suitable for 5' centre DP (1SET@65.090Kg/V-x arm) 33 KV Strain set(polymer) Unit 3 No Kg. Qty 4 4 260.36(4SET)
No.
4 5
33 KV Hard ware 33 KV Pin Insulator (polymer) Glavnized Steel Horizontal and cross bracing 5' centre with set of four back clamps (1SET@51.670Kg) Glavnized Steel Stay set 20 mm. complete with back clamps, and turn buckles Glavnized Steel Stay wire 7/4.0 mm. @ 8.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices (1.7kg/no)(4no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Dog AAAC Conductor (100 Sq.mm. Al.Eq.) PG / T Clamp Dog to Dog. Total
No. No.
6 6
Kg.
206.68(4SET)
7 8 9 10 11 12 13 14 15 16 17
8 68 4 6.8 4 30 4 6 6 0.025 3
Page |

SHEDULE FOR ERRECTION OF PLANT - 5B SCHEDULE FOR WORK OF ERRECTION MATERIAL FOR 1No. 33 KV CUT POINT ON H-Beams Sl. Particulars Unit Qty No. 1 1 2 H-Beams 152 X 152 mm., 37.1 Kg./mtr 13 Mtr. Long Glavenised Steel crossarm of 100 X 50 X 6 mm. channel suitable for cut point-5feet (1SET@30Kg/x arm) 3 Kg. 4 482.3
Kg.
30(1SET)
No.
4 5 6 7 8 9 10 11 12 13 14 15
33 KV Hard ware 33 KV Pin Insulator (polymer) Galvanized Stay set 20 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/4.0 mm. @ 8.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices(1.7kg/no)(1no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Dog AAAC Conductor (100 Sq.mm. Al.Eq.) Total
No. No. Set Kg. No. Kg. No. Kg. Kg Kg Kg Kms.
6 2 3 25 1 1.7 1 7 1 0 2 0.01
Page |

SHEDULE FOR ERRECTION OF PLANT - 6B SCHEDULE FOR ERRECTION OF MATERIAL FOR 33/11 KV, 5 MVA SUB-STATION WITH TWO OUTGOING FEEDERS, A T NEW SITE (WITH SPACE RESERVED FOR UPGRADING TO TRANSFER BUS & TRANSFER BREAKER) Sl. No. 1 1. Particulars 2 CIVIL WORKS : i) Yard fencing with chain link mesh over brick wall (As per Anexure ''C'') ii) Galvanized main and wicket gate on RCC column (As per Anexure ''C'') iii) Galvanized Sheet Shine Board, bay indication board & RYB phase indication board (As per Anexure ''C'') iv) Cost of Control room & Internal electrification work for control room (As per Anexure ''C'') v) Yard leveling and metalling (As per Anexure ''C'') vi) 60 Mtr. deep 150 mm Dia Tube well (As per Anexure ''C'') vii)1000 Liter P/F Sintex overhead tank & GI pipe fitting for water supply including providing water tap near transformer neutral earthing (As per Anexure ''C'') viii) Providing and fixing 3HP submersible pump (As per Anexure ''C'') (ix) Fire Fighting Equipment (x) Single Line Diagram Board EQUIPMENTS : i) 33/11 KV Transformers (5.00 MVA) ii)11 KV VCB for X'mer & feeder protection iii) 33 KV VCB v) 11 KV VCB Control Panel having 2 Nos. feeders Protection facility vi) VCB Control Panel having 2 Nos. x'mer Protection facility for 33 KV & 11 KV side of Transformer. vii) 33 KV CT 100/50/5,200/100/5, 300/150/5 Amp. Unit 3 Job Job Job Qty. 4 1 1 1
Job Job Job
1 1 1
Job
Job No No No No No No No No
1 1 1 1 3 1 1 1 3
Page |
viii) 33 KV CT 600/300/5,200/100/5, 300/150/5 Amp. ix) 30V-100AH Lead Acid Battery with Battery Charger x) 11/0.4 KV Station Transformer (100 KVA) Schedule C-3(B) xi) 33 KV A B Switch xii) 11 KV A B Switch xiii) 11 KV DO fuse unit xiv) 33 KV L.A.Station Type xv) 11 KV L.A. Station Type xvi) 33 KV Oil Immersed 3 Phase 4 wire CTPT Units xvii) 11 KV Oil Immersed 3 Phase 4 wire CTPT Units xviii) 110 V.,5 A. KWH electronic meter for 11KV xix) 110 V.,5 A. KWH electronic meter for 33KV xx) LTcT operated 3 Phase 4 wire Meter with CT & Modem xxi) DC Distribution box with MCB xxii) AC Distribution box with MCB xxiii) Sodium Vapour Lamp(250 Watts) xxiv) Control cable a. 2.5 Sq mm 8 Core b. 2.5 Sq mm 4 Core c. 2.5 Sq mm 2 Core xxv) PG / T Clamp Connection of Dog conductor STRUCTURES AND BUS-BAR ARRANGEMENTS : i) PCC Pole 350 Kg. 7 Mtr Long for S/s structure of 33 KV & 11 KV ii) PCC Pole 280 Kg. 9 Mtr Long for 33 KV DP Structure iii) PCC Pole 140 Kg. 8 Mtr Long for 11 KV DP Structure, S/s X'mer & yard Lightining iv) Galvanized DC cross arm 100X50 mm, of all Lengh. v) AAAC Dog Conductor vi) 33 KV pin insulators & GI pins vii)11 KV pin insulators &GI pins viii) Strain Insulator Polymer for 33 KV side For Dog ix) Hardware set for 33 KV side For Dog x) Strain Insulator for 11 KV side Polymer insulator) xi) Hardware for 11 KV side suitable for No Set No Set Set Set No. No. No. No. No. No. No. No. No. No. Mtr. Mtr. Mtr. No. 9 1 1 4 10 4 9 18 1 3 3 1 1 1 1 3 300 200 200 100
Nos. Nos. Nos. Kg,. Km. No. No. No. No. No. No.
12 4 9 2800 0.8 12 25 33 33 114 114
Page |
Dog OTHER MISCELLANEOUS ITEMS : i) Concreting of structures & foundation(1:3:6) ii) 70 sq.mm Single core XLPE cable iii50 sq.mm Single core XLPE cable iv) 2.5 sq.mm. 2 core PVC Cable v) 16 sq.mm. PVC Cable Distribution Box for S/s X'mer vi) Earthing of Sub station as per circular No.Discom/EZ/WS/1516 Dt.17.3.08 vii) Earthing of Poles (Coil) for DP viii) Earthing of transformer neutral with two numbers 50X5 mm copper strips, 3 nos. 11 KV pin insulators mounted on 50X6 mm Galvanized flat support and Al. pad Clamp with two bimetallic strips for twin panther conductor and AAAC/ACSR conductor for connection to two neutral earth pits. ix) Painting of structures x) Cable trench xi) Galvanized Nut & Bolts xii) Galvanized Washer xiii) Supply of T&P for Control Room as per Schdules 6 -III- A xiv) Supply of Safty Appliances for Control Room as per Schdules 6 -III- A xv) Supply of Furniture for Control Room as per Schdules 6 -III- A
Cmt. Mtr. Mtr. Mtr. Mtr. no. No. No.
70 24 80 100 100 1 1 10
LS
LS
LS LS Kg,. Kg,. LS LS LS
LS LS 275 27
Page |

SHEDULE FOR ERRECTION OF PLANT - 7B SCHEDULE FOR WORK OF ERRECTION MATERIAL FOR 1K.M. 11 KV LINE ON PCC POLE WITH MAXIMUM SPAN OF 80 METER USING RABBIT CONDUCTOR Sl.No. 1 1 2 Particulars 2 140 Kg., 8.0 Mtrs. long PCC Poles 11 KV 'V' cross-arms with back clamps angle type 65x65x6 mm (12N0@12.340Kg/V-x arm) 11 KV Top clamps angle type 65x65x6 mm (12N0@3.00Kg/V-x arm) Earthing Set (Coil earth as per Drg. No. G/007 ) 11 KV Pin insulator porcelain AAAC Conductor rabbit with 3 % Sag Jointing Sleeves suitable for 80/100 Sq. mm.Al. Eq. AAAC conductor Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Anti climbing devices (1.7 kg/no)(12no) Danger Boards Binding wire and tape Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire Total Unit 3 No. Kg. Qty 4 12 148.08(12NO)
3 4 5 6 7 8 9 10 11 12 13 14 15 16
Kg. No. No. Km. No. Set Kg. kg. No. Kg. Kg. Kg Kg Kg
36(12NO) 12 36 3.1 6 4 22 20.4 12 3 14 2 18 18
Page |

SHEDULE FOR ERRECTION OF PLANT - 8B SCHEDULE FOR WORK OF ERRECTION MATERIAL FOR 1No. 11 KV Double Pole structure ON PCC POLE FOR EVERY 1.6 KMS.OF 11 KV LINE Sl. No. 1 1 2 Particulars 2 140 Kg., 8.0 Mtrs. long PCC poles Galvanized crossarm of channel of 100 X 50 X 6 mm. suitable for 4' centre DP(1SET@53.381Kg) 11 KV Strain set(polymer) 11 KV Hard ware 11 KV Pin insulator porcelin Galvanized Horizontal and cross bracing 4' centre with set of four back clamps(1SET@45.020Kg) Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) Anti climbing devices (1.7kg/no)(2no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire AAAC Conductor rabbit PG / T Clamp Rabbit to Rabbit. Total Unit 3 No. Kg. Qty 4 2 53.381(1SET)
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
No. No. No. Kg. Set Kg. No. Kg. No. Kg. Kg Kg Kg Km. No.
6 6 2 45.020(1SET) 6 33 2 3.4 2 6 1 3 3 0.01 3

SHEDULE FOR ERRECTION OF PLANT - 9B SCHEDULE FOR WORK OF ERRECTION MATERIAL FOR 1No. 11 KV TRIPLE Pole structure ON PCC POLE Sl. No. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Particulars 2 140 Kg., 8.0 Mtrs. long PCC poles Galvanized crossarm of channel of 100 X 50 X 6 mm. suitable for 4' centre DP(1SET@53.381Kg) 11 KV Strain set(polymer) 11 KV Hard ware 11 KV Pin insulator porcelin Galvanized Horizontal and cross bracing 4' centre with set of four back clamps (1SET@45.020Kg) Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) Anti climbing devices (1.7kg/no)(3no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire AAAC Conductor rabbit PG / T Clamp Rabbit to Rabbit. Total Unit 3 No. Kg. No. No. No. Set Set Kg. No. Kg. No. Kg. Kg Kg Kg Km. No. Qty 4 3 106.76(2SET) 6 6 6 90.04(2SET) 6 33 3 5.1 3 10 1 5 5 0.015 3
Page |

SHEDULE FOR ERRECTION OF PLANT -10B SCHEDULE FOR WORK OF ERRECTION MATERIAL FOR 1No. 11 KV FOUR Pole structure ON PCC POLE Sl. No. 1 1 2 Particulars 2 140 Kg., 8.0 Mtrs. long PCC poles Galvanized crossarm of channel of 100 X 50 X 6 mm. suitable for 4' centre DP (1SET@53.381Kg) 11 KV Strain set(polymer) 11 KV Hard ware 11 KV Pin insulator porcelin Galvanized Horizontal and cross bracing 4' centre with set of four back clamps (1SET@45.020Kg) Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) Anti climbing devices (1.7kg/no)(4no) Danger Boards Galvanized Nuts and Bolts Galvanized washer GI Wire 8 SWG for Earthing Barbed Wire AAAC Conductor rabbit PG / T Clamp Rabbit to Rabbit. Total Unit 3 No. Kg. Qty 4 4 213.52(4SET)
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
No. No. No. Set Set Kg. No. Kg. No. Kg. Kg Kg Kg Km. No.
6 6 6 180.08(4SET) 8 44 4 6.8 4 15 1 6 6 0.025 3
Page |

SHEDULE FOR ERRECTION OF PLANT -11B SCHEDULE FOR WORK OF ERRECTION MATERIAL FOR 1No. 11 KV CUT POINT ON H-Beams Sl. No. 1 1 Particulars 2 H-Beams 152 X 152 mm., 37.1 Kg./mtr 11 Mtr. Long Galvanized crossarm of 100 X 50 X 6 mm.x1.2Mtr.channel suitable for cut point-5feet (1SET@27Kg) 11 KV Strain set(polymer) 11 KV Hard ware 11 KV Pin insulator porcelin Galvanized Stay set 16 mm. complete with back clamps, and turn buckles Galvanized Stay wire 7/3.0 mm. @ 5.5 kg.stay wire per stay set Earthing Set (Coil earth as per Drg. No. G/007 ) . Anti climbing devices (1.7kg/no)(1no) Danger Boards Galvanized Nuts and Bolts Galvanized washer Barbed Wire AAAC Conductor rabbit PG / T Clamp Rabbit to Rabbit. Total Unit 3 Kg. Qty 4 408.1
Set
27Kg.(1SET)
3 4 5 6 7 8 9 10 11 12 13 14 15
No. No. No. Set Kg. No. Kg. No. Kg. Kg Kg Km. No.
6 6 2 3 17 1 1.7 1 7 1 2 0.01 3
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Schedule for ERRECTION of plant-12B SCHEDULE FOR WORK OF ERRECTION MATERIAL FOR 1SET OF 33kV AB SWITCH ON EXISTING STRUCTURE. Sl. No. 1 1 Particulars 2 33 KV AB switch complete fitting Galvanized Angle 50x50x6 mm, 300 mm long for tightening AB switch (1.375 Kg/no.) Galvanized D.C.crossarm of channel of 100 X 50 X 6 mm. suitable for fixing of AB SWITCH ON 5' centre DP (65.090 Kg/set) Unit 3 Set Qty. 4 1
kg
4.125
kg
65.09
kg
32.5
Galvanized Angle 50x50x6 mm, 200 mm long for fixing of handle channel.(0.9166 Kg/per no.) Galvanized Angle 50x50x6 mm, 600 mm long for operating stand.(2.75 Kg/per no.) Galvanized Angle 50x50x6 mm, 250 mm long for operating stand.(1.1458 Kg/per no.) Galvanized Steel nuts & bolts (assorted size) Galvanized Steel washer AAA conductor (Dog) Total
kg
1.833
kg
5.5
kg
2.29
8 9 10
Kg Kg Mtr
7 1 12
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Schedule for ERRECTION of plant-13B SCHEDULE FOR WORK OF ERRECTION MATERIAL FOR 1SET OF11kV AB SWITCH ON EXISTING STRUCTURE. Sl. No. 1 1 Particulars 2 11 KV AB switch complete fitting Galvanized Angle 50x50x6 mm, 300 mm long for tightening AB switch (1.375 Kg/no.) Galvanized D.C.crossarm of channel of 100 X 50 X 6 mm. suitable for fixing of AB SWITCH ON 4' centre DP (53.381 Kg/set) Unit 3 Set Qty. 4 1
kg
4.125
kg
53.38
kg
26.6
Galvanized Angle 50x50x6 mm, 200 mm long for fixing of handle channel.(0.9166 Kg/per no.) Galvanized Angle 50x50x6 mm, 600 mm long for operating stand.(2.75 Kg/per no.) Galvanized Angle 50x50x6 mm, 250 mm long for operating stand.(1.1458 Kg/per no.) Galvanized nuts & bolts (assorted size) Galvanized washer AAA conductor Rabbit Total
kg
1.833
kg
5.5
7 8 9 10
kg Kg Kg Mtr
2.29 7 1 12
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SHEDULE FOR ERRECTION OF PLANT -14B SCHEDULE FOR ERRECTION OF MATERIAL FOR 1No. GAURDING Sl. No. 1 Particulars 2 Extension cross arm made by R.S. Jois 150X75 mm X1.5 mtr long duly drilled holes for top clamp & V-X Arm .(28.25kg /no) Gaurding crossarm made of 75 X 40 X 6 mm Galvanized Channel (2.25M LONG)37.57KG/SET Back Cleat for tighting of gaurding crossarm made of 50 X 50 X 6 mm G I .angle (200 M M LONG) I bolt of round Bar 16MM dia rod fully threaded 380mm long with Galvanised Nut 2 No in each bolt Galvanized Stay set 16 mm. complete with back clamps and turn buckles Galvanized Stay wire 7/3.15 mm. (5.5 kg.stay wire per stay set Galvanized Wire 8 SW G Galvanized Wire 10 SW G Galvanized Wire 24 SW G Galvanized Nuts and Bolts Galvanized washer Total Unit 3 Qty. 4
Kg.
28.25
Kg.
75.14(2SET)
No.
4 5 6 7 8 9 10 11
No. Set Kg. Kg. Kg. Kg. Kg. Kg
2 2 11 17 16 2 5 1
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INDEX
S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
PARTICULARS 33/11 KV Power Transformers (5.00 MVA) 33 KV ,11 KV VCB for X'mer & feeder protection, control panel & CTs 30V-100AH Lead Acid Battery with Battery Charger 11/0.4 KV Station Transformer 100 KVA 33 KV &11 KV A. B. Switch 33 KV L.A. Station Type 11 KV L.A. Station Type 11 KV D.O. Set 33 KV&11 KV Oil Immersed 3 Phase 4 wire CTPT Units H.T 110 V.,5 A. KWH electronic meter for 11kV LT CT operated three phase 4 W Static energy meter with CT & Modem Control cable2.5 Sq mm 8 Core ,4 Core ,2 Core 70/50 sq.mm Single core XLPE cable 2.5 sq.mm. 2 core PVC Cable 16 sq.mm. PVC Cable PG Clamp/ T Clamp AAAC Conductor Steel Sections . 350 Kg 7 Mtr Long & 280 Kg.,9.0 Mtrs. long PCC Poles 140 Kg., 8.0 Mtrs. long PCC Poles Earthing Pipe G I Earthing 33 KV Pin Insulator with G.I.Pins 33KV& 11kv Porcelin Insulator 11/15 KV & 33/35 KV 45 KN polymer (Silicon) Composite Insulator. Polymer Insulator 11 KV & 33 KV 33 KV hard ware 11 KV hard ware Galavanised Stay set 20/16 mm. complete with back clamps, and turn buckles Galavanised stay wire 7/4.0&7/3.15 mm. mm. (8.5 kg. stay wire per stay set ) Danger Boards Galavanised. Nuts and Bolts L.T. Distribution box suitable for 100 KVA transformer (without TPN switches) with MCCB on incoming and PF units on outgoing side Galvanized Wire Drawings
PAGE NO. 1-18 19-36 37-40 41-53 54-60 61-61 62-62 63-69 70-76 77-92 93-119 120-128 129-131 132-134 135-139 140-144 145-150 151-155 156-175 176-190 191-193 194-199 200-203 204-210 211-220 221-234 235-235 236-244 245-246 247-251 252-255 256-263 264-275 276-277 278-305
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THREE PHASE 33/11 KV STEP DOWN POWER TRANSFORMERS OF 5 MVA RATINGS

1. SCOPE:
The specification covers the design, manufacture testing and inspection before dispatch and delivery at places anywhere in DISCOM-CZ as per list of new substation to be commissioned. The specification covers oil immersed, naturally air cooled (type ON), outdoors type, three phase, 50 Hz, 33/11 KV step down power transformers of 5 MVA capacity.
2.
(A)
APPLICABLE STANDARDS:
Unless otherwise modified in the specification, the transformers shall comply with the requirement of ISS: 2026 (latest issue) or any equivalent International Standards and REC specification 2/1973 and ISS: 2099 (latest issue) or any equivalent International Standards. The bushings used shall conform to ISS: 2099 (latest issue) or any equivalent International Standards except as modified herein . Type: - The transformers shall be double wound, three phase oil immersed, oil natural cooled (type ON), core type suitable for outdoor installation in tropical climate and shall be insulated with minimum DPC insulation on HV & LV windings. Insulation should be of temperature class as per the temperature rise stipulated in this specification.
(B)
Climatic Conditions
i) ii) Peak outdoor temperature: Maximum oil temperature: Attainable iii) iv) v) vi) vii) viii) ix) x) Maximum relative humidity: Minimum relative humidity: Average No. Of thunderstorm Average number of rainy days per annum Number of months of tropical Monsoon conditions Average annual rainfall Wind pressure Altitudes not exceeding 50oC (50oC + 45oC) 95oC max temperature under max. Load condition 95%(sometime approaches saturation point) 10% 40 days 90 days 3 months 125 cm 100 Kg/m2 1000 meters.
(C)
Design and standardization:

i) The transformers and accessories shall be designed to facilitate operation, inspection, maintenance and repairs. All apparatus shall also be designed to ensure satisfactory operation under such sudden variations of load and voltage as may be met with under working conditions on the system, including those due to short circuits.
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ii) The design shall incorporate every reasonable precaution and provision for the safety of all those concerned in the operation and maintenance of the equipment keeping in view the requirement of Indian Electricity Rules. All material including bought out items like bushings, oil radiators, conductor and insulating materials used shall be of the best quality and of the class most suitable for working under the conditions specified and shall withstand the variation of temperature and atmospheric conditions arising under working conditions without undue distortion or deterioration or setting up of undue stresses in any part and also without affecting the strength and suitability of the various parts for the work which they have to perform. Corresponding parts liable to replacement shall be interchangeable. Cast iron shall not be used for chambers of oil filled apparatus or for any part of the equipment, which is in tension or subject to impact, stresses or where corrosion due to acidity or sludging is likely to occur. This clause is not intended to prohibit the use of suitable grades of cast iron for parts where service experience has shown it to be satisfactory e.g. large valve bodies. All outdoor apparatus, including bushing insulators with their mounting shall be designed so as to avoid external pockets in which water can collect and internally air could trap. All taper pins used in any mechanism shall be of the split type complying with IS:2593 or any equivalent International Standards for these items.
iii)
iv) v)
vi) vi)
viii) All connections and contacts shall be of ample section and surface for carrying continuously the specified currents without heating and fixed connection shall be secured by bolts or set screw of common size adequately locked against vibration. Lock nuts shall be used on stud connections carrying current.
ix)
3.
All apparatus shall be designed to minimize the risk of accidental short circuit caused by animals, birds or vermin.
STANDARD RATINGS:
The standard ratings shall be 5000 KVA with off load taps.
4.
CONTINUOUS MAXIMUM RATING:

The transformers shall have a continuous maximum rating at the specified normal ratio, frequency and temperature rises. (a) All transformers shall be capable of operation continuously in accordance with IS loading guide at their continuous maximum rating and at any ratio without exceeding temperature rise. Transformers with tapping ranges extending more than 9% below normal voltage shall meet the temperature rise limits specified in IS:2026 or any equivalent International Standards. On other tapings, they shall operate continuously without injurious heating. The loading of the transformers is to be in accordance with IS:6600 - guide for loading of oil immersed transformers natural cooled units or any equivalent International Standards.
(b)
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(c) The transformers shall be capable of operation without danger at other than rated voltage and frequency in accordance with clause 4.3 and 4.4 of IS:2026 (Part I) 1977 or any equivalent International Standards.
5.
MAXIMUM TEMPERATURE RISE:

The maximum temperature rise in each transformer tested at its continuous maximum rating shall not exceed the following limit with reference to ambient air temperature. i) ii) Temperature of oil by thermometer: 45oC
Temperature of winding by test resistance: 50oC
6.
NO LOAD VOLTAGE RATIO:

The no load voltage ratio corresponding to the principal tapping shall be 33,000/11,000 volts.
7.
MAXIMUM CURRENT DENSITY:

The current density for HV and LV winding should not exceed 2.5 Amps/mm2.
8.
(A) (B)
FLUX DENSITY: OVER FLUXING:

Flux density should not be more than 1.55 Tesla at the rated voltage and frequency. Over fluxing Requirement in this regard shall be governed by the provision contained in clause 3.1.7 of manual on transformer Section A (Revised 1987) of CBIP. According to this, over fluxing the transformer continuously for over fluxing factor up to 1.1. In addition to this requirement, operation of power transformer without any danger/damage up to 60 Sec. for over fluxing factor of 1.25.
9.
MAXIMUM GUARANTEED NO LOAD AND LOAD LOSSES:
The losses shall not exceed the value given below:
Rating in MVA
No Load losses (In KW)
Load losses at 75oC (In KW)
5.0 MVA
5.5
33.00
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The losses specified above are maximum permissible value and no plus tolerance would be allowed. One unit will be required to undergo for loss measurement by independent agency like ERDA Baroda etc. before commencement of supply.
10.
OIL:
Transformer oil to be used for first filling shall comply with the specification indicated hereunder. Generally as per IS: 335-1993 (4th revision) or any equivalent International Standards & REC specification No.39/1985 except in so far as values indicated separately as per Boards specification for EHV Grade Oil as per enclosed.
11.
TAPS:
11.1 Off-load tap transformers shall have taps ranging from +3% to -9% in steps of 3% each on HV winding for HV variation, to give normal 11 KV on LV side. 11.2 The tap changing switch shall be located in a convenient position so that it can be operated from ground level. The switch handle will be provided with a locking arrangement along with tap position, indication and direction for operation, thus enabling the switch to be operated and locked in position. Tap operation shall result in simultaneous positive change on all three phase, with spring loaded snap action and ensure positive pressure contact.
12.
WINDING CONNECTIONS & VECTORS:
12.1 The primary winding shall be connected delta and secondary winding star as per vector symbol Dy.11 (IS: 2026) or any equivalent International Standards so as to produce positive displacement of 30o from the primary to the secondary vector of the same phase (vector rotation assumed counter-clock wise). 12.2 The neutral point of the secondary (LV winding) is intended for solidly earthed system and should be brought out to a separate insulated terminal, enabling external insertion of a current transformer in the earth lead to be connected wherever required. 12.3 All windings of transformers shall have uniform insulation when tested in accordance with ISS: 2026/1977 or any equivalent International Standards. The minimum basic impulse withstands level of windings for 1.2/50 micro sec.full wave shall be as given below: i) ii) 11 KV 33 KV - 75 KV Peak - 170 KV Peak
13.
PERCENTAGE IMPEDANCE AND TOLERANCE (OTHER THAN NO LOAD AND LOAD LOSSES) SHALL BE AS UNDER: a) Percentage impedances Percentages impedance value for power transformers at 75oC on principal tap shall be as follows:
Rating
5000 KVA
Percentage impedance value at 75oC

7.15
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b) Tolerance Item Voltage ratio at no load On principal tapping Tolerance the lower of the following values: a) ( + / - ) 0.5% of the declared ratio b) A percentage of the declared ratio equal to 1/10 of actual percentage impedance voltage at rated current Impedance voltage at Rated current (Principal tapping & Other tapping) Requirement in this regard shall be governed by the provision indicated in IS:2026 (Part-IV) 1977 Para 3.1.4.1 for principal tapping and as per Provisions contained in Para 3.1.4.2 for other tapping or any equivalent International Standard. (+) 30% of the declared no load current
No load current
14.
TRANSFORMER TANK:
The main tank of the transformer shall be made of good quality steel sheet of adequate thickness to provide sturdy and robust construction to withstand extreme pressure conditions. The internal and external surfaces including oil filled chambers and structural steel work to be painted shall be shot or sand blasted to remove all rust and scale of foreign adhering matter or grease. All steel surfaces in contact with insulating oil shall be painted with two coats of heat resistant, oil insoluble, insulating varnish. Steel surfaces exposed to weather shall be given a primary coat of zinc chromate, second coat of oil and weather resistant varnish of color distinct from primary and final two coats of glossy oil and weather resisting paint in accordance with the color shade as specified. All paints shall be carefully selected to withstand extremes of weather. The paint shall not scale off or crinkle or be removed by abrasion due to normal handling. The minimum thickness of outside painting of tank shall be 20 microns and the total thickness shall be minimum 80 microns. The main tank exclusive of all accessories but with radiators shall be suitable to withstand application of vacuum up to 760 mm of HG. Adequate reinforcement shall be provided for this purpose and to withstand vibration.
14.1
Pressure Test:
One transformer tank shall be subjected to a pressure corresponding to twice the normal head of oil or to the normal pressure plus 35 KN/m2 (5lb/sq.in) whichever is lower, measured at the base of the tank and will be maintained for one hour during stage inspection. The permanent deflection of flat plates, after the excess pressure has been released shall not exceed the figure specified below: Horizontal length of flat Plate (in mm) Up to and including 750 751 to 1250 1251 to 1750 1751 to 2000 2001 to 2250 2251 to 2500 2501 to 3000 Above 3000 Permanent deflection (in mm.) 5 6.5 8 9.5 11 12.5 16 19
Page | 14.2 Conservator:
(i) A conservator complete with sump and drain valve shall be provided in such a position so as not to obstruct the electrical connections of the transformer having a capacity between highest and lowest visible levels to meet the requirement of expansion of the total oil volume in the transformer and cooling equipment from the minimum ambient temperature of (-) 5oC to 95oC. The minimum indicated oil level shall be with the feed pipe from the tank covered with not less than 15 mm depth of oil and the indicated range of oil level shall be minimum to maximum. (ii) If the sump is formed by extending the feed pipe inside the conservator, this extension shall be for at least 25 mm. (iii) One oil gauge magnetic type with provision for low levels alarm shall be mounted on conservator to indicate the minimum normal and maximum level as given below: Minimum Normal Maximum (iv) (-) 5oC 30oC 100oC
One prismatic type oil indicator should also be provided on the conservator.
(v) One end flange of the conservator shall be bolted into position so that it can be removed for cleaning purpose. (vi) The oil connection from transformer tank to the conservator vessel shall be arranged at a rising angle of 3 to 9o to the horizontal up to gas and oil actuated relay. (vii) Each conservator vessel shall be fitted with a aluminum die cast breather in which Silica gel (at least three Kg.) is the dehydrating agent and designed so that: (a) (b) The passage of air is through silica gel. The external atmosphere is continuously in contact with silica gel.
(c) The moisture absorption indicated by a change in colour of the tinted crystals can be observed from distance. Breathers shall be mounted at approximately 1400 mm. Above ground level. When the transformer mounted on plinth of 4 feet hight.
14.3
Radiators:
Arrangement for good quality sufficient number of radiators should be made to meet out the requirement of temperature rise. Following should also be given due consideration: (i) Belting of radiators to avoid vibration (ii) The gasket should be square in shape with holes for fixing radiators. Round shape gasket may be avoided. (iii) Radiator valve must indicate open and close direction clearly. (iv) Radiators must be supplied in separate packing (both the opening shall also be sealed with cork sheet packing and blanking plates)with serial number of transformer clearly indicated on packing with paint (v) Air release valve provided on radiator should not be of PVC material. It must be of cast iron duly cut in with thread for easy release of air.
14.4
Galvanising:
(a) Galvanizing where specified should be applied by the hot dipped process or by electro-galvanizing process, for all the parts other than steel, which shall consist of a thickness of 610 Gms. zinc per square meter of surface. The zinc coating shall be smooth, clean and of uniform thickness and free from defects or sharp edge.
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The preparation of galvanizing and the galvanizing itself shall not adversely affect the mechanical properties of the coated material. The quality will be established by tests as per IS: 2633 or any equivalent International Standards. Alternative to galvanizing, aluminizing shall also be considered (b) All drilling, punching, cutting and bending and welding of parts shall be completed and all burrs shall be removed before the galvanizing process is applied. (c) Surface, which is in contact with oil, shall not be galvanized or Cadmium plated.
15.
FINISH:
(a) Before painting or filling with oil, all ungalvanised parts shall be completely clean and free from rust, scale and grease and all external surface cavities on castings shall be filled by metal deposition. The interior of all transformer tanks and other oil filled chambers and internal structural steel works shall be cleaned and all scale and rust by shot blasting or other approved methods. This should be read alongwith clause 14 regarding requirement of painting of transformer tank. Except for nuts, bolts and washers, which may have to be removed for maintenance purposes, all external surfaces shall receive a minimum of three coats of paint. The primary coat shall be applied immediately after cleaning. The second coat shall be of oil, heat and weather resisting nature and preferable of a shade or color easily distinguishable from the primary and final coats shall be applied after the primary coat has been touched up where necessary. The final coat shall be of a glossy oil, heat and weather resisting nonfading, BATTLE SHIP GREY paint of shade No.631 of IS: 5. Primer paint shall be red oxide zinc chrome as per IS: 104, intermediate and final coats of grey paint shall be as per IS: 2032 or any equivalent International Standards. Nuts, bolts and washers, which may have to be removed for maintenance purposes, shall receive minimum of one coat of paint after erection. The spacing of the bolt centers on the tank and its cover should be so designed that the gaskets when pressed after bolting leave no room for either ingress of moisture or leakage of oil during transportation or normal service or full load and guaranteed temperature rise conditions.
(b)
(c) (d)
(e) (f)
16.
CORE:
The core shall be constructed from high grade, non-ageing, low loss cold rolled super grain oriented silicon steel lamination of CM-4 or better grade ensuring that boxes should not exceed the specified work grade steel or better. All stipulations under clause-8 be considered while selecting material of core.
(I) (a)
Magnetic circuit The design of the magnetic circuit shall be such as to avoid static discharges, development of short circuit paths within itself or of the earth clamping structure and the production of flux components at right angles to the plane of the laminations, which may cause local heating. Every care shall be exercised in selection, treatment and handling of core steel to ensure that so far as is practicable from distortion, burrs or sharp edge. Although the oxide/silicate coating given on the core steel is generally adequate, laminations can be insulated by the manufacturers if considered necessary.
(b) (c)
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(d) All ducts shall be provided wherever necessary to ensure adequate cooling and efficient heat transfer. The winding structure and major insulation shall not obstruct the free flow of oil through such ducts nor permit local hot spots. Where the magnetic circuit is divided into pockets by cooling ducts parallel to the planes of the lamination or by insulating material above 0.25 mm thick tinned copper strip bridging pieces shall be inserted to maintain electrical continuity conductivity between pockets. The framework and clamping arrangement shall be earthed in accordance with Clause-19 (II) of this Technical Specification.
(e)
(II) (a) (b) (c) (d)
Construction of Cores All parts of the cores shall be of robust design capable of withstanding any shocks to which they may be subjected to during lifting, transport, installation and service. All steel sections used for supporting the core shall be thoroughly sand blasted and shot blasted after cutting, drilling and welding. Adequate provision shall be made to prevent movement of the core and winding relative to the tank during transport and installation or while in service. The supporting framework of the cores shall be so designed as to avoid the pressure of pockets, which would prevent complete emptying of the tank through the drain valve or cause trappings of air during oil filling.
17.
TERMINAL ARRANGEMENT:
17.1 The transformers shall be fitted with shaded porcelain bushings of outdoor type suitable for solder less connectors on HV as well as LV side. The HV/LV bushing shall not be provided with arcing horns. Aluminum bushing stems and aluminum metal parts will not be accepted. 17.2 The bushings shall be filled with transformer oil, EHV grade, which shall be of non-oil communicating type with small aperture of 2 mm diameter. The HV/LV bushings shall have the characteristics as per IS: 2099 (latest issue) or any equivalent International Standards. LV neutral bushing requirement is identical to LV line bushing in all respect. The electrical characteristics of bushing insulators shall be in accordance with IS: 2099 (latest issue) or any equivalent International Standards as amended from time to time. All type and routine tests shall be carried out in accordance with IS:2099-1986 or any equivalent International Standards. The test voltages for various tests as stipulated in IS:2099-1986 are reproduced below:Nominal System Voltage KV 11 33 KV 12 36 Rated Voltage of the Bushing Visible discharge test One minute wet & dry withstand (Impulse Voltage) Lightning impulse withstand test KV 75 170
KV 9 27
KV 28 70
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17.3 Dimensions of the LV 12 KV bushings including the neutral (11 KV side) shall conform to IS:3347 (Part-III) or any equivalent International Standards and those of the 36 KV bushing (33KV side) shall conform to IS:3347 (Part-V) or any equivalent International Standards. Requirement of creepage distance of minimum 23 mm. Per KV of rated voltage of bushing as per provision contained in Para 7 of IS:2099-1993 or any equivalent International Standards. 17.4 Terminal connector shall be provided both for HV and LV terminal suitable for holding Raccoon Conductor up to capacity of 5 MVA and Dog/Panther conductor for 8 MVA transformers. It should be flat in shape. Its current capacity should be 600 Amps. 17.5 Bushing studs of 33 & 11KV should be of copper and conforming to IS: 3347 or any equivalent International Standards.
18.
VIBRATIONS AND NOISE:
Every care shall be taken to ensure that the design and manufacture of all transformers and accessories shall be such as to reduce noise and vibration to the level obtained in good modern practice. The manufacturers will ensure that the noise level shall not be more than 3 Db above the NEMA standard publication TR-1.
19.
(I)
INTERNAL EARTHING ARRANGEMENT:

General:
All metal parts of the transformer with the exception of the individual core laminations, core bolts and associated individual clamping plates shall be maintained at some fixed potential. (II) Earthing of core clamping structure : The top main core clamping structure shall be connected to the tank body by a copper strip. The bottom clamping structure shall be earthed by one or more of the following methods: (a) (b) (c) (III) By connection through vertical tie rods to the top structures. By direct metal-to-metal contact with the tank base maintained by the weight of the core and the windings. By a connection to the top structures on the same side of the core as the main earth connection to the tank.
Earthing of magnetic circuit (a) The magnetic circuit shall be earthed to the clamping structure at one point only through a disconnectable link placed in an accessible position beneath an inspection opening in the tank core. The connection to the link shall be on the same side of that core and the main earth connection. Magnetic circuits having an insulated sectional construction shall be provided with separate link for each individual section. When oil ducts or insulating barriers parallel to the plane of the laminations divide one magnetic circuit into two or more electrically separate parts, the ducts on barriers shall be bridged in accordance with Clause-16 (ii) and the magnetic circuit shall not be regarded as being of sectional construction.
(b)
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(IV) Size of earthing connections: All earthing connections with the exception of those from the individual cell clamping rings shall have a cross sectional area of not less than 0.8 sq.mm. Connections inserted between laminations of different section of core as per above (III) b shall have a cross sectional area of not less than 0.2 sq.mm. (V) Leads from winding to bushing and intercake connection: The leads from winding to bushing and intercake connection should be rigid enough to withstand normal vibration and transportation shocks and short circuit stresses. The end of winding to stud shall be tightened through nut and bolt arrangement and brazed at one place only.They should be spaced in such a way that necessary clearances are maintained not only in air but also with oil medium at the lowest permissive electrical strength as per relevant ISS over the period of normal service.
20.
ELECTRICAL CLEARANCE:
The clearance in air between live conductive parts and live conductive part and earthed structure shall be as follows: -
Voltage
Medium
Clearance phase to phase
Clearance phase to earth
11000 33000
21.
Air Air
280 mm 350 mm
205 mm 320 mm
PARALLEL OPERATION:
The transformers of the same service voltage shall be suitable for parallel operation, the load being shared in proportion to the capacities and percentage impedance volts, which will be within that specified in the ISS or any equivalent International Standards
22.
OVER LOAD CAPACITY:

(a) Each transformer shall be capable of carrying sustained over loads as stated in ISS: 6600 or any equivalent International Standards.
(b)
Type of load: - The transformer will supply a mixed power and lighting
Varying power factor from 0.6 lag to 0.8 lead due to capacitors.
load
with
23
PERFORMANCE WARRANTY:
The manufacturer shall among other things warranty the following: Quality and strength of material used, both electrical and mechanical. (ii) Satisfactory operation during the warranty period of 30 months from the date of receipt at Stores or 24 months from the date of commissioning whichever is earlier. This period will be
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reckoned from the day all accessories are received enabling assembly testing, commissioning and commercial operation of transformers. (iii) Performance figures are to be supplied by tenderer in the schedule of guaranteed particulars. In schedule of GUARANTEED TECHNICAL PARTICULARS, all details as required in IS:2026 or any equivalent International Standards shall be given.
24.
TOLERANCE:
The tolerance of guaranteed performance figures shall be as specified in the Clause 11.1 as per latest version of IS: 2026 or any equivalent International Standards, except for the no load and load losses which is firm and shall not exceed guaranteed values.
25.
WHEELS AND AXLES:

The transformers of 5000 KVA rating shall be provided with 4 Nos. flanged wheels suitable for use on a 1435 mm gauge Rail track. These wheels shall be suitable for being turned through an angle of 90o and locked in that position when the tank is jacked up. Other transformers shall be provided with 4 Nos. Bi-directional flat roller suitable for use on a 1000 mm. Gauge Rail track.
26.
FITTINGS & ACCESSORIES:
Unless otherwise specified in the order, the following standard fittings as detailed in Schedule X attached shall be provided. The fittings shall be in accordance with the details to the extent these are specified in IS: 2026 or any equivalent International Standards. (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) Inspection cover is needed to inspect tapping connections of bushings, tapping connections of tap changer and to inspect core-earthing connection. Rating plate. Diagram plate with tap position and relative HV/LV voltage. Two earthing terminals. Lifting lugs. 4 jacking pads Conservator with top filled cap and bottom drain valve. Dehydrating breather of required sizes in Aluminum Die. Casting with minimum three Kg. silica gel.(The plastic oil cup is not acceptable) Connecting pipe with valve and Buchholz relay. Radiator with top air release plug and connected valves and bottom for connection to main tank. Air release valve should not be of PVC material. It should be of cast iron duly cut in with thread for easy release of air. HV - 3 bushings LV - 4 bushings Off circuit tap switch with lock and 2 keys. Thermometer (dial type) with one contact for alarm pocket for sensor of thermometer (dial type) with one contact for alarm complete with provision for its mounting is needed.
(xi) (xii) (xiii) (xiv)
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(xv) Magnetic oil level gauge indicating three position of oil marked as follows: Minimum Normal (-50 C)
- ( 300C)
Maximum - (1000.C) (xvi) (xvii) (xviii) (xix) (xx) Oil filling hole and cap. Air release device on tank top. Pressure relief device through explosion vent diaphragm with fresh equalizer pipe air release plug. Please see foot note indicated in Schedule X Schedule of Fittings. Gas and oil actuated relay. 2 filter valves (top valve, lower valve to be used also as drain valve). Locking arrangement should be provided on each valve to avoid theft of transformer oil by welding U shape flat over each valve.
27.
27.1
TESTS AND INSPECTION:

Type test: The Purchaser intends to procure transformers whose design is successfully type tested for short circuit, lightning impulse test, loss measurement test and heat run test from an independent agency of national/international repute like CPRI, Bhopal/Bangalore, National Test House, Ghaziabad, ERDA, Baroda or to any recognized and reputed International Laboratory and or Institution. The tenderers are required to carry out type test. The expenses to be incurred towards the following tests shall be borne by them. This may be kept in mind while quoting the price. Type test includes following tests: (i) Short circuit withstand test as per clause 16.11 Part-I IS:2026 or any equivalent International Standards. The requirement with regard to ability to withstand short circuit shall be governed by clause-8 and demonstration of ability to withstand short circuit shall be governed by clause-9 of IS:2026(Part-I)1977 or any equivalent International Standards. Accordingly, the symmetrical short circuit current to be used for the design and tests shall be governed by the Table-4 (IS:2026Part-I 1977) or any equivalent International Standards and shall be 1000 MVA for the subject power transformers (highest system voltage 36 KV). (ii) Lightning impulse withstand test as per Clause-13 Part-III IS:2026 or any equivalent International Standards. (iii) Temperature rise test as per Clause-4 Part-II IS:2026 or any equivalent International Standards. One transformer of each rating shall be type tested at some independent laboratory of National/International repute like CPRI, ERDA etc. for temperature rise as per relevant ISS. However, the rise shall not be more than 500C for winding and 450C for oil above the ambient temperature. (iv) Loss Measurement Test With value of No Load and Load Losses obtained at 750C.
27.2 Stage inspection: The purchaser intends to ensure the quality of raw material being used and workmanship during course of manufacturing of power transformers. At time of core coil assembly, two representatives of purchaser will be deputed to carry out stage inspection. Only after clearance of stage inspection manufacturer will proceed further (tanking of core coil etc.) and will be required to offer transformer for pre-delivery final inspection.
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27.3 Routine Test: - The following tests in addition to those listed in IS:2026 or any equivalent International Standards shall be carried out for routine tests. These tests are required to be carried out by the supplier at the suppliers cost on each and every unit manufactured by them and report shall be forwarded to Addl.Chief Engineer(S&P), O/o CMD(CZ), MP MKVV Co. Ltd., Bhopal office at the time of offering transformer for pre-delivery final inspection.
(i)
Oil leakage test - All the tanks and oil filled compartments shall be tested for oil tightness by being completely filled with air/oil of a viscosity not greater than that of insulating oil conforming to IS: 335 or any equivalent International Standards at an ambient temperature and subjected to a pressure equal to the normal pressure plus 35 KN/m2 (5lb/sq.in) measured at the base of the tank. This pressure shall be maintained for a period not less than 10 minutes during which time no leakage shall occur Di-electric test on transformer oil. Checking for pre-shrinkages - The transformer will be dried out for 16 hours at temperature between 80 to 1000C. The active parts shall be tightened and height of assembled unit shall be measured. The difference between two measurements shall not be less than two percent as compared to height measured at normal temperature. Measurement of magnetizing current at low voltage i.e. 440V.
(ii) (iii)
(iv)
27.4 tests:
Acceptance Test: 1. 2.
- The Purchaser/Representative at the firms works shall witness the following
All the routine tests as mentioned in 27.3 on each and every offered transformer. Further, the Purchasers Inspector reserves the right to carry out any other test for acceptance of offered transformers as per relevant specifications.
27.5 Inspection :- All tests and inspection shall be carried out at the place of manufacture unless otherwise specifically agreed upon by the manufacturer and Purchaser at the time of purchase. The manufacturer shall offer the Inspector representing the Purchaser all reasonable facilities without charges to satisfy him that the material is being supplied in accordance with this specification. This will include Stage Inspection during manufacturing stage as well as active Part Inspection during acceptance tests. The Purchaser has all the rights to conduct the test including type tests at his own cost by an independent agency whenever there is dispute regarding the quality of supply or interpretation of test results. In the event of failure of transformers in such tests, the expenses incurred in testing and cost of transformer etc. shall be to the Suppliers account.
28.
TEST REPORTS ON THE ANALYSIS OF RAW MATERIALS:
The tender shall indicate the source(s) of raw materials(s) called for in Schedule-VI and enclose test certificates and report on the analysis of electrolytic copper used for the winding and the steel used for core insulation material as also bought out items from sub-suppliers. The quality of material used in prototype transformer, which has passed the type tests, shall be the same in all the ordered transformers. In case it is found that inferior quality of material is used, the transformer shall not be accepted.
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(Revised 1993)
B
1.0
33 KV VACUUM CIRCUIT BREAKERS

SCOPE This specification covers 3-pole, 50 Hz, 33 KV Vacuum/SF6 Circuit Breakers for outdoor installation in 33/11 KV sub-stations in rural area.. APPLICABLE STANDARDS Unless otherwise modified in this specification, the circuit breakers shall comply with the following Indian Standards as amended from time to time: IS: 13118 (Circuit Breaker) IS: 2705 (Current Transformers)
2.0
3.0
RATED VOLTAGE The rated voltage for the circuit breakers shall be 36 KV. This represents the highest system voltage corresponding to the nominal system voltage of 33 KV. RATED NORMAL CURRENT The standard rated normal current shall be 1250 A.
4.0
5.0
RATED SHORT CIRCUIT BREAKING CURRENT 5.1 The rms value of the a.c. component of the rated short circuit breaking current shall be 12.5 KA (750 MVA approximately) 5.2 The value of percentage d.c. Component shall be calculated in accordance with the recommendations contained in IS: 13118-1991
6.0
RATED SHORT CIRCUIT MAKING CURRENT The rated short circuit making current shall be taken as 2.5 times the rms value of the a.c. component of the rated short circuit breaking current. RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE (KV PEAK) The rated lightning impulse withstand voltage of the circuit breaker shall be 170 KV (peak). RATED SINGLE CAPACITOR BANK BREAKING CURRENT The rated single capacitor bank breaking current of the circuit breaker shall be 100 Amps.
7.0
8.0
10.0
CURRENT TRANSFORMERS FOR METERING AND PROTECTION The current transformers shall be supplied along with the circuit breaker and shall have the following characteristics/constructional features : 10.1 The current transformers shall be enclosed in a sealed housing and shall be suitable for outdoor installation. The CTs shall be supported on a suitable pedestal/steel structure. Mounting flanges, bolts etc., shall be hot dipped galvanised and shall be supplied along with the CTs. Suitable mounting holes shall be provided at the base for clamping to the structure.
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10.2 The CTs shall be provided with bolted type terminals to receive ACSR conductor sizes ranging from 80mm2 to 100mm2 (without requiring use of lugs) both in vertical and horizontal directions. The terminals shall be such as to avoid bimetallic action. Transformation ratio: The standard transformation ratio shall be 200/100/5-5A. The current transformers shall have separate cores for protection and metering and shall be of torroidal type. Accuracy class for the purpose of metering shall be 1.0 and for the purpose of protection shall be 5P with an accuracy limit factor of 10. Rated Output (burden) of the current transformers shall be adequate for the type and make of the relays and meters used.
10.3 10.4 10.5 10.6
11.0
CONSTRUCTIONAL FEATURES 11.1 The circuit breakers shall have fixed type of construction and the vacuum/SF6 interrupter units together with the HV connections shall be totally enclosed in a hermetically sealed housing(s) having inert atmosphere inside. The relays, meters, indicators and operating handle etc. shall be provided in a cabinet with a hinged door and locking device. The door shall open upwards (with hinge at the top) for protection against rain (when in open position). Alternatively, the door opening sideways shall be acceptable if a suitable hood is provided on the top for protection against rain. 11.2 No isolator shall be provided in the breaker. CLOSING/TRIPPING MECHANISM 12.1 The circuit breakers shall be provided with motor-operated spring-closing or solenoid mechanism. The motor/solenoid shall operate at 230 V single-phase supplies with a voltage variation of (+) 10% to (-) 20%. The closing mechanism shall have provision for manual closing. 12.2 The trip mechanism shall be suitable for operation by 30V DC with a voltage variation of (+) 10% to (-) 20%.. TESTS The circuit breakers shall be subjected to the following tests in accordance with IS: 13118-1991. 13.1.1 Routine Tests a) Power frequency voltage dry tests on the main circuit b) Voltage tests on control and auxiliary circuits c) Measurement of resistance of the main circuit d) Mechanical operating test 13.1.2 Type Tests a) Tests to prove mechanical performance b) Tests to prove mechanical operation c) Tests to prove that the temperature rise of any part does not exceed specified limit d) Tests to prove that the insulation complies with specified limits e) Tests to prove performance the short circuit making and breaking
12.0
13.0 13.1
f) Tests to prove the short circuit current performance g) Tests to prove the performance when breaking line cable-
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charging currents h) Tests to prove the performance when breaking single capacitor bank current. 13.2 The Current Transformers shall be subjected to the following tests in accordance with IS: 2705 13.2.1 Routine Tests a) b) c) d) e) Verification of terminal markings and polarity High voltage power-frequency tests on primary windings High voltage power frequency tests on secondary windings Over-voltage inter-turn test and Determination of error according appropriate accuracy class to the requirements of
13.2.2 Type Tests a) b) c) d) e) f) g) h) Verification of terminal markings and polarity High voltage power frequency test on primary windings High voltage power frequency test on secondary windings Over-voltage inter-turn test Determination of error according appropriate accuracy class Short time current test Temperature rise test and Impulse voltage test for current transformers for service in electrically exposed installations to the requirements of
14.0
INSPECTION 14.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.
14.2
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2.A
1.0 SCOPE
11KV VACUUM CIRCUIT BREAKERS
This specification covers three-pole, 50 Hz, 11 KV vacuum circuit breakers both for indoor and outdoor installations in rural area.
2.0
APPLICABLE
STANDARDS
Unless otherwise modified in this specification, the vacuum circuit breakers shall comply with the following Indian Standards as amended from time to time : IS-13118: Circuit Breakers IS-3156: Voltage Transformers IS-2705: Current Transformers
3.0
RATED VOLTAGE
The rated voltage for the circuit breaker shall be 12 KV. This represents the highest system voltage corresponding to the nominal system voltage of 11 KV.
4.0
RATED CURRENT
4.1 4.2 The standard rated normal current shall be 630A. The bus bar rating of the indoor type vacuum circuit breaker shall be 800 A.
5.0
RATED SHORT-CIRCUIT BREAKING CURRENT

5.1 The rms value of the A.C. component of the rated short-circuit breaking current shall be 12.5 KA. Note : It is recommended that 12.5 KA circuit breaker may be used only when the proposed/anticipated transformer capacity is 2x5 MVA (capacities above 2x5 MVA are not generally met with in the rural system). For lower transformer capacities, 8 KA breakers will be adequate. The value of D.C. component shall be calculated in accordance with the recommendations contained in IS: 13118.
5.2
6.0
RATED SHORT-CIRCUIT MAKING CURRENT

The rated short-circuit making current of the circuit breakers shall be taken as 2.5 times the rms value of the A.C. Component of the rated short-circuit breaking current.
7.0
RATED VOLTAGE OF OPERATING DEVICES

The standard DC voltage for the operating devices shall be 30 V. (with -20% and +10% voltage variation)
8.0
VOLTAGE TRANSFORMER FOR METERING

8.1 8.2 Voltage Ratio: The rated voltage ratio shall be 11000/110 V. The transformer shall be star-star connected and one of the secondary terminals shall be earthed. Rated Output: The standard rated output (burden) of the voltage transformer shall be 100 VA per phase. Normally, only one 3-phase voltage transformer of this rated output will be required at a 33/11 KV sub-station. Accuracy Class : The standard accuracy class shall be 1.0.
8.3
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9.0 CURRENT TRANSFORMER FOR METERING & PROTECTION 9.1 Transformer Ratio: The standard transformation ratio shall be: i) iii) 300-150/5A Note : The above double ratio current transformers will be adequate to cover the load demands of the outgoing feeders as well as the requirements of incoming panels for sub-station capacities upto 2x5 MVA. The SEBs may select the required ratings out of the above, depending upon the sub-station capacity and feeder loadings. Accuracy Class : Accuracy class for the purpose of metering shall be 1.0 and for the purpose of protection shall be 5P with an Accuracy Limit Factor of 10. Rated Output : The rated output (burden) of the current transformers which depends upon the type and make of relays and meters used, will have to be decided in each case.
9.2 9.3
11.0
CONSTRUCTIONAL FEATURES 11.2 Outdoor Application: 11.2.1 Vacuum circuit breakers for outdoor application shall have fixed type of construction and the vacuum interrupter units together with the HV connections shall be enclosed in a sealed housing (preferably of porcelain) conforming to IP-65 protection (IS: 2147). The operating mechanism, links, etc. shall be housed in a suitable cubicle and should be accessible for maintenance. The relays, meters, indicators and operating handle etc. shall be provided on the front side with a hinged door and locking device. The door shall open upwards (with hinge at the top) for protection against rain (when in open position). 11.2.2 No isolator shall be provided in outdoor breakers.
12.0
CLOSING/TRIPPING MECHANISM 12.1(a) The circuit breakers shall be provided with hand operated spring-closing mechanism. If specially required by the purchaser, 230 V single-phase AC motor shall be provided for spring-closing mechanism with provision for manual closing. Note : The hand-operated spring mechanism is very light in the case of vacuum circuit breakers as compared to the conventional oil circuit breakers and is ideal for rural sub-stations due to its simplicity and economy.
12.1(b) Alternatively, the SEBs has the option to order circuit breakers with solenoid closing mechanism suitable for operation with 30 V DC (with -20% and +10% voltage variation)
12.2(a) The trip mechanism shall be suitable for direct operation from the current Transformers in conjunction with the Series trip relays of the type indicated in clause- 10.2. Note: This tripping arrangement along-with the closing mechanism as per 12.1(a) is recommended for rural sub-stations as the need for battery is eliminated. 12.2(b) Alternatively, if closing arrangement as per 12.1 (b) above is adopted, the SEBs have the option to order circuit breakers with the trip coil operated by 30 V DC, using Shunt trip relays. (with 20% and +10% voltage variation) 13.0 TESTS The circuit breakers, voltage transformers and current transformers shall be subjected to the following routine and type tests in accordance with the details specified in the relevant Indian standards, as amended from time to time.
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13.1 Circuit Breakers - IS: 13118-1991 13.1.1 Routine Tests a) Power frequency voltage dry test on the main circuit b) Voltage test on control and auxiliary circuits c) Measurement of resistance of the main circuit d) Mechanical Operating test 13.1.2 a) b) c) d) e) f) g) h) i) j) 13.2 Type Tests Tests to prove mechanical performance Tests to prove mechanical operation Tests to prove that temperature rise of any part does not exceed specified limits Tests to prove that insulation complies with specified limits Tests to prove short-circuit making and breaking performance Tests to prove short-time current performance Tests to prove performance when breaking line charging current Tests to prove performance when breaking cable-charging current Tests to prove the performance when breaking single capacitor bank currents Tests to prove the performance when breaking small inductive currents
Voltage Transformers: - IS: 3156 (Part-I)-1992 13.2.1 Routine Tests: a) b) c) d) 13.2.2 a) b) c) d) e) f) Verification of terminal markings and polarity Power-frequency dry withstand tests on primary windings Power-frequency dry withstand tests on secondary windings Determination of errors according to the requirements of the appropriate accuracy class Type Tests: Verification of terminal markings and polarity Power-frequency dry withstand tests on primary windings Power-frequency dry withstand tests on secondary windings Determination of errors according to the requirements of the appropriate accuracy class Temperature-rise test Impulse voltage tests on voltage transformers for service in electrically exposed Installations
13.3
Current Transformers - IS: 2705 (Part-I)-1992 13.3.1 Routine Tests: a) Verification of terminal markings and polarity b) High voltage power-frequency test on primary windings c) High voltage power-frequency test on secondary windings d) Over-voltage inter-turn test e) Determination of error according to the requirements of appropriate accuracy class 13.3.2 a) b) c) d) e) f) g) Type Tests: Verification of terminal markings and polarity High voltage power frequency test on primary windings High voltage power frequency test on secondary windings Over-voltage inter-turn test Determination of error according to the requirements of appropriate accuracy class Short-time current test Temperature-rise test
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h) 14.0 Impulse voltage test for current transformers for service in electrically exposed Installations
INSPECTION 14.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with the specification. 14.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.
=====
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2C.
INDOORS CONTROL PANELS FOR 11 KV & 33 KV VCBs
SCOPE This section contains the technical specification for the Indoor Control Panel for twin Protection (that is one no. feeder Protection & one No. Transformer, or two no. feeder Protection or two no. Transfromer Protection indication, relay and metering panels associated with the outdoor switchgear for use at various sub-stations. The control and relay panels and other requirements specified under this section shall be complete in themselves with all main and auxiliary relays, fuses, links, switches, wiring, labels, terminals blocks, earthing terminals, foundation bolts, illumination, cable glands etc. PANEL FINISH AND COLOUR The Employer has standardized that the colour finish of control panel shall be opeline green as per colour no. 275 of BS: 381C (1948). Equivalent colour as per relevant Indian Standards or any other standard shall be acceptable. This colour finish shall be applied to all the exterior steel work of the panels. The exterior finish shall be semiglossy only and shall not be fully glossy. The interior of the panels shall be painted with eggshell white. PROTECTIVE RELAYS AND INSTRUMENTS The protective relays shall be manufactured, tested and supplied with the guaranteed particulars, as per following Indian Standard Specifications with latest amendment thereof : I 15-3842 (Part-I) 1967 Application guide for electric relays for A.C. Systems: over-current relays for Feeders and Transformers Ii 15-3842 (Part-IV) 1967 Application guide for electric relays for A.C. System thermal relays Iii 15-3231 (1965) Iv 15-1885 (Part-I & II) protection
Electric Relay for Power System Protection Electrovocabular Electrical Relay &
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technical Electrical Protection BIS 142 v IEC 255 Vi
y Power System
For inverse time characteristics All indicating instruments shall conform to 15722 or BS-89
The equipment meeting any other authoritative standard which ensures equal or better quality than the standards mentioned above shall also be acceptable. Equipment for which Indian Standards are not available the relevant British Standards and IEC recommendations will be applicable. PANEL CUT OUT AND DIMENSIONS
i)
The panels shall be fabricated with facility of Instalation of 2 no. Relay for protection of 2 no. feeder are 2 no. Transformer, from 14 SWG steel sheets free from all surface defects. The panels shall have sufficient structural reinforcement to ensure a plain surface to limit vibration and to provide rigidity during dispatch and installation. All control panels and switchgear cubicles shall be made absolutely vermin-proof and subjected to the approval of the Employer. Pre-treatment & painting of panels shall be done as per the procedure detailed at Sr. No. 21 of this schedule. The panels shall have the following dimensions: Height Width Depth 1475 mm 600 mm 300 mm
ii)
No deviation in height/ depth will be permitted. However, width can be increased depending upon the actual requirement, which shall be subjected to approval from the Employer. iii) iv) The preferred panel cut out dimensions for mounting of the relays shall be as per Indian Standard Specification 15-4483 (Part - I & II). The design, material selection and workmanship shall be such as to present a neat appearance, outside and inside with no works of welds, rivets, screw or bolt
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heads apparent from the exterior surface of the Control Panels. DOORS Each panel shall be completed with end enclosing sheets on both sides and door in the front. There shall be one door with handle and also turn twist locks at top and bottom. Proper. Gasketing shall be provided on the door. A type test report from the recognized Govt. Laboratory on degree of protection test (IP-55) shall also be furnished with the tender. The doors should be grounded with flexible braided copper conductor of 10 sq.mm.
PANEL LIGHTING a) For interior illumination, one no. 11 watt CFL operating at 230 Volt 50 Hz with switch shall be provided in each panel. The CFL shall be located at the ceiling and guarded with protective cage. The switch shall be mounted on one of the side walls and shall be easily accessible. One 5 Amp. 3 Pin receiptable with plug, switch and fuse shall be provided in each control panel.
b)
AUXILIARY SUPPLY a) For each Control Panel, the Employer will provide the following: i) ii) 230 V plus 10% minus 20%, 50 Hz neutral grounded A.C. supply. 30 V + 10% -20% D.C. supply.
b) H.R.C. fuses shall be provided by the agency for both the A.C. and D.C. power supplies. c) All H.R.C. fuses and links shall be with holder. The base of fuse holder shall be mounted on slant support and with identification labels.
CONTROL WIRING a) The agency shall provide complete wiring up to the terminal block for the equipment, instrument devices mounted in the control panel strictly according to the wiring diagram prepared by the bidder based on the Employer's information and schematic diagram and get approved from the Employer. All internal wiring shall be securely supported, neatly arranged, readily accessible and properly ferruled. The wiring shall be completed in all respects so as to ensure proper functioning of the control, protection and metering schemes. Agency shall supply, lay and terminate all the control cables between VCB panel, Control panel (Indoor) and CT. All control cable shall be properly ferruled along with separate ferrule for
b)
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each core. Separate tags shall also be provided at least three places between VCB and control panel (in cable trench) so that each cable can be properly identified in trench. c) d) All spare contacts of relays and switches shall be wired up to the terminal block. The Control Panels shall be supplied completely wired ready for Employer's external connections at the terminal blocks. For CT circuits the wiring shall be carried out with 1100 V Grade PVC insulated stranded copper conductor of size 2.5 sq. mm. For PT circuits and also for control circuits, the wiring shall be carried out with 1100 Volt Grade PVC insulated stranded copper conductor of size 2.5 sq. mm. Colour coded wires should be used to facilitate easy tracing, as under:
e)
i) Three Phase A.C. Circuit; Red for R Phase Yellow for Y Phase Blue for B Phase Black for Neutral ii) Single Phase A.c. Circuit: Red for Phase Green for Earthing Black for Neutral iii) D.c. Circuit: Red for Positive Black for Negative iv) Control Wiring: Gray for annunciation and other control circuits
f)
Each wire shall be identified at both ends with wire designation number by plastic ferrules, as per wiring diagram based on latest revision of 15-375 to denote the different circuit functions. The agency shall take approval for the system of wire numbering All wire termination shall be made with solder less compression type connectors. Wires shall not be tapped or spliced between terminal points. All wire shall have crimp type termination and direct connection at any place is not at all required. All series connected devices and equipment shall be wired-up in sequence. Loop-in / loop-out system of wiring shall be avoided, as far as possible and the common buses shall normally be made through the terminal block for better reliability of testing and maintenance. Fuses and links shall be provided for isolation of individual circuit from the bus wires without disturbing the other circuits' and equipments. The DC trip and DC voltage supplies and wiring to main protective gear shall be segregated from these for back up protection and also for
g)
h)
i) j)
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protective apparatus for special purposes. Each such group shall be fed through separate fuses, either direct from main supply fuses or the bus wires. k) Since a number of wires will run from one point to another, it is desired that the support arrangement should be adequate and neat. The conventional method of bunching of wire should not be adopted, since the same may create problems in case any wire is required to be removed. The wires should be accommodated in plastic channel with sliding plastic cover mounted inside the panel, suitably. Inspection/removal of wires should be possible by sliding the covers. Blank plastic channels should be provided by the sides of the panel to accommodate the Incoming cables from switchyard through the cable glands. The circuit diagram of control circuit along with operating instructions (DOS/DONTS) embossed on metallic plate duly laminated shall be provided on rear side of the door. An instruction manual along with control circuit diagram, combination diagram (cable and termination schedule) and all necessary drawings shall be supplied with panel.
I)
m)
TERMINAL BLOCKS a) Multi-way terminal blocks complete with necessary binding screws and washers for wire connections and marking strips for circuit identification shall be provided for terminating the panel wiring and outgoing cables. The terminal block shall be suitable for receiving at least 2x7/0.737 mm stranded copper or aluminum conductor wire per terminal. Terminal blocks shall have shorting and disconnection facilities. The panel-side and outgoing wires should be dis-connectable just by opening the disconnecting links which slide up or down without dislodging the wires from their position. Asea-Kirloskar type sliding links shall be provided. However, dis-connectable type terminal connectors may be limited to CT & PT circuits only. The terminal blocks shall be grouped according to circuit functions and each terminal block group shall have at least 20% spare terminals.
b)
c)
CABLE ENTRY a) The control panel shall have provision of cable entry from the bottom, 2 no, cable gland for 12 cores, 1 no. for 8 core and 2 nos. for 4 core 2.5 sq mm un-armoured cables duly fitted in gland plate and covered shall also be provided. The agency will arrange for necessary floor opening, below the panels to suit the requirement. Agency shall also be responsible for laying of control cable in trench, floor opening below the panel, trench cutting and making the damages good as per the satisfaction of Engineer in charge inside the control room.
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b) c)
The wiring through terminal blocks shall be such located so that it is convenient for floor opening. The control panel shall have provisions inside for fixing the multi-core cable glands, which shall be included by the bidder in scope of supply. For fixing these cable glands, detachable gland plates of 4 mm thickness shall be mounted at least 200 mm above the floor level. The cable gland plate and rear door shall be properly gasketed. Rigid supports shall be provided along the terminal block for holding plastic channel. Suitable clamps may also be provided in plastic channel for holding cables.
d) e)
GROUNDING a) 25 mm x 6 mm copper bus shall be provided extending along with the entire length of the panel and effectively grounding all metal structures. The earth bus should be designed for suitable inter connection with adjacent control panel which are to be placed side by side in the control room. Each continuous length of ground bus shall have provision of two terminals at two separate points for connection to ground. Potential and Current transformer neutrals shall be grounded only at the terminal blocks where they enter the control panel from the transformer. Wherever a circuit is shown grounded in the drawings, a single wire for the circuit shall run independently to the ground bus and connected to it.
b) c) d)
LABELING The labeling for the circuits shall be provided at the front control panel, as well as on the inside wall. All indicating instruments, meters and important components shall have identification labels from inside also, in addition to outside. The terminal block shall also have identification label' to them, clearly indicating phase's identifications and also circuits and instruments identification. For example, the terminal connector shall have an identification indicating that CT circuit for metering, for protection etc. Labeling should be provided by using 2 mm thick aluminum strip embossed with desired information and fitted in the panel sheet by means of rivets. CONTROL AND INDICATING CIRCUITS All indicating instruments shall conform to IS - 1248 and shall be of types and sizes specified under. They shall be capable of carrying their full load currents continuously without heating. They shall have long clearly divided and indelibly marked scales of engraved or enameled metal and the pointers shall be of clean outline. The pointers and scales shall be subject to approval. The marking on the dials shall be restricted to the scale marking. All indicating instruments, shall be provided with non-reflecting glass
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type fronts. All indicating instruments shall be of class 1.0 accuracy. The control and relay panels shall have the following instruments, relays and accessories: Common for all control panels Quantity Instrument Scheme 1 Electronic Relay 1 Control switch 7 LED Lamp / Remark
3 over current and 1 E/F Element Pistol grip with 3 Position Close /neutral / Trip For ON / OFF / Trip circuit healthy for coil 1 / Trip circuit healthy for coil 2 / Spring charge / Auto trip / DC ON Operating voltage shall be 30 volt DC (+10% and -20%) 1 Ampere meter Analog ammeter 140 x 140 mm. Square MISC type flush pattern having, class 1.0 accuracy. The ammeter shall have dual scale 0-300/150 Amps 1 Selector Switch For amp. Meter (Make before break) to indicate R, Y, B phase current and off 1 Volt meter Voltmeter 140 x 140. mm. Square MISC type flush pattern having class 1.0 accuracy the range of Voltmeter shall be 0-15 KV for 11 KV Control Panel and 0-40 KV for 33 KV Control Panel 1 Selector Switch For Volt Meter indicating voltage RY, YB, BR (breake before make type) 4 Push Button 2 for trip circuit healthy one for alarm accept and one for alarm reset 2 Switch For pre and post closing trip circuit healthy indication 1 LED Lamp 230 Volt AC for DC Fail Indication 1 Relay Alarm cancellation 1 Alarm bell / Buzzer For tripping 1 Space Heater With thermo state switch for on/ off 1 CFL 11 watt For panel illumination with on/ off switch and cage 1 Plug and socket Power type 3 pin 5 Amps plug and socket with ON-OFF switch and fuse Type test certificate for Ammeter and Voltmeter shall be submitted. For Feeder Control Panel Quantity Instrument Scheme / Remark
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Auto reclosing relay with adjustable time delay between 4 seconds to 10 seconds 3 shots for 11 KV and with adjustable time delay between 10 seconds to 60 seconds 1 shots for 33 KV Auto/ manual for auto reclosing relays selector switch
For Transformer Control Panel Quantity Instrument scheme 2 Relay 2 Relay / Remark For Buchholz indication and alarm For High oil temp and Low oil level
A trip healthy lamp shall be provided for each trip coil of circuit breaker and connected in such a way as to indicate the healthy condition of the trip circuit. The lamp should have the indication on demand when breaker is on. Such indication is also necessary when the breaker is off, but it should be possible to check the trip circuit condition before closing the circuit breaker. In brief, pre and post close trip supervision facility on demand is required and shall be included. The automatic tripping of the circuit breaker due to operation of protective relays shall be indicated by a common audible alarm. The audible alarm shall be cancelled by the flag cancellation of relay, in case of relays of hand-reset type. Space shall be provided for provision of KWH meter, with proper sealing. Separate annunciation (alarm) shall be provided for buchholz relay. Any other indications which are required for proper protection/ operation of circuit breaker should be provided in control panel, without any extra cost. RELAYS All relays shall be electromechanical type except over current and earth fault relay, shall be capable of breaking the maximum current, which shall not be affected by vibration or by external magnetic fields. The contacts shall be of silver, platinum or other approved materials and shall be capable of repeated operation, without deterioration. All relays, which are connected to complete the tripping circuit breaker coil of the auxiliary tripping relay shall be provided with approved flag indication, which whenever possible, shall be mechanically operated type. Indicators shall also be provided on such additional relay elements as it will enable the type and phase of the fault condition to be identified. Each indicator, whether of the electrically or mechanically operated type, shall be capable of being reset by hand, without opening the relay case. Each indicator shall be so designed that it cannot move before the relay has completed its operation.
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It shall not be possible to operate any relay by hand without opening case. All relays shall be so arranged that on opening the case i: shall be impossible for any dust, which may have collected in or upon the case to fall on the relay mechanism. OVER CURRENT & EARTH FAULT RELAY Relays shall be electronic /Numerical type with 3 over current and one earth fault element. Relays shall be suitable for 5 Amp. C.T. secondary current and 30 Volts DC auxiliary supply (+10%, - 20%) with 4 Programmable characteristics (3 sec., 1.3 sec. Very inverse and extremely inverse) and instantaneous tripping feature. The curve selection facility shall be available in front. Trip test facility shall also be required. The relay shall have following indication 1 2 3 4 5 DC on Phase wise tripping indication E/f tripping indication Push button for trip test Push button for reset
TYPE TEST CERTIFICATES FOR RELAYS

The bidders should submit the following type test certificates in respect of relays offered by them for their control panels: i) 5 KV Impulse peak voltage test on the relays. This type test report is essential for over current and earth fault relays. ii) Type test report for vibration test to prove the stability of relays under vibration normally encountered and also vibration under abnormal conditions. iii) Type test report for overshoots time for IDMT relays. TESTS
Each control panel shall be completely assembled, wired, adjusted and tested at the factory prior to dispatch. The tests shall include wiring continuity tests, insulation tests and functional tests to ensure operation of the control scheme and individual equipment. The test procedures shall have prior approval of the Employer. All instruments, meters and relays shall be tested and calibrated in accordance with relevant standards. All auxiliary instrument transformers shall be tested in accordance with procedure as laid down in relevant standards.
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TEST WITNESSING The tests shall be performed in presence of Employer's representative. The agency shall give atleast fifteen (15) days advance notice of the date when the tests are to be carried out. TEST CERTIFICATE Copies of test certificates for all routine and acceptance tests shall be furnished to the Employer for approval before dispatch of the equipment from the works. Test certificates for important components used shall also be furnished along with drawings.
13.0 13.1.
TECHNICAL SPECIFICATION OF 30 VOLT 100 AH LEAD ACID BATTERY
SCOPE This specification covers design, manufacturing, testing and supply of 30 Volt 100 AH Lead Acid Battery, for use at 33/11 KV substations for feeding auxiliary supply to Switchgear equipments at the time of interruption in mains supply. The batteries are to be supplied along with a wooden stand / rack as per description in clause - 17 below. CLIMATIC CONDITIONS The climatic conditions at site, under which the equipments shall operate satisfactorily, are mentioned as under:
13.2.
i) ii) iii)
Maximum temperature of air in shed Minimum temperature of air in shed Maximum relative humidity:
45oC 4 0C 95%(sometime approaches saturation point) 10% 40 days 90 days 3 months 1250 mm 150 Kg/ Sq. mm 1000 meters.
iv) v) vi) vii) viii) ix) x)
Minimum relative humidity

Average number dust storm days per annum
Average number of rainy days per annum. Number of months of tropical Monsoon conditions Average annual rainfall Maximum wind pressure Altitudes not exceeding
0
The limit of ambient temperature shall be 45 C peak and 35 C average over a period of 24 hours. 13.3. APPLICABLE STANDARDS
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The cells of Lead Acid Battery shall conform to the requirement of IS:1651: 1991 with latest amendments thereof.
13.4. STANDARD RATINGS The standards rating for 30 volt Lead Acid Battery shall be 100 AH. 13.5. CELL VOLTAGE The nominal voltage of a single cell shall be 2.1 to 2.2 Volt. 13.6. CAPACITY AT ROOM TEMPERATURE The Battery shall comprise of 15 cells with capacity not less than 100 AH at 10 Hours rate of discharge to end voltage of 1.85 volts per cell at room temperature not exceeding 32 Degree C 13.7 GENERAL DESCRIPTION 13.7.1. Cells shall be supplied in glass containers having ample space provided below the plate for accumulation of deposit. The glass containers shall be sufficiently robust transparent and free from flaws. The bidder may also quote for battery with hard rubber containers which shall conform to IS: 1146:1981 13.7.2. Lead acid battery, comprising of closed type cells shall be compete with plain tubular type positive plate assemblies, glass boxes, lids, micro porous plastic separators, polystyrene dowels and buffers, inter cell connectors and bolts & nuts. The battery shall be offered complete with (i) inter row connectors, acid jars and packing case (ii) stands (iii) stand insulators (iv) cable sockets for end and tapping connections. 13.7.3 The sulphuric acid and water used for the preparation and maintenance of electrolyte shall conform to IS 266:1977 and IS 1069: 1964 respectively. The separators used shall be either wooden or synthetic. The wooden separators when used shall conform to IS 652:1960 and the synthetic separators to IS 6071:1986.
13.7.4
13.7.5 The venting device shall be of anti-splash type with more than one exit hole and shall allow the gases to escape freely but shall effectively prevent acid particles or spray from coming out. 13.7.6 A suitable electrolyte level indicator indicating lower and upper limits shall be fitted to facilitate checking of electrolyte level in opaque containers. The materials used shall be acid proof and shall not deteriorate during service. 13.7.7 The manufactures identification shall be embossed/impressed on the container. Where it is not possible to bolt the cell terminals directly to assemble a battery, separate lead, copper or aluminium connectors of suitable size shall be provided to enable connection of the cells. 13.7.8 The material for bolts and nuts shall be brass/stainless steel. Bolts and nuts for connecting the cells shall be effectively lead-coated to prevent corrosion. 13.7.9 Open cells shall be provided with spray arrestors of adequate area over the plates. These may be of glass sheet at least 3 mm thick and shall be adequately supported. 13.8. TERMINALS
Separate terminals shall be provided for connecting load and charger leads to the battery terminals. All terminals shall be of M 12 size. Suitable Copper lugs shall be provided by the supplier,
13.9. for use of the purchaser for connecting the load wiring. TEMPERATURE RANGE
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Battery must be capable of operation at temperatures upto 55oC for prolonged period. Minimum capacity at this temperature should not be less than 2 Amps. for 5 hours.
13.10. ACCESSORIES The following accessories shall be supplied with each set of battery:i) ii) iii) iv) v) vi) vii) viii) ix) x) One Battery log book Two copies of printed instruction sheet. Cell testing Voltmeter, 3-0-3 volts scale, Industrial Grade A to IS:1248. One no. floating Hydro Meter. One no. Syringe hydro meter 0 One no. Thermo meter (0 to 100 C) with specific gravity correction scale. One set of suitable insulated spanners. One no. acid resisting funnel. One no. acid resisting jar. One pair of rubber gloves.
NOTE :- Any more accessories other than those mentioned above which are required necessarily for the battery shall be supplied by you with the battery. 13.11. CHARGE RATE
Fully discharged batteries should normally be recharged at 10 Amps. for 10 hours at room temperature. New batteries and old batteries at high temperatures may need more time. Trickle charge rate shall be about 50 to 100 mAmps.
13.12. CELL DESIGNATION & MARKING The practice indicated in relevant IS or latest version shall be followed for cell designation purpose. a) b) c) d) e) The following information shall be indelibly and durably marked on the outside of the cell Manufacturers name and/or trade mark; Month and year of manufacture; Nominal voltage; Rated ampere-hour capacity; Country of origin; and
f)
13.13.
Cell designation.
MANUAL OF INSTRUCTIONS
A copy of the instructions manual for initial treatment and the maintenance on its service shall be supplied by the manufacturer with every set of battery.
13.14. POLARITY MARKING
The polarity of the terminals shall be marked for identification. The positive terminal may be identified by P or (+) sign or Red colour mark and the negative terminal may be identified by N or
(-) sign or a Blue colour mark. Marking shall be permanent and non-deteriorating. 13.15. WARNING MARKING
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The battery/cell shall be furnished with a warning plate located at conspicuous place specifying the use of PARTICULAR ELECTROLYTE ONLY (in block letters) and specifying the
proper fill level of the electrolyte. Marking shall be permanent and non-deteriorating. 13.16. PACKING
The batteries shall be suitably packed in wooden crates suitable for handling during transit by rail/road, and secured to avoid any loss or damage during transit.
13.17. MOUNTING STAND The cells shall be accommodated in double tier stand constructed of MS steel and painted with 3 coats of acid proof paint. Necessary paint for this purpose shall be supplied. The stands shall be supported on insulators to contain necessary insulation from earth and there shall be insulators between each cell and stand. TESTS
13.18.
The following tests shall be carried out in accordance with IS: 1651:1991 or the latest version thereof:
(A) a) b) c) d) e) f) g) (B) a) b) c) d) (C) TYPE TESTS: Verification of constructional requirements. Verification of marking. Verification of dimensions. Test for capacity Test for voltage during discharge Ampere-hour and Watt-Hour efficiency test. Test for loss of capacity on storage Endurance test ACCEPTANCE TEST Marking & Packing Verification of Dimensions Test for capacity Test for voltages during discharge. ROUTINE TEST The battery shall be tested after manufacture as per the requirement of IS: 1651-1991 (with latest amendment, if any). Two copies of test certificates indicating the results obtained during the tests shall be submitted.
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TECHNICAL SPECIFICATION OF 30 VOLTS 10 AMPERE BATTERY CHARGER (SUITABLE FOR CHARGING OF 30 VOLTS, 100 AH, LEAD ACID BATTERY) Battery Charger 30 Volts 10 Ampere SCOPE This specification covers design, manufacturing, testing at manufacturers works before dispatch and supply of 30 Volt 10 Ampere Single Phase Battery Charger required for charging of 30 Volt 100 Ampere-Hour Lead Acid Battery and for feeding auxiliary supply to Switchgear equipments at 33/11 kV substations. STANDARDS Unless otherwise specified, the equipment shall conform to the latest applicable Indian standards and in particular to the following standards:1 IS: 3895 Specification for Rectifier equipments in general 2 IS: 13947(Part II) Specification for MCB 3 IS: 1248 Indication instruments 4 IS: 2147 Degree of protection for cubicles 5 IS: 375 Specification for wiring 6 IS: 4540 Mono crystalline semiconductor rectifiers assemblies & equipment 7 IS: 6619 Safety code for semiconductor rectifier equipment 8 IS: 2026 Transformers 9 IS: 4237 General requirement for switchgear and control gear for voltage not exceeding 1000 Volts 10 IS: 4064 Air Break switches and fuse combination units 11 IS: 6005 Code of practice for phosphating of Iron & Steel 12 IS: 5 Colour for ready mix paints 13 IS: 5921 Printed circuit Board 14 IS: 249 Printed circuit Board 15 IS: 5578 Guide for making insulated conductor The agency shall clearly state the standards to which the equipment offered by him conforms.
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OUTDOOR TYPE THREE PHASES 11 KV/433-250 V CONVENTIONAL DISTRIBUTION TRANSFORMERS - 100 KVA.
FOREWARD This specification was originally issued in 1971 on the basis of the decisions taken in the First Standardisation Conference. The specification was subsequently revised in 1972, 1976, 1979, 1981 and 1983 on the basis of the decisions taken in various Standardisation Conferences. The modifications mainly related to incorporation of 16 KVA rating, provision of special type of drain-cum-sampling valve, making the provision of silica gel breather optional, reducing limits of no-load and full-load losses, stipulation of short-circuit and unbalanced current tests etc. The Specifications had been revised in 1988 to incorporate use of improved quality transformer oil, provision for DPC and other improved insulating materials etc. as approved by 11th Standardisation Conference. Based on the recommendations of 13th Conference on Standardisation, Technical Development and Training in Rural Electrification, held on 4th-6th May, 1993, the specification has been further revised to stipulate the use of clamp type terminals as an integral part of the bushings to directly receive aluminium conductors/cables without requiring use of lugs and to eliminate the possibility of ingress of moisture through the exposed threads of the bushing stems. Another important provision made in the Specification is the use of built-in LT Circuit breakers for proper protection of transformer against overloads and system faults. This measure is expected to substantially increase the service life of transformers and reduce failures. The characteristic of transformer oil after three days filling had also been incorporated. Due to all these measures the warranty period had been increased to 2 years from the date of supply or 18th months from the date of commissioning, whichever is earlier. During the 14th Conference on Standardisation and Technical Development held on 25th April, 1997, at New Delhi, it was decided to delete for the time being, the provision of an LT Circuit Breaker from the specification, till such time suitable LT Circuit Breakers, with time current characteristics matching with that of the transformers, are indigenously developed, manufactured and made available to the transformer manufacturers at a reasonable cost. The Conference also recommended changes to be made in the material to be used for inter layer insulation. Based on the above recommendations, the specification is being revised and issued. SCOPE This specification covers oil-immersed, naturally air cooled, three-phase, 50 Hz, double-wound outdoor type distribution transformers of 16, 25, 63 and 100 KVA ratings for use in system with a nominal voltage of 11 KV. STANDARDS:
1.0
2.0
2.1.1.
The materials shall conform in all respects to the relevant Indian / International Standard Specification, with latest amendments thereof; some of them are listed below:
Indian Standard
Title
International & Internationally recognised standard
Page | ISS -2026/1977 IS 12444 ISS -3347/1967 Specification for Power Transformer Specification for Copper wire rod Specification bushing for porcelain IEC 76 ASTM B-49 Transformer DIN 42531,23,3
ISS-335/1983
Specification for Transformer Oil
BS 148, D-1473, D-15331934 IEC Pub 296-1969
ISS 5/1961 ISS - 2099/1973
Specification for colors for ready mixed paints Specification for High Voltage Porcelain bushings Specification for Low Voltage bushings Specification for Outdoor Bushings Specification for Al Wire rods Specification for Insulating Kraft Paper Specification for Insulating Press Board Guide for loading Transformers of oil DIN 42531 to 33 ASTM B - 233 IEC 554 IEC 641
ISS - 7421/1974 ISS 3347 ISS 5484 ISS 9335 ISS 1576 ISS / 6600/1972
Immersed IEC 76
Material conforming to other internationally accepted standards, which ensure equal or higher quality than the standards mentioned above, would also be acceptable. In case the Bidders who wish to offer material conforming to the other standards, salient points of difference between the standards adopted and the specific standards shall be clearly brought out in relevant schedule. Four copies of such standards with authentic English translations shall be furnished along with the offer. 3.0 STANDARD RATINGS The standard ratings shall be 100 KVA. NO LOAD VOLTAGE RATIO The no load voltage ratio shall be as follows: a) 11000/433-250 V for 100 KVA
4.0
5.0
TAPS
Page | No taps are to be provided in these transformers. WINDINGS 6.1 EC Grade aluminium conductor shall be used. 6.2 Unless otherwise specified, DPC insulation shall be used for HV and LV winding wires and Electrical Grade plain insulation kraft paper shall be used for inter-layer insulation of the HV and LV coils. In case PVA enameled conductor is used for HV/LV winding, electrical grade epoxy dotted, thermally upgraded kraft paper shall be used for inter-layer insulation. Use of single coil design for HV winding shall be preferred due to its better short-circuit behaviour. 6.3 Corrugated cylinder made from pre-compressed insulation board should be used between HV and LV windings. 6.4 Angle shaped End Rings made from pre-compressed board should be used between the end coil and core (with this provisions, the purchaser should not specify any minimum clearance between end coil and core). 6.5 The primary winding shall be connected in delta and the secondary winding in star(Vector Symbol Dy 11) so as to produce a positive displacement of 30 degrees from the primary to the secondary vectors of the same phase (Vector rotation assumed counter clockwise). The neutral of the secondary winding shall be connected to a separate insulated terminal. FITTINGS The following standard fittings shall be provided:a) b) Two earthing terminals Oil level gauge indicating three positions of oil marked as follows:Minimum(-50C) Normal 300C Maximum (980C) Lifting lugs Plain breathing device comprising an inverted U-pipe with wire gauze at the open end or Silica gel breather, as required by the purchaser. Drain-cum-Sampling Valve (Steel) of the type shown in Fig.1 welded to the tank. The special tool for operating this valve shall be supplied with the transformer. Thermometer pocket for 100 KVA units. Filling hole having P 1 thread (with cover) on the transformer body/conservator
6.0
7.0
c) d)
e)
f) g)
8.0
CONSERVATOR. 8-A. PAINT The paint material and procedure for the distribution transformer shall be as per details given below:
Page | 8.1.1 All paints shall be applied in accordance with the paint manufacturer's recommendations. Particular attention shall be paid to the following:
a. Proper storage to avoid exposure as well as extremes of temperature. b. Surface preparation prior to painting. c. Mixing and thinning d. Application of paints and the recommended limit on time intervals between coats. e. Shelf life for storage.
8.1.2
All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush marks or other defects.
8.1.3
All primers shall be well marked into the surface, particularly in areas where painting is evident, and the first priming coat shall be applied as soon as possible after cleaning. The paint shall be applied by airless spray according to the manufacturers recommendations. However,wherever airless spray is not possible, conventional spray be used with prior approval of purchaser.
8.1.4
The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings and similar such items.
8.2.0
Cleaning and Surface Preparation.
8.2.1
After all machining, forming and welding has been completed, all steel work surfaces shall be thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to any painting.
8.2.2
Steel surfaces shall be prepared by Sand / Shot blast cleaning or Chemical cleaning by Seven tank process including Phosphating to the appropriate quality.
Page | 8.2.3 The Pressure and Volume of the compressed air supply for the blast cleaning shall meet the work requirements and shall be sufficiently free from all water contamination prior to any painting.
8.2.4
Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly adherent mill-scale and shall only be used where blast cleaning is impractical.
8.3.0
Protective Coating.
8.3.1
As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given suitable anticorrosion protection.
8.4.0
Paint Material
Followings are the type of paints that may be suitably used for the items to be painted at shop and supply of matching paint to site: i) Heat resistant paint (Hot oil proof) for inside surface. ii) For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2 coats of Synthetic. Enamel paint. The color of the finishing coats shall be dark admiral gray conforming to No. 632 of IS 5:1961.
8.5.0
Painting Procedure.
8.5.1
All painting shall be carried out in conformity with both specifications and with the paint manufacturers recommendations. All paints in any one particular system, whether shop or site applied, shall originate from one paint manufacturer.
8.5.2
Particular attention shall be paid to the manufacturers instructions on storage, mixing, thinning and pot life. The paint shall only be applied in the manner detailed by the manufacturer e.g. brush, roller, conventional or airless spray and shall be applied under the manufacturers recommended conditions. Minimum and maximum time intervals between coats shall be closely followed.
Page | 8.5.3 All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours whichever is sooner. Chemical treated steel surfaces shall be primed a s soon as the surface is dry and while the surface is warm.
8.5.4
Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking or general softness) the supplier shall remove the unsatisfactory paint coatings and apply another. As a general rule, dry film thickness should not exceed the specified minimum dry film thickness by more than 25 %. In all instances, where two or more coats of the same paints are specifies, such coatings may or may not be of contrasting colors.
8.5.5
Paint applied to items that are not be painted, shall be removed at suppliers expense, leaving the surface clean, un-stained and undamaged.
8.6 .0
Damages Paint Work.
8.6.1
Any damage occurring to any part of the painting scheme shall be made good to the same standard of corrosion protection and appearance as that originally employed.
8.6.2
Any damaged paint work shall be made good as follows:
8.6.3
The damaged area, together with an area extending 25 mm around its boundary, shall be cleaned down to bare metal. a) A priming coat shall immediately applied, followed by a full paint finish equal to that originally applied and extending 50 mm around the perimeter of the originally damaged. b) The repainted surface shall present a smooth surface. This shall be obtained by carefully chamfering the paint edges before & after priming.
8.7.0
Dry Film Thickness.
8.7.1
To the maximum extent practicable, the coats shall be applied as a continuous film of uniform thickness and free of pores. Over-spray, skips, runs, sags and drips should be avoided. The different coats may or may not be of same color.
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8.7.2
Each coat of paint shall allow hardening before the next is applied as per manufacturers recommendations.
8.7.3
Particular attention must be paid to full film thickness at edges.
8.7.4
The requirement for the dry film thickness (DFT) of paint and the material to be used shall be as given below:
S. N o.
Paint Type
Area to be No of Coats painted
Total Dry Film Thickness (Min)
Powder Paint (a)Thermo setting powder
Inside outside
01 01
20 Micron 60 Micron
2.
Liquid paint a) Zinc Chromate (Primer) b) Synthetic Enamel (Finish Coat) c) Hot Oil paint Inside 01 35 micron Outside 02 35 micron Out side 02 45 micron
8.8.1
On transformer of 100 KVA, provision of conservator is obligatory8. 8.2 The conservator shall be provided with a drain plug and a filling hole with cover. In addition, the cover of main tank shall be provided with an air release plug to enable trapped air to be released unless the conservator is so located as to eliminate the possibility of air being trapped within the main tank. 8. 8.3 The inside diameter of the pipe connecting the conservator to the main tank shall be within 20 to 50 mm and it should project into the conservator in such a way that its end is approximately 20 mm above the bottom of the conservator so as to create a sump for collection of impurities. The minimum oil level (corresponding to 50C) should be above the sump level.
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9.0
RATING AND TERMINAL MARKING PLATE(S) Each transformer shall be provided with non-detachable rating and terminal marking plate(s) of weather -proof material, fitted in a visible position and showing complete information as given in IS:1180(Pt.I). LIMITS OF TEMPERATURE RISE. The temperature rise shall not exceed the limit of 550C (measured by resistance) for transformer windings and 450C. (Measured by thermometer) in top oil when tested in accordance with IS: 2026.
10.
11.0
LOSSES AND IMPEDANCE VALUES. 11.1 The no-load and load-losses shall not exceed the values given in the following table. KVA Rating Noload losses (Fixed loss) Watts 260 Load losses at 750C Watts 1760 The
100
The above losses are maximum allowable and there will not be any plus tolerance. capitalization of losses will be allowed for lower losses offered. 11.2 12. The percentage impedance at 750C shall be 4.5% subject to tolerance as per IS: 2026.
PERMISSIBLE FLUX DENSITY AND OVERFLUXING. The flux density at rated voltage and frequency shall not exceed 1.69 tesla. The no-load current at Rated Voltage and at 112.5 percent Rated Voltage shall not exceed values given below:KVA Rating Percentage of Rated full Load Current At 100% Rated Voltage 2.5 At 112.5% Rated Voltage 5
100
12 A.
CORE
The type of Core and Core material shall be as per given below: i) The core shall be wound or cut type. The stack type core is not permitted.
ii)
The design of magnetic circuit shall be such as to avoid static discharges development of short circuit paths within itself or in the earthed clamping structure.
Page | iii) iv) Stage level inspection for core construction shall be carried out by the owner. Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure and the action of hot transformer oil. The core shall be constructed either from high grade, non-aging Cold Rolled Grain Oriented (CRGO) silicon steel laminations conforming to grade M4 or better. The maximum flux density in any part of the cores and yoke at Normal voltage and frequency shall be such that the flux density with + 12.5 % voltage variation from rated voltage and frequency variation of -5% shall not exceed 1.9 Tesla. The bidder shall provide saturation curve of the core material proposed to be used. The bidder should offer the core for inspection and approval by the purchaser during the manufacturing stage. Bidders call notice for the purpose should be accompanied with the following documents as applicable as a proof towards use of prime core material: a) Invoice of the supplier b) Mills test certificate c) Packing list d) Bill of lading e) Bill of entry certificate to customs Core material shall be directly procured either from the manufacturer or through their accredited marketing organization of repute and not through any agent.
v)
vi)
The complete design of core must ensure permanency of the core losses with CONTINUOUS WORKING of the transformers. The value of the flux density allowed in the design and grade of lamination used shall be clearly stated in the offer.
All parts of the core shall be of robust design, capable of withstanding any shocks to which they may be subjected during handling, lifting, transportation installation and service. Clamping of core and winding assembly with tank should be done by angle iron pieces, welded to tank walls and not to be done with flat iron pieces. Adequate arrangement shall be provided to enable the core and winding to be lifted. Use of seconds CRGO steel for core construction is strictly prohibited.
13.
BUSHING TERMINALS. 13.1 To avoid bimetallic action at the point of connection to the aluminium windings and to the external aluminium cables/conductors, both HV & LV bushing stems shall be made of aluminium alloy conforming to the requirement of IS: 3347.
Page | 13.2 The busing terminals shall be of clamp type to directly receive aluminium conductors/cables without requiring use of lugs. The terminal shall be directly screwed on to the stem to secure effective sealing of the bushing. Details of the terminals are given in Appendix-II. 14. SEALING GASKETS All sealing washers/gaskets shall be made of oil and heat resistant nitrile rubber. Gaskets made of natural rubber or cork sheet are not permissible. TRANSFORMER OIL The transformer oil shall comply with REC Specification No. 39/1985(R-1993) (AppendixI). TESTS AND INSPECTION. 16.1 Routine Tests:All transformers shall be subjected to the following routine tests at the accordance with IS:2026 and IS:1180(Pt.I). a) b) Measurement of winding resistance Measurement relationship of voltage ratio and check of voltage vector
15.
16.
manufacturers
work in
c) d) e) f) g)
Measurement of impedance voltage/short circuit impedance and load loss Measurement of no-load loss and no-load current Measurement of insulation resistance Induced over-voltage withstand test Separate-source voltage withstand test
16.2. Type Tests. The following type tests shall be made on the transformers as per details given in IS:2026: a) h) i) j) k) l) to g) as indicated under routine tests: Lightning impulse test Temperature-rise test Short circuit test Air Pressure test(IS:1180 Part-I-1989). Unbalance current test: The value of unbalance current indicated by the ammeter as shown in the test arrangement in Fig.2 shall not be
Page | more than 2% of the full load current. If records of a type test on a transformer which, in essential details, is representative of the one being purchased are furnished, the purchaser may accept this as evidence of the type test instead of the actual test 16.3. The supplier shall furnish calculations in accordance with IS:2026 to demonstrate the thermal ability of the transformer to withstand short-circuit. 16.4. Inspection. 16.4.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge to satisfy him that the material is being furnished in accordance with this specification. 16.4.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply. WARRANTY. The supplier shall guarantee satisfactory performance of transformers and all the associated components for a period of 2 years from the date of receipt by the purchaser or 18 months from the date of commissioning, whichever is earlier. During the warranty period, all repairs/replacements shall be carried out free of cost and the warranty shall cover all failures except those caused by deliberate interference. MOUNTING ARRANGEMENT. The under-base of all transformers shall be provided with two 75 x 40 mm M.S. Channels 460 mm long with holes as shown in Fig.3 to make them suitable for fixing on a platform or plinth.
17.
18.
Page |
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11 KV AND 33 KV AIR BREAK SWITCHES
SCOPE:-This specification provides for manufacture, testing at works and supply of 11KV & 33KV AB switches. The 11KV and 33 KV AB switches shall conform to IS: 9920 (Part-I to IV) (2) AB SWITCHES:The 11KV & 33KV Air Break Switches are required with two poles in each phase. The AB Switches shall be supplied complete with phase coupling shaft, operating rod and operating handle. It shall be manually gang operated and vertically break and horizontal mounting type. (3) The AB Switch shall be designed for a normal current rating of 400 Amps and for continuous service at the system voltage specified as under: i) 11 KV AB Switch : 11KV + 10% continuous 50 C/s solidly grounded earthed neutral system ii) 33KV AB Switch : 33 kV + 10% -doThe length of break in the air shall not be less than 400 mm for 11KV AB Switches and 500 mm for 33 KV AB Switches. (4) The 11KV & 33KV AB Switches are required with post insulators. The AB switches should be suitable for mounting on the structure. The mounting structure will be arranged by the purchaser separately. However, the AB Switches shall be supplied with base channel for mounting on the structure which will be provided by the purchaser. The phase to phase spacing shall be 750mm in case of 11KV AB Switches & 1200mm in case of 33KV AB Switches. (5) POST INSULATORS:The complete set of three phase AB Switches shall have post insulators. 11KV AB Switches : 11KV Post Insulators 33KV AB Switches : 33KV Post Insulators The post insulators should conform to the latest applicable Indian standards IS: 2544 Specification for Porcelain Post insulator Polycon or of compact solid core or long rod
Page | insulators are also acceptable. Creepage distance should be adequate for highly polluted outdoor atmosphere in open atmosphere. The porcelain used for manufacture of AB Switches should be homogeneous free from flaws or imperfections that might affect the mechanical dielectric quality. They shall be thoroughly vitrified, tough and impervious to moisture. The glazing of the porcelain shall be of uniform brown in colour, free from blisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through the range of temperature variation shall not loose the parts or create undue internal stresses which may affect the electrical or mechanical strength. Cap and base of the insulators shall be interchangeable with each other. The cap and base shall be properly cemented with insulators to give perfect grip. Excess cementing must be avoided.
.
(6) Each 11KV & 33KV Post Insulators should have technical particulars as detailed below: 11 KV 33 KV i Nominal system voltage kV (rms) 11 33 ii Highest system voltage kV (rms.) 12 36 iii Dry Power Frequency one kV minute withstand voltage (rms) in KV 35 75 iv Wet Power frequency one minute withstand voltage (rms) in KV 35 75 v Power Frequency puncture kV (rms) voltage 1.3 times the actual dry flashover voltage vi Impulse withstand voltage kV (Peak) 75 170 vii Visible discharge voltage kV (rms) 9 27 viii Creepage distance in mm (minimum) 320 580 (7) The rated insulation level of the AB Switches shall not be lower than the values specified below:-
Page | Standard declared voltage KV/RMS Rated Voltage of the AB Switches Standard impulse with stand voltage (positive & negative polarity KV (Peak) Across the Isolating distance 1 2 11 KV 33 KV 12 KV 36 KV 85 KV 195 KV To earth & between poles 75KV 170 KV One Minute power frequency withstand voltage kV (rms)
Sr. No.
Across the Isolating distance 32KV 80 KV
To earth & between poles 28 KV 70 KV
(8) TEMPERATURE RISE:The maximum temperature attained by any part of the equipment when in service at site under continuous full load conditions and exposed to the direct rays of Sun shall not exceed 45 degree above ambient. (9) MAIN CONTACTS:AB Switches shall have heavy duty self-aligning type contacts made of hard drawn electrolytic copper/brass. The various parts should be accordingly finished to ensure inter changeability of similar components. The moving contacts of the switch shall be made from hard drawn electrolytic copper brass. This contact shall have dimensions as per drawing attached so as to withstand safely the highest short-circuit currents and over voltage that may be encountered during service. The surface of the contact shall be rounded smooth and silver-plated. In nut shell the male and female contact assemblies shall ensure. (i) Electro-dynamic withstands ability during short circuits without any risk of repulsion of contacts. (ii) Thermal withstands ability during short circuits. (iii) Constant contact pressure even when the lower parts of the insulator stacks are subjected to tensile stresses due to linear expansion of connected bus bar of flexible conductors either because of temperature variations or strong winds. (iv) Wiping action during closing and opening.
Page | (v) Fault alignment assuring closing of the switch without minute adjustments. (10) CONNECTORS:The connectors shall be made of hard drawn electrolytic copper or brass suitable for Raccoon/Dog ACSR conductor for both 11KV & 33KV AB Switches. The connector should be 4 -bolt type. (11) OPERATING MECHANISM:All AB Switches shall have separate independent manual operation. They should be provided with ON/OFF indicators and padlocking arrangements for locking in both the end positions to avoid unintentional operation. The isolating distances should also be visible for the AB Switches. The AB Switch will be supplied with following accessories:
The
Sr
Item Size of
11KV AB Switch 5.50 meter dia 25 mm
33 KV AB Switch Length 5.50 mtrs dia: 40MM Length 2700 mm Size 40 x 40 mm
AB
Operating Rod (GI dia) Length
Phase coupling square rod (GI)
Length 1800 mm Size 25x25 mm
Hot dip galvanized Operating handle (GI)
1 No
1 No
Switches shall be capable to resist any chance of opening out when in closed position. The operating Mechanism should be of robust constructions, easy to operate by single person and to be located conveniently for local operation in the switchyard. The GI pipe shall conform to ISS: 1239-68 and the vertical down rod should be provided with adequate joint in the mid section to avoid bending or buckling. Additional leverage should be provided to maintain mechanical force with minimum efforts. All iron parts should be hot dip galvanized. All brass parts should be silver plated and all
Page | nuts and bolts should be hot dip galvanized. (12) ARCING HORNS:It shall be simple and replaceable type. They should be capable of interrupting linecharging current. They shall be of first make and after break type. (13) BUSH:The design and construction of bush shall embody all the features required to withstand climatic conditions specified so as to ensure dependable and effective operations specified even after long periods of inaction of these Air Break Switches. They shall be made from highly polished Bronze metal with adequate provision for periodic lubrication through nipples and vent. (14) DESIGN, MATERIALS AND WORKMANSHIP:The successful tenderers shall assume full responsibility for co-ordination and adequate design. All materials used in the construction of the equipment shall be of the appropriate class, well finished and of approved design and material. All similar parts should be accurately finished and interchangeable. Special attention shall be paid to tropical treatment to all the equipment, as it will be subjected during service to extremely severe exposure to atmospheric moisture and to long period of high ambient temperature. All current carrying parts shall be of nonferrous metal or alloys and shall be designed to limit sharp points/edges and similar sharp faces. The firm should submit the following type test certificate along with the certified copy of the drawing (from NABL Testing Lab). The type test should be from NABL accredited testing laboratory & should not be older than 5 years from the date of opening of tender. 1. Test to prove capability of rated peak short circuit current and the rated short time current. The rated short time current should correspond to minimum of 10K Amp and the peak short circuit current should correspond to minimum of 25K Amps.
Page | 2. Lightning impulse voltage test with positive & negative polarity. 3. Power Frequency voltage dry test and wet test 4. Temperature rise test 5. Mill volt drop tests (15) Dimension of 11 & 33KV AB Switches in (Max.) Tolerance 5%.
Sr.
Particulars
11KV AB Switch
33KV AB Switch
1 2 3 4 5
Drawing No. MS Channel Creepage distance of Post Insulator Highest of Port Fixed contact assembly i) Base ii) Contact iii) GI cover iV) Spring
EB/P-6/MPSEB/7 (revised) dated 01.05.88 450x75x40 320mm (Min) 254 mm
EB/P-6/MPSEB/8 (revised) dated 01.05.88 675x100x50 580mm (Min) 368 mm
165x36x8 70x30x6 110x44 6 Nos.
165x36x8 70x30x6 140x44 6 Nos.
Moving contract assemble i Base Assembly ii Moving iii Bush iv Thickness of Grooves 135x25x8 180x25x9 Bronze Metal 7 170x40x8 290x25x14 Bronze Metal 11
(16) CONNECTORS:Connector (diamentions of each pad) 60x50x8 (Moving & fix both) 60x50x8 (Moving & fix both)
The bidder should provide AB Switches with terminal connectors, set of insulators, mechanical inter works and arcing horns sets. The base channel for the mounting of AB Switches shall also be included in the scope of AB Switches. The operating mechanisms
Page | together with down pipe operating handle etc. are also included in the scope of supply. 19 NAME PLATE: The name plate in the following design shall be fixed on each AB Switch. i) Name of supplier : ii) Name of purchaser : M.P.P.K.V.V. Co. Ltd., Bhopal iii) Order No. and date : iv) Rating : v) serial number of unit : The size of name plate shall be 2 x 1 for 11 kV & 2 x 2 for 33 KV AB Switch.
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33 KV LIGHTNING
ARRESTERS
1.0
SCOPE This Specification covers non-linear resistor type lightning arresters station class for use in effectively earthed rural distribution system with a nominal voltage of 33KV. APPLICABLE STANDARDS Unless otherwise modified in this specification, the lightning arresters shall comply with the Indian Standards Specification IS: 3070 (Pt-I)-1985 or the latest version thereof. VOLTAGE RATING The rated voltage of lightning arresters shall be 30 KV (rms). This will be applicable to the effectively earthed 33KV system (co-efficient of earth not exceeding 80 per cent as per IS: 4004) with all the transformer neutrals directly earthed. NOMINAL DISCHARGE CURRENT RATING The nominal discharge current rating of the lighting arresters shall be 10 KA class-2 GUARANTEE The contractor shall guarantee satisfactory performance of the lightning arresters for a period of 36 months from the date of installation TESTS
2.0
3.0
4.0
5.0
6.0
The following routine and type tests as laid down in IS:3070 (Part-I)-1985 shall be carried out.
6.1 6.2 ROUTINE TEST TYPE TESTS a) Voltage withstand tests of arrester insulation. b) Power-frequency spark over test. c) Hundred per cent 1.2/50 microsecond impulse spark over test. d) Front-of-wave impulse spark over test. e) Residual voltage test. f) Impulse current withstand test. g) Operating duty test. h) Temperature cycle test on porcelain housing. i) Porosity test on porcelain components. j) Galvanizing test on metal parts. Dry Power-frequency spark over test.
7.0
INSPECTION 7.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. 7.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.
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7.
1.
9 KV GAPLESS POLYMER LIGHTNING ARRESTERS

SCOPE This Specification covers non-linear resistor type lightning arresters station class for use in effectively earthed rural distribution system with a nominal voltage of 11KV. APPLICABLE STANDARDS Unless otherwise modified in this specification, the lightning arresters shall comply with the Indian Standards Specification IS: 3070 (Pt-I)-1985 or the latest version thereof. VOLTAGE RATING The rated voltage of lightning arresters shall be 9KV (rms). This will be applicable to the effectively earthed 11 KV system (co-efficient of earth not exceeding 80 per cent as per IS:4004) with all the transformer neutrals directly earthed. NOMINAL DISCHARGE CURRENT RATING The nominal discharge current rating of the lighting arresters shall be 10 KA class-2.
2.
3.
4.
5.
GUARANTEE The manufacturer shall guarantee satisfactory performance of the lightning arresters for a period of 12 months from the date of installation or 18 months from date of receipt by the purchaser, whichever is earlier. TESTS
6.
The following routine and type tests as laid down in IS : 3070 (Part-I)-1985 shall be carried
6.1 6.2 ROUTINE TEST Dry Power-frequency spark over test. TYPE TESTS a) Voltage withstand tests of arrester insulation. b) Power-frequency spark over test. c) Hundred per cent 1.2/50 microsecond impulse spark over test. d) Front-of-wave impulse spark over test. e) Residual voltage test. f) Impulse current withstand test. g) Operating duty test. h) Temperature cycle test on porcelain housing. i) Porosity test on porcelain components. j) Galvanizing test on metal parts.
out.
7.
INSPECTION 7.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the tests carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.
7.2
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TECHNICAL SPECIFICATION OF 11 KV DO FUSE UNITS

1.0 SCOPE This specification provides for manufacture, testing at works before dispatch and delivery of tendered item at site. This covers out-door open, dropout expulsion type fuses suitable for installation in 50 Hz 11KV distribution system. 2.0 APPLICATION The D.O.Fuses are intended for use on Distribution transformers for protection/isolation of the same during overload or fault conditions. APPLICABLE STANDARD Unless otherwise modified in this specification, the drop out fuse shall conform to IS: 9385 (Part-I to III) as amended from time to time. CLIMATIC CONDITIONS The climatic conditions at site under which the equipment shall operate satisfactorily, are as follows: (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) Peak Ambient Temperature in shade Maximum Ambient Temperature in 24 hours period in shade Minimum Ambient Temperature Maximum Relative humidity Average no. of thunderstorm days Average no. of rainy days level (meters) Average annual rainfall No. of months of tropical monsoon Conditions. : : : : : : : : 48C 45C 4C 95% (Some time approaches saturation point) 40 days per annum 90 days per annum 125 Cm 3
3.0
4.0
For the purpose of specification, the reference ambient temperature shall be 40C. 5.0 DROP OUT FUSES The dropout fuses (D.O.Fuses) shall be expulsion type. This shall be D type and out-door lift off type suitable for manual operation by an operating rod from the ground level. The drop out operation will be angular in vertical plane. 5.1 The equipment offered by the tenderers shall be suitable for 11KV & 33KV three phase 50 Hz solidly grounded earthed neutral systems. It shall be designed for a normal current rating of 200 Amps. The drop out fuses are required with Post Insulators. These shall be suitable for mounting on the structure. The bracket /channel hardwares for DO Fuses shall be provided with adequate sizes of nuts, bolts and washer for mounting on the structures of the purchaser.
5.2
6.0
POST INSULATORS Each 11KV D.O. Fuses Units shall have two nos. 11KV Post Insulators. Similarly each 33KV DO Fuse Units shall have two nos. 33KV Post insulators. The insulators shall conform to IS:2544 of 1973 with latest amendment. The porcelain used for manufacture of DO Fuse shall be homogeneous, free from flaws or imperfections that might effect the mechanical or dielectric strength. They shall be thoroughly vitrified tough and impervious to moisture. The glazing of the porcelain shall be of uniform brown colour free from blisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable.
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The porcelains and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through range of temperature variation shall not loosen parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Each cap and base pin shall be made of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly galvanized. The cap and base shall be properly cemented with insulators to give perfect grip. Excess use of cement shall be avoided. Each 11KV & 33KV Post Insulators should have technical particulars as detailed below:11KV 33KV [i] [ii] [iii] [iv] [v] [vi] [vii] [viii] 7.0 Nominal system voltage KV (rms) Highest system voltage KV (rms) Dry Power Frequency one minute withstand voltage KV(rms) Power Frequency puncture voltage KV (rms) Impulse withstand voltage KV (rms) Visible discharge voltage KV (rms) Creepage distance in mm (minimum) Cantilever strength (KN) 11 12 35 33 36 75
1.3 times the actual dry flashover voltage. 75 170 9 27 320 580 6.60 10.0
As stated above unless otherwise modified in this specification the drop out fuses shall conform to IS:9385 (Part-I to III) and as amended from time to time. 7.1 RATED VOLTAGE The rated voltage shall be 11KV and 33KV for 11KV and 33KV DO Fuses respectively. RATED CURRENT The rated current shall be 200 Amp. for 11KV and 33KV DO Fuses. Rated Lightning impulse withstands voltage values for the fuse base. The rated lightning impulse withstand voltage both for positive and negative polarities shall be as given below:11KV 33KV a. To earth and between poles b. Across the isolating distance of fuse base. 7.4 75 KV Peak 85 KV Peak 170 KV Peak 195 KV Peak
7.2
7.3
Rated one minute power frequency withstand voltage (dry and wet) values for the fuse base:11KV 33KV a. b. To earth and between poles Across the isolating distance of fuse base. 28KV Peak 32 KV Peak 75 KV Peak 80KV Peak
7.5
Temperature rise limit in air above ambient temperaturea. b. c. Brass contacts silver faced Terminals Metal parts acting as spring 65 C o 50 C The temperature shall not reach such a value that elasticity of the metal is changed.
o
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7.6
RATED BREAKING CAPACITY The rated breaking capacity shall be 8 KA (Asymmetrical). Submission of type test certificate of rated breaking capacity in case of 11 KV DO Fuse unit is very essential, otherwise offers may be rejected.
8.0
MAIN CONTACTS The main contacts of the D.O.Fuses shall be suitable for heavy duty, properly aligned and made from Brass material. These shall have good finish and smooth surface and shall be silver-plated. All the sharp edges shall be rounded off. These contacts shall be so designed to withstand highest short circuit breaking current that may be encountered during service. In nut-shell the contact assembly shall ensure following :i. ii. iii. Electro-dynamic withstands ability during short circuit without any risk of repulsion of contact. Thermal withstand ability during short circuits. Constant contact pressure even when the lower parts of the insulator stacks are subjected to tensile stresses due to linear expansion of connected bus bar or flexible conductors either because of temperature variation or strong winds. Proper alignment to ensure smooth operation of D.O.Fuses without adjustment.
iv. 9.0
CONNECTORS The connectors shall be made from Brass suitable for ACSR/AAAC Squirrel/Weasel/Rabbit and Raccoon. The connectors should be bolted type having 4 bolts & groove to hold the conductor. All brass parts should be silver plated for corrosion resistance and efficient current flow. All ferrous parts should be hot dip galvanized as per the latest version of IS:2633. Nuts and bolts shall conform to IS: 1364 and should be hot dip galvanized. Spring washer should be electro galvanized. FLY NUTS These shall be provided at both the ends of SRBP tube for tightening the fuse elements. The nut shall be provided with one flat washer of 25mm dia. The arrangement shall be made to ensure that the fuse wire runs centrally inside the SRBP tube after tightening. SPRING STRIPS The spring strips shall be of phosphor bronze multilane brush type having a high pressure contacts and o should retain its tension under minimum continuous service current of 200 Amps at 90 C. OPERATING HOOKS The brass-operating hook shall be fixed over the SRBP tube in such a way that the barrel can be removed for replacing the fuse element by operating rod from the ground level. The drop out fuse units shall operate efficiently. Speed of operation shall not depend on the inclination of the fuse. However, the inclination of the fuse barrel shall be adjusted in such a way that the barrel does not drop by gravitational force.
10.0
11.0
12.0
13.0
D.O.BARRELS : The D.O.Fuses Barrels shall be made from SRBP and shall conform to BSS: 1314. The supplier shall furnish the test certificate for the fuse barrels offered for use in the drop out fuses along with each lot offered for inspection to the inspecting officer. The test certificates of SRBP barrel should indicate the following test results:i. Dimension:(a) External dia : (b) Wall thickness : (c) Internal dia : ii. Max. wrapping in 12" length of : the tube. iii. Axial electric strength (Proof test : The barrel should withstand this test at 25KV rms 50 C/s. Satisfactorily for one minute.
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iv. Radial electric strength (Proof o test in oil at 90 C at 19 KV rms 50 C/s. Surface electric strength (Proof test o in air at room temp. 32 C at 14 KV rms at 50 C/s Water absorption in 14 hours Resistance to Hot Oil : --do--
v.
The barrel should withstand this test satisfactorily for one minute.
vi. vii.
: : :
viii. Cohesion between layers (Proof test) ix. 13.1 Machine ability
The tenderer should indicate the name of manufactures of SRBP tube from where they will purchase the Barrel to make available the above test certificate. The barrels should have the property to resist fire whenever the fuse is blown off. It should not catch fire easily during blowing off of fuse element inside the barrel, which causes short time high temperature.
14.0
DESIGN, MATERIALS AND WORKMANSHIP The successful tenderers shall assume full responsibility for co-ordination and adequate design. All materials used in the construction of the equipment shall be of the appropriate class, well finished and of approved design and material. All similar parts should be accurately finished and interchangeable. The connecting of cap and pin with insulator should be perfect to avoid any kind of loosening. After cementing the insulator should be cured adequately in water to attain good gripping. GUARANTEED DATA AND OTHER TECHNICAL PARTICULARS Guaranteed data and other technical particulars of the D.O. Fuse should be given in Schedule-VI enclosed herewith. Any other particulars considered necessary by the supplier might also be given in addition to those listed in the schedule.
15.0
16.0
TESTS Each D.O. Fuse shall strictly comply with requirement of all the type tests and shall be subjected to all routine tests stipulated in the relevant standard. All tests shall be made prior to despatch in the presence of the representative of the purchaser. No material should be despatched without prior approval of the tests certificate by the purchaser. The tenderer should note that along with the tender, the following type test certificate as per ISS:9385 Part-II - 1980 (with latest amendment) must be furnished on MPSEB design D.O. fuses. The type test should not be older than 5 (five) years from the date of opening of tender and should be performed in the Govt. recognized Laboratory:(i) (ii) (iii) (iv) Impulse voltage withstand test, H.V. Power Frequency dry / wet withstand test. Temperature rise test. Breaking Current test. (Mandatory in case of 11KV DO Fuse Units and optional in case of 33KV DO Fuse Unit)
The supplier should invariably furnish Routine Test certificate of DO Fuse barrels & Post Insulator of their manufacturers along with the inspection report of D.O. Fuse Units. 17.0 IMPORTANT REQUIREMENTS TO BE NOTED BY THE TENDERER:The suppliers should carefully note the following requirements and comply the same otherwise their offer shall be rejected:-
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i. ii. 18.0
All the accessories of D.O. Fuse Unit should be listed out clearly and dispatch with DO Fuse Units. Technical particulars of D.O. Fuse Units should be as given in the enclosed specification.
Each D.O. Fuse shall be provided with name plate of size 2"x 1" on steel strip in case of 11KV DO and of size 4"x 2" on steel channel in case of 33KV DO Fuse and shall be either revitted, bolted or pasted. The following shall be indicated on the name plate :Name of manufacturer Order No. & date S. No. of the equipment Rating...............Amps ... Volts Name of purchaser viz MPMKVVCo.Ltd. Please note that paper should not be used for name plate. The material should be packed in appropriate wooden cartoons, so as to sustain transport hazards.
19.0
DRAWING The following drawing of 11 KV and 33KV DO Fuses are enclosed herewith:(i) (ii) EB/P6/MPEB/5 (revised) dt.14.1.88 for 11KV DO Fuse Unit. EB/P6/MPEB/6 (revised) dt.14.1.88 for 33KV DO Fuse Unit.
The tenderers shall ensure that the design of their equipment is as per the drawing enclosed and specification of the tender. The main dimensions are given here as under :DIMENSION :SN 1 2 3 4 5 (i) (ii) (iii) (iv) 6 (i) (ii) (iii) (iv) (v) 7 (i) (ii) (iii) Particulars 11 KV Drawing No. M.S. Flat M.S.Channel Fuse Barrels Lower Contact Hinge of Barrel:Connectors Hinge Contact Length Hinge Contact Width Thickness of Hinge (i) Outer (ii) Inner Barrel take out hook:Width Thickness Length Inner dia meter Thickness between inner outer dia Operating Hook:Width Thickness Inner Radius 245x25x6 330x25x14
60x60x6 95 85 5 4 25 4 30 25 3mm 18 3 19
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(iv) 8 (i) (ii) (iii) (iv) (v) 9 (i) (ii) (iii) 10 Outer Radius Female contact :Main Contact Width Strip thickness Strip length Width Female contact height Female Contact Holder:Length Upper width Lower width Creepage of Insulator 22.5 65 1.5 100 20 75 74 34 40 320
Note: Post Insulators of following standard makes should be used for manufacturing of D.O. Fuses:(i) (ii) (iii) (iv) 20.0 M/s Allied Ceramics Pvt. Ltd. Calcutta M/s Jaya Shree Insulators, Rishra M/s India Potteries Ltd. Calcutta M/s Bharat Heavy Electricals, Bangalore.
INSPECTION 20.1 The purchasers representative shall at all times be entitled to have access to the works and all places of manufacture where equipment/material shall be manufactured and the representative shall have full facilities for unrestricted inspection of the suppliers works raw materials and process of manufacture for conducting necessary tests as detailed herein. The supplier shall keep the purchaser informed in advance of the time of starting and of the progress of manufacture of equipment/material 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 purchaser in writing. In the later case also, the equipment/material shall be dispatched only after satisfactory testing for all tests specified herein has been completed. The acceptance of any quantity of material shall in no way relieve the supplier 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. The number of sample selected to carryout the acceptance test shall be as per provision in the respective IS.
20.2
20.3
20.4
20.5
The purchaser has the right to have the tests carried out by an independent Agency subject to recovery of testing expenditure in case of failure, whenever there is dispute regarding the quality of supply. 21.0 Type test Certificate:- The tenderers shall invariably enclose with the offer, the type test certificate of MPSEB Design DO Fuses along with certified copy of the drawing and other relevant guaranteed technical particulars. The type test should not be older than 5 (five) years from the date of opening of tender and should be performed in the Govt. recognized Laboratory. Please note that offers without requisite type test certificate are liable for rejection.
20.6.
= = = ======
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TECHNICAL SPECIFICATION OF 11KV & 33 KV OIL IMMERSED CT: PT (METERING EQUIPMENT) UNITS
1. This specification covers the design, manufacturing, testing at manufacturer works inspection before despatch of Out door pole mounting type 11 KV & 33 KV Oil Immersed Combined CT:PT (Metering) units 2. The metering units shall have 3 nos. CTs to suit the requirement of 3 phase 4 wire metering. 3. 11 KV & 33 KV metering units shall comprise of 3 nos. CTs conforming to IS:2705/1992 and 1 no. 3 phase PTs conforming to IS:3156/1992 with latest amendment and upgraded. 4. The Guaranteed Technical Particulars of CTs & PTs of the combined CT:PT (metering) units is indicated in Schedule-II (B). 5. The metering equipment shall be supplied complete with first filling of EHV Grade-I (New) Transformer Oil. Only best quality of new EHV Grade-II (New) Transformer Oil should be used. The BDV of oil shall be recorded in the test certificate. The oil shall comply in all respect with the provision of latest version of IS:335 or IEC publication no. 296 (as amended upto date) and type test certificate of oil shall be produced at the time of inspection. 6. No fuses either on HT or LT side of PT shall be provided.
7. The metering equipments shall be contained in a weatherproof outdoor pole mounting type M.S. tank made by 5 & 3.15 MM. thick MS sheet ,with 6 nos. of 11 KV or 33 KV weatherproof bushings with Brass Stud as per rating of CT:PT (metering) units. 3 nos. bushing on incoming and 3 nos. bushing on outgoing terminals for all three phases R, Y & B with M and L marking embossed/engraved on the top cover of MS tank to identity incoming and outgoing terminals of the metering unit respectively. 8. The tank should be given three coats of rust preventing paint and finished with light grey No. 631-IS-5 on all external surfaces. The internal surface of the tank shall be painted with two coats of a suitable oil-insoluble paint. 9. A suitable air release valve at the top of the tank cover shall be provided. After processing and hermetically sealing of metering equipment the air release valve should be permanently sealed before despatch of metering equipment. 10. (a) The PTs shall be 3 phase star connected with HV neutral floating. The primary winding has to be designed for unearthed neutral i.e. for the highest system voltage i.e. 36 KV for 33 KV and 12 KV for 11 KV. PT winding should have uniform insulation throughout the winding from terminal to neutral end and not graded insulation. This should clearly be shown in the drawing of equipment. (b) The 11 KV metering unit should be suitably designed for single phasing operation.
11. The CT secondary winding will be epoxy cast and the leads brought out through an terminals. 12. The connection between the CT and PT inside the tank will have adequately insulation to avoid infringement of clearance in air or to the tank side insides the unit. electrostatic and electromagnetic shielding should be provided to eliminate the electromagnetic induction/electrostatic charge on the CT/PT secondary windings.
epoxy cast reinforced Adequate effects of
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13. The metering equipment shall be fitted on HV side with outdoor type porcelain bushings of appropriate voltage & current rating. These bushings shall conform to IS:2099. Further, sealing arrangement be such that oil should not leak out from the bushing/ME tank. For gasketted joints, wherever used, nitrile butyl rubber gaskets, neoprene or any other improved material shall be used. The gasket shall be fitted in properly machined groove with adequate space for accommodating the gasket under compression. The firm have to submit complete details and justify that the quality of gaskets which will be used between the joints and also for mounting of oil level indicator will be of best quality to avoid leakage of oil. The quality of gasket should be selected keeping in mind that the ambient temperature 50C. The test certificate of the gasket and its material shall be furnished. 14. The end turns insulation of PT HV winding towards bushing side should be reinforced.
15. The dimensions and electrical characteristics of the bushing shall be in accordance with relevant ISS and its subsequent amendments if any. 16. The minimum electrical clearance between phases and phase to earth as specified in ISS/IE rules shall be maintained. 17. Normal current density shall not be more than 1.5 Amps./sq.mm. in primary winding of the CT.
18. The primary winding shall be of adequate cross section to carry continuously the rated current plus 20% over load continuously. 19. The insulating materials for winding between HV & LV, between interlayer of the winding and for end turn shall be as per relevant ISS. However, end turns have to be provided with reinforced insulation and lead connecting the bushing shall be provided extra insulation of fibre glass sleeve. 20. The metering equipment shall have a built in secondary terminal box. Entry of the cable into the box on the unit shall be through one no. gland and check nuts etc. Metallic cable gland to suit 10 core 2.5 sq.mm. armoured copper control cable shall be supplied with M-seal/epoxy compound for fixing cable gland with the secondary box additionally. The secondary box shall be preferably on line side on top with a suitable arrangement that in case of water accumulation, it should be drained out automatically. The control cable entry in the secondary box should be from bottom. 21. Top cover of metering unit should be provided with sealing arrangement at all four corners.
22. Secondary terminal box cover should have 8 no. nuts & bolts with hole for sealing arrangement. For these, 8 nos. holes of 2.5 mm dia should be provided on the cover and flange of secondary terminal box at the corners and middle of each faces for fixing nut bolts. In addition to above, 4 number holes (2 nos. on upper side and 2 nos. on lower side) may also be provided in the flange and top cover. 23. (a) The ratio changing arrangement (for dual ratio) should be provided on secondary side. (b) All secondary terminals shall be of M6 stud type nickel plated brass. Each stud shall be provided with two nuts for external connection.
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(c) The stem length of primary terminal shall be adequate for connection of terminal connector and two number nuts above the terminal connector. Minimum 10 mm should be free length on the stud after connection terminal connector and two nuts. 24. The top of the tank will have slope to drain the rain water and avoid collecting pockets.
25. The metering unit shall be provided with non-detachable (riveted) anodised aluminium plate showing position of the terminals, their marking, connection diagram, specification and other details as specified in IS:2705 and IS:3156 i.e. type, PT ratio, CT ratio, Rated Burden, Class of Accuracy, Insulation Level, STC rating, Weight of oil, Weight of unit, Sr. no., Purchase Order no. & date, Month and Year of Despatch and G.P. etc. of metering unit Further, MS plate size 125 x 125 mm be got welded on width side of metering unit. On this plate name of firm, order no. & date, Sr. no. of the unit and month and year of despatch should be engraved/embossed. 26. The metering equipment shall be hermetically sealed. The metering equipment shall be provided with conservator of adequate capacity to facilitate expansion and contraction of oil due to changes in temperature. The conservator shall be provided with oil level gauge, non-return type oil filling valve with metal cap, pressure release device but without silica gel breather. The oil level in the conservator before sealing of metering equipment shall be made up to the required level in the conservator while the metering equipment filled with oil is maintained at a temperature of 45C. The volume above the oil level in the conservator tank shall be filled with nitrogen conforming to commercial grade of IS:1747:72. Nitrogen shall be filled from the cylinder. Further, an explosion diaphragm shall be provided on opposite side of metering equipment secondary terminals box which should operate at a pressure 0.4 kg / sq.mm. before the pressure inside the tank reaches the tank pressure. Thus, pressure of nitrogen gas, pressure relieving device and an explosion diaphragm shall be properly co-ordinated and shall be mentioned clearly in the drawing of the equipment. The oil in the ME shall be filled under vacuum & after processing and thereafter sealed with nitrogen gas to eliminate breathing and to prevent air and moisture from entering the tank. Oil drain valve or sampling cock, if provided to facilitate factory processing and non-return type oil filling valve should be permanently sealed before despatch of ME. 27. The gaskets used should be of best quality having a thickness of 5 mm for main tank and 3 mm or more for other side. The information about the gasket material used on the metering equipment should be mentioned in the drawings. 28. The tank shall be of robust construction having thickness of sheet enclosure minimum 3 mm. The welded joints of the metering unit shall be strengthened by providing 25x25x3mm angle all along the length and welded properly inside the tank. All joints of the tank and fitting shall be oil tight and no bulging shall occur during service. The tank should be design in such a way that it can be installed on a DC cross arm of D.P. structure easily. 29. The tank shall be reinforced by welded angle of size 25x25x3mm on all the outside wall on the edge of tank to form two equal compartments. One face of reinforcement angle should be continuous welded with the tank surface such that other side of the angle forms inverted L.
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30.
The mounting of the bushing on the Metering Equipment should be in oblique plane.
31. All the welded joints in the metering equipment tank should be leak-proof and pressure-tested as per relevant IS. 32. (a) Secondary Terminals marking:- The secondary terminal marking of the CT-PT unit shall be as under:-
(i) PT a, b, c & n CT R-Phase Single ratio aS1-aS2 Double ratio aS1-aS2-aS3
Y-Phase bS1-bS2 bS1-bS2-bS3
B-Phase cS1-cS2 cS1-cS2-cS3
(b) Primary Terminal Markings:- The primary terminal marking of the CT-PT unit shall be as under:PT R-Phase Y-Phase B-Phase Incoming Side AM BM CM Outgoing Side AL BL CL
33.
The CT:PT (metering) equipment shall have the following:i) ii) iii) iv) v) Riveted rating and diagram plate 2 nos. welded lifting lugs of MS plate 4 mm thick. 2 nos. base mounting channels size 75x40mm across length of metering unit. 2 nos. Earthing terminals of size M-12 with lugs & hot dip galv. bolt. 6 nos. Bi-metallic clamps suitable for ACSR Dog Conductor.
The terminal connector shall conform to the latest version of IS:5561 or equivalent International Standard. The details of current take-off as required by us should be detailed out in drawing. In respect of terminal connector, following should be ensured:(a) The terminal connector should be made of A6 Aluminium Alloy and by gravity diacast only. Sand casted terminal connectors are not acceptable. All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges should be rounded off. No parts of clamp shall be less than 12 mm thick. The bi-metallic strips/sleeve shall be 2 mm thick. All nuts/bolts/washers shall be of a stainless steel only. The conductor should be tightened by min. 6 bolts. Conductor hold must not be less than 100 mm.
(b)
(c) (d) (e) (f)
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35. TYPE TESTS:- The offered design of metering unit are type tested for short time current test, temperature rise test, lightning impulse test, accuracy test, high voltage power frequency voltage withstand test and Determination of errors/accuracy class, as per IS:2705/1992 and IS:3156/1992 (with latest amendment) from CPRI, ERDA or from any Govt. Standard Test Laboratories in India or from laboratories of International repute.
36. ROUTINE TEST:- Before despatch, each of completely assembled metering unit shall be subjected to following routine tests as specified in IS:2705:1992 & IS:3156 with latest amendments, at the manufacturers works :-
(a) (b) (c) (d) (e) (f) (g) (h) (i) 37.
Verification of terminal marking & polarity test of CT and PT of metering unit. Power frequency dry-withstand tests on primary winding of CT and PT of metering unit. Power frequency dry-withstand test on secondary windings of CT and PT of metering unit. Over -Voltage inter turn test on CT of metering unit. Determination of errors and other characteristics according to the requirement of the appropriate designation or accuracy of CT and PT of metering unit. Induced over voltage withstand test on PT of metering unit. Break-down voltage of transformer oil. Pressure test on tank of metering unit at 0.8 kg. per sq.cm. for 30 minutes. Ratio & phase angle error test of CTs of metering unit for zero burden i.e. by shorting the secondary terminals directly and on PT keeping the secondary terminals open. In case any change in design/type of metering unit already type tested and one offered against this specification, the purchaser reserves the right to demand repetition of tests without any extra cost.
GUARANTEED TECHNICAL PARTICULARS OF OIL IMMERSED 11 KV & 33 KV CT:PT UNITS
SNo. Particulars 1. Standard reference 2. Type and designation 3 4 5 6 Nominal system voltage Highest system voltage Frequency (A) Current transformer: (i) Type (ii) Transformation ratio
11 KV CT:PT UNITS IS:2705/1992 Outdoor Oil immersed pole mounted 11 KV 12 KV 50 Hz 5% Out door oil immersed 5/5, 7.5/5, 10/5, 15/5 25/5, 50/5, 300-150/5A
33 KV CT:PT UNITS IS:2705/1992 Outdoor Oil immersed pole mounted 33 KV 36 KV 50 Hz 5% Out door oil immersed 2.5/5, 5/5, 10/5, 20/5, 30/5, 50/5, 100/5, 150/5, 175/5, 200/5, 400-200/5A 0.5S
(iii) Accuracy class
0.5S
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(iv) Rated Output (v) Insulation level a. Primary (kv rms) b.Secondary (kv rms) c. Impulse Withstand Voltage(KV P) d. One minute power frequency wet withstand voltage (kv peak) (vi) Short time thermal current for one second (vii) Short time thermal current rating for two seconds (for dual ratio metering unit) (viii)Saturation factor (ix) Normal current density of primary winding (x) a. Insulation class b. Insulation material used B) Potential transformer Standard reference (i) Type (ii) Transformation ratio (iii) Accuracy class (iv) Rated Output (v) Insulation level (vi) Method of connection HV/LV
10 VA 28 KV(rms) 3.0 KV(rms) 75 KV(peak) Root 2 X 28 13.1 KA (for ratio 5/5A-6 KA) 13.1 KA
10 VA 70 KV(rms) 3 KV(rms) 170 KV(peak) Root 2 X70 13.1 KA 13.1 KA
<10 <1.5
<10 <1.5
A Kraft paper/Polyster IS:3156/1992 Three phase, Out door oil immersed 11 KV/110 V 0.5S 25 VA/ phase 28 KV(rms)/ 75 KV(peak) HV line leads taken out through HV bushings & HV neutral floating. Only crimped joints shall be allowed. The secondary terminal of winding taken out to secondary terminal box Star/Star 55C 300 mm Minimum 5 mm
A Kraft paper/Polyster S:3156/1992 Three phase, Out door oil immersed 33 KV/110 V 0.5S 25 VA/ phase 70 KV(rms)/ 170 KV(peak) HV line leads taken out through HV bushings & HV neutral floating. Only crimped joints shall be allowed. The secondary terminal of winding taken out to secondary terminal box. Star/Star 55C 900 mm Minimum 5 mm
(vii) Winding connection
7 8 9
Maximum temperature rise of winding Minimum creepage distance Tank sheet thickness :Top & Bottom
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10
11
Side Surface Minimum clearances :(a) Phase to phase (b) Phase to earth (c) Between live parts & earth Terminal connector with two check nuts
Minimum 3.15 mm As per IE Rules/ IS Suitable for ACSR Dog conductor & with 1.5 times of rated current capacity but should not be less then 100 Amp M-12 up to 50 Amp, 16 MM for upper capacities
Minimum 3.15 mm As per IE Rules/ IS Suitable for ACSR Dog conductor & with 1.5 times of rated capacity but should not be less then 100 Amp M-16 up to 150 Amp&M-20 for upper ratings
12
Size of primary terminals
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TECHNICAL SPECIFICATION OF 0.5S CLASS HT STATIC TRIVECTOR ENERGY METER

1. SCOPE: This specification covers design, manufacturing, testing and supply of high precision three phase four wire static tri-vector energy meters of accuracy class 0.5S or better, capable of performing functions of energy audit in sub-transmission system & load survey applications. 2. STANDARD APPLICABLE : The meters shall be of class 0.5S accuracy and shall meet all the requirements specified in standard specifications IS:14697/1999, IEC:62053-22 and CBIP report no.88, with its latest amendment. 3. CLIMATIC CONDITIONS : The meter shall be suitable for operating under the following climatic conditions and shall be capable of maintaining desired accuracy under duly hot tropical climates. o A Maximum ambient air temperature 55 C B C Maximum ambient air temperature in shade Maximum temperature attainable by the meter exposed to sun Minimum ambient temperature Average daily ambient air temperature Maximum relative humidity Number of months of tropical monsoon condition Maximum altitude above mean sea level Average annual rain fall Maximum wind pressure Isoceraunic level (days per year) Seismic level (horizontal accn.) Permitted noise level 45 C 60 C
o o
D E F G H I J K L M
(-) 5 C 40 C 95% 4 months 1000 meters 150 cms 200 kg/sq.m 40 0.30 g 45.db
o
4. TECHNICAL REQUIREMENT & DESIGN CRITERION 4.1 Meters are required for installation in the premises of HT consumers or in sub-stations. The basic system parameters for which these meters will be used shall be as under:Primary voltage Secondary voltage Primary current 11KV/3, 33KV/3, (phase to neutral) 110/3 volts (phase to neutral) 11KV 5A to 25 Amp. for tariff meters 150 for energy audit 33KV 5A to 150 Amp. for tariff meters 200A for energy audit 1Amp, 5 Amps
Secondary current
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Meters shall be designed on 3 phase 4 wire measurement principle & should have 3 current & 3 voltage measuring circuit i.e. one for each phase. 4.2 The meters shall work satisfactorily in the absence of neutral and shall work even if any two voltage wires are extended to the meter. 4.3 The meters shall be designed for 1Amp or 5Amps CT Secondary and 200% overloading. 4.4 Accuracy - 0.5S 4.5 The meters shall have Non Volatile Memory (NVM) for storage of Billing and Tamper data. There shall be no battery back up for retaining data. 4.6 Computation of demand shall be on the basis of Real Time Clock of the meter itself. 4.7 Meters covered under this specification shall be fully static type with non volatile memory to register various billing parameters and complete with other features as detailed in this specification. Any other design meeting technical specification requirements or features/accuracy etc., better than this specification and as per relevant IEC/IS shall also be acceptable. 4.8 Meters shall be suitable for measurement of energy and other billing parameters within the specified limits of errors under balanced and unbalanced loads conditions in a poly phase network. 4.9 POWER FACTOR RANGE:- Meters shall be suitable for measurement of billing parameters with specified accuracy for PF range as per relevant standard. 4.10 Computation of apparent energy shall be based on following principle. S = Sa + Sb + Sc 2 2 2 Sa =Pa + Qa 2 2 2 Sb =Pb + Qb 2 2 2 Sc =Pc + Qc S stands for Total apparent power Sa, Sb & Sc stands for apparent power in phase A, B & C P stands for Active energy Q stands for Reactive energy 4.11 KVAh computation shall be on the basis of power factor lag+lead Principle / lag only principle. It should also be possible to change from (lag+Lead) to lag principle with the help of MRI & BCS. Dial multiplying factor for the specified CTs & PTs ratio shall be unity. The display of energy & also demand shall have minimum seven digits with fixed decimal. The energy & demand shall be displayed in KWH & KVA or MWH & MVA respectively depending on CT and PT ratio. The meter shall be programmable by the user for TOD timings, billing dates etc. The meter constants shall be freeze and it shall not be possible by the manufacturer or the user to alter the meter constants at factory or at site. Provision shall be made to read various billing parameters and also load survey data through a Common Meter Reading instrument. This arrangement can be through an optical coupler or any other suitable device galvanically isolated from meter circuit. Provision shall be made to seal the optical coupler to ensure proper security. Indications shall be provided on display to show the healthiness of phase voltage and also the status of abnormal electrical connections, if any persist at the meter terminals. Meters shall be designed for satisfactory operation with the following supply voltage/frequency variation:-
4.12 4.13
4.14 4.15
4.16
4.17
4.18
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Voltage - V.Ref + 15% to -30% as per standards Frequency - 47.5 Hz to 52.5 Hz (ref. frequency 50 Hz) For above voltage and frequency range, the meters shall measure, register and display various parameters as per standards. 4.19 DISPLAY PARAMETERS 4.19.1 The data shall be displayed on LCD display in 7 segment-7 digits which shall be clearly visible from distance. a) On pressing of Read push button i.e. billing parameters i ii iii iv v vi vii viii ix x xi xii b) LCD segment check Date Time Cumulative active energy import Cumulative active energy export Cumulative apparent energy during KWh import Cumulative apparent energy during KWh export Maximum demand during the month Import mode Maximum demand during the month Export mode Cumulative Maximum demand during Import & Export mode separately MD reset counter Tamper Information
DD:MM:YY HH:MM:SEC KWh/MWh KWh/MWh KVAh/MVAh KVAh/MVAh KVA/MVA KVA/MVA KVA/MVA No. of reset
Programmable Optional Requirements of display on pressing push button. i.) Phase Current A ii.) Phase Voltage KV iii.) Instantaneous active Power KW/MW iv.) Instantaneous reactive Power KVAr/MVAr v.) Instantaneous demand KVA/MVA vi.) Instantaneous PF vii.) Frequency Hz viii.) Reactive energy import while KWH import ix.) Reactive energy export while KWH import x.) Reactive energy import while KWH export xi.) Reactive energy export while KWH export xii.) Active TOD energy registers xiii.) Apparent TOD energy registers xiv.) TOD MD xv.) KVA (RISING DEMAND) Import/Export xvi.) Billing TOD MD xvii.) Billing main active energy xviii.) Billing active TOD energy xix.) Billing main apparent energy xx.) Billing apparent TOD energy Auto display: (a) KWH cumulative Import/Export (b) KVAH cumulative Import/Export
c)
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(c) KVA Maximum demand during the month Import/ Export (d) Instantaneous power factor (e) Active TOD energy registers (f) TOD MD (g) Billing TOD MD (h) Billing main active energy (i) Billing active TOD energy (j) Billing main apparent energy (k) Billing apparent TOD energy 4.19.2 VIEW PARAMETERS (display/information required through MRI/BCS) i.) Reactive energy import while KWh import ii.) Reactive energy export while KWh import. iii.) Reactive energy import while KWh export iv.) Reactive energy export while KWh export v.) Present demand - KVA/MVA vi.) Power Factor vii.) Maximum demand during the month KW/MW Import & Export viii.) Tamper information. ix.) All balance parameters of (a) & (b) above. Meter Reading at Power Outage: Provision to read the meter in no power condition shall be made. The same push button shall be used for display the readings during power outage. A suitable external device could be used so that display of readings could be possible. Reading through MRI shall also be possible in power outage condition. 4.20 MAXIMUM DEMAND REGISTRATION 4.20.1 Maximum demand computation shall be based on sliding window concept/ block interval concept (user selectable) with integration period of 30 minutes or 15 minutes programmable. For sliding window MD, there shall be three updates of 10 minutes or 5 minutes for 30 minutes or 15 minutes integration period respectively. By default computation shall be based on sliding window concept and integration period should be 15 minutes with 5 minutes update. 4.20.2 The MD integration cycle shall be on the basis of real time. However the real time clock of the meter shall be used only for the purpose of time matching. For computation of maximum demand the internal clock of the meter shall be made use of. Provision should also be made for automatic reset of MD at pre-defined period. The billing parameter at the time of automatic reset of the MD along with one previous record shall be stored and display shall be possible on demand. Period as to when automatic reset of maximum demand is required shall be programmable. In addition reset of maximum demand shall be possible through a hand held terminal capable of communicating with the meter. In every case the design shall include provision of updating of cumulative demand register with updating of reset counter. TAMPER DETECTION FEATURES : The meter should have features to detect the occurrence and restoration of, at least, the following common ways of tamper and fraud: a. Missing Potential: The meter shall be capable of detecting and recording occurrences and restoration of missing potential (one phase or two phases) which can happen due to intentional / accidental disconnection of potential leads, along with the total number of such occurrences for all phases.
4.20.3
4.21
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b. CT Polarity Reversal: The meter shall be capable of detecting and recording occurrences and restoration of CT polarity reversal of one or more phases. c. CT Short (Bypass) / Open : The meter shall be capable of detecting and recording occurrences and restoration of shorting (bypassing) / opening of any one or two phases of CT when the meter is connected to a 3 phase 4 wire system. This feature shall not be available if and when the meter is connected to a 3 phase 3 wire system. d. Current Unbalance: The meter shall be capable of detecting and recording occurrences and restoration of current unbalance as a tamper event. e. Magnetic influence : The Meter shall be capable of detecting and recording presence of external magnetic field near the meter as per relevant standard, and declare it as a magnetic influence
f.
Power on & off: The meter shall be capable of logging power on & off events in the meter memory.
Snapshots (numerical values) of voltage, current, power factor and active import & apparent energy readings as well as the date and time of logging of the occurrence and restoration of all tamper events, subject to meter-memory space as described herein under, should be logged in the meter-memory and available for retrieving through the meter's optical port via HHU and downloading to the BCS. Minimum 200 events (occurrence + restoration) of all types of tamper with date and time shall be available in the meter memory on first-in, first-out basis. It shall be possible to retrieve the tamper data along-with all related snap-shots' data through the meter's optical port with the help of a HHU and download the same to the BCS where it shall be available for viewing. All this information shall be available in simple and easily understandable format. The threshold values for voltage, current and P.F. etc. for the purpose of logging occurrence and restoration of various types of tamper will be mutually decided by the purchaser and supplier. The Supplier should, however, propose these values in their offer. Logics for design of above indicated tamper, the value of voltage, current, time etc. to be selected for design of tamper logics shall be in consultation with the purchaser. The tamper at (a) above is to be included in the DISPLAY PARAMETERS and information regarding rest of the tampers/unbalance etc. are required to be included as in information in the VIEW PARAMETERS. a) Over current - to indicate number of hours there has been over current beyond the CT ratio limits. b) Power Fail - The meter should log power down and power up event. c) Security - The meter shall have the following unique security feature for different levels described below. Password Security level Operation READ ONLY OPERATIONS 1 Read only such as Readings, Load Survey Event Reading. LOW LEVEL WRITE 2 Set time, MD reset, Tamper reset HIGH LEVEL WRITE 3 Tariff definitions, change bill dates, Persistence time change, MD reset options, Load survey configuration, changes in energy definition. Change of passwords for level 1, 2 and 3.
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1. Passwords shall be zero for all 3 levels initially. With zero passwords the operations will be available without getting password clearance. This will allow the user to choose whether to use passwords to prevent readings in particular, or to use only the authenticators to validate any data change transactions at levels 2 and 3. 2. Give tamper/fraud evidence where it is not possible to be tamper / fraud proof. This means that meter has to record all authenticated transactions performed with it and communicate the recorded data in meter readings. Recording may include lock/unlock, password change, and transactions like change of energy definition, billing date programming, change of tariff for TOD tariff, tamper reset, load survey configuration, MD IP change etc. operation which involve change in meter configuration given in BCS scheduling with date and time. 4.22 4.23 4.24 Provision shall be made for push button to initiate display parameter in the front of the meter. Provision shall be made for MD reset push Button with provision to seal it. An operation indicator in the form of blinking optical Signal shall be provided to indicate that the meter is operating satisfactorily. Supplier has to ensure the blinking optical signal is of weighted pulse and this can be effectively used for verification of accuracy & should also be ensured that the intensity of blinking signal is sufficient for detection by the optical sensor. Meter shall be programmed for auto display of billing parameters with provision of:- Programmable time display of each billing parameters. - Programmable time of display cycle. Tamper information shall be roll over type and shall be FIFO based with facility to reset the same through MRI. TOD Tariff/Demand: The meter shall be capable of registering time of day energy consumption data on stand-alone basis. The meter shall be provided with an internal time clock and timer both controlled by a quartz crystal with a battery totally independent of power supply and shall be capable of being set into a minimum of 6 time zones in a 24 hour cycle to cover morning and evening peak and off peak periods separately. Sufficient registers shall be provided to record and display the "display parameters (Billing parameters) i.e. export & import active and apparent energy and demands for each time zone. The accuracy of the built in calendar and clock shall be better than one minute per month. It should be possible to change the time period for these registers through the hand held meter-reading device with special authenticated command from the BCS so that only authorized person(s) can make such changes. The main control for this change along with proper security password/code should be available on the computer located at the metering office. (The meter should be able to record energy consumption up to the specified time of day {as programmed} to help conducting regular energy balance study). 4.28 Load Survey Capability: It should be possible to store previous data of at least 31 days of every 15 minutes or 62 days of every 30 minutes (depending upon the integration period) of energy consumed and also demand i.e. load survey is needed for the demand and energy consumed in every MD integration time cycle (15 min. or 30 min.). The demand to be recorded in the load survey shall match with the demand recorded in the "DISPLAY PARAMETERS". The demand and energy consumed shall be recorded separately under energy Import and energy Export periods. Load survey based on MD integration period shall be selectable from the following parameters. -KWH -KWH -KVAH -KVAH -RKVAH -RKVAH Import Export Import (While active import) Export (While active import) Import While KWH Import(KVAr lag with Active import) Export While KWH Import(KVAr lead with Active import)
4.25
4.26
4.27
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-RKVAH Import while KWH Export (KVAr lag while Active export) -RKVAH Export while KWH Export(KVAr lead while Active export) It should be possible to retrieve load survey data by hand held meter reading device through the communication port provided on the energy meter. Out of the above-indicated parameters included in the load survey capability it shall be possible to select any four parameters for load survey data. To clarify, the load survey memory shall be capable of accommodating and storing every 15 minutes data of at least four parameters. Choice of any four parameters out of the parameters indicated above shall be user's selectable. By default the meters shall be programmed and supplied with following four parameters:-KWH -KWH -RKVAH -RKVAH 4.29 Import Export Import While KWH Import(KVAr lag with Active import) Export while KWH Export(KVAr lead while Active export)
BILLING POINT REQUIREMENTS: The predefined date and time for registering the billing parameters of active ,reactive, apparent energies of import and export along with its supported TOD registers and MD/ TOD MD as well as Tamper Count and Power-On hours readings shall be at 00.00 hours of the first day of each calendar (billing) month or any predefined date of the month. All billing parameters shall be transferred to billing registers The above billing data, TOD register's data, load survey data, tamper information and instantaneous parameters data shall all be retrievable through the meter's communication port through a common meter reading instrument (CMRI) and shall be transferred (downloaded) to a PC with Windows based software to get complete details in numerical and/or graphic form. The necessary base computer software (BCS) for this purpose shall be provided by the supplier with complete details. Further, apart from instantaneous parameters like voltage, current, PF, and readings of billing parameters, energy registers, TOD registers etc., the following additional parameters should be made available at the BCS end: a) MD reset count. b) Billing Parameters for last 6 Histories.
4.30
It should be possible to down load view parameters and load survey data on to compatible computer and obtain full details of demand and consumption in statement form and also in graphic form. Meters shall be four Quadrant meter capable of recording active reactive and apparent energy and also demand in four quadrants. Meter shall be capable to measure fundamental frequency energy and total energy. Meters shall be designed to withstand EMI-EMC level in accordance with clauses as mentioned in IEC/IS Standards for Class 0.5S. It is obligatory on the part of bidder to confirm this requirement and also to submit a type test/test report confirming successful performance
4.31
Necessary software for various programmable features as discussed above in the meter and also necessary software for the IBM compatible computer to obtain various details as discussed above and additional if any shall be provided by the supplier. No separate cost will be borne by the purchaser on this account. The software shall include provision for load survey, graphic presentation and other reports generation in BCS from the data collected from the meter through meter reading instruments. In the forthcoming paragraphs requirement of a D-port/RJ-11 for tele-metering purpose has been described. Meters covered under this tender will be employed for metering at our Sub-stations or in the premises of HT consumers for tariff applications. In the cases the instantaneous parameters, load survey data and tamper information etc. will be monitored remotely through computer installed in central station. The data from meter will be transferred to the central station through GSM communication links as such meter should have capability of remote meter reading. It will be obligatory on the part of the bidders to supply the software in adequate copy needed for remote meter reading. No separate cost towards remote metering reading software will be born by the purchaser.
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4.32
Lithium or any better quality battery of adequate storage energy shall be used for energy supply to real time clock during no voltage or power off condition. Under battery weak condition, an indication shall appear on MRI/Laptop/BCS. The life of the lithium battery for supplying energy to real time clock during no voltage or power off condition should not be less than 10 years. Output Device:- The meters shall have a test out put in the form of a blinking LED for testing of the meters accuracy. Testing shall also be possible through optical port accessible from the front and can be monitored with Meter Reading Instrument having high-resolution display. The meters shall give high-resolution energy values directly to meter reading instrument. The resolution will be sufficient to enable conduction of the starting current and accuracy test in less time. Meters shall have two numbers RS-232 communication port out of which one shall be galvanically isolated type and other D/RJ11 type for collection of data through the meter reading instrument and remote meter reading purpose. While designing these ports, due care shall be taken and it shall be ensured that damage to the meter/meters circuitry is not possible by injecting magnetic/electrical charges through these ports. A specific confirmation that these considerations have been taken care of shall be made by the bidder. The port for load survey data collection shall be suitable to receive the coupler of MRI and certain changes in the meter configuration as discussed else where in the tender should be possible through this and only this port. The other D-port/RJ-11 is exclusively for remote meter reading purpose only. Communication with meter through this port (D/RJ-11) for programming purpose should not be possible. Provision for sealing shall be made for both communication ports. For the output ports available in the meter standard internationally approved protocol shall be adopted. A detail of protocol used is necessarily required to be intimated by the supplier to the purchasers. In case any proprietary protocol/API is used, it will be obligatory on the part of the bidders to furnish complete details of proprietary protocol to the purchasers so that there may not be any difficulty in extraction of data from the meter through the available ports when connected to the communication bus (prepared for some other data communication purpose).
4.33
4.34
4.35
The meter should have provision for testing of meter in the meter testing laboratory or testing of meter at site with the help of ESS and phantom load test set in order to reduce test time high resolution display on MRI should be provided. Meter shall operate and record satisfactorily independent of phase sequence of input supply so long as phase association between voltage and current circuits is in order. The performance of meter should not be affected by the external electromagnetic interference such as electrical discharge of cable and capacitor, harmonics, electrostatic discharge, external magnetic field and injection of D.C. Current in A.C. circuits etc. The basic meter shall be designed for overloading up to 200% No setting point / setting register etc. shall be provided for adjustment of measurement errors.
4.36
4.37
4.38 4.39 5
CONSTRUCTION OF THE METER
5.2 Body of the meter shall be designed suitable for projection mounting. The meter should be made of high quality raw materials to ensure higher reliability and longer life. The meter should be compact and reliable in design e.g. to transport and immune to vibration and shocks involved in transportation/handling. The construction of the meter shall be suitable for its purpose in all respects and give stable and consistent performance under all conditions especially during dust storms/heavy rains/very hot days. 5.3 All insulating material used in the construction of the meter shall be non-hygroscopic non ageing and of tested quality. All parts that are likely to develop corrosion shall be effectively protected against corrosion.
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5.4 Meters shall be installed in Sub-stations/lines/HT consumer's premises out door inside a metal box, directly under the sun and extreme weather conditions. Suitability of such a use shall also be confirmed.
5.5
SEALING OF THE METER: Proper sealing arrangement shall be provided on the meter to make it tamper proof and avoid mishandling by unauthorised person. At least two (2) seals on the body, 2 nos. tamper evident sticker seals between the base and cover of the meter body. two (2) seals on the terminal block cover and one seal each on maximum device and communication port shall be provided. All the seals should be provided on front side only. Rear side sealing arrangement will not be preferred. The meter body one sealing screw shall be provided with good quality 7 digit numbered polycarbonate seal or any superior body sealing arrangement with embossing on sides, one side with the logo of firm and other side MPCZ. The nos. of the seal shall be unique and should not be repeated in any case. Access to the working part should not be possible without breaking the seals. The polycarbonate seals shall have proper locking to avoid opening of the seal in any case by means of tampering.
Meter body cover and base shall be solidly welded (seamless) such that it should not be opened without breaking the meter body.
TRACKING SOFTWARE FOR SEALS: It is mandatory to provide Tracking and recording software for all new seals so as to track total movement of seals starting from manufacturing, procurement, storage, record keeping, installation, series of inspections, removal and disposal etc.
5.6
TERMINAL BLOCK COVER: The terminal block cover for the meter shall be extended transparent type, which can be sealed independently & over the meter cover. The terminal cover shall enclose the actual terminals, the conductor fixing screws and 10mm of the external conductors and their insulation for which the terminal cover shall be of extended type. The terminals shall not be accessible without removing the seals of the terminal cover when energy meter is mounted on the meter board. CONNECTION DIAGRAM & TERMINAL MARKING:The connection diagram of the meter shall be clearly shown on inside portion of terminal cover and should not fade with time. Meter terminals shall also be marked and should appear in the above diagram. Meter shall have a name plate clearly visible, secured against removal & indelibly and distinctly marked with all the essential particulars as per relevant standards i.e. a. b. c. d. e. f. g. h. Manufacturers name and trademark Serial number Type and description Rated current, voltage and frequency Relevant ISS/IEC No. along with ISI certificate mark, wherever available. Meter constant shall invariably be indicated. Name of the owner, purchase order no. & date and month/year of manufacturing shall be printed. Guarantee Period
5.7
5.8
ISI CERTIFICATION MARK: The meters must bear ISI certificat GUARANTEE
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The meter shall be guaranteed for the period of two years from the date of commissioning or two and half year from the date of despatch, whichever is earlier. The meters and also software if found defective within the above guarantee period shall be replaced/ repaired by the supplier free of cost within one month of receipt of intimation. If the defective meters/software are not replaced/repaired within the specified period, the Discom shall recover an equivalent amount from any of the bills of the supplier. 7 MINIMUM TESTING FACILITIES: Manufacturer should posses fully computerized Meter Test Bench for carrying out routine and acceptance tests as per relevant ISS. In addition this facility should produce Test Reports for each and every Meter. The bidder should have the necessary minimum testing facilities for carrying out the following tests.
7.1 TYPE TEST:- The type test certificate for all tests as indicated in relevant standards (with latest amendments) or CBIP report No.88 shall be furnished along with the bid. Type test certificates from any one of the standard laboratories NABL accredited for particular equipment/test shall only be considered. Type test report, amongst other details, should contain the following information clearly: Type of meter Class of Accuracy.
Type test certificate from educational institute(s) will not be accepted. The type test certificate shall not be more than 24 months old as on the date of opening of bid. 7.2 ACCEPTANCE TEST:- All acceptance test as per IS:14697/1999, IEC:62053-22 & CBIP report No.88 shall be carried out on the meter. 7.3 ROUTINE TEST:- All routine tests as per IS-14697, IEC:62053-22 & CBIP report No.88 shall be carried out on all the meters. 8 PRE DESPATCH INSPECTION: All acceptance tests and inspection of meter/software shall be carried out at the place of manufacturer unless otherwise specially agreed upon by the manufacturer and purchaser. The manufacturer shall offer to the inspector representing the purchaser all the reasonable facilities, free of charge for inspection and testing to satisfy him that the material is being supplied in accordance with this specification. The Discoms representative/Engineer attending the above testing will carry out testing as per, IS:14697 /IEC:62053-22 & CBIP report No.88 and this specification. i) C. Voltage test ii) Insulation Resistance Test iii) Test on limits of errors iv) Test on meter constant v) Test of starting condition vi) Test of no load condition vii) Repeatability of error test viii) Test of power consumption ix) Vibration test x) Tamper conditions - as per MPEZ Specification
The manufacturer should have duly calibrated ESS meter of class 0.1 or higher accuracy.
QUALITY ASSURANCE PLAN: The designed life of the meter shall be minimum 20 years and to prove the designed life, the firm shall have at least the following Quality Assurance Plan:-
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a. The factory shall be completely dust proof. b. The testing rooms shall be temperature and humidity controlled as per relevant standards. c. The testing and calibrating equipments should be automatic and all test equipment shall have their valid calibration certificates. d. Power supplies used in testing equipment shall be distortion free with sinusoidal, wave- forms and maintaining constant voltage, current and frequency as per the relevant standards. e. During the manufacturing of the meters the following checks shall be carried out. i. Meter frame dimensions. ii. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated. iii. The meters shall be batch tested on automatic, computerized test bench and the results shall be printed directly without any possibility of human errors.
The Bidder shall invariably furnish the following information along with his bid, failing which his bid shall be liable for rejection. Information shall be separately given for individual type of material offered.
(i)
Statement giving list of important raw materials, names of sub-suppliers for the raw materials, list of standards according to which the raw materials are tested, list of tests normally carried out on raw material in presence of bidders representative and copies of test certificates.
(ii)
Information and copies of test certificates as in (i) above in respect of bought out accessories.
(iii)
List of manufacturing facilities available.
(iv)
Level of automation achieved and list of areas where manual processing exists.
(v)
List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of such tests and inspections.
(vi)
List of testing equipments available with the bidder for final testing of equipment specified and testplant limitations, if any, vis--vis type, special acceptance and routine tests specified in the relevant standards and this specification. These limitations shall be very clearly brought out in schedule of deviations.
(vii)
The manufacturers laboratory must be well equipped for testing of the meters. They must have computerized standard power source and standard equipment calibrated not later than a year (or as per standard practice). The details of testing facilities available for conducting (a) The routine tests and (b) Acceptance tests shall be furnished in Schedule annexed with tender document.
10 MANUFACTURING ACTIVITIES:-
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(i) Meter should be manufactured using SMT components and by deploying automatic SMT pick and place machine and reflow solder process. Further, the Bidder should own or have assured access (through hire, lease or sub-contract) of above facilities. Quality control should be ensured at the following stages: At PCB manufacturing stage, each board shall be subjected to computerized bare board testing. At insertion stage, all components should undergo computerized testing for conforming to design parameters and orientation. Complete assembled and soldered PCB should undergo functional testing using Automatic Test Equipments (ATEs). Prior to final testing and calibration, all meters shall be subjected to aging test (i.e. meters will be kept in ovens for 72 hours at 55C temperature and atmospheric humidity under real life condition at its full load current. After 72 hours meters should work satisfactorily to eliminate infant mortality. The calibration of meters shall be done in house.
(ii) (a) (b) (c) (d)
(iii) 11 PACKING:-
Each meter should be shrink packed to avoid any scratches on metre body, dust from entering etc. and should be packed in a cushion cartoon of 10 meter or any appropriate quantity. The packing cases should be marked to indicate the fragile nature of the contents. 12 DRAWING AND TECHNICAL LEAFLETS:Individual meters should contain connection diagram on transparent terminal cover. All other details such as general arrangement, installation details operation instructions etc. should be given in the manual, which shall be supplied to the consignee. Two sets of such manuals shall be supplied to each consignee and two sets to this office.
13 AFTER SALES SERVICE:In order to provide prompt and smooth after sales support/service etc., it shall be preferred to post/engage an engineer/technician in M.P. preferably at Jabalpur by the manufacturer, who shall be fully conversant with the manufacturers meter, to attend any minor defects immediately and to educate the users about proper installation of meter and programming of MRI, base computer, taking reading, billing data, load survey, tamper information etc. through MRI and down load to PCs to get print outs etc.
15
GENERAL : a) Principle of operation of the meter, outlining the methods and stages of computation of various parameters starting from input voltage and current signals including the sampling rate, if applicable, shall be furnished by the bidder. b) The bidder shall indicate the method adopted to transform the voltage and current to the desired low values with explanation on devices used such as CT/shunt, potential divider as to how they can be considered superior in maintaining ratio and phase angle for variation of influencing quantities during its service period. c) The bidder shall furnish details of memory used in the meter.
TECHNICAL SPECIFICATION OF GSM / GPRS ENABLED MODEM 1. SCOPE This specification covers the design, engineering, manufacture, assembly, inspection, testing at manufacturers Works before dispatch and supply of intelligent GPRS Enabled GSM modem and suitable accessories for automatic and remote data transfer from Electronic energy meters.
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The overall system setup shall consist of the following: Meter end (consumer premises) Intelligent GPRS enabled GSM modem Suitable communication cable between modem and meter External Antenna with cable Universal AC adoptor with power supply cords Central Station end PC with offered Base Computer Software GSM modem with communication cable
2. TECHNICAL SPECIFICATION OF GSM MODEM The supplied modem shall be suitable for communication with electronic energy meters, installed at various consumer premises (HT/LT consumers). The system shall be used for remote meter reading of the consumer end meters via GSM infrastructure. The communication and reading shall be enabled with suitable Base Computer Software (BCS). The modem shall offer in-built intelligence and high speed data transfer rate or a kind of store forward facility by which data from the meter is read at regular intervals and stored in modems internal memory and forwarded to remote central station (as configured) for viewing billing and reporting via Base Computer Software.
Various features of GSM modem (to be installed with electronic energy meter) are described as below:
2.1 2.1.1
Power Supply Section Input specifications a. b. c. The modem shall have an AC input supply of 110V/230V + 30%, 50 Hz. + 5% The modem should be capable of proper functioning within the power supply range of 77 to 310V AC. Average Power consumption of the modem shall not be more than 3 VA under idle condition and 6 VA during data transfer.
Note: Power consumption may vary from site to site depending on signal strength at that particular location. Above values are typical values.
2.1.2 2.1.3 2.1.4
Withstand capacity against surges should be according to Indian conditions i.e. 6.0 kV. Input terminals: The power supply input shall be a suitable two core integrated cable coming out from modem box. The modem shall have capability to work under continuous power on condition.
2.2
GPRS enabled GSM Section The GSM module shall comply with the following: The modem shall operate in Dual Band GSM 900/1800MHz. The modem shall be compliant with ETSI GSM Phase 2+ Standard.
2.2.1 2.2.2
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Class 4 (2W) @ 900 MHz Class 1 (1W) @ 1800 MHz 2.2.3 2.2.4 2.2.5 2.2.6 The modem shall support Point-to-Point transmission and Cell Broadcast features. It shall have auto dial feature. Serial binary and suitable data format for data transfer. Short messaging service (SMS) features.
SIM Card Section For placing the SIM Card, a SIM Card Holder shall be provided on the GSM motherboard and shall be accessible only by removing the cover of the GSM modem. The SIM Card supported shall be of 3V Interface. Interlocking facility shall be provided under the device cover. Separate ESD (Electro-static Discharge) Protection for SIM Card on PCB shall be provided to protect from normal operation of SIM Card during putting in or out. The bidder shall specify the specification of the SIM Card to be used for offered Modem.
Communication Interface A RS232 Serial Link supporting up to 115,200 bauds with an auto-bauding option shall be provided. However the data transfer rate for remote meter reading shall depend on meter compatibility. The RS232 output shall be provided on a 9-pin female connector which can be connected to electronic energy meters optical / serial communication port through suitable communication cable.
RF section A SMA interface shall be provided on the GSM modem to which either a fixed or a wired (with magnetic base) Dual Band built-in Antenna of minimum 3db gain can be connected.
Provision shall also be made to connect 14db high gain external yagi antenna to improve poor signal strength.
Network Identification Section For determining the health of the device an LED shall be provided on the modem which shall depict the current functioning status (power up/ registered in network/ transmitting data).
3.
EMI/EMC Specifications The GSM modem shall meet the following EMI/EMC specifications:
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a. Electrostatic Discharge IEC61000-4-2 b. Fast Transient Burst IEC61000-4-4 c. Surges Immunity IEC61000-4-5 (Under Line to Earth & Line to Line immunity) d. Conducted Emission CISPR22 (class B)
4.
Mechanical Specifications The Mechanical Specifications of the modem shall be as follows: a. Mounting Arrangement: A suitable wall mounting arrangement shall be provided. b. The GSM modem shall comply with IP50 rating. c. Sealing Arrangement: The Top and Base Cover shall have a suitable sealing arrangement so that the GSM SIM Card cannot be tampered with. d. The modem shall be housed in an enclosure of ABS Plastic.
5.
Environmental specifications The modem shall meet the following environmental specifications: Temperature: Humidity: -10 degrees to +55 degree 95% RH (non condensing)
6.
Functional specifications The modem should be an intelligent device and capable of providing the following functionalities: Inbound dialing (a) The modem should have inbound dialling facility ie. modem shall automatically dial to a particular GSM number (number of modem placed at central station end along with BCS server) at specified time (once in a day/week/month) for the purpose of meter reading. This configuration of the modem shall be made available to the user via offered Base Computer Software. (b) If modem could not establish connection to the modem placed at central station at specified time, then it shall retry the same as configured.
6.1
6.2 Outbound Dialling (a) In case the data is required by dialling from the Central station end (Server end), then connection shall be established by the server to the device using AT commands & transparent communication mode shall be established. (b) User shall have option to get the data directly from the meter or the data already available in the memory of intelligent modem. (c) Provision to generate reports of successful automatic meter reading(AMR) calls and unsuccessful AMR calls separately shall be provided. (d) Provision for flexible scheduling of meter reading by BCS automatically on a pre-defined daily, weekly or monthly basis. (e) Provision shall be made to read the groups of energy meters in one go from the BCS and the searchable by Meter number, Consumer Number or Zone/Regions/Circle/Division/Sub Dn. 6.3 Event based dialing (a) Other than regular dialling, the modem shall have feature of event based dialling in case of logging of tamper by the meter, without waiting for the interrogation from central station (BCS server) and meter data shall be sent to the central station (b) Further, the modem shall sent an SMS to predefined mobile number and the SMS shall contain meter serial no. The mobile number shall be configurable via BCS. (c) Event based dialling and SMS shall be applicable for the event types (tamper/anomally) as supported/recorded by the meter
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When the modem is busy in collecting the data from the meter and the call comes to get the data, then priority shall be given to outbound call rather than data collection from meter. (e) The feature of event based dialling shall be user configurable. Provision of enabling and disabling of the feature shall be provided. 6.4 Baud Rate (Communication Speed) :(b) The modem shall have capability to send/receive data in asynchronous mode, transparent and non transparent upto 9600 bits/sec. (c) The modem shall have non transparent data transmission at 1200/2400/4800/9600bps. The data shall be selectable. (d)
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TECHNICAL SPECIFICATION FOR THREE PHASE FOUR WIRE ISI MARK LT ELECTRONIC TRIVECTOR METER OF ACCURACY 0.5S WITH IN BUILT LT CT OF ACCURACY 0.5, SYSTEM ACCURACY CLASS 1.0 FOR DISTRIBUTION TRANSFORMER METERING UP 100 KVA TRANSFORMER
Scope:
This specification covers design, engineering, manufacture, assembly, stage testing, inspection and testing before supply and delivery at site of existing Distribution Transformers for installation of 3 phase 4 wire LT in built CT Electronic Trivector Meters outdoor type of System accuracy class 1.0 with IN BUILT GSM Inteligent Modem for distribution transformer metering. After successful commissioning of proposed work , energy audit shall be performed for two years.
Standards Applicable :
While drafting this specification, reference has been made to the following Indian and international standard specifications.
IEC 62052-11
General Requirements, tests & conditions Metering equipments Specification for AC static TRANSFORMER OPERATED watt-hour and VAR-HOUR meters CLASS 0.2 & 0.5S A.C. Static watt-hour meters for active energy (Class 1 & 2) A.C. static watt-hour meters for active energy (class 1.0 & 2.0) Specification for AC static electrical energy of CBIP, New Delhi with its latest amendments.
IS:14697-1999
3 4
IEC 62053-21 IS 13779
CBIP Tech report 88 (July 96) & further amendments issued ( Apr 99Sep99)
Climatic Conditions:
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The meters shall be suitable to work satisfactorily under the following climatic conditions:
1 2 3 4 5
Minimum Ambient Temperature Maximum Ambient Temperature Minimum relative humidity Maximum relative humidity Altitude
0 C 50C 26% 95% Upto 1000m above sea level
Supply System:
3 x 240 V - Phase to Neutral (3 phase 4 wire systems) 3 x 415 V - Phase to Phase Current Rating (Ib) 40 A Maximum Current Rating (Imax) 200 A (500 % of Ib) Meters shall be suitable for 3 phase 4 wire connections for balanced and unbalanced loads at all power factors. Power Factor Range : The meter shall be suitable for power factor range from 0.5 (lagging) through unity to 0.8 (leading).
Rated Voltage (Vref)
Power Supply Variation:
The meter should be suitable for working with following supply system variations : Specified operating range - 0.8 to 1.2 V ref. Limit range of operation - 0.7 to 1.3 V ref. Frequency - 50 Hz +/- 5% Accuracy :
Class of accuracy of the metering system (Meter + LT CTs) shall be 1.0. Power Consumption : Voltage circuit: The active and apparent power consumption in each voltage circuit including the power supply of meter at reference voltage, reference temperature and reference frequency shall not exceed 2.0 Watt per phase and 10 VA per phase respectively. (ii) Current circuit: The apparent power taken by each current circuit at basic current, reference frequency and reference temperature shall not exceed 1 VA per phase.
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Starting Current : The meter should start registering the energy at 0.4% Ib and unity power factor. Maximum Current:
The rated maximum current of the meter shall be 500% I basic current (Ib).
General and Construction Requirements : i) Meters shall be designed and constructed in such a way so as to avoid causing any danger during use and under normal conditions. However the following should be ensured: a) b) c) d) Personnel safety against electric shock Personnel safety against effects of excessive temperature. Protection against spread of fire. Protection against penetration of solid objects, dust and water.
ii) All the materials and electronic power components used in the manufacture of the meter shall be of highest quality and reputed make to ensure higher reliability, longer life and sustained accuracy. iii) The meter shall be designed with application specific integrated circuits. iv) All insulating materials used in the construction of meters shall be non - hygroscopic, non-ageing and of tested quality. All parts that are likely to develop corrosion shall be effectively protected against corrosion by providing suitable protective coating v) The meter shall have an operation indication device such as a blinking LED/LCD. The operation indicator shall be visible from the front window. vi) The meter shall conform to the degree of protection IP 51& 54 of IEC: 529 for protection against ingress of dust, moisture and vermins. The meter-base & meter-cover shall be made of high grade, fire- resistant, non-inflammable, highgrade and good quality engineering plastic. The meter shall have provision in such a way that secondary cable of distribution transformer shall be directly passed through the meter for measurement. Piercing screws shall be used in the meter for voltage connection. 2 The meter shall be suitable to accommodate aluminum cable up to 300 mm for a 450 A current carrying capacity. The meter connection arrangement should be such that so there is no need to remove insulation for connecting cable for current measurement. Design should support thread through concept where connecting cable directly passed through the meter for measurement. As the cable directly passed through the meter, the offered meter should not have provision for meter terminal connection as well as terminal block similar to conventional meters. The entire design and construction shall be capable of withstanding stresses likely to occur in actual service and rough handling during transportation. The meter shall be convenient to transport and immune to shock and vibrations during transportation and handling.
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The meter shall be designed with application specific integrated circuits. The electronic components shall be mounted on the printed circuit board using latest Surface Mount Technology (SMT). 12. Sealing Arrangement of the Meter: Reliable sealing arrangement should be provided to seal the meter and avo id fiddling or tampering by unauthorised persons. For this, at least two (2) Nos. seals on meter body, two (2) no. seal on meter terminal cover and one no. (1) seal on MD reset button ( if such button is provided ) shall be provided. All the above seals should be provided on front side only. Rear side sealing arrangement will not be preferred. All seals shall be patented and made of polycarbonate. 13. Marking of Meter: Every meter shall have name plate on the meter cover and the name plate shall be marked indelibly. The name plate marking should not fade with lapse of time. The basic markings on the meter nameplate shall be as follows: i. Manufacturer's name and trade mark. ii. Type Designation. iii. Number of phases and wires. iv. Serial number. v. Year of Manufacture. Reference voltage. vii. Current Rating (Ib/Imax). viii. Principal unit(s) of measurement. ix. Meter constant (imp/KWh, KVArh, KVAh). x. Class index of meter. xi. Purchase Order Number & Date. Xii ISI mark xii. Guranted up to .......... month ...... year
14.
Salient Features: The meter shall have the following additional salient features:
The meter shall have provision of meter display & to be read through communication port in the absence of power through an external source. An inductive coupling arrangement should be required so that it should not be possible to damage the circuitry of the meter by applying excess voltage directly in the meter. The meter should work satisfactorily irrespective of phase sequence of the mains supply. The meter should remain powered up and functional even when either of any two phases or any one phase along with neutral is available to the meter. v) The meter should continue to record satisfactorily as per prevailing electrical conditions even if the neutral of potential supply gets disconnected. a) The meter shall record active energy in forward direction even if one or more CT's are reversed. b) The current vector direction shall always be considered as positive (import) for the computation of 3 Phase active energy which shall be added in the main active energy (import) register. 15. . Display of measured value:
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The measured value(s) shall be displayed on seven segments, seven digit Liquid Crystal Display (LCD) display unit/register, having minimum character height of 10 mm for main digits. The data should be stored in non-volatile memory. The non-volatile memory should retain data for a period of not less than 10 years under unpowered condition. Battery back-up memory will not be considered as NVM. It should be possible to easily identify the single or multiple displayed parameters through symbols/legend on the meter display itself or through display annunciator. The register shall be able to record and display starting from zero, for a minimum of 1500 hours, the energy corresponding to rated maximum current at reference voltage and unity power factor. The register should not roll over in between this duration. 16. Meter Serial Number : In addition to providing serial number of the meter on the display plate, the meter serial number shall also be programmed into meter memory for identification through CMRI/meter reading print out. 17. Display Sequence: The meter shall display the required parameters in two different modes as follows:a) Auto Display Mode:
The offered meter shall be capable of recording and displaying automatically following data in order
Display Test Real time Date Active forwarded energy Reactive forwarded Energy (Lag) Reactive forwarded Energy (Lead) Apparent forwarded Energy Max. Demand in Apparent Forwarded (kVA Forwarded) Max. Demand in Active Forwarded (kW-Forwarded) MD reset count Total Abnormal occurrence events count Cumulative Power-On hours Cumulative Power off hours
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b) Push Button Mode:
The following additional parameters along with auto mode parameter shall be displayed on pressing the push button(s): Instantaneous Phase to Neutral Voltage Instantaneous Line Currents (Amps.) Instantaneous Power factor with sign for lag/lead Present Status of Abnormality Latest Occurrence of Abnormality with date & time Latest Restoration of Abnormality with date & time Frequency. Instantaneous load in i) Active ii) Apparent
18.
Output Device: The meter shall have a test output accessible from the front and be capable of being monitored with suitable testing equipment. The operation indicator, if fitted, must be visible from the front. Test output device shall be provided in the form of one common LED for active, reactive & apparent with the provision of selecting the parameter being tested. The relation between test output and the indication on display shall comply with the marking on the name plate (imp per kWh/kVArh/kVAh).
19.
Communication Support: Communication Port : The meters shall have a galvanically isolated optical communication port as per PACT/IEC 1107 so that it can be easily connected to a hand-held common meter reading instrument for data transfer. Remote Communication Mode for data retrieval from meter :
Meter shall have inbuilt GSM modem GPRS compatible to facilitate data transfer over wireless communication. Such modem shall operate in Dual Band GSM 900/1800MHz at 9600 bps. For placing the SIM Card, a SIM Card Holder shall be provided at suitable place on the meter front and shall be sealable to restrict unauthorised access. To determine the health of the device a LED shall be provided which shall indicate the current status of the Modem whether registered to the network or transmitting data. High Gain wired antenna with magnetic base mounting shall be available for installations where GSM signal is not sufficient to establish a connection using default antenna.
20.
Maximum Demand (MD) Registration: The meter shall continuously monitor and calculate the average demand in Active & apparent during the integration period set and the maximum, out of these, shall be stored along with date and time when it occurred in the meter memory. The maximum registered value shall also be made available on meterdisplay. The demand calculation should be sliding window principal/ block principal user programmable through CMRI at site. The rising demand under the current integration period should be displayed along with the elapsed time. The integration period shall be set as 30 minutes, on real- time basis.
21.
Maximum Demand Reset:
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The resetting of MD shall be automatic at predefined date & time. The meter shall display the maximum demand reset count.
22.
Load Survey Requirements:
The meter shall be capable of recording half an hour load survey of 11 parameters for 65 days. Following parameters shall be logged at peak kVA,
a) b) c) d) e)
Individual phase wise kW value (Import only) Individual phase wise kVAr (net) value with lag/lead sign R, Y, B Individual voltage of phases Power down time during hour interval (in minutes) Active forwarded energy of an hour cumulative value
(3 parameters) (3 parameters) (3 parameters) (1 parameter) (1 parameter)
It shall be possible to select either demand or energy view at the BCS end. The above load survey data should be available in the form of bar charts as well as in spreadsheets. The BCS shall have the facility to give complete load survey data both in numeric and graphic form. The load survey data, abnormality event information and instantaneous parameters data shall all be retrievable through the meter's communication port and through radio communication from a common meter reading instrument (CMRI)/ Hand Held Unit and shall be transferred (downloaded) to a PC with Windows based software to get complete details in numerical and/or graphic form. The necessary base computer software (BCS) for this purpose shall be provided by the supplier with complete details. The meter shall have sufficient non-volatile memory for recording history of energy parameters for last six st billing cycles (Bill date shall be 00 hrs of the 1 date of the calendar month by default programmable) and information should be made available at the BCS end: 23. Time OF Day (TOD) Tariff/ Demand: The meter should be capable of registering the time-of- day energy and maximum demand. It shall be possible to define TOD register for active forwarded, reactive lag and apparent forwarded energy type. The meter should have in-built capacity to define up to eight (8) time zones through operation of CMRI .The change of the TOD time-period(s) or changing number of TOD zones should be possible through CMRI with special authenticated command from the BCS so that only authorised person(s) can make such changes. The main control of this system along with proper security password/code should be available on one or more computers located at the authorised location(s) as per the directions to be given by the Purchaser 24. Abnormality Events Detection: The meter should have features to detect the occurrence and restoration of, at least, the following common ways of abnormalities: Potential failure: The meter shall be capable of detecting and recording occurrences and restoration of potential failure (one phase/two phases) which can happen due to intentional / accidental disconnection of potential leads. The meter should also record event as a potential failure, when one phase line fuse failure from the main side.
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Voltage High / Voltage Low: In case the average three phase voltage remains less (between 0.75 Vref to 0.65 Vref by default) than or above (above 1.15 V ref by default) for a predefined period, the meter shall log such incidences with date & time. This abnormal condition shall be logged only when all the three-phase voltage is available.
Current Polarity Reversal: The meter shall be capable of detecting and recording occurrences and restoration of current polarity reversal of one or more phases which can be happen due to wrong connection of current leads. Current Circuit Short: The meter shall be capable of detecting and recording occurrences and restoration of shorting of any one or two phases of current circuit. Event detection logic should be capable of discriminating the system abnormalities form source side and load side and it should not log /record event due to source side abnormalities. Current Circuit Open: The meter shall be capable of detecting and recording occurrences and restoration of opening of any one or two phases of current circuit which can happen due to intentional / accidental disconnection of current circuits. No load condition should record in meter memory as a Current circuit open event. Current Unbalance: The meter shall be capable of detecting and recording occurrences and restoration of current unbalance as an event. The above information should be possible to download from the meter through hand held unit and available at BCS end. The current unbalance more than 30 % should be recorded as an event in the meter memory. Voltage Unbalance: The meter shall be capable of detecting and recording occurrences and restoration of voltage unbalance as an event. The above information should be possible to download from the meter through hand held unit and available at BCS end. Over load/ low load Event: The meter shall be capable of recording the over load / low load Event in Apparent in the meter memory. The over loads limit shall be in terms of % of Transformer rating in kVA (programmable using CMRI & BCS). The over load limits shall be defined by the purchaser during the time of contract. Power on/off: The meter shall be capable to record power on /off events in the meter memory. All potential failure should record as power off event. Minimum one fifty (150) events (including occurrence & restoration) of all types of abnormality event with date and time shall be available in the meter memory on first-in, first-out basis. It shall be possible to retrieve the event data along-with all related snapshots' data through the meter's optical port and through radio with the help of a hand held unit (HHU) and download the same to the BCS where it shall be available for viewing. All this information shall be available in simple and easily understandable format. 25. Event Detection Logic: Properly designed meter event logic should be provided. There shall be separate compartments for logging of potential related event, current related event and power on/off event. The bidder should explain the events details in each compartment under their offer. The logging of various events in each compartment should be as under: Once one or more compartments have become full, the last event pertaining to the same compartment will be entered and the earliest (first one)-event should disappear. Thus, in this manner each succeeding event will replace the earliest recorded event, compartment wise. Events of one compartment/category should overwrite the events of their own compartment/category only. 26. Accuracy Requirement:
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The accuracy of parameters measured by the meter shall be tested in accordance with the relevant standards described in clause 2.0 of this specification. 27. Electrical Requirement: The electrical requirement of the meter shall be as specified in the relevant standards described in clause 2.0 of this specification. 28. Electromagnetic Compatibility and Interference Requirement: The meter shall meet EMI/EMC requirements as specified in the relevant standards described in clause 2.0 of this specification except radiated & conducted emission test.
Note: - As the meter shall read through Low Power Radio, Radiated & conducted emission test will not applicable to these meters
29.
Mechanical Requirement: The meter shall meet the mechanical requirements as specified in the relevant standards described in clause 2.0 of this specification. Climatic Influence Requirements: The meter shall meet Dry Heat/Cold/Damp heat cyclic test requirements as per the relevant standards described in clause 2.0 of this specification.
30.
31.
Minimum Testing Facilities: The tenderer should have the necessary minimum testing facilities for carrying out the following tests: i) AC voltage test ii) Insulation resistance test iii) Test of limits of errors iv) Test of meter constant v) Test of starting condition vi) Test of no load condition vii) Repeatability of error test viii)Test of power consumption xi) Abnormality Event conditions --as per Purchaser's specifications.
32.
TEST AND TEST CONDITIONS
ROUTINE & ACCEPTANCE TESTS :
Acceptance test: All acceptance tests as per relevant standards shall be carried out in the presence of SEBs representatives.
Routine Test: All the routine tests as per relevant shall be carried out and routine tests certificates shall be submitted for approval of purchaser.
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Type Test:
The type / model of meters should be type tested as per CT operated meter in National / Govt. recognised standard laboratories like NPL, ERTL, CPRI, ERDA,YMPL etc. as per IEC standards outdoor type meter. The LT CT shall be type tested at one of above lab. All these type tests have been conducted within three years preceding to schedule date of bid opening. Each Bid shall contain a copy of type test certificates issued by the National / Govt. recognised Laboratory.
33. TECHNICAL SPECIFICATION FOR BASE COMPUTER SOFTWARE
For efficient and speedy recovery of data read through CMRI/HHU, Base computer software shall be supplied having the following specifications as below:
(A)
Base Computer Software (BCS): --
The BCS software shall be user friendly. Windows based Base computer software shall be supplied. Base Computer software shall give all details adequate for analysis and load surveys parameters. The software shall have the facility to convert all the consolidated information / data of selectable parameters into ASCII format. EDP department of purchaser can generate its own DBF (data base files) to downloaded all the required information into it.
Platform : The BCS shall be executable on MS WINDOWS 98 system. The BCS shall be suitable to run on IBM PC or compatible hardware platform.
Meter Data Display :
The software shall show electrical condition existing at the time of reading the meter in tabular forms as well as graphical format (Phase diagram)
All the information about energy, maximum demand and their respective TOD register reading, billing register readings shall be shown in a manner which user can easily understand.
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All the load survey data shall be available in numerical as well as graphical format. It shall be possible to view this data daily, weekly, and monthly format. The load survey graph will show values where the cursor is placed for the selected or for all parameter. All the information about abnormality events shall be accompanied with date and time stamping along with 'snap-shot' of respective electrical conditions. This information shall be displayed in the sequence in which it happened in cumulative format as well as summary format.
The software shall be capable of preparing CMRI to read the meter information or time setting of the meter.
Support Display :
There shall be "user friendly" approach for viewing meter data for the reading collected now or for the reading collected in the past. All information about a particular consumer will be sorted out and available at one place so that locating any consumer 's past data is easy. It shall be possible to retrieve/locate data on the basis of either one of the following particulars:
Consumer's ID/Numbers. Meter Sr. No. Date of meter reading. Location. The Data Transfer :
It shall be possible to transfer data to and fro from CMRI through serial interface.
Configurablity :
It shall be possible to have selective printing out of all available data of the meter. Print out shall not include anything and everything available with the BCS. The software shall support "print wizard" whereby user can decide what to print out. The use of the software need not revert back to the supplier of the software for modifying the software just to print what he desires.
BCS shall have facility to export data to ASCII or spreadsheet format for integrating with the purchaser's billing system. Here again an "Export wizard" or similar utility shall be available whereby user can select file format, what data to export, the field width selection etc.
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Security :
The BCS shall have multilevel password for data protection and security. The first level shall allow the user to enter the system. The different software features shall be protecting by different passwords. The configurable of passwords shall be user definable. The software installed on one PC shall not be copiable on another PC.
Help :
The exhaustive online help shall be available with the software so that user can use all the features of the software by just reading the help contents.
34 Technical Specification Intelligent GSM modem Scope This specification covers supply, installation and commissioning of intelligent GSM modem and suitable accessories for automatic and remote data transfer from Electronic energy meters installed at the consumer premises. The overall system setup shall consist of the following: Meter end (consumer premises) Intelligent GSM modem Suitable communication cable between modem and meter Central Station end PC with offered Base Computer Software GSM modem with communication cable Technical Specification for GSM modem The offered modem shall be suitable for communication with electronic energy meters, installed at various consumer premises (HT/LT consumers). The system shall be used for remote meter reading of the consumer end meters via GSM infrastructure. The communication and reading shall be enabled with suitable Base Computer Software (BCS). The modem offers in-built intelligence, a kind of storeforward facility by which data from the
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meter is read at regular intervals and stored in modems internal memory and forwarded to remote central station (as configured) for view and reporting via Base Computer Software.
Various features of GSM modem (to be installed with electronic energy meter) are described as below: Power Supply Section Input specifications The modem shall have an AC input supply of 110V / 230V + 30%, 50 Hz. The modem should be capable of proper functioning within the power supply range of 77 to 310V AC. Average Power consumption of the modem shall not be more than 3 VA under idle condition and 6 VA during data transfer. Note: Power consumption may vary from site to site depending on signal strength at that particular location. Above values are typical values. Withstand capacity against surges should be according to Indian conditions i.e. 6.0 kV. Input terminals: The power supply input shall be a suitable two core integrated cable coming out from modem box. The modem shall have capability to work under continuous power on condition. GSM Section The GSM module shall comply with the following: The modem shall operate in Dual Band GSM 900/1800MHz. The modem shall be compliant with ETSI GSM Phase 2+ Standard. Class 4 (2W) @ 900 MHz Class 1 (1W) @ 1800 MHz The modem shall support Point to Point transmission and Cell Broadcast features. The modem shall have suitable memory (up to 128 kB) for application program and meter data storage. The modem shall support Short Messaging Service feature. It shall have auto dial feature. SIM Card Section For placing the SIM Card*, a SIM Card Holder shall be provided on the GSM motherboard and shall be accessible only by removing the cover of the GSM modem. The SIM Card supported shall be of 3V Interface.
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Interlocking facility shall be provided under the device cover.
* A data enabled (with required data settings) SIM card must be procured separately from the Service Provider for the location where the modem is to be fitted. Communication Interface A RS232 Serial Link supporting 300 bauds to 115,200 bauds with an auto-bauding option from 300-38,400 bits/s shall be provided; however the data transfer rate for remote meter reading shall depend on meter compatibility. The RS232 output shall be provided on a 9-pin female connector which can be connected to electronic energy meters optical / serial communication port through suitable communication cable.
RF section A SMA interface shall be provided on the GSM modem to which either a fixed or a wired (with magnetic base) Dual Band Antenna can be connected. The antenna should be of minimum 3dbi gain. *Optional High gain antenna may be provided for the locations where signal strength is not found to be suitable/ poor for communication. Network Identification Section For determining the health of the device an LED shall be provided on the modem which shall depict the current functioning status (power up/ registered in network/ transmitting data). EMI/EMC Specifications The GSM modem shall meet the following EMI/EMC specifications: Electrostatic Discharge Fast Transient Burst Surges Immunity IEC61000-4-2 IEC61000-4-4 IEC61000-4-5
(Under Line to Earth & Line to Line immunity) Conducted Emission Mechanical Specifications The Mechanical Specifications of the modem shall be as follows: CISPR22 (class B)
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Mounting Arrangement: A suitable wall mounting arrangement shall be provided. The GSM modem shall comply with IP50 rating. Sealing Arrangement: The Top and Base Cover shall have a suitable sealing arrangement so that the GSM SIM Card cannot be tampered with. The modem shall be housed in an enclosure of Engineering Plastic. Environmental specifications The modem shall meet the following environmental specifications: Temperature: Humidity: -10 degrees to +55 degree 95% RH (non condensing)
Functional specifications The modem should be an intelligent device and capable of providing the following functionalities: When the data is required by dialing from the Central station end (Server end), then connection shall be established by the server to the device using AT commands & transparent communication mode shall be established. User shall have option to get the data directly from the meter or the data already available in the memory of intelligent modem. When the modem is busy in collecting the data from the meter and the call comes to get the data, then priority shall be given to call from server rather than data collection from meter. But if the call comes to get the data from outbound dialing three times continuously within five minutes, the request of outbound dialing shall be ignored. Other than regular dialing, the modem shall have feature of event based notification in case of logging of anamoly event by the meter, without waiting for the interrogation from central station (BCS server) and server should read meter data. Further, central station software shall send an SMS to predefined mobile number and the SMS shall contain meter serial no, type of event, date and time of event. The mobile no. should be configured via BCS. Event based dialing and SMS shall be applicable for the event types (tamper/anomaly) as supported / recorded by the meter. 35. L.T. Current Transformer cum Meter Box:
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1.1 The specification provides for design, manufacture, testing before despatch, supply and delivery of LT CT Box with four current transformers for metering of distribution transformers. Four CTs will be required because as per Technical Specification we have asked for forward recording in case of CT reversal.
2.01
Enclosures The CT cum meter enclosure shall be made of three folds type 1.6 mm CRCA sheet/Moulded with high grade, fire resistance, poly phenylene Oxide or equivalent engineering plastic material quoted separately for CRCA sheet/Engineering Plastic Material as per price schedules and in accordance with relevant drawing attached at annexure A & B. The box shall be suitable for outdoor installation, conforming to IP-54 degree of protection as per IS:2147/1962. Roof of the box should be tapered. The box should be provided with two doors in front and having internal locking arrangement for each portion i.e. for meter & CTs. Extra padlock arrangement shall also be provided. The latches provided inside the door, which are locked in position by the keys, should be such that the door gets locked just by closing (for opening the door, keys will then be required). 5 lever brass padlocks with three keys should be provided with each LT CT box. Arrangement of sealing the door at two different places should be made i.e. meter box portion, CT Box portion and front door. Neoprene rubber gasket shall be used on front door and inner doors of two compartments. The provision for entry of power cables from the one side and exit from the one side and exit from the other side of the box are to be made with single compression glands. Additional sealing should also be provided so that water ingress should be prevented inside the box. The cables are properly clamped inside the box by means of 25x3 mm flat clamps at both the sides of the CTs and the CTs are to be mounted on slotted angle size 35x35x3 mm width provided inside the meter box. Painting of Box (In case of CRCA sheet Box): All sheet steel surface of the box shall be thoroughly degreased and shall be followed by anti - acid cleaning so as to produce smooth and clean surface free from scale grease and dust. After cleaning, the surface shall be given phosphate coating followed by two coats of anti rust paint primer (i.e. red zinc chrome primer). After which, 2 coats of synthetic paint of light grey colour (no.631 as specified in Indian Standard 5 of 1961) shall be applied on internal and external, surface of the steel structure of the box with a spray gun. The box shall be baked in the oven so as to give an elegant and durable finish to the box. Note: Engineering plastic Box shall be of dark admiralty gray color. The box should have a slope of 5 in front side. Leakage Proof: The box shall be vermin proof and weatherproof.
0
The assembly, comprising of the enclosure, framework and CTs, etc shall be provided with earthing terminals readily accessible and of adequate size. Two earthing studs of 12x50mm dia size shall be welded to the enclosure on either and shall be provided with locking nuts and washers. All the nuts, bolts and washers should be stainless steel. The earthing terminal shall be clearly marked.
Danger Board: Specifications are shown in Technical Specifications of the package.
Knock-out Holes: Knockout holes for incoming and outgoing cables will be provided as per the cable capacity. The holes shall be suitable to accommodate four nos. single core aluminum conductor LT cable of appropriate size.
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The holes should be in alignment with the terminals of incomer and outgoing bus bars so that the cable may be directly crimped with lugs. Bending of cable inside the box for terminal connection should be minimized.
2.02
CT mounting arrangements:
f)
The incoming and outgoing single core cable shall enter from one side of the enclosure and shall exit from other side of the enclosure. The CT should be housed in cable property by fixing it over MS slotted angle of size 35x35x3 mm (2 Nos.)
GENERAL:
(i) The boxes shall be strictly as per technical specification and drawings, which are to be submitted by the bidder and approved by the MPSEB before taking up the manufacturing. (ii) Crimping type Aluminum lugs of suitable size shall be used for all incoming and outgoing cable connection. The size of cable used for incoming and outgoing for various boxes are as follows:
Transformer Capacity 10 KVA 16/25 KVA 50/63 KVA 100 KVA 150/160/200 KVA 250/300/315/350 KVA
Incoming 1 C X 16 Sq mm 1 C X 25 Sq mm 4 C x 70 Sq mm 4 C X 150 Sq mm 2x4C x 150 Sq mm 2x4C x 300 Sq mm
Outgoing 1 C X 16 Sq mm 1 C X 25 Sq mm 4 C x 70 Sq mm 4 C x 150 Sq mm 2x4C x 150 Sq mm 2x4C x 300 Sq mm
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The specifications of LT CT Boxes are detailed below:
Technical Specification Of LT Current Transformer cum meter box for metering of distribution transformers of capacities25 KVA, 63 KVA, 100KVA, 200 KVA & 315 KVA Ratings S.No. Particulars RATINGS 25/63/100 KVA 200 KVA 315 KVA
SCOPE
Design, Manufacture & Testing, Installation, commissioning of LTCT Boxes AC 3 Phase 4 Wire 50 C/S
2 3 a) b) c) 4 a)
SYSTEM
MATERIAL SHOULD BE SUITABLE IN THE WEATHER CONDITIONS AS BELOW: Temperature Range Relative Humidity Altitude SYSTEM DETAILS Capacity of transformers Voltage Frequency Approximate full load current APPLICABLE STANDARDS - AMENDED UPTO DATE Enclosure Box Rated Insulation Rated Impulse withstand voltage (KV IS:2147/1962 Should be more than 660 volts AC 12 Suitable for use with Suitable for use with 315 200 KVA X'mer KVA X'mer 415 V AC 50 C/S 300A 450A 0 to 50 C 20% to Max. 100% 0 to 1000 Meters
o o
b) c) d)
5 a) b) c)
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d)
Rated Thermal current (Amps) Rated Operational current at 240V (Amp) Short-withstand current for second
1.2 Times rated primary current as per IS-2705
e)
400 Amps
630 Amps
f)
5 KA one
5 KA
(A) Made up of CRCA sheet in accordance with drawing attached at annexure-A 6 ENCLOSURES The box will have two separate compartments for meter and CT having separate doors the outer box will be made of sheet without joints. The outer box will be fixed by kabja welded from inside. The CTs will be mounted on MS angle of size 35 x 35x 3 mm with saddles for fixing LT CTs, sealing hook made up of 25 mm x 2 mm MS sheet welded from inside to be provided for meter and CT box separately. MS sheet cover for paper seal and lead seal welded with kabja to be provided with sealing arrangement of hook made up of 25x2 mm MS sheet welded from inside over the front side of the CT meter box. MS handles to be provided for the 2 doors. Earthing bolt 2 nos to be provided on both the side of the meter box. 4 Nos. threaded nobs to be provided on inner boxes (i.e. CT and meter boxes). The two portion of CT housing and meter housing will be separated by CRCA sheet of 1.6 mm with a central hole of 25 mm dia with rubber gas ket. Rubber lining to be provided in the grove of the box and transparent poly corbonet sheet fixed for viewing reading. Wire mash of size 6x8 to be provided over the front door in front of poly corbonet transparent sheet (Provided in the inner side of the door.) (B) Moulded with high grade, fire resistance, poly phenylene Oxide or equivalent engineering plastic material. The design features shall be the same as that for the box made up of CRCA sheet and shall be in accordance with drawing attached at annexure-B. i) ii) Size Material & Thickness as per drawing Hot dip galvanized as per IS, CRCA Sheet of 1.6 mm thickness/Engineering Plastic material to be quoted for each material separately
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iii)
Arrangement for Pad lock
Arrangement to be provided for pad lock and padlock is to be provided
iv)
Weather Auto lock is Auto lock is to be provided in such & manner that the cover of the box to be provided on cannot be left open and it gets latched automatically when closed front of door manually. Latch should be provided with master key for opening of the door. Slopping of Roof Slopping with 5 degree on back side
v) vi)
Front door of the Box Aluminum sheet engraved with details should be provided duly revitted. (Identification plate) Each box must have identification plate on the front cover a) MPSEB, b) Rating Box, c) Serial No., d) Name of firm and e) APDRP Work Knock out Holes in Holes with single compression brass glands suitable for the required size the Bottom plate of cables to be provided Instructions to Instruction printed in Hindi to be provided in side each box working personnel Danger Board Hinges To be provided as per specifications detailed in technical specifications To be approved, it should be suitable for movement of 120 degree of front door.
vi)
vii)
x) xi)
xii)
Other parts such as All Nut, Bolts & Washers used in current carrying parts should be of good Nuts, Bolts & Washers quality stainless steel EARTHING BOLTS Required No. Fixing Size Others Two (One on each side) 12 mm diameter bolts are to be fixed by welding on both the sides. 50x12 mm bolt One spring washer and two plain washers should be provided on the earthing bolt
7 a) b) c) d)
PAINTING & FIXING ARRANGEMENT FOR BOX Process No. Painting 3 Tank process 4 Tank process 5 Tank process
a) b)
With synthetic enamel With synthetic With synthetic enamel paint of good quality enamel paint of good paint of good quality
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quality c) Colour (outside)(inside) Fixing for box Grey White Grey White Grey White
d)
Arrangement Four No. MS flat 150 mm long of section 50x6 mm flat shall be welded near the corners on the back side for mounting the box. 2 nos, clamp and cleat as per the structure shall be provided approximately 10 center of the box. Meter view window to be provided with transparent polycarbonate sheet in inner door of the meter box and wire mash of 6x8 on outer door of the meter box.
Meter view window
10
APPLICABLE STANDARDS BOX
A) IS:2147/1962 with latest amendments, FOR B) IP-54 IS:8623(Pt-II)/1993
11 (I)
TEST & TEST CERTIFICATE Routine Certificate Test
A) Overall dimension, B) Insulation Resistance Test, C) H.V. withstand test for 3.0KV for one minute, D) Operation test separately Each LT CT Box should be tested for the routine test as indicated.
Note: -1.Technical Specification of LT Current Transformer for metering of distribution transformers of capacities 400 KVA, 500KVA, 630KVa, 750 KVA & 1000 KVA Ratings will be in line with the above parameters. The deviation in the size of the box and due to size of the CTs may occur bidders are to give the detailed drawing in line with the drawing enclosed with the package. The drawing enclosed with the package is indicative one. The bidder will be required to get approved the drawing before manufacturing.
CT cum Meter Mounting Box
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A) Box made up of CRCA sheet: The design of the box shall be in accordance with drawing attached at annexure A. The box will have two separate compartments for meter and CT having separate doors having locking arrangement. The outer box will be mode of sheet without joints. The outer box will be fixed by kabja welded from inside. The CTs will be mounted on MS angle of size 35 x 35x 3 mm 2 Nos. with saddles for fixing LT CTs. Sealing hook made up of 25mm x 2mm MS sheet welded from inside to be provided for meter and CT box separately. MS sheet cover for paper seal and lead seal welded with kabja to be provided with sealing arrangement of hook made up of 25x2mm MS sheet welded from inside over the front side of the CT meter box. MS handles to be provided for the 2 doors. Earthing bolt 2 nos to be provided on both the side of the meter box. 4 Nos. threaded nobs to be provided on inner boxes(i.e. CT and meter boxes). The two portion of CT housing and meter housing and meter housing will be separated by CRCA sheet of 1.6 mm with a central hole of 25 mm dia with rubber gas ket. Rubber lining to be provided in the grove of the box and transparent poly corbonet sheet fixed for viewing reading. Wire mash of size 6x8 to be provided over the front door in front of poly corbonet transparent sheet (provided in the inner side of the door.
The CT cum Meter box shall be suitable to house one three-phase four-wire energy meter in one compartment and 4 nos. CTs in other compartment.
The meter box shall contain a door, which shall be provided with a window for taking the readings of the meter. The window shall be made of scratch and break resistant, UV stabilized transparent polycarbonate of minimum 2.0mm thickness. Window shall be ultrasonically welded with meter box from inside. The viewing window shall have a proper shade/arrangement to protect meter display from direct sunlight.
A general arrangement for fixing the meter shall be made inside the box as per drawing. Meter box cover shall be fixed on minimum two concealed hinges. The meter box cover shall be able to open by a 0 minimum of 120 . Soft rubber gasket for protection from ingress of dust and water shall be provided on all around meter mounting box cover. Suitable handles shall be provided on the meter box for opening of the boxs door.
The door of the box shall be provided with U-shaped latches with one hole for riveting on the base and other for sealing the meter box.
The meter box shall be of dark admiralty gray color. For earthing of all metal parts, earthing bold 50x12 mm with nut and washer shall be provided. Box shall be provided with 4 Nos. fixing holes of minimum dia with washer at four corners of meter box.
The over all dimensions (in mm) of the box shall be provided so that minimum air gap of 50 mm is maintained between front, both sides and top of energy meter and from back side.
All control cable wiring should be tied with cable ties and clamped with the body of the box. Wiring diagram of cables inside the box should be provided on 2 mm thick aluminum sheet and depicted on the inner wall of the meter for clear instructions to the user.
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A danger board of 440V supply should be depicted on the meter box.
Name Plate: The Purchase order No. & Date shall be engraved on metallic aluminum sheet of 2 mm thick and depicted on the top cover of the box. The manufacturers name shall be engraved/printed or marked on the bottom half of the box such that it shall not remove easily.
CT secondary terminals brought from CT secondary should be directly connected to meter.
Note: The design features for Box moulded with high grade, fire resistance, poly phenylene Oxide or equivalent engineering plastic material shall be the same as that for the box made up of CRCA sheet and shall be in accordance with drawing attached at annexure B.
36.0
CABLE GLANDS AND LUGS
The cable glands shall be tested as per BS: 6121. The cable glands shall also be duly tested for dust proof and weather proof termination.
Cables lugs shall be tinned copper solder less crimping type conforming to IS: 8309 and 8394 suitable for aluminum conductor. The cable lugs shall suit the type of terminals provided. The cable lugs shall be of Dowell make or equivalent.
37.0
RESIN CAST L.T. CURRENT TRANSFORMER
A set of 4 nos. of Resin cast current transformers (CT), of accuracy class 0.5 shall be supplier with each meter/meter box. A tentative scheme is enclosed here with the specification.
GENERAL TECHNICAL REQUIREMENT
CTs of all ratios shall be of bar primary type (Ring Type)
Rated Voltage Rated Current (I Basic) Rated Frequency
: :
230 Volts (Phase to Neutral), 440V (ph-Ph) 5 Amps balanced & unbalanced load : 50 Hz
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Accuracy Class Power Factor Temperature : : 0.5 : Unity to Zero (all power factor lag / or lead). The standard reference temperature for Performance 27C. : 5VA : IS 2705 Part I and Part II of 1992 : Voltage Vref + 20% to 30% Frequency 50 Hz 5% Highest System Voltage Current Transformer Ratio Insulation Material Insulation level : : : : 1100 V 5 A Secondary (Primary as per BoQ) Resin Cast 2.5KV for 1 minute shall be
Burden Reference Standard Supply system variation
CONSTRUCTION (CORE MATERIAL)
Material
: Low loss, CRGO M4 or better grade (Core loses not exceed 0.8 Watts/Kg. at 1.5 tesla) : : Less than or equal to 0.27 mm.
should
Thickness Bore diameter
should not be less than 35 mm. the ring type CTs should be supplied with suitable clamp to fix the CT to panel / CT box.
COPPER WIRE
Material Test Certificate Secondary leads
: :
Enameled Wire as per IS 4800 Part IX / IEC 317 To be submitted
: Tinned copper ring type contacts to be terminated on suitable ring type terminals.
INSULATION
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a) b) c) Coil should be insulated with Electrical grade polyester tape. Outer insulation should be with vacuum mixed, homogenous Resin casting. Minimum 2 mm thickness of resin above the coil of the CT to be ensured.
SECONDARY TERMINAL Secondary lead must be secured during casting against loosening while connection. Secondary terminal shall have proper marking for identification which shall not be remove easily.
RATING PLATE Printed label must be having following details: 1. Ratio, Burden & Accuracy Class 2. Applicable Standard 3. Insulation Level 4. STC Rating 5. Continuous thermal current 6. Caution against open secondary 7. Batch No. 8. Manufacturers name 9. Manufacturing month and year Rating plate shallbe screwed on body of ct. DRAWING APPROVAL
Party must get final drawing approval before commencement of supply.
TEST AND TEST CONDITIONS
ROUTINE & ACCEPTANCE TESTS : METERS
Acceptance Test
All acceptance tests as per relevant standards shall be carried out in the presence of MPSEBs representatives.
Routine Test
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All the routine tests as per CBIP Technical report 88 shall be carried out and routine tests certificates shall be submitted for approval of purchaser.
Type Test
The type / model of meters shall have been type tested in National / Govt. recognized standard laboratories like NPL, ERTL, CPRI, ERDA etc. as per relevant standards. All these type tests have been conducted within three years proceeding to schedule date of bid opening. Each Bid shall contain a copy of type test certificates issued by the National / Govt. recognized Laboratory.
ROUTINE & ACCEPTANCE TESTS: LTCT
Schedule of type test for CT (As per Reference Standard) to be conducted and certified by GOVT. approved laboratory / test house:
Schedule of routine & acceptance test for CT:
Verification of terminal marking and polarity. High voltage power frequency test Over voltage inter0turn test Determination of error according to the requirement of appropriate accuracy class at 5%, 20%, 100% and 120% with Full and Quarter Burden. Temperature rise test
Verification of terminal marking and polarity. Determination of error according to the requirement of appropriate accuracy class at 20% and 120% with Full and Quarter Burden.
INSPECTION
The inspection shall be carried out, by the MPSEBs authorized representatives, at any stage of manufacture. The manufacturer shall grant all reasonable facilities free of charge for inspection and testing to satisfy the purchaser that the materials to be supplied are in accordance with their specification.
The supplier shall keep the purchaser informed in advance, about the manufacturing Programme so that arrangement can be made for inspection. The representative/engineer of the purchaser attending the above attesting shall carry out testing as per relevant standards and issue test certificate approval to the manufacturer and give clearance for dispatch.
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PACKING & FORWARDING The equipment shall be packed in crates suitable for vertical/horizontal transport as the case may be and suitable for handling during transport and outdoor storage in transit. The easily damageable materials shall be packed carefully and marked with appropriate caution symbol. Any material found short inside the packing cases, supplier shall provide short material without any extra cost.
38.0
ALUMINIUM LUGS Aluminum tubular lugs will be provided on the ends of the cable suitable for the rating of the cable. The details of the lugs are as under:
2
ALUMINIUM TUBULAR TERMINALS (LUGS) following sizes (mm )
1. 2. 3. 4. 5.
16 Sq mm cable (4 core) 25 Sq mm Cable (4 Core) 70 Sq mm Cable (3 /2 Core) 150 Sq mm Cable (3 /2 Core) 300 Sq mm Cable (3 /2 Core)
1 1 1
Suitable for stud size 8/10 mm
- Suitable for stud size 10/12 mm Suitable for stud size 10/12 mm Suitable for stud size 12/16 mm Suitable for stud size 16/20 mm
MATERIALS
ALUMINIUM IS-5082
LUGS CONFORMS
IS 8309 & IS 8394
Note : Cable Lugs shall be aluminum crimping type suitable for aluminum conductor. The cable lugs shall suite the type of terminal provided. Cable shall be Dowell/Comet make or equivalent.
lugs
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CONTROL CABLES
SCOPE: This specification calls for design, manufacture, stage testing, inspection and testing before dispatch, packing and delivery of Copper Control Cables for substations in the state of Madhya Pradesh.
It is not the intent to specify completely herein all the details of design and construction of Control CABLES. However the material shall conform, in all respect, to the high standards of design and workmanship and be capable of performing the duties specified herein.
The Control CABLES shall be 1.1 KV Grade. The cores shall have a size of 2.5 sq.mm, 4 sq.mm (for Copper Control Cables) , as called for using solid Copper Conductor with different number of cores as specified below:-
COPPER CONTROL CABLES: Unarmoured 19 Core 2.5 Sq.mm. 12 Core 2.5 Sq.mm. 08 Core 2.5 Sq.mm. 04 Core 2.5 Sq.mm. 02 Core 2.5 Sq.mm.
STANDARDS: The Control CABLES shall conform to the latest applicable Indian Standards. In case bidders offer Control CABLES conforming to any other International Standards which shall be equivalent or better than IS, the same is acceptable.
S. No 1
Standard Ref. No. IS: 1554
Title PVC insulated (Heavy Duty) Control Cables for working voltage & including 1100 Volts.
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Recommended current ratings for PVC insulated and PVC sheathed heavy duty cables Mild steel wires, strings and tapes for armouring of cables Methods of random sampling PVC insulation and sheath of electric cables Conductors for insulated electric cables and flexible cords Wooden drums of electric cables Methods of tests for cables
2 3 4 5 6 7 8
IS: 3961 IS: 3975 IS: 4905 IS: 5831 IS: 8130 IS: 10418 IS: 10810
ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS

In above paragraph relevant Indian Standard have been mentioned. However, the cables meeting any other authoritative International Standard which ensures equal or better quality than the standards mentioned shall also be acceptable. Cables for which Indian Standards are not available, the relevant equivalent International Standards will be applicable. Please attach photocopy of all such standards according to which the cables has been offered.
In this bid, the Bidders will have to furnish confirmation in regard to compliance of our entire technical requirement. The bid should clearly describe various technical particulars of the Control CABLES as per details given in this specification. Based on above information all details required in Schedule-II should be furnished so that we may be able to examine whether the Bid submitted is technically acceptable or not. Also all details and confirmation required as per Schedule-II will form part of technical bid.
CLIMATIC CONDITIONS: The Control CABLES to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions :-
1 2 3 4
Location Maximum ambient air temperature Minimum ambient air temperature Maximum Daily average ambient air temperature
At various substations in the State of M.P. 50C 1C 40C
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5 6 7 8 9 10 11 Maximum Yearly Weighted average temperature Maximum Relative Humidity 32C 95%(Sometimes approaches saturation) 1000 Meters 125 cm 150 Kg/Sq. Meter 50
Maximum altitude above mean sea level Average Annual Rainfall Maximum Wind Pressure Isoceraunic level (Average Number of thunderstorm days per year) Seismic Level (Horizontal acceleration)
0.3 g
SYSTEM PARTICULARS: The Cables offered under this specification shall conform to the parameters given below : S. No. 1 2 3 4 Particulars Nominal System Voltage Highest System Voltage Frequency Earthing System Voltage 400 KV 220 KV 132 KV 33 KV 420 KV 245 KV 145 KV 36 KV 50 Hz 50 Hz 50 Hz 50 Hz
Effectively Earthed
GENERAL TECHNICAL REQUIREMENTS AND CONSTRUCTIONAL DETAILS: The cables shall be suitable for laying on racks, in ducts, trenches, conduits and underground buried installation with chances of flooding by water. Cables shall be designed to withstand mechanical, electrical and thermal stresses developed under steady-state and transient operating conditions as specified elsewhere in this specification.
COPPER CONTROL CABLES: Control cables shall be of 1.1 KV grade, multicore (as specified in Clause 1.3 above), PVC insulated, PVC inner sheathed, armoured/unarmoured, PVC outer sheathed with solid copper conductor conforming to latest version of IS: 1554 or equivalent International Standards.
CONDUCTOR: The conductor shall be made from high conductivity copper rods complying with latest version of IS:613 or equivalent International Standards. The conductor shall consist of annealed copper wires complying with IS: 8130 with latest amendments or equivalent International Standards.
INSULATION: The conductor shall be provided with PVC insulation applied by extrusion in accordance with latest version of IS: 5831 or equivalent International Standards. The average thickness of insulation shall be in accordance with the IS: 1554 (Part-I) with latest amendments or equivalent International Standards.
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The insulation shall be so applied that it fits closely on the conductor and shall be possible to remove it without damages to the conductor.
CODE IDENTIFICATION: Colouring of insulation shall identify cores of the cables of upto 5 cores. Following colour schemes shall be adopted:-
S. No. 1 2 3 4 5
Number of Cores 1 Core 2 Cores 3 Cores 4 Cores 5 Cores
Colour Scheme Red, Black, Yellow or Blue Red and Black Red, Yellow and Blue Red, Yellow, Black and Blue Red, Yellow, Black, Blue and Grey Two adjacent cores (counting and direction core) in each layer, Blue and Yellow, remaining cores Grey or in accordance with the scheme given in IS: 1554 Clause 10.3
6 Cores and above
For reduced neutral conductors, the insulation colour shall be Black. The cables having more than 5 cores, as an alternate to the provision of (6) above, the core identification may be done by numbers as indicated in latest version of IS: 1554 (PART-I) 10 core identification.
LAYING UP OF CORES: In multi-core cables, the cores shall be laid up together with a suitable lay, the outer most layer shall have righthand lay and successive layer shall be laid with opposite lay, where necessary, the interstices shall be filled with non hygroscopic materials.
INNER SHEATH: The laid up cores shall be provided with inner sheath applied by extrusion. It shall be ensured that the shapebe as circular as possible. The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible to remove it without damage to the insulation. The thickness of inner sheath shall be conforming to latest version of IS: 1554 (Part-I) or equivalent International Standards.
FILLER AND INNER SHEATH:
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The filler and inner sheath shall be of the following: Unvulcanised rubber, or Thermoplastic materials, or Proofed tape (for inner sheath only)
Unvulcanised rubber or thermoplastic material used shall not be harder than PVC used for insulation and outer sheath. The material shall be chosen to be compatible with temperature ratings of the cable and shall have no deterious effect on any other component of the cable.
OUTER SHEATH: The outer sheath shall be applied by extrusion. It shall be applied:
Over the inner sheath in case of unarmoured multicore cables. Over the armouring in case of armoured multicore cables.
The outer sheath shall be so applied that it fits closely over insulation inner sheath/armouring. It shall be possible to remove it without damage to the insulation/inner sheath. The colour of the outer sheath shall be black.
The thickness of outer sheath insulation shall conform to latest version of IS: 1554 Part-I or equivalent International Standards.
IDENTIFICATION: In addition to Manufacurers identification on cable as per Clause-17.1 of IS: 1554 (Part-I) with latest amendments, following marking shall also be embossed over outer sheath at every three meters:-
Cable size and voltage grade Word MPMKVVCL and Name of manufacturer
The embossing shall be increasive, automatic in line throughout the length of the Cable and shall be legible and indelible.
PACKING AND MARKING: Cables shall be supplied in non-returnable wooden drums or steel drums of heavy construction. The surface of the drum and outer most cable layer shall be covered with waterproof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC or rubber caps, secured by U nails so as to eliminate ingress of water during transportation storage and erection. Wooden preservative antitermite shall be applied to the entire drums. Wooden drums should comply with latest version of IS: 10418 or equivalent International Standards. The following information shouldbe stenciled on the drum:
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Reference to relevant Indian or International Standard. Manufacturers name, brand name or trade mark Type of cable and voltage grade Number of cores Nominal cross-sectional area of the conductor Cable Code Colour of cores Length of Cable on the Drum Number of Lengths on Drum (if more than one) Direction of Rotation of Drum by means of an arrow Approximate gross weight Running end of cable Country of manufacturer and year of manufacture
As mentioned, the cable drum must bear relevant Indian/International Standard certification Mark. In this connection,a certified photostat copy of valid standard marking license rights duly attested must be submitted along with the inspection offer as documentary evidence. In absence of these documents, the inspection offer will not be considered.
STANDARD DRUM LENGTH: The standard drum length for Copper Control Cable shall be 500 Meters
TOLERANCE: Tolerance on the overall diameter of the Cable shall be 2 mm over the declared value in the techanical data sheets of Guaranteed Technical Particulars.The length per drum shall be subjected to maximum tolerance of 5% of the standard drum length. The purchaser shall have option to reject cable drums with shorter length. Over all tolerance in total quantity for each type and size of cables shall be 2%.
TESTS: All types and sizes of cable being supplied shall be subjected to Type tests, Additional test, Routine tests and Acceptance tests as specified below at the expense of Supplier and according to relevant standards.
TYPE TESTS AND ADDITIONAL TESTS: It is essential to furnish all the type test reports for each type and size of cable as stipulated in latest version of IS: 1554 (Part-I) and following Additional Tests along with the bid :
Loss of mass test Heat shock test Thermal stability test
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Accelerated water absorption test Dielectric strength retention test
Above tests shallbe conducted in Government / Reputed Testing laboratories.
ACCEPTANCE TEST
Acceptance test shall be caried out on each type and size of cables on cable drumsselected at random as per following plan :S.No. 1 2 3 4 5 Numbers of Drums in the Tests Upto 50 Upto 51 to 100 From 101 to 300 From 301 to 500 Above 501 Number of Drums to be taken as samples 2 5 13 20 32
The following shall constitute acceptance tests : Annealing Test Conductor Resistance Test Wraping Test Tensile Test Test for Thickness of Insulation and Sheath Tensile Strength and elongation test before ageing and after ageing at break of insulation and sheath High Voltage Test (Water Immersion Test) High Voltage Test at Room Temperature
ROUTINE TESTS: Routine test shall be carried out for each drum of cables of all types and sizes. Following shall constitute routine tests : Conductor Resistance Test Resistance Test High Voltage Test at Room Temperature
INSPECTION: The purchasershall have access at all times to the works and all other places of manufacture, where the Cables are being manufactured and the Bidder shall provide all facilities for unrestricted inspection of Bidders works, raw materials, manufacture of all the accessories and for conducting necessary tests as detailed in the bid document.
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The Successful Bidder shall kep the purchaser informedin advance of the time of starting and of the progress of manufacture of Cables in its various stages, so that arrangement could be made for inspection.
No material shall be dispatched from the point of manufacture unless the material has been satisfactorily inspected and tested.
The acceptance of any quantity of the equipment shall in no way relieve the successful bidder of this responsibility for meeting all the requirement of this specification and shall not prevent subsequent rejection if such equipment are later found to be defective.
QUALITY ASSURANCE PLAN
The Bidder must estalish that they are following a proper quality assurance programme for manufacture of Cables. The Bidder shall invaiably furnish following information along with his bid. Information shall be separately given for each type of Cable: Statement giving list of important raw-materials, names of sub-suppliers for the raw-material, list of standards according to which the raw-material in purchased and copies of test certificates thereof.
Information and copies of test certificates as in (i) above in respect of bought out items.
List of manufacturing facilities available.
Levels of automation achieved and list of areas where manual processing exists.
List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of such tests and inspetions.
List of testing equipment available with the Bidder for final testing of cable specified and test plant limitation, if any, vis-a-vis type, special, acceptance and routine tests specified in the relevant standards. These limitations shall bevery clearly brought out in schedule of deviations from specified test equipments.
The successful Bidder shall within 30 days of placement of order, submit following informatuion to the Purchaser :
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List of raw-material as well as bought out accessories and the names of sub-suppliers selected from the lists furnished along with Bid.
Type test certificates of the raw-material and bought out accessories.
Quality Assurance Plan (QAP) with hold-up points for purchasers inspection. The quality assurance plans and hold-up points shall be discussed between the purchaser and supplier before the QAP is finalized.
The successful Bidder shall submit the aroutine test certificates of bought out items and form raw-material at the time of routine testing of cable.
CABLE DRUMS
Cables shall be supplied in wooden or steel drums of heavy construction and drum shall be properly seasoned sound and free from defects. Wood preservative shall be applied to the entire drum.
Bidder shall indicate in the offer the standard lengths for each size of power and control cables, which can be furnished on one drum. The cable length per drum shall be subject to a tolerance of plus or minus 5% of the standard drum length agreed between Employer and Contractor. The Employer has the option of rejecting drums with shorter lengths.
A layer of waterproof paper shall be applied to the surface of the drums and over the outer most cable layer. A clear space of at least 40 mm shall be left between the cables and the logging.
Each drum shall carry the manufacturers name, Employers name and address, contract number, item number and type, size and length of the cable, net and gross weight stenciled on both sides of drum. A tag with same information shall also be attached to the leading end of the cable. An arrow and suitable wordings shall be marked on one end of the reel indicating the direction in which it should be rolled. 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.
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TECHNICAL SPECIFICATION FOR ISI MARKED 1100 VOLT GRADE,SINGLE CORE, STRANDED ALUMINIUM CONDUCTOR, XLPE INSULATED,PVC SHEATHED, UNARMOURED CABLE
1. SCOPE: The specification covers the design, manufacture, testing before dispatch, transportation, supply and delivery to the owners stores anywhere in West Discom of ISI marked 1100 volt grade, single core, stranded Aluminium conductor, XLPE insulated, PVC sheathed, un-armoured Cable suitable for effectively earthed system conforming to IS: 7098 (Pt1)1988 and its latest amendment, if any
2. APPLICABLE STANDARDS: Unless otherwise stipulated in this specification the following standards shall be applicable. (i) IS-7098-Part-I, XLPE Cable. (ii) IS- 10810/1984: Methods of test for cables. (iii) IS 8130/1984: Conductors for insulated cables. (iv) IS 10418/1982: Drums for electric cables.
(v) IS- 5831-1984: Specification for PVC Insulation and sheath of electric cables. 3. GENERAL TECHNICAL REQUIREMENT:3.1 CONDUCTOR: - Aluminium conductor used in cables shall be of stranded construction complying with the requirement to IS: 8130-1984, with latest amendments and shall be in accordance with clause-8 of IS: 7098(Part-1)1988. 3.2 INSULATION: - The conductor shall be provided with Cross Linked Polyethylene insulation applied by extrusion conforming to the requirements given in clause-9 of IS: 7098 (Pt-1)1988. The manufacturing process shall ensure that insulation shall be free from voids. The insulation shall withstand mechanical and thermal stresses under steady state and transient operative conditions. The insulation shall be so applied that it fits closely on the conductor and it shall be possible to remove it without damaging the conductor. XLPE insulation shall be suitable for 90C continuous conductor temperature and 250C under short circuit condition. The thickness of insulation of cable shall not be less than the nominal value (ti) specified in table-3 of IS:7098 PartPage
Supply of ISI marked 1100 volt grade, single core, stranded Aluminium conductor, XLPE insulated, PVC sheathed, un-armoured Cable
I/1988. The smallest of measured value of thickness of insulation shall not fall below the nominal value (ti) by more than 0.1 mm+ 0.1 ti. 3.3 CORE IDENTIFICATION:-Identification of cores, wherever applicable, shall be by using different colorings of XLPE insulation of Red, Yellow, Blue and Black Colors and shall conform to IS-7098 (Part-1)1988 to identify phase conductors. 3.4 SHEATH: - The outer sheath shall be of PVC Compound type ST-2 (conforming to the requirement of IS: 5831-1984, with latest amendments) and black in color. The outer sheath shall be applied by extrusion over the insulation. The thickness of outer sheath shall be as specified intable-8 of IS: 7098(Pt-I) 1988. Minimum thickness of outer sheath shall not fall below the nominal value (ts) by more than 0.2 mm+0.2ts. 3.5 IDENTIFICATION, PACKING & MARKING:-
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3.5.1 IDENTIFICATION: - Following marking shall also be embossed over the sheath at every three meters. (a) Cable size and Voltage Grade. (b) Word `MPPKVVCL, INDORE' & Name of Manufacturer. The embossing shall be increasive, automatic in line throughout the length of the cable and shall be legible and indelible. 3.5.2 PACKING & MARKING:(a) The cable shall be wound on a drum (refer-IS: 10418-1982) of suitable size and packed. The packing shall be robust enough for rough handling that is occasioned during transportation by Rail/Road. The ends of the cable shall be sealed by means of non-hygroscopic sealing material. (b) The Cable should carry the following information stenciled on the drum:(i) Reference to Indian Standard IS: 7098(Pt-I), (ii) Manufacturer's name or trade mark, (iii) Type of cable and voltage grade, (iv) Number of cores, (v) Nominal cross-sectional area of the conductor, (vi) Length of cable on the drum, (vii) Number of lengths on drum (if more than one), (viii) Direction of rotation of drum by means of an arrow.
(ix) Gross weight of the drum (Approx.) (x) Country of Manufacturer. (xi) Year of manufacture. (xii) Name of purchaser- MPPKVVCL, INDORE, T.S. No.
(xiii) ISI certification mark.
(c) ISI Certification Mark:- The Cable (Drum) must bear ISI certification Mark. In this connection, a certified photo copy of valid ÌSI' Marking License rights duly attested must be submitted along with the tender as documentary evidence. In absence of this, offer is liable for rejection. 3.5.3. Standard Length: - The standard length of cable shall be 500/1000 Mtrs. with Plus Minus 5% tolerance. 4.0 TESTS:Following type tests, acceptance tests and routine tests are to be carried out in accordance with IS: 7098(Part-I) 1988, with its latest amendments detailed here as under4.1.1 TYPE TESTS: - The following shall constitute type tests:Sl. No. Tests For requirement Ref. to For Test method Ref. to Part no. of IS:10810 (A) TEST ON ONDUCTOR Conductor resistance Test IS:8130-1984 5 (B) TEST FOR THICKNESS OF INSULATION AND SHEATH IS:7098 Clause 9&14 6 (C) PHYSICAL TEST FOR INSULATION: (i) Tensile Strength and elongation at break IS:7098 Table-1 7
[
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(ii) Ageing in Air Oven ---do--- 11 (iii) Hot Set test ---do--- 30 (iv) Shrinkage Test ---do--- 12 (v) Water absorption (gravimetric) ---do--- 33 (D) PHYSICAL TEST FOR OUTER SHEATH (i) Tensile Strength and elongation at break IS:5831-1984 7
Sl. No. Tests For requirement Ref. to For Test method Ref. to Part no. of IS:10810 (ii) Ageing in Air oven ---do--- 11 (iii) Loss of mass in air oven ---do--- 10 (iv) Shrinkage Test ---do--- 12 (v) Hot deformation ---do--- 15 (vi) Heat sock test ---do--- 14 (vii) Thermal stability ---do--(E) INSULATION RESISTANCE (VOLUME RESISTIVITY TEST) IS:7098 Table-1 43 (F) HIGH VOLTAGE TEST IS:7098 clause 16.2 45 (G) FLAMMABILITY TEST IS:7098 clause 16.3 53 4.2 Acceptance test: The following shall constitute acceptance tests:a. Conductor resistance test, b. Test for thickness of insulation and sheath, c. Hot set test for insulation d. Tensile strength and elongation at break of insulation and sheath, e. High voltage test, f. Insulation resistance (volume resistivity) test All the above acceptance tests will be carried out by MPPKVVCL representative as per relevant ISS at the time of material inspection for the purpose of clearing the lot offered by the bidder. Acceptance test shall be carried out in each type and size of cable, on cable drum selected at random as given in appendix A of IS:7098(Pt-1)
No. of drums No. of drums to be Permissible number in the lot taken as sample of defectives
Upto 50 2 0 51 to 100 5 0 101 to 300 13 0 301 to 500 20 1 501 and above 32 2

4.3. Routine Test: The following shall constitute routine test:(a) Conductor Resistance test, (b) High voltage test. The above routine test shall be conducted by the bidder in accordance with relevant ISS and test certificate in proof of this shall be submitted to this office along with each inspection offer. In absence of routine test certificate the inspection offer shall
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be considered as fake and all complication arising out of this shall
TECHNICAL SPECIFICATION OF UNARMOURED FLAT 1100 VOLTS L.T.PVC INSULATED TWIN FLAT CORE 2.5mm CABLE WITH ROUND ALUMINIUM CONDUCTOR YELLOW SHEATHED.
I. SCOPE: This specification covers Manufacture, testing at works, supply and delivery of unarmoured flat LT PVC insulated and PVC sheathed cables, twin core 2.5mm of H2 Grade aluminum conductor to any MPMKVVCL stores in Bhopal. II. Climatic Conditions: The unarmoured L.T. PVC cables are required to be laid outdoors either for giving power supplies to domestic and commercial consumers. The climatic conditions will be as under:a) Temperature Variation b) Relative humidity c) Altitude d) No.of tropical monsoon months e) Max. wind pressure f) Average annual rainfall g) Average thunderstorm base h) Terrain : : : : : : : : 5C to 55C Upto 95% 0 to 1000 Mtrs. 3 (Three) 150 Kg/cm 750/800mm 15 per annum. Coastal saline, desert, chemically polluted, Heavily/moderately polluted and normal atmosphere.
III. Installations: These cables are required to be laid indoor or outdoor between LT Dist. Poles and the consumers premises i.e. as LT overhead lines supported between poles and houses/shops, Commercial establishment. These cables are required to be laid overhead, hung, expose to atmosphere in a climatic condition as maintained above. IV. Applicable Standards: 1. 2. 3. 4. IS IS IS IS 1554 (Part-1) 1988 - 5831 of 1984 Re-affirmed 1991 - 8130 of 1984 " - 10810 of 1984 (Methods of test for cable) Re-affirmed 1991.
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The above standards with latest amendment/revision in force on date of tender shall be applicable. However, for type test certificates, samples submitted for type testing will have to be got tested at Govt. approved laboratory as per the IS-1554(Part-1) /1988 with latest amendment/revision as in force on the date of inviting tender. All acceptance and routine tests on offered lots shall be carried according to IS-1554(Part-1) /1988 with latest amendment revision in force on date of inviting tender during the execution or order placed and till complete supply is over. V. TECHNICAL PARTICULARS
A) GENERAL ::-
Standard Applicable Voltage rating
IS-1554(Part-1) /1988
1100 volts
B)
CURRENT RATING
::::::As per IS:3961 25 amp 21 amp 21 amp 700 C 1600C
Continuous current rating under normal condition at 40 OC ambient In ground(continuous) In duct(continuous) In air(continuous) Corresponding conductor temperature for above testing Corresponding conductor temperature S.C.Rating
C)
CONDUCTOR
Material :-Aluminum Conductor (H2) EC-Grade Standard applicable:- IS:8130/84 Solid/Stranded/Flexible:- Solid Circular/Shaped:- Round Circular Nominal Cross Sectional area:- 2.5 sq.mm Maximum cond. Resistance per K.M. at 200 C ,D.C.(stranded):- 12.100 ohm/km Number of Strand:- 1 no. D) INSULATION
Material:- Extruded PVC Type A IS:5831 Standard applicable :- IS:5831/84 Nominal thickness main :- 0.7 mm Min. volume Resistivity at 270 C :- 1X 10*13 ohm-cm Min. volume Resistivity at 700 C :- 1X 10*10 ohm-cm Colour of Insulation:- Phase Red, Neutral-Black E) OUTER SHEATH
Material: - Extruded PVC Type ST-1 Colour:- Black Standard applicable:- IS:5831/84 Nominal thickness main:- 1.0 mm
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F) G) H) I) J) K) DIMENSION OF CABLE:- 10.5 x6.4 mm Net weight of cable 100 Mtr (approx):- 5.600 kg Min. Bending radius for installation: - 8X O.D mm Normal delivery length (+/- 10% tolerance in length) :- 100 (Coil) +/- 10% Marking on cable:- SEPL 1100 V Electric Cable Core identification:- As per IS-1554(Part-1)-1988 Table 7 Clause no.11.1
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ÌSI' MARKED PVC INSULATED & PVC SHEATHED HEAVY DUTY GALVANISED SINGLE FLAT STEEL ARMOURED 3.5 CORE CABLES: 16SQ.MM,
1.0 SCOPE The specification covers the design, manufacture and testing and delivery at site of ÌSI' marked 1100-volt grade, weatherproof 3.5-core 16SQ.MM with stranded aluminium conductor, PVC Insulated, PVC sheathed Heavy duty Galvanised Single Flat steel armoured cable. APPLICABLE STANDARD All the cables shall conform to the requirements of following standards with latest amendments, if any. (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) IS: 1554(Part-I)1988 IS: 8130-1984 IS: 5831-1984 IS: 3975-1979 IS: 10810-1984 IS: 3961(Part-II) 1967 IS: 4905-1968 IS: 10418-1972 PVC Insulated (Heavy Duty) electric Cables for working voltages upto and including 1100 V. Specification for conductors for insulated electric cables. Specification for PVC Insulation and sheath of electric cables. Specification for mild steel wires, strips and taps for armouring cables. Methods of test for cables. Recommended current ratings for PVC insulated and PVC sheathed heavy duty cables. Methods for random sampling. Wooden drum for electric cables.
2.0
3.0
GENERAL TECHNICAL REQUIREMENT 3.1 CONDUCTOR Aluminium conductor used in power cables shall comply with the requirement to IS: 8130-1984 with latest amendments and shall be in accordance with clause 8.1 & 8.2 of IS: 1554 (Pt-I)/1988 with latest amendments. PVC INSULATION, FILLER & INNER SHEATH PVC Insulation and sheath used shall comply with requirement of IS: 5831-1984 with latest amendments. PVC insulation shall be suitable for continuous conductor temperature of 70C under normal operation & 160C under short circuit conditions. Insulation shall be of` Type A' PVC compound. The average thickness of insulation shall be not less than nominal value specified in Table 2 of IS: 1554(Part-I) 1988. The insulation shall be applied by extrusion so that it fits closely on the conductor and it shall be possible to remove it without damage. The smallest of the measured value of thickness of insulation shall not fall below the nominal value (ti in mm) specified in Table 2 of IS: 1554(Part-I) 1988 by more than 0.1mm+0.1ti. The filler and inner sheath shall be of unvulcanised rubber or thermoplastic material or proofed tape (for inner sheath only). Unvulcanised rubber or thermoplastic material used shall not be harder than PVC used for insulation and outer sheath. The material shall be chosen to be compatible with temperature ratings of the cable and shall have no deleterious effect on any other component of the cable. The laid-up cores shall be provided with inner sheath applied either by extrusion or wrapping. It shall be ensured that the shape is as circular as possible. The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible to remove it without damage to the insulation. The thickness of inner sheath shall be as in Table-4 of IS: 1554 (Part-I)/1988. 3.3. ARMOURING The galvanized steel wires/strips shall comply with the requirement of IS: 3975/1979 with latest amendment. Armouring shall be applied over the inner sheath. The armour wire/strips shall be
3.2
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applied as closely as practicable. A binder tape should be provided on the armour. Type of armour and its dimension and procedure for its laying and joints shall comply with the requirement of Clause-13.2, 13.3, 13.1.3 & 13.4. respectively of IS: 1554 (Pt-I)/1988. The D.C. resistance of galvanized steel wire/strips armour shall be measured and the result when corrected at 20C shall comply with approximate value given in Table-6 of IS: 1554(Pt-I)/1988. 3.4 OUTER SHEATH The outer sheath shall be of type "ST1 PVC Compound conforming to the requirements of IS: 5831/1984. The outer sheath shall be applied by extrusion over the armouring and shall be so applied that it fits closely over armouring. It shall be possible to remove it without damage to inner sheath. The colour of outer sheath shall be black. The minimum thickness of PVC outer sheath shall not fall below the nominal value (ts) specified in Table-7 of IS: 1554[Part-I]/1988 by more than 0.2 mm Plus-minus 0.2 ts. CORE INDENTIFICATION Core shall be identified by different colouring of PVC in accordance with Clause-10 of IS: 1554 (Part-I)/1988. IDENTIFICATION, PACKING & MARKING3.6.1. Manufacturer's Identification In addition to Manufacturers identification on Cable as per Clause-17.1 of IS: 1554(Part-I) following marking shall also be embossed over outer sheath at every three metre:(a) Cable size and Voltage Grade. (b) Word `M.P.M.K.V.V.C.' & `Name of Manufacturer'.
3.5
3.6
The embossing shall be increasive, automatic in line throughout the length of the Cable and shall be legible and indelible. 3.6.2 Packing & Marking:-
(a) The cable shall be wound on a drum (ref. IS: 10418-1972) of suitable size and packed. The packing shall be robust for rough handling that is occasioned during transportation by Rail/Road. The ends of the cable shall be sealed by means of non-hygroscopic sealing material. (b) The cable should carry the following information stenciled on the drum: (i) Reference to Indian Standard IS: 1554(Part-I) (ii) Manufacturer's name, brand name or trademark. (iii) Type of cable and voltage grade (iv) Number of cores (v) Nominal cross-sectional area of the conductor. (vi) Cable code (vii) Colour of cores (viii) Length of cable on the drum (ix) Number of lengths on drum (if more than one) (x) Direction of rotation of drum by means of an arrow. (xi) Approximate gross weight (xii) Running end of cable (xiii) Country of Manufacturer & (xiv) Year of manufacture. (c) ÌSI Certification Mark The Cable (Drum) must bear ÌSI' certification Mark. In this connection, a certified Photostat copy of valid ÌSI' Marking License rights duly attested must be submitted along
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with the inspection offer as Documentary evidence. In absence of 'ISI' License documents the inspection offer will not be considered. 3.6.3. Standard Length The standard length of cable shall be 250 mtrs. with plus minus 5% tolerance in case of 150 esq. and 300 sq.mm. cable and 250 mtrs./500 mtrs. with plus minus 5% tolerance in case of 70 sq.mm cable.
4.0
TESTS Following type tests, acceptance tests and routine tests are to be carried out in accordance with clause15 of IS:1554(Part-I)/1988 with its latest amendments as indicated below:4.1 TYPE TESTS: - The following shall constitute type tests:------------------------------------------------------------------------------------------------------S. Tests For requirement For Test method No. Ref. to Ref.to Part No. of IS:10810 -----------------------------------------------------------------------------------------------------(A) TEST ON CONDUCTOR:: (i) Tensile Test IS: 8130-1984 2 (ii) Wrapping Test IS: 8130-1984 3
(iii) Conductor Resistance IS: 8130-1984 5 Test -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------S. Tests For requirement For Test method No. Ref. to Ref.to Part No. of IS:10810 ------------------------------------------------------------------ -----------------------------------(B) TEST ON ARMOURING WIRES/STRIP : (i) Measurement of Dimension Table-5 of IS: 1554(Pt-I)/1988 IS: 3975-1979 ---do-----do--36
(ii) Tensile Test (iii) Elongation Test (iv) Torsion Test (For round wires only) Winding test (for strips only) Uniformity of zinc coating test
37 37 38
(v)
---do---
39
(vi)
---do---
40
(vii) Mass of zinc coating test (viii) Resistance Test
---do-----do---
41 41
(C) TEST FOR THICKNESS OF Clause 9, 12, 14 INSULATION AND SHEATH Table 2, 4 & 7 of IS: 1554(Pt-I) 1988
Page |
(D) (i) PHYSICAL TEST FOR INSULATION AND OUTER SHEATH:: Tensile Strength and elongation at break. Ageing in Air oven Shrinkage Test Hot deformation Loss of mass in air oven Heat shock test IS: 5831-1984 7
(ii) (iii) (iv) (v) (vi)
---do-----do-----do-----do-----do-----do---
11 12 15 10 14
(vii) Thermal stability
Test method as per IS: 5831-1984 shall be followed. ------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------------------------S. Tests For requirement For Test method No. Ref. to Ref.to Part No. of IS:10810 -----------------------------------------------------------------------------------------------------(E) INSULATION RESISTANCE TEST - IS: 5831/1984 43 (F) High Voltage Test. Clause 16.3 of (Water immersion test) IS: 1554(Part-I) (G) High voltage Test (at room temperature) (H) Flammability test Clause 16.2 of IS: 1554(Part-I) 45
45
4.2
Clause 16.4 of 53 IS: 1554(Part-I) ------------------------------------------------------------------------------------------------------4.1.1 The tenderers are advised to submit certified photocopy of type test certificates in respect of each size of cable tendered in this tender for type tests indicated in para 4.1 & 5.2 of the cable tested from reputed recognized Govt. Laboratory along with their offer. The above type test certificate should not be more than five years old from the due date of opening of the tender. In absence of requisite type test certificates, the offer is liable for rejection. Acceptance Tests:- The following shall constitute acceptance tests :a. Tensile Test (for aluminium) b. Wrapping Test (for aluminium) c. Conductor resistance test d. Test for thickness of insulation and sheath e. Tensile strength and elongation at break of insulation and sheath. f. Insulation resistance test g. High voltage test at Room temperature. All the above acceptance tests will be carried out by Companys /Boards representative as per relevant ISS: at the time of material inspection for the purpose of clearing the lot offered by the tenderers. Acceptance test shall be carried out in each type and size of cable. On cable drum selected at random as per following sampling plan:------------------------------------------------------------------------------------------------------No. of drums No. of drums to be Permissible number in the lot taken as sample of defectives ------------------------------------------------------------------------------------------------------Upto 50 2 0
Page |
51 to 100 5 0 101 to 300 13 0 301 to 500 20 1 501 and above 32 2 ------------------------------------------------------------------------------------------------------4.3. Routine Tests- The following shall constitute routine tests:(a) (b) Conductor Resistance test High voltage test at room temperature.
The above routine tests shall be conducted by the tenderers in accordance with relevant ISS and test certificate in proof of this shall be submitted to this office along with each inspection offer. In absence of routine test certificate the inspection offer shall be considered, as fake and all complication arising out of this shall be to the supplier's account. 5.0 OTHER IMPORTANT TECHNICAL REQUIREMENT OF TENDER 5.1 Cable shall be designed to withstand mechanical, electrical and thermal stress developed under steady state and transient operating conditions. 5.2 Additional type test for dielectric strength retention test as per clause-6-7-4 of NEMA WC-5 of IEC for all sizes of cables tendered in this tender. For this test, the tenderers have to submit certified photocopy of test certificates duly issued by a Govt. approved laboratory or Govt. recognized Test Laboratory. This test since being type test shall not be conducted at the firm's works in the pre-dispatch inspection of the material and all suppliers have to submit the type test certificate for this irrespective of the fact whether they have facility for conducting this test in their sizes of cables offered by the tenderers. Type Test Certificate The tenderers are advised to submit the certified photocopy for type test certificate in respect of all the type tests indicated in clause-4.1 and 5.2 of Technical Specification from the Govt. National Test House or any other reputed Govt. Laboratory along with the tender. In absence of non-submission of type test certificate for all the type tests, the offer is liable for rejection. The tenderers shall confirm that they will supply the material exactly for the design for which type tests have been conducted. The above type test certificates should not be more than five years old from the date of opening of tender. Inspection All the tests and inspection shall be made at the place of manufacturer unless otherwise specially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall offer all reasonable facilities to the purchaser, without charges to satisfy him that the material is being furnished in accordance with the specification. In order to ensure that quality of raw materials used during manufacturing of PVC Cables is as per requirement of IS: 1554(Pt-I)/1988, the inspecting officer shall check quality of raw material, obtain necessary invoices in proof that required quality of raw materials used are of desired quality. The purchaser has the right to have any or all types of acceptance test carried out by an independent agency whenever there is dispute regarding the quality of supply. In case the material fails to pass the test as per specification, the testing charges along with the other charges which were actually incurred for arranging the testing through independent agency shall be recovered from the supplier. In addition to this, action as deemed fit may be taken against the supplier.
5.3
5.4
Page | (DETAILED TECHNICAL SPECIFICATION AND PARTICULARS) GENERAL & TECHNICAL PARTICULARS FOR AAA CONDUCTOR
1. 2.
SCOPE:- This specification provides for the manufacture, testing before despatch, supply and delivery of ISI Marked All Aluminum Alloy (AAA) Conductors. STANDARD:- The conductor shall strictly comply with the Indian Standard Specification IS:398 (Part-IV)1994 with latest amendments unless otherwise stipulated in this specification, or any other International Standards which ensure equal or higher quality material and workmanship. MATERIAL:The conductors offered shall be of best quality and workmanship. The wires shall be smooth and free from all imperfections such as spills and splits and rolling and wire drawing defects etc. resulting in reduction in cross-sectional area over the entire length. TOLERANCE:The following tolerances shall be permitted: Tolerance on nominal diameter wires 1% (plus minus one percent). MODULUS OF ELASTICITY AND COEFFICIENT OF LINER EXPANSION: The values of the final modulus of elasticity and co-efficient of liner expansion for AAA Conductor shall be as given here under:
3. 3.1 3.2
4. (i) 5.
Item
No. of wires
Final modulus of Elasticity GN/Sq.mm. (practical) 0.6324x10+6 Kg/cm2
Coefficient of Linear expansion per oC
Density at temp. of 20oC
AAAC
23.0x10-6 (Alu. Alloy)
2.7 Kg/dm3 (Alu. Alloy)
The wires of Aluminium alloy conductor shall be of heat treated Aluminium, magnesium, silicon alloy having composition appropriate to the technical and electrical properties as specified in Table-I of IS:398(Pt-IV)/1994.
6.
JOINTS IN WIRES:- In AAA Conductors there shall be no joint in any wire of stranded conductor containing wires except those made in the base rod or wire before final drawing.
7.
STRANDING:
Page | 7.1 The wires used in manufacture of a stranded conductor before stranding, satisfy all requirements of IS: 398 (Part-IV/1994 with its latest amendments. The lay ratio of the layer shall be within the limit given under class-8 below. In all constructions, the successive layers shall have opposite directions of lay. The outermost layer being right handed, the wires in each layer shall be evenly and closely stranded. LAY RATIO:-The lay ratio (Ratio of the axial length of a complete turn of the helix formed by an individual wire in a stranded conductor to the external diameter of the helix) shall be within the limits given below :Item No. of Wires Ratio of Al. wire dia to Steel wire dia N.A. Lay ratio for Al. wire Max. 14 Min. 10
7.2
8.
Outer Aluminum AAA Conductor 9. (A) 6
Central Aluminum 1
Total 7
PACKING AND MARKING: The conductor shall be wound in non-returnable reels or drums conforming to IS:1778 1961 (Specification for Reels and Drums for bare wire) or the latest version thereof. The drums shall be marked with the following details:(a) (b) (c) (d) (e) (f) (g) (h) (i) Manufacturers name. Trade mark, if any. Drum number & identification number. Size of conductor. Number and lengths of pieces of conductor in each drum. Gross mass of the packing. Net mass of conductor ISI or relevant International standard specification mark, if any. Name and address of the consignees
10. 10.1
PACKING CONDITION:-. The reels/drums shall be of such constructions as to assure delivery of conductors free from displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that conductor surface is not dented, scratched or damaged in any way during manufacturer, transport and erection. The conductor shall be properly lagged on the drums. The conductor drum should be suitable for wheel mounting. Before reeling, the cardboard or other suitable material shall be secured to the drum and inside flanges of the drums. After reeling the conductor, the exposed surface should be wrapped with suitable soft material e.g. polythene sheet etc. across the flanges to protect the conductor from dirt, grit and damage during transportation and handling and also prevent ingress of rain water during storage/transport.
10.2
Page | 10.3 All wooden components shall be manufactured out of seasoned wood of good quality free from defect that may materially weaken the component parts of the drums. Preservatives treatment for anti-termite/anti-fungus shall be applied to the entire drum with preservatives of a quality which is not harmful to the conductor.
11.
STANDARD LENGTH AND GROSS WEIGHT OF CONDUCTOR:(i) The gross weight of each package shall not exceed the following limits, subject to a tolerance of + 10% (ten percent):(i) For Aluminium alloy conductors of sizes 22 mm2 & 34 mm2 (Squirrel & Weasel) : 1000 Kg
(ii) For Aluminium alloy conductors of sizes 55 mm2, 80 mm2 & 100 mm2 (Rabbit, Raccoon & Dog respectively
1500 Kg
(ii) The stranded length of AAA conductor shall be as under:-
SNo 1. 2. 3. 4. 5.
AAA Conductor of size 22 mm2 34 mm2 55 mm2 80 mm2 100 mm2
Code Word Squirrel Weasel Rabbit Raccoon Dog
Stranded length 2.000 KMS 2.000 KMS 1.500 KMS 1.200 KMS 1.200 KMS
12.
VARITION IN THE ORDERED QUANTITY:
Supply to each destination can vary plus/minus 3% (three percent) of the quantity as indicated in Despatch Instructions. However, variation in the total quantity supplied shall be limited to within plus minus 1% (one percent) of the ordered quantity in each size. 13. 13.1 TESTS : Samples of individual, Aluminium Alloy wires for tests shall be taken before stranding from not less than 10% of the spools/coils. If samples are taken after stranding, they shall be obtained by cutting 1.2 meters from the outer end of the finished conductor from not more than 10% of the reels. The mechanical tests shall be carried out on single wires only and not on complete conductor.
13.2
Page | 13.3 The following tests shall be carried on Aluminium Alloy wires as per detailed procedure given in IS:398(Part-IV)/1994:(a) (b) (c) (d) 13.4 14. 14.1 14.2 Breaking load test Elongation test Wrapping test Resistance test.
The rejection and re-test procedure shall be followed as stipulated in IS:398(Part-IV)/ 1994. CHECKING AND VERIFICATION OF LENGTH OF CONDUCTORS: END SEALING:- Both the ends of each length of the conductor should be properly sealed with epoxy compound/metal crimp with embossing/punching of suppliers identification (Trade Mark) and Drum Identification number on the seal. The supplier/manufacturer of Conductor should arrange for the inspection by the representative of purchaser specially authorized for this purpose. At least 5% of the total number of drums of conductors taken at random should be checked to ascertain the lengths of conductor adopting either of the following two methods:The drum along with the conductor should be weighed and six empty drums along with protective laggings & studs etc. normally used for winding the conductor should also be weighed. Net weight of the conductor should be calculated by subtracting the average weight of the six empty drums from the gross weight of the conductor and drums. Having known the weight of the conductor, the length of the conductor can be computed. In case of empty conductor drums, a check weighment of every one in ten empty drums shall also be done before the conductors are wound on the drums.
(a)
(b)
Arrangements should be made available in the works of the the conductor from one reel to another at the same time conductor so transferred by means of a meter. Percentage thus obtained and as declared by the supplier in the packing drums.
manufacturer for transferring measuring the length of the shortage if any in the length list shall be applied to all the
15.
CHECK MEASUREMENT: Where length of conductor is verified by weighment basis the determining factor will be length /weight ratio of the sample drums verified at the firms premises of the lot of which the drum under measurement at the consignees end forms a part: Wherever at the end of the consignee, length measurement machines are available conductors shall be accepted by verification of length only and where the length measurement machines are not available, conductor shall be accepted on weighment basis. In case, where the recorded weight on the drum tallies with the measured weight at consignee end, then the conductor length shall be accepted as recorded on the drum. In other cases, the determining factor will be weight/ length ratio of the sample(s) inspected at the firms premises of the lot of which the drum under measurement at the consignees end
ii
Page | forms a part. The factors of weight/length ratio shall however be made available to the consignees in the dispatch instructions itself. If such factors are not available due to some reasons, actual measurement of diameter shall be made and weight/length ratio shall be obtained for the purpose of computing length. TABLE I (A) SIZE AND PROPERTIES OF AAA CONDUCTORS
Sr. No.
Actual Area
Stranding Approximate Approximate Calculated Approximate & wire overall dia mass maximum calculated dia resistance breaking o at 20 load mm 7/2.0 7/2.5 7/3.15 7/3.81 7/4.26 mm 6.0 7.5 9.45 11.43 12.78 Kg/Km 60.16 94.00 149.20 218.26 272.86 Ohm/km 1.5410 0.9900 0.6210 0.4250 0.3390 KN 6.45 10.11 16.03 23.41 29.26
mm2 1. 2. 3. 4. 5. 22 34 55 80 100
(B) PROPERTIES OF ALUIMINIUM ALLOY WIRES USED IN THE CONSTRUCTION OF AAA CONDUCTORS Size (CodeWord) Diameter Nominal Min. Max. Gross Sectional Area of nominal dia wire 5 (mm2) 3.142 4.909 7.793 Mass Resistance 20oC Breaking load (Min.) Before stranding 8 KN 0.97 1.52 2.41 After stranding 9 KN 0.92 1.44 2.29
1 mm2 22 (Squirrel) 34 (Weasel) 55 (Rabbit)
2 (mm) 2.0 2.5 3.15
3 (mm) 1.98 2.47 3.12
4 (mm) 2.02 2.53 3.18
6 Kg/km) 8.482 13.25 21.04
7 (Ohm/Km) 10.653 6.845 4.290
Page | 80 (Raccoon) 100 (Dog) 3.81 4.26 3.77 4.22 3.85 4.30 11.400 14.250 30.78 38.48 2.938 2.345 3.52 4.40 3.34 4.18
=========
Page | TECHNICAL SPECIFICATION FOR STEEL SECTIONS AND SUPPORTS
1.0
SCOPE: This specification covers the design, manufacture, testing and delivery at our site of various steel sections (viz. Mild Steel, Angle, Channel, Flat, Bar, H-Beam and Rail Pole etc.).
2.0
STANDARDS: 2.1 Materials shall conform to the latest applicable Indian standards. In case bidders offer Steel Section and supports conforming to any other international specifications, which shall be equivalent of better that IS, the same is also acceptable.
Sl. No.
Standard No. Title
1.
IRS T-2 IRS T-18
Specification for Rail Pole (52 Kg per Meter (For Industrial use)
2.
IS : 2062 & IS 808 : 1989 IS : 12308 (Part-1 to 11) IS : 1985 :1985 & 12779 : 1989
Specification for M.S. angles, M.S. Channel, M.S. Flats and M.S. Bar Chemical and physical composition of material
3.
4.
Rolling and cutting tolerances for HT rolled steel product
3.0
LENGTH:
The materials to be supplied shall be in the following lengths:-
(i) (ii) (iii)
Rail Poles (52 Kg/Meter) H-Beams R.S. Joist
11 metres to 13 metres 8/9/11/13 metres( Required as per schedule) 8/ 9.3 metres to 11 metres ( Required as per schedule)
(iv)
G.S. Angles
Required as per schedule
Page |
(v) G.S. Channel Required as per schedule
(vi) G.S. Flat & G.S. Bar Required as per schedule Any tolerance on negative or positive side shall not be accepted.
4.0
WEIGHMENT: The consignee shall witness the weighment of Steel Sections and Supports at the time of taking delivery. The weight recorded in the Material Receipt Certificate issued by the consignees shall be final. The tenderers are exclusively responsible for any loss in transit.
WEIGHT OF STANDRED SIZES AS PER IS 808 : 1989
Sr. No. 1 2 4 5
Particulars
Size in mm
Weight Kg./ Mtr.
Remark
RS Joist RS Joist H-BEAM Channel
MB 175 x 85 x 5.8 MB125 x 70 x 5 MB 152 x 152 x 7.9 MC 75 x 40 x 4.8 MC 100 x 50 x 5.0
19.6 13.3 37.1 7.14 9.56 1.8 4.5 6.8 5.8 3.1 2.4 1.9 2.5
Angle
25 x 25 x 5 50 x 50 x 6 75 x 75 x 6 65 x 65 x 6
MS Flat
50 x 8 50x 6 40 x 6 40 x 8
5.0
TOLERANCES The dimensional and Mass tolerance of various steel section shall confirm to the appropriate positive values stipulated in the IS 1852:1985 and IS 12779:1989. It may be clearly noted that no negative values of tolerances shall be allowed.
Page |
6.0
TECHNICAL PARTICULARS:
(A) CHEMICAL COMPOSITION AND MECHANICAL PROPERTIES OF IU RAIL POLES [IRS T-12, IRS T-18 High Conductivity (only R-52) IU grade]
CHEMICAL COMPOSITION
PHYSICAL PROPERTIES Mn. Max. 0.80 1.40 840 Min 840 Min
MECHANICAL
SI Max
S Max. 0.055 0.055
P Max. 0.055 0.055
Tensile Strength Mpa
Percentage Elongation 10.00 Min 10.00 Min
0.60 0.85 OR
0.10 0.50
0.40 0.65
0.5 0.5
0.06 0.06
0.06 0.06
0.80 1.5
Note:- I.U. Rails shall comply either of one above.
(B) CHEMICAL COMPOSITION & PHYSICAL PROPERTIES OF G.S. ANGLES, G.S. CHANNEL, G.S. FLAT AND G.S. BAR CONFORMING TO IS: 2062 : 1992 & 12308 ( Part 1 to 11)
CHEMICAL COMPOSITION:-
S.No. 1. 2. 3. 4. 5.
CHEMICAL COMPOSITION C Mn S P SI
FOR Fe 410 WA GRADE 0.23% 1.5% 0.050% 0.050% 0.40% Max. Max. Max. Max. Max.
Page |
6. CE (Carbon Equivalent) 0.42% Max.
MECHANICAL PROPERTIES:1. 2. Tensile strength (Min.) Yield stress Min. for thickness / diameter < 20 mm 20-40 mm > 40 mm 3. 4. Elongation % (Min.) Bend test (internal Dia) 26 kgf/mm OR 250 N/mm 24 kgf/mm OR 240 N/mm 23 kgf/mm OR 230 N/mm 23 % Min. 3 t
2 2 2 2
42 kgf/mm or 410 N/mm
(t is the thickness of the material) It may be noted carefully that with each copy of the offer (Part-I), the following documents should invariably be enclosed:-
(i) (ii) (iii) (iv) (v)
Chemical composition of the offered materials. Tensile strength. Yield stress. Elongation. Length in metres.
7.
MARKING: It is desirable that the Bidder should put his legible identification marks on the finished materials so that there is no difficulty to identify the materials supplied by them to the Board.
8.
INSPECTION AND TEST CERTIFICATE:
The materials to be supplied will be subject to inspection and approval by the Company/Boards representative in case of Re-rollers. The firm is required to offer the finished material for inspection well in advance to this office. The finished materials shall be delivered to our consignees only after the same are inspected and approved for delivery by our Inspecting Officer / this office. It is to be noted that your are required to deliver the inspected materials approved for delivery WITHIN 21 DAYS time from the date of dispatch clearance given from this office or by inspecting officer whichever is earlier, failing which the penalty clause as mentioned above shall be applicable on such supplies which are made after one month period counted from the date of dispatch clearance given by this office / Inspecting Officer.
Page |
The BILLETS / INGOTS from which materials shall be re-rolled and supplied to us shall be of tested quality as per IS: 2830 / 6914 (Latest revision) respectively and shall be arranged from their own source. The Chemical Composition and Physical properties of the finished materials shall be as per relevant specification indicated above.
The materials shall be tested in ISI approved Laboratory of the tenderer having all facilities available for conducting all the tests as prescribed in relevant ISS. The materials shall be tested either in their ISI approved Laboratory or in any Govt. approved laboratory. The testing charges whatsoever shall be to the tenderers account. It may be mentioned here that the Board reserves right to get the materials tested at its discretion or any Laboratory at the cost of the tenderer.
The tenderers are required to specifically indicate that:-
(i)
They hold valid ISI License against respective ISS.
(ii) 9.
That the materials offered against this tender are bearing ISI certification marks. All channels, angles, flats should be galvanized as per IS:2629-1966, IS:4826-1979 with up-to-date amendment, IS 2633-1972 with upto date amendment.
======
Page |
PRESTRESSED CONCRETE POLES FOR 33 KV LINES ( M P E B APPROVED & REC APPROVED)

FOREWORD Of the various types of poles being used for overhead distribution lines, PCC poles have been found to be the most economical. REC has already issued a Specification No.15/1979 for PCC poles for use on 11 KV & LT lines, which is based on the economical designs evolved by the Cement Research Institute of India now known as the National Council for Cement and Building Materials (NCBM) at the instance of REC. These designs have been widely adopted by the SEBs, which has led to substantial economy. On the demand of the SEBs, another research project was entrusted by REC to the NCBM some time back for developing suitable design of PCC poles for use on 33 KV lines. The basic design parameters for these poles, as given in Clause 6, were finalised in a meeting convened by the REC with the representatives of the SEBs and NCBM. Based on these design parameters and the relevant provisions of the Indian Standards cited in Clause 2, designs were evolved by NCBM for both Solid and Virendeel types of poles for two values of Factor of Safety, i.e. 2.5 and 2.0. Based on these designs, prototype poles were made by the NCBM and these poles were found to withstand the load tests satisfactorily. The designs evolved by the NCBM were discussed in Seventh meeting of the Standardization Committee held in April, 1982 and the Committee approved the standardisation of only virendeel type of poles with FOS 2.0 in the interest of economy and light weight. This specification was drawn up on the basis of the economical designs developed by the NCBM which were approved by the Tenth Standardisation Conference held in April 1983. This Specification was further reviewed in the 12 Standardisation Conference held in July, 1987. Some of the SEBs expressed difficulty in casting virendeel type poles as also in transportation and erection due to higher risk of breakage. It was decided to incorporate designs of solid rectangular poles also in this Specification. This Specification has accordingly been modified and the SEBs will have the discretion to use either virendeel or solid rectangular designs depending upon their preference. 1.0 SCOPE This specification covers solid rectangular and Virendeel type PCC poles with FOS 2.0 with an overall length of 9.0 and 9.5M suitable for use in overhead 33 KV power lines. APPLICABLE STANDARDS Except when they conflict with specific requirements in this Specification, the poles shall comply with the relevant provisions made in the following Indian Standards or the latest versions thereof. a) IS: 1678-1978, Specification for prestressed concrete poles for overhead power, traction and telecommunication lines. b) IS : 2905-1966. Methods of test for concrete poles for overhead power and telecommunication lines. c) IS : 7321-1974. Code of Practice for selection, handling and erection of concrete poles for overhead power and telecommunication lines. TERMINOLOGY For the purpose of this standard, the following definitions shall apply:3.1 Average Permanent Load That fraction of the working load, which may be considered of long duration over a period of one year. Load Factor The ratio of ultimate transverse load to the transverse load at first crack.
th
2.0
3. 0
3.2
Page |
3.3 Transverse The direction of the line bisecting the angle contained by the conductor at the pole. In the case of a straight run, this will be normal to the run of the line. Transverse Load at First Crack For design, the transverse load at first crack shall be taken as not less than the value of the working load. Working Load The maximum load in the transverse direction, that is ever likely to occur, including the wind pressure on the pole. This load is assumed to act at a point 600mm below the top with the butt end of the pole planted to the required depth as intended in the design. Ultimate Failure The condition existing when the pole ceases to sustain a load increment owing to either crushing of concrete, or snapping of the prestressing tendon or permanent stretching of the steel in any part of the pole. Ultimate Transverse Load The load at which failure occurs, when it is applied at a point 600 mm below the top and perpendicular to the axis of the pole along the transverse direction with the butt end of the pole planted to the required depth as intended in the design.
3.4
3.5
3.6
3.7
4.0
APPLICATION 4.1 9.0 M Poles These poles shall be used at tangent locations of 33 KV lines using conductor formation and clearances as per REC Construction Standard M-3. The requirement of working loads of the poles in different wind pressure zones would be as per REC Construction Standard M-2, which is reproduced below:
Working load of Pole a) 200kg b) c) 300 kg 400 kg
Zone 50 kg/M 75 kg/M

2
2 2
100 kg/M
The maximum permissible spans shall be as per REC Construction Standard M-2. 4.2 in 4.3 higher be 9.5 M Poles These poles shall be used for special locations of 33 KV lines such as road crossings etc. the same wind pressure zones, as in Clause 4.1. The poles are not suitable for use in cyclone affected Coastal areas, or in areas with wind pressures than indicated in Clause 4.1. Special designs of poles would have to evolved for such areas.
Page |
5.0
MATERIAL 5.1 Cement The cement used in the manufacture of prestressed concrete poles shall be ordinary /Pozzollona/ rapid hardening portland cement conforming to IS : 269-1976 (Specification for ordinary and low heat portland cement) or IS : 8041 E-1978 (Specification for rapid hardening portland cement), or high strength ordinary portland cement conforming to IS : 8112-1976 (Specification for high strength ordinary portland cement). 5.2 Aggregates Aggregates used for the manufacture of prestressed concrete poles shall confirm to IS: 383-1970 (Specification for coarse and fine aggregates from natural sources for concrete). The nominal maximum size of aggregates shall in no case exceed 10 mm. Water Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally suitable. Admixture Admixtures should not contain Calcium Chloride or other chlorides and salts which are likely to promote corrosion of prestressing steel. Pre-stressing steel The pre-stressing steel wires, including those used asuntensioned wires (See Annex.I and II), should conform to IS : 1785(Part-I)-1983 (Specification for plain hard-drawn steel wire for prestressed concrete, Part-I cold drawn stress relieved wire)
5.3
5.4
5.5
or
IS:6003-1983 (Specification for indented wire for prestressed concrete) or the latest versions thereof. The type designs given in Annexure-I and II are for plain wires of 4 mm diameter with a 2 guaranteed ultimate strength of 175 kg/mm and for plain wires of 5 mm diameter with a guaranteed 2 ultimate strength of 160 kg/mm . 5.6 The concrete mix shall be designed to the requirements laid down for controlled concrete (also called design mix concrete) in IS : 1343-1980 (Code of practice for prestressed concrete) and IS : 456-1978 (Code of practice for plain and reinforced concrete), subject to the following special conditions: 2 a) Maximum works cube strength at 28 days should be at least 400 kg/cm . 2 b) The concrete strength at transfer should be atleast 200 kg/cm . c) The mix should contain at least 380 kg of cement per cubic meter of concrete. d) The mix should contain as low water content as is consistent with adequate workability. If it becomes necessary to add water to increase the workability, the cement content also should be raised in such a way that the original value of water cement ratio is maintained. 6.0 Design requirements The poles shall be designed for the following requirements: a) b) The poles shall be planted directly in the ground with a planting depth as per IS : 1678-1978. The working load on the poles should correspond to those that are likely to come on the pole during their service life. Designs given in Annex. I and II are for 200 kg., 300 kg. and 400 kg. applied at 0.6 M from top. The factor of safety for all these poles shall not be less than 2.0. The average permanent load shall be 40% of the working load.
c) d)
Page |
e) f) g) for h) i) j) The F.O.S. against first crack load shall be 1.0. 2 At average permanent load, permissible tensile stress in concrete shall be 30 kg/cm . 2 At the design value of first crack load, the modulus of rupture shall not exceed 53.0 kg/cm M-400 concrete. The ultimate moment capacity in the logitudinal direction should be at least one fourth of that in the transverse direction. The maximum compressive stress in concrete at the time of transfer of prestress should not exceed 0.8 times the cube strength. The concrete strength at transfer shall not be less than half the 28 days strength ensured in the 2 design, i.e. 400 x 0.5 = 200kg/cm . Dimensions and Reinforcements The cross-sectional dimensions and the details of prestressing wires should conform to the particulars given in Annexure-I and II. The provisions of holes for fixing cross-arms and other fixtures should conform to the REC standards referred to in clause 4. of this specification and in accordance with the construction practices adopted by the State Electricity Boards.
6.1
7.0
MANUFACTURE 7.1 All prestressing wires and reinforcements shall be accurately fixed as shown in drawings and maintained in position during manufacture. The untensioned reinforcement, as indicated in the drawings, should be held in position by the use of stirrups which should go round all the wires. 7.2 All wires shall be accurately stretched with uniform prestress in each wire. Each wire or a group of wires shall be anchored positively during casing. Care should be taken to see that the anchorages do not yield before the concrete attains the necessary strength. Cover The cover of concrete measured from the outside of pre-stressing tendon shall be normally 20 mm. Welding and Lapping of Steel The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire. Compacting Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical Hand compaction shall not be permitted. Curing The concrete shall be covered with a layer of sacking, canvass, hessian or similar absorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of prestress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit, the interval should depend on the atmospheric humidity and temperature. The prestressing wires shall be detensioned only after the concrete has attained the specified 2 strength at transfer (i.e. 200 kg/cm ). The cubes cast for the purpose of determining the strength at transfer should be cured, as far as possible, under conditions similar to those under which the poles are cured. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated above is reached. Thereafter the test on concrete shall be carried out as detailed in IS : 1343-1980 (Code of practice for prestressed concrete). The manufacturer shall supply, when required by the purchaser or his representative,
7.3
7.4
7.5 means. 7.6
7.7
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result of compressive test conducted in accordance with IS : 456-1978 (Code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles. If the purchaser so desires, the manufacturer shall supply cubes for test purposes and such cubes shall be tested in accordance with IS : 456-1978 (Code of practice for plain and reinforced concrete). The detensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to the poles. The rate of detensioning may be controlled by any suitable means either mechanical (screw type) or hydraulic. The poles shall not be detensioned or released by cutting the prestressing wires using flames or bar croppers while the wires are still under tension. 7.8 Separate eye-hooks or holes shall be provided for handling the transport, one each at a distance of 0.15 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided for lifting purposes, should be perpendicular to the broad face of the pole. Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack should be supported on timber sleepers located as 0.15 times the overall length, measured from the end. The timber supported in the stack should be aligned in a vertical line. Poles should be transported with their broad faces placed vertically and in such a manner that shocks are avoided. Supports should be so arranged that they are located approximately at a distance equal to 0.15 times the overall length from the ends. The erection of the pole should be carried out in such a way that the erection loads are applied so as to cause moment with respect to the major axis, i.e. the rope used for hoisting the pole should be parallel to the broader face of the pole. 7.9 Earthing 7.9.1 Earthing shall be provided by having length of 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 100mm at 250 mm from top and 150 mm below ground level. Earth wire shall not be allowed to come in contact with the prestressing wires. The possible location of earth wire for different varieties of poles has been shown in Nos. 1 to 8.
7.9.2
7.9.3 Drawing 8.0
TESTS 8.1 Transverse Strength Test 8.1.1 Poles made from ordinary portland cement shall be tested only on the completion of 28 days and poles made from rapid hardening cement only on the completion of 14 days, after the day of manufacture. 8.1.2 The poles may be tested in either horizontal or vertical position. If tested in horizontal position, provisions shall be made to compensate for the overhanging weight of the pole, for this purpose, the overhanging portion of the pole may be supported on a movable trolley or similar device. 8.1.3 The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting.
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8.1.4 Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually increased to the design value of the transverse load at first crack. The deflection at this load shall be measured. A prestressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack. The load shall then be reduced to zero and increased gradually to a load equal to the first crack load plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be repeated until the load reaches the value of 80 per cent of the minimum ultimate transverse load and thereafter increased by 5 per cent of the minimum ultimate transverse load until failure occurs. Each time the load is applied, it shall be held for 2 minutes. The load applied to prestressed concrete pole at the point of failure shall be measured to the nearest five Kilograms. The pole shall be deemed not to have passed the test if the observed ultimate transverse load is less than the design ultimate transverse load. 8.2 Measurement of Cover After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The cover of the pole shall be measured at 3 points, one within 1.8 meter from the butt end of the pole, the second within 0.6 meters from the top and the third at an intermediate point and the mean value compared with the specified value. The mean value of the measured cover should not differ by more than () 1mm from the specified cover. The individual values should not differ by more than () 3mm from the specified value. If these requirements are not met, the workmanship with reference to aligning of the end plates and prestressing wires and assembly of moulds should be improved and inspection at pre-production stage tightened suitably. 9.0 9.1 SAMPLING AND INSPECTION Scale of Sampling 9.1.1 Lot: In any batch, all poles of the same class and same dimensions shall be grouped together to constitute a lot. 9.1.1.1 Sub-lot: If the number of poles in a lot exceeds 500, the lot shall be divided into a suitable number of sub lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise of sub-lot shall be determined on the basis of performance of samples selected from it. 9.1.2 The number of poles to be selected from a lot or a sublot shall depend upon its size and shall be in accordance with Col. 1 and 2 of the following table:
SAMPLE SIZE AND CRITERION FOR CONFORMITY Clause 9.1.2, 9.2.2 & 9.3.2 Size of lot or sub-lot 1 Dimensional Requirement Sample size 2 Permissible No. of defective samples 3 No. of poles for transverse strength test 4
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Upto 100 101 to 200 201 to 300 301 to 500 10 15 20 30 1 1 2 3 * 3 4 5
* The no. of poles to be tested shall be subject to the agreement between purchaser & supplier. 9.1.3 These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the sub-lot may be arranged in a serial order and starting from any random pole, every rth pole may be included in the sample, r being the integral part of N/n where N is size of the lot or the sub-lot and n is the sample size.
9.2
Number of Tests 9.2.1 All the poles as selected in 9.1.2 shall be tested for overall length, cross-section and uprightness. The tolerance shall ()3 mm on cross sectional dimensions and 0.5 percent on uprightness. 9.2.2 The number of poles to be tested for transverse strength test shall be in accordance with Col. 4 of the above table. These poles may be selected from those already tested in 9.2.1.
9.3
Criteria for Conformity 9.3.1 A lot or sub-lot shall be considered as conforming to this specification if the conditions under 9.3.2 and 9.3.3 are satisfied. 9.3.2 The number of poles which does not satisfy the requirements of overall length, crosssection and uprightness shall not exceed the corresponding number given in Col. 3 of Table in 9.1.2. If the number of such poles exceeds the corresponding number, all poles in the lot or sub-lot shall be tested for these requirements and those not satisfying the requirements shall be rejected. 9.3.3 All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or more poles fail, twice the number of poles originally tested shall be selected from those already selected and subjected to the test. If there is no failure among these poles, the lot or the sub-lot shall be considered to have satisfied the requirements of this test.
10. 0
MARKING The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to be easily read after erection in position: a) Month and year of manufacture b) Transverse strength of pole in Kg. c) Makers serial No. and mark.
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ANNEXURE-II (REFER DRG. NO.6 TO 10)
ECONOMICAL DESIGNS FOR SOLID RECTANGULAR TYPE

PRESTRESSED CONCRETE POLES FOR 33 KV LINES FACTOR OF SAFETY =2.0 CONCTETE GRADE = M - 400 REINFORCEMENT DETAILS
OVERALL DIMENSIONS S. OVER ALL WORKING REFER BOTTOM No. LENGTH OF LOAD TO DRG. DEPTH POLE (M) (Kg.) NO. (cm)
TOP BREADTH DIAMETER OF NO. OF CONCRETE STEEL WEIGHT DEPTH (cm) PRE TENSIONED QUANTITY QUNTITY Kg./ POLE (cm) STRESSING WIRES CUBIC Mtr Kg. / POLE WIRES (mm) PER POLE (B) (K) M 6 14.5 7 8.5 8 4 9 12 10 0.176 Cubic M PER POLE 11 10.65 12 425 Kg./POLE
(L) M 1 1 2 9.0
(P) Kg. 3 200
(D) Cm 4 6
(dt.) Cm 5 31.5
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2 3 4 5 6
9.0 9.0 9.5 9.5 9.5
300 400 200 300 400
7 8 6 7 6
35.5 39.5 31.5 36.5 40.5
16.5 22.5 14.5 18.5 22.5
10.0 10.0 10.0 10.0 10.0
4 4 4 4 4
16 20 12 16 20
0.243 0.279 0.218 0.261 0.299
14.20 17.76 11.25 14.99 18.74
585 670 525 625 720
APPROVED BY MP ELECTRICITY BOARD

7 8 9.1 7 280 350 9 10 36 36 13 18.3 15 15 4 4 16 16 0.360 0.280 15.21 11.69 830 700
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MPMKVVCL,Bhopal /T.S. No.; 330; TS of Supply, Erection, Testing and Commissioning of New 11KV Addl. Bay, & LT Lines and 11/0.4 KV Distribution Substations Under RGGVY Scheme of Harda District
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PRESTRESSED CEMENT CONCRETE POLES ( F.O.S. 2.5 ) FOR 11 KV AND LT LINES ( M P E B APPROVED & REC APPROVED)
FOREWORD A research project for evolving economical designs of cement concrete poles for use on 11 KV and LT Lines was entrusted to the Cement Research Institute (CRI) of India. The basic design parameters for these poles as given in Clause 6 of this Specification were approved by the Fifth Conference on standardisation of Specifications and Construction Practices in Rural Electrification held in May, 1974. Some of these design parameters which were based on certain foreign codes/practices and certain other provisions of this Specification, although at variance with the stipulations of IS:1678 - 1960, had been adopted to achieve economy in the designs. However, these modifications have since been incorporated in the revised IS:1678 - 1978. This specification, drawn up in consultation with the CRI and ISI had been issued after approval by the Technical Committee on Standardisation in its meeting held in April,1978 and subse quently by the Eighth Conference on Standardisation, Research and Training in Rural Electrification held in February, 1979.Based on certain practical th difficulties experienced by the SEBs, some amendments to this specification were approved by the 9 & th 10 Conference on Standardisation, Technical Development and Training in Rural Electrification held in April, 1981 and April 1983 respectively. These amendments relate to provision of full length untensioned wires in lieu of part length wires, grouping of pre-stressing wires and the position of earth wire in the pole. The revised specification incorporates all these amendments. 1.0 SCOPE This Specification covers PCC poles with an overall length of 7.5 M, 8.0 M and 9.0 M suitable for use in overhead 11 KV and L.T. power lines and double pole structures for 11/0.4 KV substations. APPLICABLE STANDARDS Except when they conflict with specific requirements in this Specification, the poles shall comply with the relevant provisions made in the following Indian Standard Specifications: a) IS: 1678-1978, Specification for prestressed concrete poles for overhead power, traction and telecommunication lines. b) IS: 2905-1966. Methods of test for concrete poles for over-head power and telecommunication lines. c) IS: 7321-1974. Code of practice for selection, handling and erection of concrete poles for overhead power and telecommunication lines. 3.0 TERMINOLOGY For the purpose of this standard, the following definitions shall apply: 3.1 Average Permanent Load That fraction of the working load which may be considered of long duration over a period of one year. 3.2 Load Factor The ratio of ultimate transverse load to the transverse load at first crack. 3.3 Transverse The direction of the line bisecting the angle contained by the conductor at the pole. In the case of a straight run, this will be normal to the run of the line.
2.0
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3.4
3.5
3.6
3.7
Transverse Load at First Crack For design, the transverse load at first crack shall be taken as not less than the value of the working load. Working load The maximum load in the transverse direction, that is ever likely to occur, including the wind pressure on the pole. This load is assumed to act at a point 600 mm below the top with the butt end of the pole planted to the required depth as intended in the design. Ultimate Failure The conditions existing when the pole ceases to sustain a load increment owing to either crushing of concrete, or snapping of the prestressing tend on or permanent stretching of the steel in any part of the pole. Ultimate Transverse Load The load at which failure occurs, when it is applied at a point 600 mm below the top and perpendicular to the axis of the pole along the transverse direction with the butt end of the pole planted to the required depth as intended in the design.
4.0
APPLICATION 4.1 7.5 M and 8.0 M Poles These poles shall be used at tangent locations for 11KV and L.T. lines in wind pressure zones of 2 2 2 50 kg/M , 75 Kg/M and 100 Kg/M in accordance with REC Construction Standards referred to in the following table: Pole Line description Reference to REC Constn. Stds.
7.5M 8.0M
11KV lines without earthwire L.T. lines, horizontal A-4, B-5 formation 11KV lines with earthwire L.T. lines, vertical A-5, B-6 formation
4.2
The adoptable spans shall be as per REC Construction Standards A-8 (for 11 KV Lines) and B-8 (for L.T. Lines) 9.0 M Poles These poles shall be used for double pole structures of distribution transformer centres as per REC Construction Standards F-1 to F-4 and for special locations in 11 KV and L.T. Lines, such as road crossings etc.
5.0
MATERIALS 5.1 Cement The cement used in the manufacture of prestressed concrete poles shall be ordinary pozzollna/ rapid hardening portland cement conforming to IS: 269 - 1976 (Specification for ordinary and low heat portland cement) or IS : 8041 E-1978 (Specification for rapid hardening portland cement). 5.2 Aggregates Aggregates used for the manufacture of pre-stressed concrete poles shall conform to IS : 383 1970 (Specification for coarse and fine aggregates from natural sources for concrete). The nominal maximum size of aggregates shall in no case exceed 12 mm. 5.3 Water Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally suitable. 5.4 Admixtures
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5.5
5.6
Admixtures should not contain Calcium Chloride or other chlorides and salts which are likely to promote corrosion of pre-stressing steel. Pre-stressing Steel The pre-stressing steel wires, including those used as untensioned wires (See Annex.I), should conform to IS : 1785 (Part-I) - 1966 (Specification for plain hard-drawn steel wire for prestressed concrete. Part-I cold drawn stress relieved wire), IS: 1785 (Part-II) - 1967 (Specification for plain hard-drawn steel wire)., or IS : 6003 - 1970 (Specification for indented wire for pre-stressed concrete). The type designs given in Annexure-I are for plain wires of 4 mm 2 diameter with a guaranteed ultimate strength of 175 Kg/mm . The concrete mix shall be designed to the requirements laid down for controlled concrete (also called design mix concrete) in IS : 1343 - 1980 (Code of practice for prestressed concrete) and IS : 456 - 1978 (Code of practice for plain and reinforced concrete), subject to the following special conditions; 2 a) Minimum works cube strength at 28 days should be at least 420 Kg/cm . 2 b) The concrete strength at transfer should be at least 210Kg/cm . c) The mix should contain at least 380 Kg. of cement per cubic meter of concrete. d) The mix should contain as low water content as is consistent with adequate workability. If it becomes necessary to add water to increase the workability, the cement content also should be raised in such a way that the original value of water cement ratio is maintained.
6.0
DESIGN REQUIREMENTS The poles shall be designed for the following requirements: a) The poles shall be planted directly in the ground with a planting depth of 1.5 meters. b) The working load on the poles should correspond to those that are likely to come on the pole during their service life. Designs given in Annexure-I are for 140 Kg. and 200 Kg. Applied at 0.6 M from top. c) The factor of safety for all these poles shall not be less than 2.5. d) The average permanent load should be 40% of the working load. e) The F.O.S. against first crack load shall be 1.0. 2 f) At average permanent load, permissible tensile stress in concrete shall be 30 Kg/cm . 2 g) At the design value of first crack load, the modulus of rupture shall not exceed 55.2 kg/cm for M420 concrete. h) The ultimate moment capacity in the longitudinal direction should be at least one fourth of that in the transverse direction. i) The maximum compressive stress in concrete at the time of transfer of prestress should not exceed 0.8 times the cube strength. j) The concrete strength at transfer shall not be less than half the 28 days strength ensured in the 2 design, i.e. 420 x 0.5= 210 Kg/cm . For model check calculations on the design of poles, referred to in Annexure-I, a reference may be made to the REC Manual on Manufacturing of solid PCC poles, Part-I - Design Aspects 6.1 Dimensions and Reinforcements The cross-sectional dimensions and the details of prestressing wire should conform to the particulars given in Annexure-I. The provisions of holes for fixing cross-arms and other fixtures should conform to the REC standards referred to in clause 4 of this specification and in accordance with the construction practices adopted by the State Electricity Boards.
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7.0
MANUFACTURE 7.1 All prestressing wires and reinforcements shall be accurately fixed as shown in the drawings and maintained in position during manufacture. The untensioned reinforcement, as indicated in the drawings, should be held in position by the use of stirrups which should go round all the wires. 7.2 All wires shall be accurately stretched with uniform prestress in each wire. Each wire or group of wires shall be anchored positively during casting. Care shall be taken to see that the anchorages do not yield before the concrete attains the necessary strength. 7.3 Cover The cover of concrete measured from the outside of the prestressing tendon shall be normally 20 mm.
7.4
Welding and Lapping of Steel

The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire. Compacting Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand compaction shall not be permitted. Curing The concrete shall be covered with a layer of sacking, canvas, hessian or similar absorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of prestress. Thereafter, the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit, the interval should depend on the atmospheric humidity and temperature. The prestressing wires shall be detensioned only after the concrete has attained the specified 2 strength at transfer (i.e. 210 Kg/cm ). The cubes cast for the purpose of determining the strength at transfer should be cured, as far as possible, under conditions similar to those under which the poles are cured. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated above is reached. Thereafter the test on concrete shall be carried out as detailed in IS : 1343 - 1960 (Code of practice for prestressed concrete). The manufacturer shall supply when required by the purchaser or his representative, result of compressive test conducted in accordance with IS : 456 - 1964 (Code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles. If the purchaser so desires, the manufacturer shall supply cubes for test purposes and such cubes shall be tested in accordance with IS : 456 1964 (Code of practice for plain and reinforced concrete). The dimensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to the poles. The rate of dimensioning may be controlled by any suitable means either mechanical (screw type) or hydraulic. The poles shall not be detensioned or released by cutting the prestressing wires using flames or bar croppers while the wires are still under tension. Separate eye-hooks or holes shall be provided for handling and transport, one each at a distance of 0.15 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided for lifting purposes, should be perpendicular to the broad face of the pole. Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack should be supported on timber sleepers located at 0.15 times the overall length, measured from the end. The timber supports in the stack should be aligned in a vertical line.
7.5
7.6
7.7
7.8
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Poles should be transported with their broad faces placed vertically and in such a manner that shocks are avoided. Supports should be so arranged that they are located approx. at a distance equal to 0.15 times the overall length from the ends. The erection of the pole should be carried out in such a way that the erection loads are applied so as to cause moment with respect to the major axis. i.e. the rope used for hoisting the pole should be parallel to the broader face of the pole. 7.9 Earthing 7.9.1 Earthing shall be provided by having a length of 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 50 mm. At 250 mm from top and 150 mm below ground level. 7.9.2 The earth wire shall not be allowed to come in contact with the prestressing wires. General For further details on the process of manufacture, a reference may be made to REC Manual on Manufacturing of Solid PCC Poles Part II Manufacturing Aspects.
7.10
8.0
TESTS 8.1 Transverse Strength Test 8.1.1 Poles made from ordinary Portland cement shall be tested only on the completion of 28 days and poles made from rapid-hardening cement only on the completion of 14 days, after the day of manufacture. 8.1.2 The pole may be tested in either horizontal or vertical position. If tested in horizontal position, provisions shall be made to compensate for the overhanging weight of the pole, for this purpose the over-hanging portion of the pole may be supported on a movable trolly or similar device. 8.1.3 The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting i.e. 1.5 M. 8.1.4 Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually increased to design value of the transverse load at first crack. The deflection at this load shall be measured. A prestressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack. The load shall then be reduced to zero and increased gradually to a load equal to the first crack load plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be repeated until the load reaches the value of 80 per cent of the minimum ultimate transverse load and thereafter increased by 5 per cent of the minimum ultimate transverse load until failure occurs. Each time the load is applied, it shall be held for 2 minutes. The load applied to prestressed concrete pole at the point of failure shall be measured to the nearest five Kilograms. The pole shall be deemed not to have passed the test if the observed ultimate transverse load is less than the design ultimate transverse load. 8.2 Measurement of Cover After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The cover of the pole shall be measured at 3 points, one within 1.8 meters from the butt end of the pole, the second within 0.6 metre from the top and the third at an intermediate point and the mean value compared with the specified value.
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The mean value of the measured cover should not differ by more than()1 mm from the specified cover. The individual values should not differ by more than () 3 mm from specified value. If these requirements are not met, the workmanship with reference to aligning of the end plates and prestressing wires and assembly of moulds should be improved and inspection at preproduction stage tightened suitably. 9.0 SAMPLING AND INSPECTION 9.1 Scale of Sampling 9.1.1 Lot: In any batch, all poles of the same class and same dimensions shall be grouped together to constitute a lot. 9.1.1.1 Sub-lot: If the number of poles in a lot exceed 500, the lot shall be divided into a suitable number of sub lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise of a sub-lot shall be determined on the basis of the performance of samples selected from it. 9.1.2 The number of poles to be selected from a lot or a sub-lot shall depend upon its size and shall be in accordance with Col. 1 and 2 of the following table: SAMPLE SIZE AND CRITERION FOR CONFORMITY (Clauses 9.1.2, 9.2.2 & 9.3.2) Size of lot or Dimentional Requirement subSample Permissible No. of lot size defective samples Upto 100 101 to 200 201 to 300 301 to 500 10 15 20 30 1 1 2 3 No. of poles for transverse strength test * 3 4 5
*The number of poles to be tested shall be subject to the agreement between the purchaser and supplier 9.1.3 These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the sub-lot may be arranged in a serial order and starting from any random pole, every rth pole may be included in the sample, being the integral part of N/n where N is the size of the lot or the sub-lot and n is the sample size.
9.2
Number of Tests 9.2.1 All the poles as selected in 9.1.2 shall be tested for overall length, cross-section and uprightness. The tolerance shall be () 15 mm on overall length()3 mm on cross sectional dimensions and 0.5 per cent on uprightness. 9.2.2 The number of poles to be tested for transverse strength test shall be accordance with Col. 4 of the above table. These poles may be selected from those already tested in 9.2.1. Criteria for Conformity 9.3.1 A lot or sub-lot shall be considered as conforming to this specification if the conditions under 9.3.2 and 9.3.3 are satisfied. 9.3.2 The number of poles which does not satisfy the requirements of overall length, crosssection and uprightness shall not exceed the corresponding number given in Col. 3 of Table in 9.1.2. If the number of such poles exceeds the corresponding number, all
11KV
9.3
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9.3.3
poles in the lot or sub-lot shall be tested for these requirements and those not satisfying the requirements shall be rejected. All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or more poles fail, twice the number of poles originally tested shall be selected from those already selected and subjected to the test. If there is no failure among these poles, the lot or the sub-lot shall be considered to have satisfied the requirements of this test.
10.
MARKING The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to be easily read after erection in position. a) Month and year of manufacture b) Transverse strength of pole in Kg. c) Makers serial No. and mark
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ANNEXURE-I (REFER DRG. NO. I TO 7 )
ECONOMICAL DESIGNS FOR PRESTRESSED CONCRETE POLES

FACTOR OF SAFETY =2.5 CONCTETE GRADE = M - 420 DIAMETER OF PRESTRESSING WIRES = 4mm WITH A MINIMUM ULTIMATE TENSILESTRENGTH OF 175 Kg./mm sq.
Sr. No. LENGTH OF

POLE
LOAD
REFER TO DRG. NO.
BOTTOM DEPTH
TOP DEPTH
BREADTH
NO. OF NO. OF TENSIONED UNTENSIONED WIRES PER POLE WIRES PER POLE
LENGTH OF EACH UNTENSIONED WIRE
CONCRETE QUANTITY
STEEL QUNTITY
(L) M 1 2 3 4 5 6 7 2 7.5 7.5 8 8 9 9
(P) Kg. 3 140 200 140 200 140 200
(D) Cm 4 1 2 3 4 5 6
(dt.) Cm 5 25.5 27.5 27.5 29 27 31.5
(B)
(K) M
Cubic M PER POLE 11 0.115 0.134 0.137 0.157 0.169 0.203
Kg./POLE
6 10.5 14.5 10.5 14.5 10.5 11.5
7 8.5 8.5 9 9 10 10.5
8 8 12 8 12 10 12
9 2 2 2 2 2 2
10 4.55 3.75 4.7 3.95 4.5 4.45
12 6.81 9.61 7.24 10.25 9.76 11.54
APPROVED BY MP ELECTRICITY BOARD

MPMKVVCL,Bhopal /T.S. No.; 330; TS of Supply, Erection, Testing and Commissioning of New 11KV Addl. Bay, Distribution Substations Under RGGVY Scheme of Harda District 11KV & LT Lines and 11/0.4 KV
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140
27
10
10
10
6.35
0.148
8.5
NOTE:- UNTENSIONED WIRES OF THE GIVEN LENGTH SHOULD BE PLACED AT THE BOTTOM END OF THE POLE, AS SHOWN IN THE DRAWINGS.
MPMKVVCL,Bhopal /T.S. No.; 330; TS of Supply, Erection, Testing and Commissioning of New 11KV Addl. Bay, Distribution Substations Under RGGVY Scheme of Harda District
11KV & LT Lines and 11/0.4 KV
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MPMKVVCL,Bhopal /T.S. No.; 330; TS of Supply, Erection, Testing and Commissioning of New 11KV Addl. Bay, Lines and 11/0.4 KV Distribution Substations Under RGGVY Scheme of Harda District
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11KV & LT
268
11KV & LT
269
11KV & LT
270
11KV & LT
271
11KV & LT
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GI EARTHING PIPE
Earthing pipe should be made of 40 mm diameter 151 marked B class GI Pipe. 12 mm dia suitable holes on its circumference shall be made as per approved drawing. The pipe should be in one piece. No joints or welding would be allowed on its length. Clamps made of 50x6mm GI flat duly drilled with 12 mm size holes should be welded at the top end for connection of earth conductor.
Pipe used shall be 40mm NB diameter, 151 marked Galvanized Mild Steel Tubes continuously welded Electric Resistance Welded ERW/High Frequency Induction welded (HFIW)/Hot finished welded (HFW) type, conforming to 15554-1985 with latest amendment of MEDIUM quality (Class B).
MANUFACTURE: GI earth pipe (40 mm diameter & 3 metre long) shall be made of tubes that shall be made from tested quality steel manufactured by any approved process as follows:
a) Electric Resistance Welded (ERW). b) High Frequency Induction Welded (HFIW) and c) Hot finished Welded (HFW).
Tubes made by manual welding are not acceptable.
DIMENSIONS:
The dimensions and weights of tubes shall be in accordance with Table-I and Table-II of IS: 1239 (Part-I)/1990
with latest amendments, subject to tolerance permitted therein. Necessary 12 mm diameter holes across the circumference shall be provided as per approved drawing. Drawings shall be approved by the owner before start of the manufacturing work. The tube, earthing pipe shall be provided with 50x6mm GS clamps on one end, one clamp is to be welded with the pipe and another is removable to enable measurement of earth resistance of the pit. Other end of the earth pipe should be cut half in slop to make it a sharp.
GALVANIZING: Tubes shall be galvanized in accordance with 15-4736-1986 with latest amendment for not dip zinc coating of Mild Steel Tubes. The minimum mass of zinc coating on the tubes shall be in accordance with clause 5.1 of 15-4736-1986 (specification for hot dip zinc) and when determined on a 100mm long test piece in accordance with IS: 6745:1972 shall be 400 g/m2. The zinc coating shall be uniform adherent reasonably smooth and free from such imperfections as flux,
MPMKVVCL,Bhopal /T.S. No.; 330; TS of Supply, Erection, Testing and Commissioning of New 11KV Addl. Bay, Lines and 11/0.4 KV Distribution Substations Under RGGVY Scheme of Harda District 11KV & LT
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ash and dross inclusions, bare patches, black spots, pimples, lumpiness, rust, stains, bulky white deposits and blisters.
HYDRAULIC TEST: (Before applying holes) Each tube shall withstand a test pressure of 5 M Pa maintained for at least 3 seconds without showing defects of any kind. The pressure shall be applied by approved means and maintained sufficiently long for proof and inspection. The testing apparatus shall be fitted with an accurate pressure indicator.
TEST ON FINISHED TUBES AND SOCKETS: The following tests shall be conducted by the manufacturer of finished tubes and sockets.
1.
The tensile strength of length of strip cut from selected tubes when tested in accordance with 15-18941972, (Method for tensile testing of steel tubes), shall be at least 320N/mm2.
2. The elongation percentage on a gauge length of 5.65/so (where so is the original cross-sectional area of test specimen) shall not be less than 20%. 3. When tested in accordance with 15-2329-1985 (Method for Bend test on Metallic tubes) the finished tube shall be capable of with standing the bend test without showing any sign of fracture or failure. Welded tubes shall be bent with the weld at 90 degree to the plane of bending. The tubes shall not be filled for this test.
4. Galvanized tubes shall be capable of being bent cold without cracking of the steel, through 90 degree round a former having a radius at the bottom of the groove equal to 8 times the outside diameter of tube.
5.
Flattening Test on Tubes above 50 mm Nominal Bore: Rings not less than 40 mm in length cut from the ends of selected tubes shall be flattered between parallel plates with the weld, if any, at 90 degree (point of maximum bending) in accordance with 15-2328-1983. No opening should occur by fracture in the weld unless the distance between the plate is less than 75 percent of the original outside diameter of the pipe and no cracks or breaks in the metal elsewhere than in the weld shall occur, unless the distance between the plates is less than 60% of the original outside diameter. The test rings may have the inner and outer edges rounded.
6. GALVANISHING TEST:
Weight of zinc Coating: For tubes thickness upto 6 mm the minimum weight of zinc coating, when determined on a 100 mm long test piece in accordance with 15-4736-1986 shall be 400 grm/m2. . The weight of the coating expressed in gram/m2 shall be calculated by dividing the total weight of the zinc (inside plus outside) by the total area (inside plus outside) of the coated surface. Test specimen for this test shall be cut approximately 100 mm in length from opposite ends of the length of tubes selected for testing. Before cutting the test specimen, 50 mm from both ends of the samples shall be discarded.
7. Free Bore Test: A rod 230mm long and of appropriate diameter shall be passed through relevant nominal bore of
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the sample tubes to ensure a free bore. 8. Uniformity of Galvanized Coating: The galvanized coating when determined on a 100 mm long test piece[see V (a) (iii)] in accordance with 15-2633-1986 (Method for testing uniformity of coating on zinc coated articles) shall with stand 4 one minute dips.
WORKMANSHIP: The tubes shall be cleanly finished and reasonably free from injurious defects. They shall be reasonably straight, free from cracks, surface flaws, laminations, and other defects, both internally and externally. The screw tubes and sockets shall be clean and well cut. The ends shall be cut cleanly and square with the axis of tube.
MARKING
1. The medium class of tubes shall be distinguished by Blue colour bands which shall be applied before the tubes leaves the manufacturers' works. 2. Tubes shall be marked with the standard mark.
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EARTHING
(AS PER IS 3043-1987)
Earthing shall generally be carried out in accordance with the requirements of Indian Electricity Rules 1956 amended from time to time and relevant regulations under Electricity Supply Authority concerned.
In case of high and extra high voltages, the neutral points shall be earthed by not less than two separate distinct connections with earth, each having its own electrodes at the generating station or sub-station and will be earthed at any other point provides no interference is caused by such earthing. If necessary, the neutral may be earthed through suitable impedance.
As far as possible, all earth connections should be visible for inspection. Each earthing system shall be so designed, that, the testing of individual earth electrodes is possible. It is recommended that the value of any earth system resistance shall be such as to conform to the degree of shock protection desired.
It is recommended, that a drawing showing the main earth connections and earth electrodes be prepared for each installation.
No addition to the current carrying system, either temporary or permanent, shall be made which will increase the maximum available fault current on its duration until it has been ascertained that the existing arrangement of earth electrodes, earth bus-bar etc., are capable of carrying the new value of earth fault current which may be obtained by this addition.
All materials, fittings etc., used in earthing shall conform to Indian Standard Specifications, wherever they exist.
GENERAL REQUIREMENTS AND PROCEDURES FOR EARTHING AT SUB-STATIONS.
The ground resistance for sub-stations should not exceed a value 2(two) ohms. The joints/connections in the earthling, system shall be welded only, except the connections, which require opening for testing/maintenance. Such connections should be bolted tightly, using spring and ring washers for proper contact pressure. The G.S. flats to be provided for the horizontally laid earth grid should have overlap welded joints, with length of welding at least twice the width of the flat, e.g., 100 MM for 50x6 MM G.S. flats. There should not be any dirt, grease, oil, enamel, paint or any such nonconductive coatings on the surfaces being joined/ connected. Only the finished joints/connections above ground may be
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provided with red-oxide or any other protective coating. Underground earth electrodes and earth grid elements, when laid, should have a clean metallic surface, free from paint, enamel, grease or any such non-conductive coatings.
As far as possible, all earth connections should be accessible for visual inspection. No cut-outs, links or switches, other than linked switches arranged to operate simultaneously on the earthed or earthed neutral conductor and the live wire shall be inserted in the supply system. Earth electrodes or mate should not be installed in close proximity to metal fence to avoid possibility of fence becoming live. Separate earth electrodes, isolated from the earth grid, are to be provided for grounding the fence wires.
Pipes & rods used as electrodes should be in one piece, as far as possible, with a minimum allowable length of 3 mtrs. Except where rock or hard stratum is encountered, the pipe/rod electrodes should be driven into the ground to a minimum depth of 3 mtrs. The strip electrodes, forming the horizontal gild, should be buried underground to a minimum depth of 0.5 mtrs. The path of earth wire should be out of normal reach of any person, as far as possible.
For high receptivity soils, above 100 Ohm-mtrs., attempts should be made to bring the soil resistively in the range of 50 to 60 Ohm-mtrs. By digging and treating the soil mass around the earth grid/electrodes with a mixture of salt and charcoal.
In case of rocky top soil and sub-stratum, having very high resistively, with no scope of improvement by other means, the procedure given below should be followed, straightly carefully and invariably: -
1. At least two bores of diameter little less than 40 mm, with a minimum distance of 10 mtrs. between them, should be made in the ground at suitable locations inside the S/S yard. The boring should be cons until soil sub-stratum rich in moisture and low in resistively is encountered. G.I. pipes of 40 MM dia. should be descended in each bore, such that, the soil mass around the pipes grips them tightly, Back filling of bores, if required, with wet soil/clay may be cone to ensure this condition. The G.I. pipes in these deep bores should be interconnected with the main earthing grid of the S/S through 50x6 mm G.S. flat, with all the joints/connections and terminations being either fully welded, or clamped/bolted and welded simultaneously. The G.I. pipes in the bores should also be interconnected with each other. In extreme cases, the bores may have to be made at remote locations i.e. outside the S/S yard, with interconnections, through 50x6 MM flats, as explained before.
2. The procedures to be observed stringently for making connections and joints between various elements of the earthing system are as follows:
a.
G.S. flat to Structure/flat the G.S. flat should be welded to the metallic portion (leg) of the structure after thoroughly cleaning the surfaces to be welded. The length of the welding should be at least twice the width of the G.S. flat, e.g.-minimum 100 mm for 50x6 mm G.S. flat. Exactly similar procedure is to be adopted for joints between two G.S. flats.
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b.
G.I. wire to structure. The G.I. wire should be bolted to the structure after making an eye formation and kept tight with the help of spring and ring washer. Then, the entire arrangement should be welded.
c.
G.I. wire to G.S. flat- The G.I. wire rod should be bolted and then welded to G.S. flat, as explained above.
d.
G.I. rod to G.S. flat- The G.I. rod should be securely clamped to the G.S. flat with the help of bolts and washers and the entire arrangement should then be welded.
e.
G.I. wire to G.I. pipe wire should be bolted to the G.I. pipe and then welded, keeping in view the relevant precautions, mentioned before.
f.
G.I. fist to G.I pipe the G.I. The GI flat should be bolted tightly to the G.I. pipe and then the connection should be welded.
Before making connections and joints, it should be ensured that, the elements to be joined have a clean metallic contact surface without any non-conductive coating.
Earth Grid System
Grid system of interconnected conductors forming a closed loop mesh is to be installed using 50x6 mm GS flat for peripheral and branch conductors. Interconnections are made by welding them. This earth grid will be laid at a depth of about 0.5 mtr. bonded to general mass of the earth by 3 mtrs. long earth electrode of GI rod (or pipe) of dia 40mm. The G.I. pipe 40 mm. dia 3 mtrs. long in the earthing pits, driven vertically.
It is to this earth grid that the transformer neutral, apparatus, frame work and other non-current carrying metal work associated like transformer tank switchgear frame etc. are to be connected. All these connections should be made in such a way that reliable and good electrical connection is ensured. Aluminum/ other paint, enamel, grease and scale should be removed from the point of contact before connections are made. No part of the ground connection leads should be embedded in concrete.
Arrangement of connection of earth connection shall be as follow:
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1. Structures: Structures including frames, metal supports within the substation grid at least two legs, preferably diagonally opposite (where more than two legs are provided) on each metal structure shall be connected to earth grid with GI wire of 4mm dia or 6 mm dia.
2. AB switches: The operating handle shall be connected to earth grid independent of the structure earthing or through the steel mounting structure, through 4 mm dia G.I. wire.
3. Lightning Arrestor: The bases of lightning arrestors shall be directly connected to the earth electrodes (nods) by 4 mm dia /6 mm dia. G.I. wires as short and as straight as practicable, to ensure minimum impedance. Separate earth leads should be used for L.A. in each phase. In addition there shall be as direct connections as practicable from the earthed side of the lightning arrestors to the frame of the apparatus being protected. Surge counters, could also be inserted in the circuit where lightning incidences are high, but in such cases, the lightning arrestor should be mounted on insulated base. Invariably, earth connections for lightning arrestors should be separate, and in no case should they be joined looped or meshed with other conductors. For lightning arrestors mounted near transformers, earthing connections shall be done with the earthing pits and earthing leads shall be laid clear of the tank and collars in order to avoid possible oil leakage caused by arcing. The earth connection should not pass through iron pipes, as it would increase the reactive impedance of the connection.
4. Power Transformer:
The tank of the transformer shall be directly connected to the main earth grid. In addition there shall be a separate and as direct a connection as practicable from the tank to the earth side of protecting LA using 4 mm dia /6 mm dia GI wire.
The earthing of the neutral shall be by two separate, distinct and direct connections of 50x6 mm GS flat to earth pits, which form a part of the earth grid, and shall be run clear of the tank and collars. Alternatively, stay wire 7/8 SWG or 7/10 SWG may be used with proper lugs.
The transformer track rails shall be connected to earth either independently or by bonding to tank.
5. Out door VCB:
a. At least two legs, preferably diagonally opposite of the supporting structure frame work of each circuit breaker unit shall be connected to the earth grid, through 50x6 mm G.S. flats.
6. Fencing:
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a. All metal fencing wire-mesh and fencing poles (if metallic) where provided shall be separately earthed through earth rods isolated from the main earth grid. b. Gates shall have each support post (if metallic) earthed by means of 8 SWG GI earth wire.
7. Current transformers potential transformers: The bases of the current transformers should be directly connected to the earth grid through 4 mm dia /6 mm dia G.I. wires. The base (neural side) of the P.Ts. should be directly connected to the earth grid through 4 mm dia /6 mm dia G.I. wires. Separate earth leads should be used for P.Ts. in each phase. The termination of leads on the P.T. neutral should be bolted/clamped and not welded, to facilitate opening of the earth connection for testing purposes. In addition, all bolted cover plates to which bushings are attached, should be connected to the earth grid, both in case of C.Ts. and P.Ts.
8. Cables and Supports:
9. Armoring of armored metal-sheathed cables within the station grid area shall be connected to the earth grid.
10. Substation L.T. Supply Transformer: Same as above except that the neutral earthing conductor used shall be 4 mm dia /6 mm dia G.I. wire.
11. Capacitor Banks; Same as before.
Note for drawing of earthing systems for semi- urban/rural 33/11 kV Substations:
1. The earth mat shall consist of 50x6 mm G.S. flat (200 m (47kgs.) @ 2.36 kgs./mtr.
2. The earth rods (19 nos.) shall be 3 mtrs. Long 40 mm dia GI rods driven into the ground (not to be painted enameled grease etc)
3. The earthing pits (3 nos.) shall consist of 3 mtrs. Long 40 mm GI pipes buried vertically inside the ground (not to be painted enameled grease etc.)
4. All joints in the earthing grid shall be welded only. The GS flats in the earth mat should be joined by overlap welded joints, with welding length at least twice the width (i.e. 100 mm)
5. The dimensions of individual meshes in the grid may vary slightly according to requirements of the layout but the overall area (438 sq. m. end to end dimensions and number of meshes (13 nos.) should be as per the drawings.
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6. The fencing/ gates are to be kept isolated from the main earthing grid and metallic portions of the fences gated (if having metallic support posts) are to be earthed separately using 4 nos. earth rods, as shown in the drawings.
Note for drawings of earthing system for urban 33/11 kV Substations.
1. The earth matt shall consist of 50x6 mm. MS flat (2.36 Kgs./ Mtr. laid underground to a minimum of 0.5 meters (not to be painted enameled greased etc.)
2. The earth rods (16 nos.) shall be 3 mtrs. Long, 25 mm dia GI rods driven into the ground (not to be painted, enameled greased etc.)
3. The earthing pits (3 nos.) shall consists of 3 mtrs long 40 mm GI pipes buried vertically inside the around (not to be painted enameled greased etc.)
4. All joints in the earthing grid shall be welded only. The MS flats in the earth mat should be joined by overlap welded joints, with welding length at least twice the width (i.e. 100 mm)
5. The dimensions of individual meshes in the grid may vary slightly according to requirements of the layout but the overall area (834 Sq. mtrs.) End-to-end dimensions and number of meshes (9 nos.) should be as per the drawings.
The fencing/ gates are to be kept isolated from the main earthing grid and metallic portions of the fences gated (if having metallic support posts) are to be earthed separately using 4
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GENERAL PARTICULARS AND TECHNICAL SPECIFICATION OF 11 KV & 33 KV PORCELAIN PIN INSULATORS

SCOPE:This specification covers the design, manufacture, testing, supply and delivery of 11 KV and 33 KV Porcelain Pin Insulators for use on 11 KV and 33 KV overhead power lines. 2. STANDARD:Except where they conflict with specific requirement in the specification, the Pin Insulator shall comply with the Indian Standard Specification IS:731/1971 and its amendment from time to time. The insulators conforming to any other internationally accepted standard which ensures equal or better quality than the above standard would also be acceptable. Where the material is offered according to the international standards, an English version of the specifications shall be attached with tender. ATMOSPHERIC CONDITIONS:The material offered shall be suitable for operation under the climatic conditions indicated in Clause-32 of Annexure-II General Terms and Conditions of Purchase appended with this tender specification. Reference atmospheric conditions at which insulators characteristics shall be expressed for the purpose of comparison shall be:Ambient Temperature Barometric Pressure Absolute Humidity - 20 Degree Centigrade - 1013 millibar - 11 gms of water per cubic metre corresponding to 63% relative humidity at 20 Degree Centigrade.
0 degree
3. 3.1.
3.2.
NOTE:- A pressure of 1013 millibars is equivalent to a pressure of 750 mm of Mercury at centigrade.
3.3.
Tests for the purpose of this standard shall preferably be carried out under conditions of temperature and humidity specified in IS:196-1966 (that is at a temperature of 27 2 degree centigrade and relative humidity of 65 2 percent) and at the prevailing atmospheric pressure. When this is not possible, test may be carried out under conditions naturally obtained at the time of the test. The barometric pressure, air temperature and
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humidity shall be recorded for the purpose of correction. Corrections of test voltage for atmospheric conditions is given in Appendix A of IS:731-1971. 4. 4.1. GENERAL REQUIREMENTS:The porcelain shall be sound free from defects, thoroughly vitrified and smoothly glazed. Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelain parts of the Insulators except those areas which serve as supports during firing or are left unglazed for the purpose of assembly. The design of insulators shall be such that stresses due to expansion and contraction in any part of the insulators shall not lead to deterioration. The porcelain shall not engage directly with hard metal. Cement used in the construction of the insulators shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as uniform as possible. The Thimble for 11 KV Pin Insulator should be suitable for use with Galvanized Steel Pins conforming to reference S-165 of IS:2486 (Part II) of 1989 with shank length 150 mm which is provided with a small steel head. Similarly, the thimble of 33 KV Pin Insulator should be suitable for use with 33 KV Galvanized steel pins conforming to reference L-300-N of fig. 6 with shank length of 150 mm and with large head of ISS-2486 (Part-II) of 1989. INSULATOR CHARACTERISTICS:The insulator shall have the electrical and mechanical characteristics which are given below:The test voltage of insulator shall be as under:SNo. Particulars (1) (2) (3) (4) (5) 11KV Pin Insulator 12 KV (rms) 35 KV (rms) 33 KV Pin Insulator 36 KV (rms) 75 KV (rms)
4.2.
4.3.
5.
6.
(6) (7)
(8)
Highest system voltage Wet power frequency withstand voltage test for one minute Visible discharge voltage 9 KV (rms) 27 KV (rms) Power frequency puncture withstand voltage 105 KV(rms) 180 KV (rms) Impulse withstand voltage 75 KV (peak) 170 KV (peak) (In the above standards, power frequency voltage is expressed as peak values divided by 2 and impulse voltage is expressed as peak value). The withstand and flashover voltage are referred to the reference atmospheric conditions. Mechanical Loads Type of Insulators Minimum Failing Loads (i) 11 KV Pin Insulator 5 KN (ii) 33 KV Pin Insulator 10 KN CREEPAGE DISTANCE :-
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The insulators shall have the following minimum creepage distance for a moderately polluted atmosphere :(i) 11 KV Pin Insulator 230 mm (ii) 33 KV Pin Insulator 580 mm
7.
TESTS:The insulators shall comply with the following tests as per IS-731-1971.
7.1.
TYPE TESTS:The following constitute the type tests:a. b. c. d. e. f. g. h. i. Visual Examination Verification of dimensions Visible discharge test Impulse withstand voltage tests Wet Power frequency withstand voltage test Temperature Cycle test Mechanical failing load test Puncture test Porosity test
Test certificate from recognized Govt. Lab. giving the result of type tests, made on not less than two insulators identical in all essential details with those to be supplied as per IS:731/1971 shall be enclosed with the tender. 7.2. ROUTINE TESTS:The following shall be carried out as Routine Tests:a. b. c. 7.3. Visual examination Electrical routine tests Mechanical routine test following
ACCEPTANCE TESTS:The test samples after having withstood the routine tests shall be subject to the acceptance tests in the order indicated below:a. b. c. Verification of dimensions Temperature cycle test Mechanical failing load test
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d. e. 7.4. 8.
Puncture test Porosity test
Tolerance in insulator dimensions shall be as per the relevant Indian Standards. MARKING:Each insulator shall be legibly and indelibly marked to show the followings :a. b. c. d. Name and trade mark of the manufacturer Month and year of manufacture Minimum failing load in Newtons Company Logo CMD(CZ)
Marking on porcelain shall be engraved/embossing and shall be applied before firing. 9. PACKING:-
All insulators shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail and road transport. 10. STANDARDISATION OF DIMENSIONS OF TOP AND NECK OF 11 KV PIN INSULATORS Please note that now a days Board is using preformed time for binding conductor with the Pin Insulator instead of Conventional method of binding by Aluminium binding wire and tape. The design of the preformed ties depends upon the dimensions of top and neck of 11 KV Pin Insulator. For proper gripping of the conductor with the help of preformed fittings, it has become necessary to standardize the dimensions of the insulator top and neck. Accordingly, a drawing which indicates the standardized dimensions of top and neck of 11 KV Pin Insulator is enclosed with Tender Specification. This drawing has been approved by REC, New Delhi, therefore, the tenderers are advised to offer material based on this drawing.
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33 KV PORCELAIN INSULATORS AND INSULATOR FITTINGS FOR OVERHEAD POWER LINES

1. SCOPE This specification covers the details of the porcelain insulators and insulator fittings for use on 33 KV lines in rural electric sub-transmission systems. APPLICABLE STANDARDS
2.
Unless otherwise stipulated in this Specification, the insulators shall comply with the Indian Standard Specification IS: 731-1971 and the insulator fittings with IS: 2486(Pt.I)-1971 and IS: 2486 (Pt.II)-1974 or the latest version thereof. 3.0 INSULATORS 3.1 General Requirements 3.1.1 The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. 3.1.2 Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelain parts of the insulator except those areas, which serve as supports during firing or are left unglazed for the purpose of assembly. 3.1.3 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. The porcelain shall not engage directly with hard metal. 3.1.4 Cement used in the construction of the insulator shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fittings, and its thickness shall be as uniform as possible. 3.2 Classification 3.2.1 Only Type B insulators as defined in Indian Standards shall be used. 3.2.2 The string insulators shall only be of ball and socket type. Basic Insulation Levels 3.3.1 The test voltages of the insulators shall be as under: Table (Clause 3.3.1) Visible Discharge Test KV (rms) 27 Wet Power Frequency Withstand Test KV (rms) 75 Power Frequency Puncture Withstand Test Pin KV (rms) 180 String Insulator Units KV (rms) 1.3 times the actual dry flash over voltage of the Unit. Impulse Voltage Withstand Test KV (Peak) 170
3.3
Highest System Voltage KV (rms) 36
3.3.2 3.3.3
In this specification, power frequency voltages are expressed as peak values divided by 2 and impulse voltages are expressed as peak values. The withstand and flashover voltages are referred to the Reference Atmospheric Conditions as per Indian Standard.
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3.4
Mechanical Load The insulators shall be suitable for the minimum failing load specified as under: Pin Insulator Failing Loads String Insulator Units Failing Load 45KN Recommended Pin Ball Shank Diameter 16mm
10KN 3.5
Creepage Distance The minimum creepage distance shall be as under : Highest System Voltage 1 36KV Normal and Moderately Polluted Atmosphere (Total) 2 580mm Heavily polluted Atmosphere (Total) 3 840mm
Note:
For insulator used in an approximately vertical position the values given in Col.(2) or (3) shall apply. For insulators used in an approximately horizontal position, the value given in Col.(2) shall apply but the value in Col.(3) may be reduced by as much as 20%. Tests: The insulators shall comply with the following tests as per IS: 731-1971 and latest version thereof. 3.6.1 Type Tests a) Visual examination, b) Verification of dimensions, c) Visible discharge test, d) Impulse voltage withstand test, e) Wet power-frequency voltage withstand test, f) Temperature cycle test,
g) Electro-mechanical failing load test to be carried out as per procedure described at Sub-clause 3.6.4.
3.6
h)
Mechanical failing load test (for those of Type B string insulator units to which electro mechanical failing load test (g) is not applicable) to be carried out as per procedure described at Sub-clause 3.6.4. Twenty four hours mechanical strength test (for string insulators only when specified by the purchaser. Puncture Test Porosity test and Galvanising test Thermal Mechanical Performance Test (for Strain insulators only) to be carried out as per procedure described at Sub-clause 3.6.4.
i)
j) k) l) m)
3.6.2
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3.6.3
Verification of dimensions. Temperature cycle test Twenty four hours mechanical strength test (for string insulator units only when specified by the purchaser) d) Electro-mechanical failing load test to be carried out as per procedure described at Sub-clause 3.6.4. e) Puncture test. f) Porosity test and g) Galvanising test Routine Test a) Visual examination. b) Mechanical routine test (for string insulator units only) and c) Electrical routine test (for string insulator units only) d) Hydraulic Internal Pressure test on shells for strain insulators to be carried out as per procedure described at Sub-clause 4.
a) b) c)
3.6.4
Following procedure shall be used for conducting tests on insulators:
1.0
Hydraulic Internal Pressure Test on Shells (For Disc Insulators) The test shall be carried out on 100% shells before assembly. The detail and methodology for conducting this test has been illustrated at attached Annexure 1.
2.0
Thermal Mechanical Performance Test (if applicable) Thermal Mechanical Performance Test shall be performed in accordance with IEC-383-1-1993 Clause 20 with the following modifications:
(1)
The applied mechanical load during this test shall be 70% of the rated electromechanical or mechanical value. The acceptance criteria shall be (a) X greater than or equal to R + 3S. Where X-Mean value of the individual mechanical failing load. R- Rated electro-mechanical / mechanical failing load. S-Standard deviation. (b) The minimum sample size shall be taken as 20 for disc insulator units.
(2)
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(c)
The individual electromechanical failing load shall be at least equal to the rated value. Also puncture shall not occur before the ultimate fracture.
3.0
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-Mean value of the electro-mechanical/mechanical/failing load. R-Rated electro-mechanical / mechanical failing load. S-Standard deviation. (ii) The minimum sample size shall be taken as 20 for disc insulators units. However, for larger lot size, IEC 591 shall be applicable. (iii) The individual electro-mechanical/mechanical failing load shall be at least equal to the rated value. Also electrical puncture shall not occur before the ultimate fracture.
3.7 Marking 3.7.1 Each insulator shall be legibly and indelibly marked to show the following : a) Name or trade mark of the manufacturer b) Month and year of manufacture c) Minimum failing load in Newtons d) Country of the manufacture and e) ISI Certification mark, if any. 3.7.2 Marking on porcelain shall be printed and shall be applied before firing.
3.8 Packing All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail transport. Where more than one insulator are packed in a crate, wooden separators shall be fixed between the insulators to keep individual insulators in position without movement within the crate. Disc insulators, however, may be assembled instring and packed inside a crate to prevent movement. 4.0 INSULATOR FITTINGS 4.1 Pins for Pin Insulators 4.1.1 General Requirements 4.1.1.1 The pin shall be a single piece obtained preferably by the process of forging. It shall not be made by joining, welding, shrink fitting or any other process from more than one piece of material. It shall be of good finish, free from flaws and other defects. The finish of the collar shall be such that a sharp angle between the collar and the shank is avoided.
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4.1.1.2 All ferrous pins, nuts and washer except those made of stainless steel shall be galvanised. The threads of nuts shall be cut after galvanising and shall be well oiled and greased. 4.1.2 Type & Dimensions 4.1.2.1 Pins with large steel head Type L300N as per IS: 2486 (Pt.II) having stalk length of 300 mm and shank length of 150 mm with minimum failing load of 10 KN shall be used. 4.1.2.2 The complete details of the pin are given in Fig.1. 4.1.3 Tests Insulator pins shall comply with the following tests as per IS: 2486 (pt. I). 4.1.3.1 Type Tests a) Visual examination test b) Checking of threads on heads c) Galvanising test and d) Mechanical test 4.1.3.2 Acceptance Tests a) Checking of threads on heads b) Galvanising test and c) Mechanical test 4.1.3.3 Routine Test
Visual examination
4.2 4.2.1 String Insulator Fittings General Requirements 4.2.1.1 All forgings and castings shall be of good finish and free of flaws and other defects. The edges on the outside of fittings, such as at the ball socket and holes, shall be rounded. 4.2.1.2 All parts of different fittings, which provide for interconnection, shall be made such that sufficient clearance is provided at the connection point to ensure free movement and suspension of the insulator string assembly. All ball and socket connections shall be free in this manner but care shall be taken that too much clearance between ball and socket is avoided. 4.2.1.3 All ferrous fittings and the parts other than those of stainless steel shall be galvanised. Small fittings like spring washers, nuts, etc. may be electro-galvanised.
4.2.2. Type and Dimensions 4.2.2.1 Only ball and socket type insulator sets shall be used. The nominal dimensions of the ball and sockets, ball eye and cross-arm straps are given in Fig. 2. An assembly drawing of the complete insulator string is given in Fig. 3. 4.2.2.2 Strain clamps shall be suitable for ACSR conductors 7/3.35 mm2 (50 mm2 Al. area), 7/4.09mm 2 2 (80mm Al. Area) and 6/4.72mm + 7/1.57 mm (100 mm Al. area). The ultimate strength of clamps shall not be less than 41 KN. 4.2.3 Tests String insulator fittings shall comply with the following tests as per IS: 2486 (Pt.I). 4.2.3.1 Type Tests
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a) b) c) d) e) f) g)
Slip strength test Mechanical test Electrical resistance test Heating cycle test Verification of dimensions Galvanising/Electroplating test, and Visual examination test
4.2.3.2 Acceptance Tests a) Verification of dimensions b) Galvanising/Electroplating test, and c) Mechanical tests 4.2.3.3 Routine Tests a) b) 4.2.4 Marking 4.2.4.1 The caps and clamps shall have marked on them the following: a) Name or trade mark of the manufacturer and Year of manufacture 4.3 Packing 4.3.1 For packing of GI pins, strain clamps and related hardware, double gunny bags (or wooden cases, if deemed necessary) shall be employed. The heads and threaded portions of pins and the fittings shall be properly protected against damage. The gross weight of each packing shall not normally exceed 50 Kg. Different fittings shall be packed in different bags or cases and shall be complete with their minor accessories fitted in place. All nuts shall be hand-tightened over the bolts and screwed up to the farthest point. The packages containing fittings may also be marked with the ISI certification mark. Visual examination test and Routine mechanical test
4.3.2
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TECHNICAL SPECIFICATION FOR Polymer Insulator FOR USE IN 11 kV and 33kV SYSTEM
1.0
SCOPE:: This specification covers design, manufacture, testing and supply of composite Insulators for use in the 33 KV overhead transmission lines and substations. The composite Insulators shall be of the following type:
i)
Long rod Insulators for conductors in tension application at angle/cut points. The Insulators tongue & Clevis type.
shall be of
2.0
APPLICABLE STANDARDS::
2.1
Standards:Following Indian/International Standards, which shall mean latest revision, with amendments/changes adopted and published, unless specifically stated otherwise in the Specification, shall be referred while accessing conformity of Insulators with these specifications.
2.1.1
In the event of supply of Insulators conforming to standards other than specified, the Bidder shall confirm in his bid that these standards are equivalent or better to those specified. In case of award, salient features of comparison between the standards proposed by the Bidder and those specified in this document will be provided by the Supplier to establish equivalence.
SNo.
Indian Standard Standard
Title
International Standard IEC:1109 IEC:60060-1 IEC:60120 IEC:60374
1 2 3 IS:2071 IS:2486
4 5
Definition, test methods and acceptance criteria for composite Insulators for A.C. overhead lines above 1000V. Methods of High Voltage Testing. Specification for Insulator fittings for overhead power lines with a nominal voltage greater than 1000V General Requirements and Tests Dimensional Requirements locking devices. Thermal Mechanical performance test and mechanical performance test on string Insulators units Characteristics of string Insulator units of the long rod type.
IEC:60575 IEC:60433
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SNo.
Indian Standard Standard
Title
International Standard
6 7 8 9 10 11 12 13 14 15 16 17 IS:4699 IS:8263
IS:4759 IS:2629 IS:6745 IS:3203 IS:2633
Hydrophobicity Clarification Guide. STRI guide 1.92/1 Radio interference characteristics of overhead power lines CISPRl18-2 Part 2 and high voltage equipment. Methods of RI Test of HV Insulators IEC:60437 Standard for Insulators Composite-Distribution Dead -end ANSI-C29.132type. 2000 Hot dip zinc coatings on structural steel & other allied ISO:1459 products. Recommended practice for Hot Dip galvanization for iron ISO:1461(E) and steel Determination of weight of zinc coating on zinc coated Iron ISO:1460 and steel articles. Methods of testing of local thickness of electroplated ISO:2178 coatings. Testing of Uniformity of coating of zinc coated articles. Standard specification for glass fiber standards. ASTM D 578-05 Standard specification for compositional analysis by ASTM D Thermogravimetry. 578-05 Specification for refined secondary zinc
3.0
TECHNICAL DESCRIPTION OF COMPOSITE INSULATORS::
3.1
Service condition:The polymer Insulators to be supplied shall be suitable for satisfactory continuous operation under condition s as specified below:
45oC 4oC 95% (The humidity some time approaches saturation point) (iv) Minimum relative humidity 10 % (v) Average number of dust-storm days per annum 40 days (vi) Average number of rainy days per annum 90 days (vii) Number of months of tropical monsoon conditions 3 months per annum (viii) Average annual rainfall 1250 mm (ix) Maximum wind pressure 150 Kg / Sq. mm (x) Altitude not exceeding 1000 metres o o (The limit of ambient temperature shall be 45 C peak and 35 C average over a period of 24 hours) (i) (ii) (iii) Maximum temperature of air in shed Minimum temperature of air in shed Maximum relative humidity
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3.2
Composite Insulators long rod type for tension locations:-
3.2.1
The Insulators shall be suitable for 3 , 50 Hz, effectively earthed 33kV O/H distribution system in a moderately polluted atmosphere. Long rod Insulators shall be of tongue & clevis type.
3.2.2
Bidder must be an indigenous manufacturer and supplier of composite Insulators of rating 33kV or above OR must have developed proven in house technology and manufacturing process for composite Insulators of above rating OR possess technical collaboration/ association with a manufacturer of composite Insulators of rating 33 kV or above. The Bidder shall furnish necessary evidence in support of the above along with the bid, which can be in the form of certification from the utilities concerned, or any other documents to the satisfaction of the owner.
3.2.3
Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing, projection etc, and selection in respect of polluted conditions shall be generally in accordance with the recommendation of IEC-60815/IS: 13134.
3.2.4
The size of Composite insulator, minimum creepage distance and mechanical strength along with hardware fittings shall be as follows:
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SN
Type of composite Insulator
Nominal system voltage kV (rms)
Highest system voltage kV (rms)
Visible discharge test voltage kV(rms) 27
i.
Long Rod Insulators
33
36
Wet power frequency withstand voltage kV (rms) 75
Impulse withstand voltage kV (rms)
Minimum creepage distance (mm)
Min. failing load KN
170
720
45
Pin ball shank dia meter (mm) 16
Note: Creepage distances have been considered in line with IS-13134 (which specifies 20mm/ kV for moderately polluted environment).
3.3
Dimensional Tolerance of Composite Insulators :-
The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed as follows in line with-lEC 61109: {0,04d+1.5) mm when d<300 mm, (0.025d-r-6J mm when d>3GQ mm.
Where, d being the dimensions in millimeters for diameter, length or creepage distance as the case may be,
However, no negative to f era nee shall be applicable to creepage distance.
3.4
Interchangeably:The composite Insulators including the end fitting connection shall be of standard design suitable for use with the hardware fittings of any make conforming to relevant IEC/IS standards.
3.5
Corona and Rl Performance:All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to excessive localized pressure. The insulator and metal parts shall be so designed and
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manufactured that it shall avoid local corona and not generate any radio interference be end specified limit under the operating conditions. 3.6 3.6.1 Maintenance:-
formation
The composite Insulators offered shall be suitable for use of hot line maintenance technique so that usual hot line operation can be carried out with ease, speed and safety.
4.
BASIC FEATURES::
4.1
Design and construction:The composite insulator shall have a core, housing & weather shed of insulating material and steel/aluminum alloy hardware components for attaching it to the support/conductor.
4.1.1
Core:It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass fibers and resin shall be optimized in the FRP rod. Glass fibers shall be Boron free electrically corrosion resistant (ECR) glass fiber or Boron free E-Glass and shall exhibit both high electrical integrity and high resistance to acid corrosion. The matrix of the FRP rod shall be Hydrolysis resistant. The FRP rod shall be manufactured through Pollution process. The FRP rod shall be void free.
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4.1.2
Housing (Sheath):The FRP rod shall be covered by a seamless sheath of a silicone electrometric compound or silicone alloy compound of a thickness of 3mm minimum.
It should protect the FRP rod against environmental influences, external pollution and humidity. It shall be extruded or directly molded on the core and shall have chemical bonding with the FRP rod. The strength of the bond shall be greater than the tearing strength of the polymer. Sheath material in the bulk as well as in the sealing/bonding shall be free from voids.
4.1.3
Weather sheds:The composite polymer weather sheds made of silicone electrometric compound or silicon alloy shall be firmly bonded to the sheath, vulcanized to the sheath or molded as part of the sheath and shall be free from imperfections. The weather sheds should have silicon content of minimum 30% by weight. The strength of the weather shed to sheath interface shall be greater than the tearing strength of the polymer. The interface, if any, between sheds and sheath (housing] shall be free from voids.
4.1.4
End Fittings:End fittings transmit the mechanical load to the core. They shall be made of spheroidal graphite cast Iron, malleable cast iron or forged steel or aluminum alloy. They shall be connected to the rod by means of a controlled compression technique. The gap between fitting and sheath shall be sealed by a flexible silicone electrometric compound or silicone alloy compound sealant. System of attachment of end fitting to the rod shall provide superior sealing performance between housing, i.e. seamless sheath and metal connection. The sealing must be moisture proof.
The dimensions of end fittings of Insulators shall be in accordance with the standard dimensions stated in IS: 2486 / IEC: 60120.
5. 5.1
WORKMANSHIP:: All the materials shall be of latest design and conform to the best engineering practices adopted in the high voltage field. Bidders shall offer only such Insulators as are guaranteed by them to be satisfactory and suitable for continued good service in power transmission lines.
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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.
5.3
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.
5.4
The core shall be sound and free of cracks and voids that may adversely affect the Insulators.
5.5
Weather sheds shall be uniform in quality. They shall be clean, sound, smooth and shall be free from defects and excessive flashing at parting lines.
5.6
End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings should be effectively sealed to prevent moisture ingress; effectiveness of sealing system must be supported by test documents. All surfaces of the metal parts shall be perfectly smooth with out projecting points or irregularities, which may cause corona. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly.
5.7
All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to 610 gm/Sq.m, or 87 m thickness and shall be in accordance with the requirement of IS: 4759, The zinc used for galvanizing shall be of purity 99.5% as per IS: 4699, 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 four successive dips each lasting for one H) minute duration under the standard preece test. The galvanizing shall be carried out only after any machining.
6. 6.1
EQUIPMENT MARKING:: Each insulator unit shall be legibly and indelibly marked with the following details as per IEC-61109:
(a) (b)
Month &Year of manufacture Min. failing toad/guaranteed mechanical strength in kilo Newton followed by the word 'KN' to facilitate easy identification.
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(c)
Manufacturers name/Trade mark
6.2
One 10mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on the end fitting of each composite long rod of particular strength in case of 33 kV Insulators for easy identification in case both types of Insulators are procured by the utility. The paint shall not have any deteriorating effect on the insulator performance. Following codes shall be used as identification mark:
For 45 kN long rod unit: Blue For 70 kN long rod unit: Red (Not applicable)
7. 7.1
BID DRAWINGS:: The Bidder shall furnish full description and illustration of the material offered.
7.2
The Bidder shall furnish along with the bid the outline drawing (3 copies) of each insulator unit including a cross sectional view of the long rod insulator unit. The drawing shall include but not be limited to the following information:
(a) (b) (c) (d)
Long rod diameter with manufacturing tolerances Minimum Creepage distance with positive tolerance Protected creepage distance Eccentricity of the long rod unit (i) Axial run out (ii) Radial run out Unit mechanical and electrical characteristics Size and weight tongue & clevis Weight of composite long rod unit. Materials (i) Identification mark (ii) Manufacturer's catalogue number
(e) (f) (g) (h)
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7.3
The bidder shall submit full dimensioned manufacturing insulator drawings containing all the details in four (4) copies along with copies of all the type tests.
7.4
After placement of award the Supplier shall also submit fully dimensioned insulator crate drawing for different type of Insulators for approval of the owner. TESTS AND STANDARDS:: Insulators offered shall be manufactured with the same configuration & raw materials as used in the Insulators for which design & type test reports are submitted. The manufacturer shall submit a certificate for the same. The design & type test reports submitted shall not be more than 05 years old.
8.
8.1
Design tests:Manufacturer should submit test reports for Design Tests as per IEC - 61109 (clause - 5) along with the bid. Additionally following tests shall be carried out or reports for the tests shall be submitted after award of contract: + UV test: The test shall be carried out in line with clause 7.2 of ANSI C29.13
8.2
Type Tests:The following type tests shall be conducted on a suitable number of individual insulator units, components, materials or complete strings:
The bidder shall submit type test reports as per IEC 61109 along with the bid. Additional type tests as required below shall be carried out by the manufacturer, after award of contract for which no additional charges shall be payable. In case, the tests have already been carried out, the manufacturer shall submit reports for the same.
SN 1. 2. 3. 4. ,.
Description of type test Dry lightning impulse withstand voltage test Wet power frequency test Mechanical load-time test Radio interference test
Ten procedure/standard As per IEC 61109 (clause 6.1) Ai per IEC 61 109 (clause 6,2) As per IEC 61 109 (clause 6 4) As per IEC 61109 (clause 6.4)
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5.
Recovery of Hydrophobicity test
Annexure-A This test may be repealed every 3 yrs by the manufacturer Annexure-A Or any other rest method acceptable to the owner Annexure A
6. 7.
Chemical composition test for silicon content Brittle fracture resistance test
8.2.2 It shall be the option of the owner to accept the Insulators based on type test reports submitted by the manufacturer. The owner shall be free to repeat the type test & may witness the same.
Note: The owner, for the purpose of facilitating the type tests, may ask the bidders to quote test charges separately
8.2.3
All the type test given in Clause No. 8.2 in addition to routine & acceptance test shall be carried out on insulator along with hardware fittings wherever required.
8.3 Acceptance (sample) Tests 8.3.1 For Composite Insulators
(a) (b) (c) (d) 8.4.1 Routine Tests:-
Verification of dimensions Verification of the locking system applicable) Galvanizing test Verification of the specified mechanical load
: : : :
Clause 7.2 IEC: 61109, Clause 7.3 IEC: 61 109 IS:2633/IS:6745 Clause 7.4 IEC: 611 09,
sn 1 2 3
Description Identification of marking Visual Inspection Mechanical routine test
Standard As per IEC: 61 109 Clause 8.1 As per IEC 61 109 Clause 8.2 As per IEC: 61 109 Clause 8.3
8.5
Tests During Manufacture Following tests shall also be carried out on all components as applicable
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a) b) c)
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.
8.6 8.6.1
Sample Batch for Type Testing The bidder shall offer material for sample selection for type testing only after getting Quality Assurance Programme approved by the Owner, The bidder shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. The sample foe type testing will be manufactured strictly in accordance with the Quality Assurance Programme approved by the Owner,
8.7 8.7.1
Additional Tests:The Owner reserves the right at his own expenses, for carrying out any other test(s) of reasonable nature carried out at Supplier's premises, at site, to in any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the material comply with the Specifications.
8.7.2
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 Supplier's premises or at any other test center. In case of evidence of non compliance, it shall be binding on the part of the Supplier 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,
8.8 8.8.1
Co-ordination for Testing:The Supplier shall have to co-ordinate testing of Insulators with hardware fittings to be supplied by other Supplier and shall have to guarantee overall satisfactory performance of the Insulators with the hardware fittings.
8.9 8.9.1
Quality assurance plan:The successful bidder shall submit following information to the owner:
8.9.1.1 Test certificates of the raw materials and bought out accessories.
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8.9.1.2 Statement giving list of important raw materials, their grades along with names of sub-suppliers for raw materials, fist of standards according to which the raw materials are tested. List of tests normally carried out on raw materials in presence of bidder's representative.
8.9.1.3 List of manufacturing facilities available.
8.9.1.4 Level of automation achieved and lists of areas where manual processing exists.
8.9.1.5 List of areas in manufacturing process, where stage inspections are normally carried out for quality control and details of such tests and inspections.
8.9.1.6 List of testing equipments available with the bidder for final testing of equipment along with valid calibration reports.
8.9.1.7 The manufacturer shall submit Manufacturing Quality Plan (MQP) for approval & the same shall be followed during manufacture and testing,
8.9.2
The successful bidder shall submit the routine test certificates of bought out raw materials / accessories and central excise passes for raw material at the time of inspection.
8.10
Guarantee:The Supplier of Insulators shall guarantee overall satisfactory performance of the Insulators for the period of 18 months from the date of supply.
8.11
Test Reports:-
8.11.1 At least three copies of type test reports shall be furnished. One copy shall be returned duly certified by the owner, only after which the commercial production of the concerned material shall start
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8.11.2
Copies of accepts nee test reports shall be furnished in at least three [3) copies. One copy shall be returned duly certified by the Owner, only after which the material shall be dispatched.
8.11.3
Record of routine test reports shall be maintained by the Supplier at hi^ works for periodic inspection by the Owner's representative.
8.11.4 Test certificates of test during manufacture shall be maintained by the Supplier. These shall be produced for verification as and when desired by the Owner.
9 9.1
INSPECTION:: The Owner's 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 Supplier's and sub-Supplier's works, raw materials, manufacture of the material and for conducting necessary test as detailed herein.
9.2.
The material for final inspection shall be offered by the Supplier only under packed condition. The Owner shall select samples at random from the packed lot for carrying out acceptance tests. The lot offered for inspection shall be homogeneous and shall contain Insulators manufactured in 3-4 consecutive weeks.
9.3
The Supplier 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.
9. 4
No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the owner in writing. In the later case also the material shall be dispatched only after satisfactory testing specified herein has been completed.
9.5
The acceptance of any quantity of material shall in no way relieve the Supplier of his responsibility for meeting all the requirements of the specification and shall not prevent subsequent rejection, if such materials are later found to be defective.
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10 10.1
PACKING:: Al I Insulators shall be packed in strong corrugated box of min, 7 ply duly paletted or wooden crates. The gross weight of the crates along with the material shall not normally exceed 100 Kg to avoid handling problem. The crates shall be suitable for outdoor storage under wet climate during rainy season.
10.2
The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and subsequent handling in the field.
10.3
Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent damage or deformation during transit and handling.
10.4
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/corrugated box shall have all the markings stenciled on it in indelible ink.
10.5
The bidder shall provide instructions regarding handling and storage precautions to be taken at site.
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FITTINGS FOR STRAIN INSULATORS WITH HELICALLY FORMED CONDUCTOR DEAD-ENDGRIPS 5.1 Fittings for Strain Insulators of Tongue & Clevis Type 5.1.1 The fittings shall consist of the following components: a) b) Cross arm strap conforming to IS: 2486 (Pt.II)-1989. Aluminium alloy die cast thimble-clevis for attaching to the tongue of strain insulator on one end and for accommodating the loop of the helically formed dead-end fitting at the other end in its smooth internal contour. The thimble shall be suitable for all sizes of conductors ranging from 7/2.11mm to 7/3.35mm ACSR. The thimble clevis shall be attached to the insulator by a steel cutter pin used with a non-ferrous split pin of brass or stainless steel. The thimble shall have clevis dimensions as per IS: 2486 (Pt.II)1989. Helically formed dead-end grip having a pre-fabricated loop to fit into the grooved contour of the thimble on one end and for application over the conductor at the other end. The formed fitting shall conform to the requirement of IS: 12048-1987.
c)
Note : As the helically formed fittings are made to suit specific sizes of conductors, the purchase should clearly specify the number of fittings required for each size of conductor. 5.1.2 5.2 Nominal dimensions of the T&C type insulator fittings are shown in Fig. 5.
Fittings for Strain Insulators of Ball & Socket Type 5.2.1 The fittings shall consist of the following components: a) b) c) Cross arm strap conforming to IS: 2486 (Pt.II)-1989. Forged steel ball eye for attaching the socket end of the strain insulator to the cross arm strap. Forgings shall be made of steel as per IS: 2004-1978. Aluminium alloy thimble-socket made out of permanent mould cast, high strength aluminium alloy for attaching to the strain insulator on one end and for accommodating the loop of the helically formed dead-end fittings at the other end in its smooth internal contour. The thimble-socket shall be attached to the strain insulator with the help of locking pin as per the dimensions given in IS: 2486 (Pt.II)-1989 and Helically formed dead-end grip as per clause 5.1.1(c) above.
d) 5.2.2
Nominal dimensions of the Ball & Socket type insulator fittings are shown in Fig. 6.
5.3
Tests The helically formed fitting for strain insulators shall be subjected to tests as per IS: 12048-1987. The other hardware fittings shall be tested as per IS: 2486 (Part-I).
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6.0
FITTINGS FOR STRAIN INSULATORS WITH CONVENTIONAL DEAD-END CLAMPS ALTERNATIVE TO FITTINGS COVERED IN CLAUSE 5) 6.1 Fittings for strain insulators with conventional dead-end clamps for use with tongue & clevis or ball & socket type insulators shall consist of the following components: a) b) Cross arms strap conforming to IS: 2486 (Pt.II)-1989 Dead-end clamp made of aluminium alloy to suit ACSR conductors from 7/2.11mm to 7/3.35mm. The ultimate strength of the clamp shall not be less than 3000 Kg. The shape and major dimensions of clamps suitable for B&S and T&C insulators are shown in figures 7 & 8 respectively.
6.2
TESTS The fittings shall be subjected to type, routine and acceptance tests in accordance with the stipulations of IS: 2486 (Pt.I). Note: Fittings for strain insulators as stipulated in Clause 5 are preferable to the fittings stipulated in Clause 6 both from the point of view of better quality of construction and ease of application.
7.0
PACKING 7.1 For packing of GI pins, strain clamps and related hardware, double gunny bags or wooden cases shall be used. The heads and threaded portions of pins and the fittings shall be properly protected against damage. The gross weight of the packing shall not normally exceed 50 Kg. Helically formed fittings shall be packed in cardboard / wooden boxes. Fittings for different sizes of conductors shall be packed in different boxes and shall be complete with their minor accessories fitted in place and colour codes on tags/fittings shall be marked to identify suitability for different sizes of conductors as per IS: 120481987.
7.2
8.0
INSPECTION 8.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being furnished in accordance with this specification. The purchaser has the right to have the test carried out at his own cost by an independent agency whenever there is dispute regarding the quality of supply.
8.2
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REC Specification 46/1986
G I STAY WIRES
1.0 2.0
SCOPE This Specification covers details of G.I. Stranded stay wires for use in rural distribution system. APPLICABLE STANDARDS Except when they conflict with the specific requirements of this specification, the G.I. Stranded Wires shall comply with the specific requirements of IS: 2141-1979. IS: 4826-1979 & IS: 6594-1974 or the latest versions thereof. APPLICATION AND SIZES 3.1 The G.I. stranded wires covered in this Specification are intended for use on the Overhead power line poles, distribution transformer structures etc. 3.2 The G.I. stranded wires shall be of 7/2.5mm, 7/3.15mm and 7/4.0mm standard sizes. MATERIAL The wires shall be drawn from steel made by the open hearth basic oxygen or electric furnace process and of such quality that when drawn to the size of wire specified and coated with zinc, the finished strand and the individual wires shall be of uniform quality and have the properties and characteristics as specified in this specification. The wires shall not contain Sulphur and phosphorus exceeding 0.060% each. TENSILE GRADE The wires shall be of tensile grade 4, having minimum tensile strength of 700 N/mm2 conforming to IS: 2141. GENERAL REQUIREMENTS 6.1 The outer wire of strands shall have a right-hand lay. 6.2 The lay length of wire strands shall be 12 to 18 times the strand diameter.
3.0
4.0
5.0
6.0
7.0
MINIMUM BREAKING LOAD The minimum-breaking load of the wires before and after stranding shall be as follows: No. wires const. 7(6/1) 7(6/1) 7(6/1) of Wire dia Min. breaking load of Single Min. breaking load of & (mm) wire before stranding (KN) the standard wire (KN)
2.5 3.15 4.0
3.44 5.45 8.79
22.86 36.26 58.45
8.0
CONSTRUCTION 8.1 The galvanized stay wire shall be of 7-wire construction. The wires shall be so stranded together that when an evenly distributed pull is applied at the ends of completed strand, each wire shall take an equal share of the pull. 8.2 Joints are permitted in the individual wires during stranding but such joints shall not be less than 15 metres apart in the finished strands. 8.3 The wire shall be circular and free from scale, irregularities, imperfection, flaws, splits and other defects.
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9.0
TOLERANCES A tolerance of () 2.5% on the diameter of wires before stranding shall be permitted. SAMPLING CRITERIA The sampling criteria shall be in accordance with IS: 2141. TESTS ON WIRES BEFORE MANUFACTURE The wires shall be subjected to the following tests in accordance with IS: 2141. i) Ductility Test ii) Tolerance on Wire Diameter TESTS ON COMPLETED STRAND 12.1 The completed strand shall be tested for the following tests in accordance with IS: 2141. a) Tensile and Elongation Test : The percentage elongation of the stranded wire shall not be less than 6%. b) Chemical analysis c) Galvanising Test: The Zinc Coating shall conform to Heavy Coating as laid down in IS: 4826 MARKING Each coil shall carry a metallic tag, securely attached to the inner part of the coil, bearing the following information: a) Manufacturers name or trademark b) Lot number and coil number c) Size d) Construction e) Tensile Designation f) Lay g) Coating h) Length i) Mass j) ISI certification mark, if any PACKING The wires shall be supplied in 75-100 Kg. coils. The packing should be done in accordance with the provisions of IS: 6594.
10.0
11.0
12.0
13.0
14.0
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GALVANIZED STAY SETS (16 MM & 20 MM DIA)
16MM DIA STAY SETS (GALVANIZED)
The stay sets (Line Guy set) will consist of the following components:-
ANCHOR ROD WITH ONE WASHER AND NUT: Overall length of rod should be 1800 mm to be made out of 16 mm dia GS Rod, one end threaded upto 40mm length with a pitch of 5 threads per cm and provided with one square GS washer of size 40x40x1.6mm and one GS hexagonal nut conforming to IS: 1367:1967 & IS: 1363:1967. Both washer and nut to suit threaded rod of 16mm dia. The other end of the rod to be made into a round eye having an inner dia of 40mm with best quality welding.
ANCHOR PLATE SIZE 200x200x6MM: To be made out of GS plate of 6mm thickness. The anchor plate should have at its centre 18mm dia hole.
TURN BUCKLE & EYE BOLT WITH 2 NUTS: To be made of 16mm dia GS Rod having an overall length of 450 mm, one end of the rod to be threaded upto 300 mm length with a pitch of 5 threads per cm and provided with two GS Hexagonal nuts of suitable size conforming to IS:1363:1967 & IS:1367:1967. The other end of rod shall be rounded into a circular eye of 40mm inner dia with proper and good quality welding.
BOW WITH WELDED ANGLE: To be made out of 16mm dia GS rod. The finished bow shall have an overall length of 995mm and height of 450 mm, the apex or top of the bow shall be bent at an angle of 10 R. The other end shall be welded with proper and good quality welding to a GS angle 180mm long having a dimension of 50x50x6mm. The angle shall have 3 holes of 18mm dia each.
THIMBLE: To be made on 1.5 mm thick GS sheet into a size of 75x22x40mm and shape as per standard shall be supplied.
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GALVANIZING: The complete assembly shall be hot dip galvanized.
WELDING: The minimum strength of welding provided on various components of 16mm dia stay sets shall be 3100 kg. Minimum 6 mm fillet weld or its equivalent weld area should be deposited in all positions of the job i.e. at any point of the weld length. The welding shall be conforming to relevant IS: 823/1964 or its latest amendment. Minimum length of weld to be provided at various places in the stay sets shall be indicated by the bidder. Welding if, found short in lengths as per final approved drawings shall be rejected.
THREADING: The threads on the Anchor Rod, Eye Bolt & Nuts shall be as per specification IS: 4218:1967 (ISO Metric Screw Threads). The nuts shall be conforming to the requirement of IS: 1367:1967 & have dimensions as per IS; 163:1967. The mechanical property requirement of fasteners shall conform to property clause .6 each for anchor rod & Eye bolt and property clause 4 for nuts as per IS: 1367:1967.
AVERAGE WEIGHT OF FINISHED 16MM STAY SETS 7.702 KG. (MINIMUM) (EXCLUDING NUTS THIMBLES AND WASHERS) 8.445 KG. (MAXIMUM)
20 MM DIA STAYS SETS FOR 33KV LINES (GALVANIZED)
THE STAY SET (LINE GUY SET) WILL CONSIST OF THE FOLLOWING COMPONENTS:
ANCHOR ROD WITH ONE WASHER AND NUT: Overall length of Rod should be 1800mm to be made out of 20mm dia GS Rod, one end threaded upto 40mm length with a pitch of a threads per cm. And provided with one square G.S. Washer of Size 50x50x1.6mm and one GS Hexagonal nut conforming to IS:1367:1967 & IS:1363:1967. Both washer & nut to suit the threaded rod of 20mm. The other end of the rod to be made into a round eye having an inner dia of 40mm with best quality welding. Dimensional and other details are indicated and submitted by bidders for Employers approval before start of manufacturing.
ANCHOR PLATE: Size 300x300x8mm: To be made out of G.S. Plate of8mm thickness. The anchor plate to have at its centre 22mm dia hole.
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TURN BUCKLE, EYE BOLT WITH 2 NUTS: To be made of 20mm dia G.S. Rod having an overall length of 450 mm. One end of the rod to be threaded upto 300mm length with a pitch of 4 threads per cm. The 20mm dia bolt so made shall be provided with two G.S. Hexagonal nuts of suitable size conforming to IS:1637/1967 & IS:1363/1967.
The other end of the rod shall be rounded into a circular eye of 40mm inner dia with proper and good quality of welding. Welding details are to be indicated by the bidder separately for approval.
BOW WITH WELDED CHANNEL: To be made out of 16mm dia G.S. Rod. The finished bow shall have and overall length of 995 mm ad height of 450 mm. The apex or top of the bow shall be bent at an angle of 10R. The other end shall be welded with proper and good quality welding to a G.S. Channel 200mm long having a dimension of 100x50x4.7 mm. The Channel shall have 2 holes of 18 mm dia and 22 dia hole at its centre as per drawing No.3 enclosed herewith.
THIMBLE 2 Nos.: To be made of 1.5mm thick G.S. sheet into a size of 75x22x40mm and shape as per standard.
GALVANISING: The complete assembly shall be hot dip galvanised.
WELDING: The minimum strength of welding provided on various components of 20mm dia stay sets shall be 4900 kg. Minimum 6mm filet weld or its equivalent weld area should be deposited in all positions of the job i.e. at any point of the weld length. The welding shall be conforming to relevant IS: 823/1964 or its latest amendment.
THREADING: The threads on the Anchor Rods, Eye Bolts and Nuts shall be as per specification IS: 4218:1967 (ISO Metric Screw Threads). The Nuts shall be conforming to the requirements of IS: 1367:1967 and have dimension as per IS 1363:1967. The mechanical property requirement of fasteners shall confirm to the properly clause 4.6 each for anchor rods and Eye bolt and property clause 4 for nuts as per IS: 1367:1967.
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THREADING: The threads on the Anchor Rods, Eye Bolts and Nuts shall be as per specification IS: 4218:1967 (ISO Metric Screw Threads). The Nuts shall be conforming to the requirements of IS: 1367:1967 and have dimension as per IS 1363:1967. The mechanical property requirement of fastener shall confirm to the properly clause 4.6 each for anchor rods and Eye bolt and property clause 4 for nuts as per IS: 1367:1967.
AVERAGE WEIGHT OF FINISHED 20MM STAYS SET: 14.523 KG. (MIN.) (EXCLUDING NUTS THIMBLE & WASHER): 15.569 KG. (MAX.)
TEST CERTIFICATE: The contractor shall be required to conduct testing of materials at Govt./Recognized testing laboratory during pre dispatch inspection for Tensile Load of 3100 Kg/4900 Kg. applied for one minute on the welding & maintained for one minute for 16 mm and 20 mm dia stay sets respectively.
IDENTIFICATION MARK: All stay sets should carry the identification mark of word APDRP and size of the stay set. This should be engraved on the stay plate and on stay rods to ensure proper identification of the materials.
The nuts should be of a size compatible with threaded portion of rods and there should be no play or slippage of nuts.
Welding wherever required should be perfect and should not give way after erection.
TOLERANCES: The tolerances for various components of the stay sets are indicated below subject to the condition that the average weight of finished stay sets of 16mm dia excluding nuts, thimbles and washers shall not be less than the weight specified above :-
No . 1
Item
Section Tolerances
Fabrication Tolerances
Material
Anchor Plate
6mm thick + 12.5% - 5%
200x200mm + 1%
GS plate 6mm thick
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8mm thick + 12.5% - 5% 2 Anchor Rod 16mm dia + 5% - 3%
300x300mm + 1%
GS plate 8mm thick
Length 1800mm + 0.5%
GS Round 16mm dia GS Round 16mm dia GS Round 20mm dia GS Found 20mm dia GS Round 16mm dia GS Angle GS Channel 100x50x4.7mm GS Round 16mm dia
Rounded Eye 40 mm inside dia + 3%. Threading 40mm+11% - 5 20mm dia - 2% Round Eye 40mm inside dia + 3%. Threading 40mm +11% -5% 3 Turn Buckle Bow 16 mm dia + 5% - 3% Length 180mm + 1% 50x50x6mm Channel length 200mm + 1% Length 995mm + 1% 16mm dia + 3% Length 1800mm + 0.5%
Eye Rod
Bolt
16mm dia + 5% - 3%
Length 450mm + 1% Threading 300mm + 1% Round Eye 40mm inside dia + 3%
20mm dia + 3% - 2%
Length 450mm + 1% Threading 300mm + 1% Round Eye 40mm inside dia + 3%
GS Round 20mm dia
REC Specification 57/1993
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DANGER NOTICE PLATES

FOREWORD As per provisions of IE Rules 1956, Danger Notice Plates in Hindi or English and, in addition, in the local language with the sign of skull and bones are required to be provided on power line supports and other installations. It is further stipulated in the I.E. Rules that such Notice Plates are not required to be provided on supports like PCC, tubular, wood, steel rails, etc. which cannot be climbed easily without the aid of ladder or special appliances. To adopt a uniform pattern and for helping easy procurement, a specification on Danger Notice Plates has been drawn up. This Specification was approved by the 13th Conference on Standardisation, Technical Development and Training in Rural Electrification held on 4th-6th May 1993. 1. SCOPE This Specification covers Danger Notice Plates to be displayed in accordance with rule No. 35 of Indian Electricity Rules, 1956. APPLICABLE STANDARDS Unless otherwise modified in this specification, the Danger Notice Plates shall comply with IS:2551-1982 or the latest version thereof. DIMENSIONS 3.1 Two sizes of Danger Notice Plates as follows are recommended: a) For display at 415 V installations - 200x150mm b) For display at 11 KV (or higher voltages) installations - 250x200mm 3.2 3.3 The corners of the plate shall be rounded off. The location of fixing holes as shown in Figs. 1 to 4 is provisional and can be modified to suit the requirements of the purchaser.
2.
3.
4.
LETTERINGS All letterings shall be centrally spaced. The dimensions of the letters, figures and their respective position shall be as shown in figs. 1 to 4. The size of letters in the words in each language and spacing between them shall be so chosen that these are uniformly written in the space earmarked for them. LANGUAGES 5.1 Under Rule No. 35 of Indian Electricity Rules, 1956, the Employer of every medium, high and extra high voltage installation is required to affix permanently in a conspicuous position a danger notice in Hindi or English and, in addition, in the local language, with the sign of skull and bones. 5.2 The type and size of lettering to be done in Hindi is indicated in the specimen danger notice plates shown in Fig. 2 and 4 and those in English are shown in Figs. 1 and 3. Adequate space has been provided in the specimen danger notice plates for having the letterings in local language for the equivalent of' Danger',' 415' '11000' and 'Volts'.
5.
5.3
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6.
MATERIAL AND FINISH The plate shall be made from mild steel sheet of at least 1.6mm thick and vitreous enameled white, with letters, figures and the conventional skull and cross-bones in signal red colour (refer IS: 5-1978) on the front side. The rear side of the plate shall also be enameled. TESTS The following tests shall be carried out : i) Visual examination as per IS: 2551-1982 ii) Dimensional check as per IS: 2551-1982 iii) Test for weatherproofing as per IS: 8709-1977 (or its latest version) MARKING Maker's name and trademark and the purchaser's name shall be marked in such a manner and position on the plates that it does not interfere with the other information. PACKING The plates shall be packed in wooden crates suitable for rough handling and acceptable for rail/road transport.
7.0
8.0
9.0
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ISI MARK GALVANIZED STEEL HEXAGONAL HEAD BOLTS AND NUTS
1.0
SCOPE All bolts and nuts shall have hexagonal heads, the heads being forged out of solid mild steel truly concentric, and square with the shank, which must be perfectly straight.
2.0
General requirements
2.1 Bolts up to M16 and having length upto 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 5.6 grade 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.
2.2 Nuts should be double chamfered as per the requirement of IS: 1363 Part III 1984. The manufacturer should ensure that nuts should not be over tapped beyond 0.4 mm oversize on effective diameter for size upto M16. 2.3 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.
2.4
All bolts shall be threaded to take the full depth of the nuts and threaded enough to permit firm grip of the component parts but no further. It shall be ensured that the threaded portion of the bolt protruded not less than 3 mm and not more than 8 mm when fully tightened.
2.5
All nuts shall be 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-galvanised. The thickness of washers shall conform to IS: 2016. The Bidder 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.
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2.9
Fasteners of grade higher than 8.8 are not to be used.
3.0 RAW MATERIALS MS round bare of size 16mm / 12mm to be used. These shall be tested for quality as per IS: 2062 Gr. A.
4.0
All Bolts and nuts shall conform to IS: 6639. All bolts and nuts shall be galvanised as per IS: 1367 Part 13)/IS-2629.
5.0
SPECIFICATION OF FINISHED PRODUCTS
5.1
The bolts & Nuts shall be ISI Mark Galvanized Mild Steel of shall be round with hexagonal head. The Bolts and Nuts shall be manufactured by Hot/Cold forging process neatly and cleanly finished and shall have metric threads as per IS: 4218/1967 with its latest amendments. The dimensions of the bolts & nuts and tolerances should conform to IS: 1363 with their latest amendments in all respect. The eccentricity and angular errors of various elements of various elements of further shall be within specified limits as per IS: 1367/1967 with its latest amendments. The bolts & nuts shall be free from forging and threading defects such as cuts, splits, burns, bulging, taper, eccentricity, loose fill etc. which may affect their serviceability.
5.2
5.3 The bolt heads and nuts shall be chamfered on one face only and other face shall be machined made.
5.4 Mechanical property requirement of tester shall confirm to IS: 1367 (Part-III) 1979 property class for bolts & property class-5 for nuts as per IS: 1367 (Part VI) 1980. 5.5 The bolts & nuts shall be supplied in well-cleaned conditions and suitably protected against corrosion in individual bags of 50 kgs.
6.0
TECHNICAL REQUIRMENT
SL. No.
Description
Relevant ISS with their latest amendments
Bolts & nuts guaranteed value for 16 mm (308 Mpa Min. 62 KN
Minimum shearing strength of bolts
IS-12427/1988 IS -1367/1967 with its parts
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and latest amending? 2 Ultimate tensile strength bolts (Kg/sq.mm) Value of hardness test A. For bolts: i) Rock well hardness test (HRB) ii) Brinell hardness test (HB) B. For nuts: (Vickers-hardness test) Rock weel hardness test (HRB) IS-12427/1988 IS-1367 Part-III-1979 IS-12427 /1988 IS-1367 Part VI/80 147-238 HB 79-99.5 HRB IS-1367 / 1967 IS-1367 Part-III-1979 3 51
IS-12427 / 1988 and IS-1367 Part VI / 1980 IS-1367 Part-III-1979 4 Proof load test (applied load for 15 secs.) a) Bolt Value b) Nut Value IS-1367, Part- (III) /1991 IS-1367, Part- (VI)/ 1980
130-302
71-107 HRB
4500Kgs. (44 KN) 9766 Kgs. (95.8KN)
Test for strength under wedge loading
IS-1367, Part (III) / 1991
51 Kgs. (500N/sq.mm) No fracture shall be observed during test As per ISS
Head soundness test
IS-1367, Part- (III) /1979
Designation of standard for bolts & nuts dimensions
IS-12427/1988 and IS-1363, Part I. /1984 & {Part III /1992
Designation of standard for threading dimension of bolts & nuts
IS-4218, Part- (V)/1979 IS-4218, Part- (VI)/ 1978
As per ISS
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IS-1367 Part 2 9 Designation of standard for hot dip galvanizing IS-12427 /1988 IS 1367 Part (XIII) / 1983 IS-2629/1985 IS-2633 / 1986 As per I SS
10
Designation of standard for test on bolts & nuts
IS-12427/88 IS-1363 Part-3/ 1992 IS-1367 Part-I / 1980 IS-1367 Part-II / 1979 IS-3891, 1367 Par-VI of 1980, 1367 Part-XIII of 1983, IS-2633 / 1986 IS-2629 / 1985 with Late amendment if any
As per ISS
11
Designation of standard for raw materials for bolt & nuts Guaranteed count weight for each size of bolts with nuts per 50 Kgs. i) ii) iii) Manufacturing process for 16mm Dia bolts Manufacturing process for threads of 16 mm Dia bolts Process of making nuts
IS-2062 / 1992
As per ISS
12
IS-12427 / 1988 and IS-1363 Part -3 / 1992
As Per ISS
13
IS-1367 Part-1/ 1980 IS-1367 Part- 2/1979
Cold forged
--
Rolled
Hot forging
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14
A) Process details for preparing of metal surface & galvanising
----
Alkaline degreasing rinsing acid pickling rinsing- fluxing drying galvanising Centrifuzing-cooling
B) Degreasing Alkaline chemicals/ fluxing / vapour degreasing ---C) Picking by acid
Done
D) Precaution to be taken to avoid over pickling
H2SO4 ---Add inhibitors IS-2629 / 1985
E) Fluxing details of preparing flux solution and how specific gravity is maintained
F) Process adopted for drying of bolts & nuts NH4CI and ZnCL2 Specific gravity is maintained by hydrometer
G) Temperature of bolts & nuts before galvanising
IS-2629 /1985
H) Details of the constn. of furnace and heating system. IS-2629 / 1985
Open drying on hot plate
I)
Details of the constn. of galvanising tank in meters
J) System of temperature control of Zinc bath IS-2629 / 1985
120 deg .C
K) Process adopted to remove the excess deposit of zinc from bolt threads immediately after galvanizing
Tangential heating by burners on sound pot
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-Circular tank of dia 24X 20 L) Constructional details about centrifuging / spinning equipments i) for spinning ii) Time of spinning
-Prob analysis at short intervals
M) Oversize tapping of nuts after galvanising
IS-2629/85 & other relevant IS Centrifuzing
N) Coating requirement (Testing procedure as per IS-2633/1972) i) Stripping test adopted ii) Coating weight of zinc coating in gm/sq.mtr
-Do-
--iii) Coating thickness measurement system adopted 400 30sec. Max -Do-
----Galvanizing is done on tap nuts then retapped
IS-136 Part-7 (XIII)/1983
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IS-4218, Part- (V)/ 1979 IS-4218, Part (VI)/ 1978
As per ISS
IS-1367, Part (XIII) / 1983 IS-2633 / 1986, and IS-2629 / 1985 -Do-
Yes
Min. 381 gm/m2
-Do-
Manual
-Do15 16 17 18 Property class of Hexagon bolts ----------IS-2614 - 1969 5.6 5 Cold roll threading As per ISS
Property class of Hexagon nuts

Method of threading Sampling of bolts & nuts
7.0
ACCEPTANCE TESTS
The bidder should furnish test certificate from his own/recognized Govt. Laboratory giving the results of tests as per IS: 1367 (Part-III) 1979 & IS: 1367 (Part-VI) 1980 witnessed by Boards inspecting officer for each lot under inspection. The test certificate shall be in respect of the following for all sizes of both bolts & nuts as applicable given below:-
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Dimensional particulars (Sampling in accordance with IS: 2614 for both bolts & nuts (tolerance as per drawing). Tensile strength test on full size (for bolts minimum 400 N/ Sq. mm and for Nuts Proof Stress test Min 610 N/Sq. mm). Power load test on full size bolts and M-12-51400 N for 15 Sec. Head soundness tests for bolts (no fracture). Brinell hardness tests or Rockwell Hardness or Vickerss Hardness tests for bolts min-114 & max. 209 or min. 67 & max. 95 or min. 120 & max. 220 respectively. For nuts Vickerss Hardness min. 130 & max. 302.
8.0
PRE-DESPATCH INSPECTION AND TEST
The contactor shall arrange to carryout acceptance tests in presence of Boards inspecting officer in his own laboratory. In case testing facilities are not available at his works he will make necessary arrangements for carrying out these tests at a Govt. recognized at his own expense(s) and will provide all testing arrangement for Boards representative to witness the tests.
In case of any lot for which inspections will be waived from this office, tests certificate from your end with dimensions/results strictly as per relevant clause above shall invariably be submitted to this office.
9.0
MARKINGS
On the bolt head, there shall be identification marking of the manufacturer as well as MPSEB and property class 4.6. If possible property class 5 shall be marked on Nuts also. Further ISI Mark shall be marked on Gunny Bags for proper identifications.
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TECHNICAL SPECIFICATION OF LT DISTRIBUTION BOXES (FOR 100 KVA RATINGS)

1. SCOPE: This specification covers the design, manufacture, testing before despatch, supply and delivery of 63KVA and 100KVA L.T. Distribution Boxes.
2. 2.1 CLIMATIC CONDITIONS: The climatic conditions at site under which the equipment shall operate satisfactorily are as under:1 2 3 4 5 6 7 8 9 10
Location
Maximum ambient air temp. Minimum Ambient Air Temperature Average Daily Ambient Air Temperature
In the State of Madhya Pradesh , India 50 0C (-) 1 0C 32 0C 90% Sometimes approached to saturation. 1200 mm Not more than 1000 meters (Average 200 to 600 meters) 20/50 45 0.1 g
Maximum relative humidity

Average rainfall per annum(mm) Maximum Altitude above mean sea level (meters) Isoceraunic level (Day/annum) Maximum Wind Pressure (Kg/Sq. meters) Seismic level (Horizontal acceleration)
The Distribution Box generally be for use in moderately hot and humid tropical climate, conducive to rust and fungus growth unless otherwise specified.
2.2
Reference atmospheric condition at which insulator characteristics shall be expressed for the purpose of comparison shall be:-
Ambient temperature Barometric Pressure Absolute Humidity
: 20 Degree Centigrade : 1013 milibars : 11 gms of water per cubic meters : corresponding to 63% relative humidity at 20 Degree C.
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Note: A pressure of 1013 milibars is equivalent to a pressure of 750mm of mercury at 0 degree centigrade.
Tests for the purpose of this standard shall preferably be carried out under conditions of temperature and humidity specified in IS:196-1966 (i.e. at a temperature of 27 + 2 degree centigrade and relative humidity of 66+2 percent) and at the prevailing atmospheric pressure. When this is not possible, test may be carried out under conditions naturally obtained at the time of the test. The barometric pressure, air temperature and humidity shall be recorded for the purpose of correction. Corrections of test voltage for atmospheric conditions are given in Appendix A of IS:731-1971.
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3.
GENERAL REQUIREMENTS:
SNo. 01. 02. 03.

(a) (b) (c)
Particulars SCOPE SYSTEM
100 KVA
Manufacture, Testing & Supply of L.T. distribution Boxes 433 Volts, AC 3 Phase 4 Wire 50 C/S with effectively grounded neutral system
MATERIAL SHOULD BE SUITABLE FOR OPERATING IN WEATHER CONDITIONS STATED BELOW :-
Temperature Range Relative Humidity Altitude SYSTEM DETAILS [a] K.V.A. [b] Voltage [c] Frequency [d] Approximate full load current. [e] No. of Outgoing ircuit per phase
- 1oC to 50oC 20% to max. 100% 1000 Meters (Maximum)
04.
Suitable for use with 100 KVA X'mer. 433 VAC - 3 PHASE 50 C/S 150 Amps 2 nos. (i)The Switch Disconnector Fuse Unit shall be Triple Pole & Neutral Link ISI marked conforming to IS:13947-1993 with latest amendments. Front operated, positive break double isolation switch mechanism, multi break arcing contact per pole for higher electrical life, with stationary fuse link for prevention of loosening of HRC Fuses, Handle with pad-lock, door inter lock and defeat mechanism facility. Fitted in rugged steel sheet enclosure. (ii) Rated-current in enclosure 200A (Minimum) (iii) Rated Insulation Voltage level 1100 V (iv) Rated fused short-circuit breaking capacity 40 KA (v) Rated short time withstand current (Icw) with shorted links for 1.0 sec. - Min. 5KA (rms) (vi) Rated impulse withstand voltage (U-Imp) 8 KV (vii) Mechanical Endurance (No of operations) 10000 (Minimum) (viii) Terminal capacity (Main) 185 mm2
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APPLICABLE STANDARDS AMENDED UPTO DATE
[a] Switch Dis-connector Fuse
337
SNo.
Particulars [b] Horn Gap type Fuse Unit
100 KVA
[c] Connectivity between switch dis-connector to Horn gap fuse unit
06.
[d] Enclosure Box [e] General Regulator Manufacturing/ Constructional Details
07.
Screening barriers partition between phases
(ix) Terminal capacity (Neutral) 95 mm2 Horn Gap fuse unit must be made of EC Grade Aluminium Flat/moulded with pressure die cast and it should be mounded on Epoxy Insulator Bush as per enclosed drawing No. MDB-63/100 EZ1-5 and as per Schedule-II (Technical Specifications). Circuit distribution through Robust type Horn gap Aluminium fuse unit, connected by L.T. XLPE insulated Cables with Switch Dis-connector. Long barrel type ISI Marked copper lugs are to be used at Switch Dis-connector terminals as per drawings and long barrel type Aluminium lugs at fuse unit terminal. 2x95mm2 XLPE All Aluminium L.T. Cables to be used for interconnecting Switch Dis-connector and horn gap fuse unit. IS:2147/1962 with latest amendments IS:4237/1992 with latest amendments One triple Pole, Neutral Link Switch Disconnector of 200 Amps (Minimum) rating on incoming side with 6 nos. Robust type Horn gap Aluminium fuse unit mounted on epoxy supports as per drawing No. MDB-63/100 EZ 1-5, in 3 groups for R-R, Y-Y, B-B with bakelite sheet barrier partition. Barrier partition of 6 mm thick Bakelite sheet for phase to phase flash over protection of dimensions as per drawing should be provided.(Laminated brown paper varnish impregnated sheet is not acceptable)
08.
Details Of Incoming Circuit With Triple Pole Switch Dis-connector (Handle Should Be Detachable)
(a) Rated Insulation VAC voltage (b) Rated Impulse withstand voltage (c) Rated Thermal current in enclosure
(d) Rated Operational current at 250 V in enclosure
660 Volts 8 KV 200 Amps 200 Amps (Minimum)

As per relevant clause of ISS:13947 (Pt-III) with latest amendments i.e. 10 times of the rated operational current. As per relevant clause of ISS:13947 (Pt-III) with latest amendments i.e. 8 times of the rated operational
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(e) Rated making capacity at 433 VAC at 0.45 PF (f) Rated breaking capacity 433
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SNo.
Particulars VAC at = 0.45PF (g) Mechanical Endurance Operating Cycles) (Nos.) (h) Electrical Endurance (Operating Cycles) (i) Maximum terminal capacity (j) Material of the terminal strips (in-coming & out-going)
current.
100 KVA
10,000 nos. 1,000 nos. 185 mm2 Tinned Electrolytic Copper
(k)Length of Operating Handle and Switch Dis-connector should be front operated as position of handle. per drawing. The handle must be detachable and its length should be not less than 80mm. (l) Switch Dis-connector
(a) Mechanism:- The complete mechanism is enclosed in a fully insulated DMC moulded housing should have excellent combination of mechanical & electrical properties. Phase barriers are provided for protection against phase to phase flash over. Switches should be suitable for base mounting. All steel components should be zinc plated and current carrying parts should be silver plated. (b) Enclosure:- These switches are required in enclosure made of sheet steel which are robustly built, chimerically phosphatized & electrostatistically powder painted. They should be ideally suited for adverse environmental conditions. This enclosure should be equipped with operating handle with pad-lock, door inter-lock and defeat mechanism. The Switch Dis-connector for Distn. Box should be type tested as per IS:13947-III)/1993 with latest amendment for Seq.I, II & III. Furnishing of manufacturers type test reports must be of NABL accredited Lab., is mandatory. The type test report shall not be more than 5 years old from the date of opening of tender.
[m] Applicable ISS for type test
09.
Metal Box (i) (ii) Size Material 1250 x 1100x350 As per drawing Cold Rolled Mild Steel sheet 2 mm (Min.) Uniform for Pad lock Arrangement to be provided for pad-lock as per drawing
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(iii) Thickness (iv) Arrangement
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Particulars (v) Auto lock for front door
100 KVA
Auto lock is to be provided in such a manner that the cover of the box can not be left open and it gets latched automatically when manually closed. Latch should be provided with master key for opening of the door. The slope of roof shall be on rear side with provision for draining of rain water on both sides as per drawing. The Distribution Boxes must be provided with non-detachable doors as per drawing (riveted at all the four corners) Name Plate of Aluminium anodized material should be riveted on all the four corners at the top left corner of the front door (as per drawing). The name plate shall be embossed/ engraved type and on this plate the following details must be provided:a/ Property of MPKVVCL b/ Name of the firm c/ Rating d/ Serial No. e/ Date of Manufacture
(vi) Slopping of Roof
(vii) Front door of the Box
Name Plate & Danger Board containing details as below:(a) Name Plate (125mm x 125mm)
f/ Order No. & date (b) Danger Board (150mm x 200mm) (viii) Door Gasket (ix) Thickness of bottom plate (x)Holes & PVC Glands for main cables entry (xi) Holes & PVC Glands for outgoing circuit cables entry (xii) Bottom Cleats of Box Danger Board Plate must be riveted at all the four corners of the Board on the front door as per drawing no.MBD-63/100/EZ/5 & 6 The good quality rubber gasket for door shall be affixed between the door and box all round. 2 mm 4 nos. holes with PVC Glands to accommodate 150mm2 L.T. XLPE single core cable as per drawing. 8 nos. as per drawing with providing of PVC Glands to accommodate 70 mm2 L.T. XLPE single core cable. Bottom cleat made up of 80x110x3 mm thick sheet to be provided at the bottom at all corner sides so that box does not come in direct contact
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SNo.
Particulars
100 KVA
with ground when stored and PVC glands may be not be damaged. (xiii) Air Circulation & ventilation in the Box. (xiv) Clearance between the terminals of bus bar switch disconnector and Horn Gap (xv) Instructions to Lineman Both side louvers with wire mesh, vermin proof ventilation. Creepage should be as per IS:4237 with latest amendments Instruction printed in Hindi on plastic coated self adhesive sticker affixed inside each box. (As per drawing no. MBD-63-100/EZ-7)
10.
Door Hinges & Handles for Box
(i) Hinges (ii) Other parts such as Nuts, Bolts Washers etc. 11. and
As per drawing All Nut, Bolts & Washers used in current carrying parts should be of M.S. Hot dip galvanized as per relevant ISS Two (one on each side) Earthing should be welded. 12mm , 40mm long as per drawing no. 1 to 5
1mm thick 1 no. spring washer and 1.5mm thick 2 nos. plain washers should be provided on the earthing bolt.
EARTHING BOLTS FOR BOX

[a] Required No. [b] Fixing [c] Size [d] Others
12.
PAINTING & FIXING ARRANGEMENT FOR BOX:

[a] Process [b] Painting As per Clause-4 Schedule-II (Technical Specifications) Poly urethane paint of good quality.
[c] Colour (outside) (inside) [d] Fixing Arrangement for Box 13.
Smoke Grey White Suitable arrangement on a double pole structure as per drawing no.1-5 2 nos. on each side bus
NEUTRAL BUSBAR: (Aluminium) [a] Size [b] Fixing ISI Mark Aluminium 40x10 Sq.mm as per drawing no. 1-5. As per drawing
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SNo.
Particulars [c] Lugs
100 KVA
ISI Mark Aluminium lugs 95Sqmme as per drawing no.1-5 (enclosed). 2 nos. on each side bus ISI Mark Tinned copper long barrel type lugs on incoming terminals of Switch Disconnector and outgoing side from Single Pole Horn Gap Aluminium Fuse Units, Aluminium long Barrel type lugs be provided along with 2 nos. 1.5mm thick plain washers & 1 no. spring washer of 1mm thick as per drawing No.63-699 suitable for the required size of L.T. XLPE outgoing Cable. The lugs should be ISI marked and conform to IS: 8337 (e.g. clause 4.1.1, Clause 4.1.3 and Clause 4.2).
150 Sqmm Single core L.T. XLPE Cable with suitable single hole ISI Mark tinned copper lugs should be provided with 2 nos. 1.5mm thick plain washer & 1 no. spring washer of 1mm thick.. 70 Sqmm XLPE Single core Cable with suitable single hole ISI Mark Aluminium lugs should be provided with 2 nos. 1.5mm thick plain washer & 1 no. spring washer of 1mm thick.. Cable holding clamp be made of 25mmx2mm thick M.S. strip fixed on 4mm M.S. base plate to be provided on in coming side as per drawing. There should be free space available for proper circulation of Air between Switch Disconnector, bus bar & Horn Gap Fuse Unit at back and front so that the inside temp. does not exceed beyond permissible limits.
14.
LUGS ON INCOMING AND OUTGOING TERMINALS
[a] Size of Incoming side cable & lugs.
[b] Size of Outgoing cable & lugs
15.
CABLE HOLDING CLAMP
16.
OTHER REQUIREMENTS
17. 17.1
APPLICABLE STANDARDS FOR BOX TEST CERTIFICATE (I) Type Test Certificate of Switch Dis-connector Fuse Unit. Submission is mandatory. (II) Routine Test Certificate:Each Distbn. Box should be tested for the routine test as indicated. The
A. IS:2147/1962 with latest amendments B. IP-20 IS:8623 (Pt-I)/1993 1. Temperature rise test as per IS:8623/Pt-I/93 with latest amendments 2. High Voltage Test should be done at 3 KV for one minute on all live parts. 1. Over all dimension 2. Insulation Resistance Test 3. H.V. withstand test at 3 KV for one minute of all live parts to earth.
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SNo.
Particulars routine test certificate indicating S. no. of each unit must be submitted with the inspection call. (III) ACCEPTANCE TEST ON COMPLETE BOX: These tests should be carried out as acceptance test in addition to routine test on one Random sample in each rating out of the lot offered for inspection.
100 KVA
TEMPERATURE RISE TEST For this test, the Box should be kept in an enclosure with the temp. maintaining at 50C and the full load current of 200 Amps is passed in all circuit and maintained till the temp. is established and max temp. rise is recorded. This test should be carried on complete box unit with Horn gap fuse. The type test of the Switch Dis-connector (as per relevant ISS with latest amendments) should be carried out by NABL accredited national Laboratory / test houses such as CPRI Bangalore/ Bhopal / and ERDA, Vadodara etc.
18.
INSTRUCTION FOR SUBMISSION OF TYPE TEST CERTIFICATES:
4.
Type test certificate for Triple Pole Switch Disconnector Fuse Unit will have to be submitted for high voltage test and temperature rise test as per point 17.1 I (1 & 2) of clause-3 above. However, the type test report for short time current test need not be obtained afresh if the test has been conducted for 4 KA with 2 Sec. The type test report should not be more than five years old from the date of opening of the tender. SURFACE PREPARATION, PAINTING AND FINISHING:
19.
INSTRUCTION FOR SUBMISSION OF TYPE TEST CERTIFICATES:-
(A) (i)
GENERAL All paints, when applied in a normal full coat, shall be fee from runs, sags, wrinkles, patchiness, brush marks or other defects. All primers shall be well marked into the surface, particularly in areas where painting is evident and the first priming coat shall be applied as soon as possible after cleaning. The paint shall be applied by airless spray according to manufacturers recommendations. However, wherever airless spray is not possible, conventional spray be used with prior approval of purchaser.
(ii).
(B) (i)
CLEANING AND SURFACE PREPRATION: After all machining, forming and welding has been completed; all steel work surfaces shall be thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to any painting.
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(ii)
Steel surfaces shall be prepared by shot blast cleaning (IS9954) to grade Sq. 2.5 of ISO-8501-1 or chemical cleaning including phosphating of the appropriate quality (IS 3618). Chipping, scarping and steel wire brushing using manual or power driven tools can not remove firmly adherent mill-scale. These methods shall only be used where blast cleaning is impractical. Manufacturer to clearly explain such areas in his technical offer.
(iii)
(C)
PROTECTIVE COATING: As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given suitable anti-corrosion protection.
(D) (i)
PAINT MATERIAL: Following are the types of paint which may be suitably used for the items to be painted at shop and supply of matching paint to site.
(ii)
For internal & external surfaces both, one coat of epoxy primer followed by two coats of polyurethane base paint. These paints can be either air drying or stoving.
(E) (i)
PAINTING PROCEDURE: All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours, whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the surface is dry and while the surface is still warm. Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking or general softness) the supplier shall remove the unsatisfactory paint coating and apply another coating. As a general rule, dry film thickness should not exceed the specified minimum dry film thickness by more than 25%.
(ii)
(F) (i)
DAMAGE PAINT WORK: Any damage occurring to any part of a painting scheme shall be made good to the same standard or corrosion protection and appearance as that was originally applied. Any damaged paint work shall be made good as follows:-
(ii)
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(a)
The damaged area, together with an area extending 25 mm around its boundary, shall be cleaned down to bare metal. A priming coat shall be immediately applied, followed by a full paint finish equal to that originally applied and extending 50 mm around the perimeter of the original damage. The repainted surface shall present a smooth surface. This shall be obtained by carefully chamfering the paint edges before and after priming.
(b)
(c)
(G)
DRY FILM THICKNESS: i. To the maximum extent practicable the coats shall be applied as a continuous film of uniform thickness and free of pores. Overspray, skips, runs, sags and drips should be avoided. The different coats may or may not be of the same colour. ii. Each coat of paint shall be allowed to harden before the next is applied as per manufacturers recommendation. iii. Particular attention must be paid to full film thickness at the edges. iv. The requirements for the dry film thickness (DFT) of paint and the materials to be used shall be as given below:-
Sl. No. 1.
Paint type
Area to be painted
No. of coats
Total dry film thickness (min.) (microns) 30 25 each
Liquid paint:(a) Epoxy (primer) (b) P.U. Paint (Finish coat)
Outside & Inside both
01 02
(H) (i) (ii)
TESTS FOR PAINTED SURFACE: The painted surface shall be tested for paint thickness. The painted surface shall pass the cross hatch adhesion test and impact test as acceptance tests and Salt spray test and Hardness test as type test as per the relevant ASTM standards.
Note:- Supplier shall guarantee the painting performance requirement for a period of not less than 3 years.
(I)
COLOUR:The colour of the finishing coats shall be SMOKE GREY (Outside) and WHITE (In side) of the Distribution Boxes.
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5. (i)
TEST & TEST CERTIFICATE FOR SWITCH DISCONNECTOR FUSE UNIT:Type Test:- The Switch Disconnector Fuse Unit must be ISI marked of reputed make (e.g. Havells, L&T etc.) and it should conform to IS:13947-1993 with latest amendments. The Switch Disconnector for Distribution Box should be type tested from NABL accredited Lab. (e.g. CPRI, ERDA, Vadodara etc.) as per IS:13947-III)/1993 with latest amendment for Temperature rise test as per IS:8623/Pt-I/93 with latest amendments & High Voltage Test for 3 KV for one minute on all live parts. The copy of the manufacturers type test reports should not be older than 5 years from the date of opening of the tender and the type test report necessarily be furnished by the tenderer along with their offer. The offer shall be ignored if the test certificates as mentioned above are not furnished and as such, their price bid shall not be opened. Routine Test & Acceptance Test:(a) The routine test report indicating sr. no. of the Distribution Box must be submitted with the offer for pre-dispatch inspection of the material. (b) The routine test and acceptance test on one random sample in each rating out of the lot offered should be carried out at the works of the manufacturer during the pre-dispatch inspection of the material. Use of ISI Marked HRC Fuses & Switch Disconnector:The ISI marked HRC Fuse should only be used. These HRC Fuses should conform to IS:13703 (Pt-I)1993 with latest amendments. The rated current of HRC Fuse must be 120 Amps for 63KVA and 200 Amps for 100KVA Switch Disconnector and ISI certificate of HRC Fuse should be submitted with the offer.
(ii)
(iii)
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G I WIRES
1.0
SCOPE This specification covers details of solid G.I. Wires for use in rural distribution system. APPLICABLE STANDARDS Except when they conflict with the specific requirements of this specification, the G.I. wires shall comply with the provisions of IS: 280-1978 and IS: 7887-1975 or the latest version thereof. APPLICATION & SIZES G.I. Wires covered in this Specification are intended for the following applications: Application Bearer wire for service Sizes (nominal dia) 3.15mm (for single phase cables services) 4 mm (for three phase services) 4 mm 4 mm
2.0
3.0
Earthing of Transformers, poles & Fittings. Continuous Earth wire for. 11 KV lines
Protective guarding at the crossing of overhead power lines with roads, railway tracts 3.15, 4 and 5 mm and telecommunication lines
4.0
MATERIAL 4.1 The wires shall be drawn from the wire rods conforming to IS: 7887-1975 or the latest version thereof. 4.2 4.3 The requirements for chemical composition for the wires shall conform to IS:7887. The wires shall be sound, free from split surface flaws, rough jagged and imperfect edges and other detrimental defects on the surface of the wires.
5.0 6.0
GALVANISING The wires shall be galvanised with Heavy Coating as per IS: 4826-1979 or the latest version thereof. GRADES GI wires shall be classified into two grades based on their tensile strength: Tensile (MPa) Strength
Grade
Annealed Hard
300-550 550-900
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7.0
TOLERANCE IN DIAMETER The tolerance on nominal diameter at any section of wire shall not exceed () 2.5%. Further, the maximum difference between the diameters at any two cross-sections of wires shall not exceed 2.5%.
8.0
TESTS The following tests shall be carried out in accordance with IS: 280-1978 or the latest version thereof as per sampling criteria stipulated therein: i) Dimensional check (dia) - refer clause 7 above. ii) Visual inspection regarding freedom from defects refer clause 4.3 above. iii) Tensile test iv) Wrapping test (for wire diameters smaller than 5mm) v) Bend test (for wire diameters 5mm only) vi) Coating test - refer clause 5 above vii) Chemical composition PACKING The wires shall be supplied in 50-70 kg. coils, each coil having single continuous length. Each coil of wire shall be suitably bound and fastened compactly and shall be protected by suitable wrapping. MARKING Each coil shall be provided with a label fixed firmly on the inner part of the coil bearing the following information: a) Manufacturers name or trademark b) Lot number and coil number c) Size d) Grade (Annealed or Hard) e) Mass f) Length g) ISI Certification mark, if any
9.0
10.
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DRAWINGS
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MPMKVVCL,Bhopal /T.S. No.; 330; TS of Supply, Erection, Testing and Commissioning of New 11KV Addl. Bay, 11KV & LT Lines and 11/0.4 KV Distribution Substations Under RGGVY Scheme of Harda District
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MP Vidyut Vitaran Nd08adb Vol2 11feb11

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MP Vidyut Vitaran Nd08adb Vol2 11feb11

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MADHYA PRADESH MADHYA KSHETRA VIDYUT VITARAN COMPANY LTD., BHOPAL

Madhya Pradesh Energy Efficiency Improvement Investment Program

BID IDENTIFICATION NO.MPMKVVCL/ADB/II/D/08

CHIEF GENERAL MANAGER (ADB) CELL

TELEPHONE NO. FASCIMILE E-MAIL ADDRESS

0755-2602033, 0755-2602034 ext-138 0755-2589821/2586636 seadbcell@mpmkvvc.com

SCHEDULE I COMMERCIAL QUESTIONNAIRE

POINTS TO BE CONFIRMED IN RESPECT OF CLAUSES UNDER

Section-2 (Volume-I) Bid Data Sheet (BDS)

18.17 18.18 18.19 19

SIGNATURE AND SEAL OF BIDDER

Signature & Seal of Bidder

No. No. No. No.

No. No. No. No. No. No.

ONLY FOR EXECUTION PURPOSE SHEDULE FOR SUPPLY OF PLANT - 1A

Set Kg. No. Kg. No. Kg. Kg Kg Kg Kms. No.

ONLY FOR EXECUTION PURPOSE SHEDULE FOR SUPPLY OF PLANT - 3A

Set Kg. No. Kg. No. Kg. Kg. Kg Kg Kms. No.

ONLY FOR EXECUTION PURPOSE SHEDULE FOR SUPPLY OF PLANT - 4A

Set Kg. No. Kg. No. Kg. Kg Kg Kg Kms. No.

ONLY FOR EXECUTION PURPOSE SHEDULE FOR SUPPLY OF PLANT - 5A

Page | ONLY FOR EXECUTION PURPOSE SHEDULE FOR SUPPLY OF PLANT - 6A

Job Job Job

Job No No No No No No No No No Set No Set

12 4 9 2800 0.8 12 25 33 33 114 114

Cmt. Mtr. Mtr. Mtr. Mtr.

ONLY FOR EXECUTION PURPOSE

Page | ONLY FOR EXECUTION PURPOSE

6 6 2 45.020(1SET) 6 33 2 3.4 2 6 1 3 3 0.01 3

Page | ONLY FOR EXECUTION PURPOSE

Page | ONLY FOR EXECUTION PURPOSE

6 6 6 180.08(4SET) 8 44 4 6.8 4 15 1 6 6 0.025 3

ONLY FOR EXECUTION PURPOSE

Page | ONLY FOR EXECUTION PURPOSE Schedule for supply of plant-12A

ONLY FOR EXECUTION PURPOSE

No. Set Kg. Kg. Kg. Kg. Kg. Kg No.

Page | ONLY FOR EXECUTION PURPOSE

ONLY FOR EXECUTION PURPOSE

Set Kg. No. Kg. No. Kg. Kg Kg Kg Kms. No.

Page | ONLY FOR EXECUTION PURPOSE

Set Kg. No. Kg. No. Kg. Kg. Kg Kg Kms. No.

ONLY FOR EXECUTION PURPOSE

Set Kg. No. Kg. No. Kg. Kg Kg Kg Kms. No.

ONLY FOR EXECUTION PURPOSE

No. No. Set Kg. No. Kg. No. Kg. Kg Kg Kg Kms.

ONLY FOR EXECUTION PURPOSE

Job Job Job

12 4 9 2800 0.8 12 25 33 33 114 114

Cmt. Mtr. Mtr. Mtr. Mtr. no. No. No.

ONLY FOR EXECUTION PURPOSE

36(12NO) 12 36 3.1 6 4 22 20.4 12 3 14 2 18 18

ONLY FOR EXECUTION PURPOSE

6 6 2 45.020(1SET) 6 33 2 3.4 2 6 1 3 3 0.01 3

Page | ONLY FOR EXECUTION PURPOSE

ONLY FOR EXECUTION PURPOSE

6 6 6 180.08(4SET) 8 44 4 6.8 4 15 1 6 6 0.025 3

ONLY FOR EXECUTION PURPOSE

ONLY FOR EXECUTION PURPOSE

ONLY FOR EXECUTION PURPOSE

ONLY FOR EXECUTION PURPOSE

No. Set Kg. Kg. Kg. Kg. Kg. Kg

THREE PHASE 33/11 KV STEP DOWN POWER TRANSFORMERS OF 5 MVA RATINGS