JHARKHAND URJA SANCHARAN NIGAM LIMITED
Regd. Office – Engineering Building, H.E.C., Dhurwa, Ranchi – 834 004
Fax No. – 0651 – 2400123 (E-mail – cetjseb@rediffmail.com/ cetjusnl@gmail.com)
Tender Notice No. – 122/ PR/ JUSNL/ 2015 – 16
For
Design,
Engineering,
Supply,
Erection,
Testing
&
Commissioning of 220/132/33 kV (2x150 + 2x50) MVA Grid
Sub-Station at Jasidih.
VOLUME - II
GENERAL TECHNICAL REQUIREMENT
Issue to: ………………………………………
………………………………………
………………………………………
Price of Tender Document
Rs. 25,000/- (Vol. I + II)
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SECTION-II
TECHNICAL SPECIFICATION
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VOLUME-II
INDEX
1. Section Project
2. GTR
3. LT Switchgear
4. LT Transformer
5. Surge Arrestor
6. Power & Control Cables
7. Control & Protection Panels
8. PLCC
9. 132 KV Circuit Breaker
10. 132 KV Isolator
11. 33 KV Equipment Specification/ System Parameters
12. Air Conditioning System
13. Diesel Generator Set
14. Lighting System
15. Battery & Battery Charger
16. Switch Yard Erection
17. Instrument Transformers
18. Sub-station Structures
19. Clamps and Connectors
20. Hardware Fittings
21. Post Insulator
22. i)
220/132/33 150 MVA Auto Transformer
ii)
132/33 KV, 50 MVA Power Transformer
23. Civil Work
24. Fire fighting system
25. Sub Station Automtion System(SAS)
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1.0 Section Project
1.0
2.1
3.0
GENERAL
SCOPE: Construction of 220/132/33KV Grid sub-station at IN JASIDIH of
capacity 2x150 MVA at 220/132 KV level and 2X50 MVA at 132/33 KV level.
IN JASIDIH 220/132/33kV new sub-station
(a) 220/132kV, 2x150 MVA Auto-transformers and 132/33kV, 2x50MVA
Transformers
(b) 220kV, 132kV Circuit breakers, Isolators, Current transformers, Surge
arresters, Capacitor voltage transformers 220KV, 132kV portable discharge
rods and 33kV Circuit breakers, Isolators, Current transformers, Surge
arresters, Potential transformers and Horn gap fuses
(c) 2 nos. 33/0.433kV, 630kVA Auxiliary LT transformer
(d) Complete control, relay and protection system
(e) Wave traps
(f) PLCC System for the following lines:
(g) Remote terminal unit (RTU) near with Cabling work of all bay.
(h) Fire protection system.
Hydrant system shall be provided for Control room building, DG Set, LT
Transformers area, Fire fighting pump house, Stores and Auto-transformers.
HVW spray system shall be provided for 220/132kV and 132/33kV
transformers.
Fire detection system shall be provided for entire control room building
including corridor and toilets.
Portable fire extinguishers for control room building, Fire fighting pump
house and DG Set.
(i) Air conditioning system.
(j) LT switchgear (AC/DC Distribution boards)
(k) 100kVA capacity DG Set
(l) 220V battery (500AH) & battery charger(60A/50A), 48V battery(500AH) and
battery charger(60A/50A)
(m) 1.1 kV grade Power & Control cables along with complete accessories.
(n) Lattice and pipe structures(galvanised) for towers, beams, LM and equipment
support structures (excluding CB support structure which will be as per
manufacturer’s design). LM, 220kV Towers, Beams and equipment support
structures shall be as per JUSNL Standard drawings.
(o) Bus post Insulators(including requirement for wave traps), insulator (Antifog)
strings and hardware, clamps & connectors, Aluminium tube, conductor, Bus
bar and earthing materials, Bay marshalling box, cable supporting
angles/channels, Cable trays, Junction box, buried cable trenches for lighting,
PVC pipes for cabling etc.
(p) Complete lighting and illumination of the switchyard area, Control Room
building,Fire fighting pump house and street lighting including lighting for
approach road outside switchyard fencing and boundary wall.
(q) Complete earthmat including all associated works.
(r) Complete Direct stroke lightning protection (DSLP)
(s) Mandatory Spares.
(t) Maintenance & Testing equipment.
(u) Sub-Station Automation System.
(v) Any other item required for completion of scope of works.
Before proceeding with the construction work of the new substations the Contractor
shall fully familiarize himself with the site conditions and General arrangements &
scheme etc. Though the Employer shall assist the contractor to the extent possible in
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4.0
5.0
6.0
6.1
7.0
8.0
8.1
8.2
9.0
obtaining the required information, it shall not be binding for the Employer to provide
the same. The bidders are advised to visit the substation sites to acquaint themselves
with the topography, infrastructure, design philosophy and to collect required inputs
so as to assess the total requirement for completion of specified scope. The bidder
shall be fully responsible for providing all equipment, materials, system and services
specified or otherwise which are required to complete the construction and successful
commissioning, operation & maintenance of the specified scope in all respects.
All materials required for the Civil and construction/installation works shall be
supplied by the Contractor. The cement and steel shall also be supplied by the
Contractor.
The complete design (unless specified otherwise in specification elsewhere) and
detailed engineering shall be done by the contractor based on conceptual tender
drawings.
The Contractor shall also be responsible for the overall co-ordination with
internal/external agencies, project management, training of Employer’s manpower,
loading, unloading, handling, moving to final destination including Employer
supplied material for successful erection, testing and commissioning of the
substation/switchyard.
Design of substation and its associated electrical & mechanical auxiliaries systems
includes preparation of single line diagrams and electrical layouts, erection key
diagrams, electrical and physical clearance diagrams, design calculations for Earth
mat, Direct Stroke Lighting Protection (DSLP), Bus Bar & Spacers, control and
protection schematics, wiring and termination schedules, design of firefighting
system, designs and drawings of civil works and structures including proto corrected
drawings for structures, indoor and outdoor lighting/illumination and all other
relevant drawings & documents required for engineering of all facilities to be
provided under this contract, are covered in the scope of the Contractor.
Specific exclusions.
The following items of work are specifically excluded from the scope of the
specifications:
(a)
Employer’s site office and stores
(b)
Land Filling and Land Development.
(c)
Boundary wall along substation property line
(d)
Blank
(e)
Blank
(f)
Cable for colony feeder
(g)
Local Data Monitoring System(LDMS)
Any other item not specifically mentioned in the specification but which are required
for erection, testing and commissioning of the specified scope and satisfactory
operation of the substations are deemed to be included in the scope of the
specification unless specifically excluded.
Employer has standardised its technical specification for various equipments and
works for different voltage levels. Items which are not applicable for the scope of
these packages, the technical specification for such items shall not be referred to.
PHYSICAL AND OTHER PARAMETERS
Meteorological data
Meteorological data for all the sub-stations shall be furnished to the successful bidder.
However for design purposes, ambient temperature should be considered as 500 C.
Soil Data
To be surveyed and investigated.
SCHEDULE OF QUANTITIES
The requirement of various items/equipments and civil works are indicated in Bid
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10.0
10.1
10.2
11.0
12.0
12.1
proposal sheets.All equipments/items and civil works for which bill of quantity has
been indicated in PRICE SCHEDULE shall be payable on unit rate basis. During
actual execution, any varation in such quantities shall be paid based on the unit rate
under each item incorporated in the Letter of award.
Wherever the quantities of items/works are not indicated, the bidder is required to
estimate the quantity required for entire execution and completion of works and
incorporate their price in respective Bids . For erection hardware items, Bidders
shall estimate the total requirement of the works and indicate module-wise lump
sum price bay wise and include the same in relevant Bid s. For module identification,
Bidder may refer typical drawings enclosed with the specifications. Any
material/works for the modules not specifically mentioned in the description in
PRICE SCHEDULE, as may be required shall be deemed to be included in the
module itself.
The detailed bill of quantities of the mandatory spares for which break up is not given
in the bid proposal sheets are indicated at Annexure-I of this section.
Bidder should include all such items in the bid proposal sheets which are not
specifically mentioned but are essential for the execution of the contract. Item which
explicitly may not appear in various schedules and required for successful
commissioning of substation shall be included in the bid price and shall be provided
at no extra cost to Employer.
BASIC REFERENCE DRAWINGS
For 220kV Substations double main and transfer bus arrangement and for 132kV &
33 kV Substations single main and transfer bus arrangement shall be followed. The
standard lay out and arrangement shown in CBIP sub-stationmannual is tobe
followed.
The reference drawings which form a part of the specifications is given at AnnexureII. The bidder shall maintain the overall dimensions of the substation, buildings, bay
length, bay width, phase to earth clearance, phase to phase clearance and sectional
clearances, clearances between buses, bus heights but may alter the locations of
equipment to obtain the statutory electrical clearances required for the substation.The
enclosed drawings give the basic scheme, layout of substation, substation buildings,
associated services etc. In case of any discrepancy between the drawings and text of
specification, the requirements of text shall prevail in general. However, the Bidder
is advised to get these clarified from Employer before submission of their bids.
DIFFERENT SECTIONS OF TECHNICAL SPECIFICATION
For the purpose of present scope of work, technical specification (Vol II) shall consist
of following sections and they should be read in conjunction with each other.
In case of any discrepancy between Section-PROJECT and Section-GTR / other
technical specifications on scope of works, Section-PROJECT shall prevail over
all other sections.In case of any discrepancy between Section-GTR and
individual sections for various equipments, requirement of individual equipment
section shall prevail.
SPARES
Mandatory Spares
The mandatory spares shall be included in the bid proposal by the bidder. The prices
of these spares shall be given by the Bidder in the relevant schedule of PRICE
SCHEDULE (Vol. I) and shall be considered for evaluation of bid. It shall not be
binding on the Employer to procure all of these mandatory spares.The bidder is
clarified that no mandatory spares shall be used during the commissioning of the
equipment. Any spares required for commissioning purpose shall be arranged by the
Contractor. The un utilized spares if any brought for commissioning purpose shall be
taken back by the contract.
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13.0
14.0
14.1
14.2
15.0
15.1
15.2
15.3
SPECIAL TOOLS AND TACKLES
The bidder shall include in his proposal the deployment of all special tools and
tackles required for erection, testing, commissioning and maintenance of equipment.
However a list of all such devices should be indicated in the relevant schedule
provided in the PRICE SCHEDULE. In addition to this, the Contractor shall also
furnish a list of special tools and tackles for the various equipment in a manner to be
referred by the Owner during the operation of these equipment.
Facilities to be provided by the Employer
Auxiliary HT (33 or 11 KV) power supply (Discom) at new sub-stations and LT
supply (415 V) at existing sub-stations will be made available on chargeable basis at
a single point in the sub-station. The prevailing energy rates of the state shall be
applicable. All further distribution from the same for construction supply shall be
made by the contractor. However, in case of non availability or failure of power due
to any unavoidable circumstances, the contractor shall make his own necessary
arrangements like diesel generator sets etc. at his own cost so that progress of work is
not affected and Employer shall in no case be responsible for any delay in works
because of non-availability of power.
Construction water supply will be made available at a single point in the substation.
All further distribution for the same shall be made by the Contractor. In case of non
availability or inadequate availability of water for construction work, the contractor
shall make his own arrangement at his own cost and the Employer shall in no case be
responsible for any delay in works because of non-availability or inadequate
availability of water.
SPECIFIC REQUIREMENT
The contractor shall be responsible for safety of human and equipment during the
working. It will be the responsibility of the Contractor to co-ordinate and obtain,
Electrical Inspector's clearance before commissioning. Any additional items,
modification due to observation of such statutory authorities shall be provided by the
Contractor at no extra cost to the Employer.
blank
1.
2.
3.
4.
5.
6.
7.
i)
i) blank
ii) In the technical requirements for Control and Relay panels specified under
clause 24.10.1 and 24.10.2 (Section-GTR), 400kV and 220kV shall be replaced
by 220kV and 132kV respectively.
Bidders shall note that 250V D.C. auxiliary supply shall be considered at all
sub-stations.
The technical parameters for 33kV level i.e. 33kV system parameters, technical
parameters for 33kV equipment and configuration of 33kV control, relay and
protection panels and protection panels for 132/33kV transformer which are not
available in the model technical specification are furnished at Annexure-III.
a) The technical parameters for 50MVA, 132/33kV transformers are enclosed
at Annexure-IV. The technical specification of Auto-transformers shall be
applicable for all Power transformers except stated otherwise elsewhere in the
specification.
b) The requirement to be met in case of parallel operation is specified in SectionAutotransformer.
The detailed specification for Maintenance & testing equipment is enclosed at
Annexure – V
The specification for Auto transformer/Reactor foundation, Rail track/Road cum
rail track is given in Annexure-VI enclosed herewith.
Painting details for 220/132kV and 132/33kV Transformers:
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The painting details for transformer main tank, pipes, conservator tank, radiator, control
cabinet/ marshalling box etc. shall be as given below. The detailed painting procedure
shall also be submitted along with the bid which shall be finalized before award of the
contract.
Surface
preparation
Primer
coat
Intermediate
undercoat
Finish
coat
Main tank,
pipes,
conservator
tank etc.
(external
surfaces)
Main tank,
pipes (above
80 NB),
conservator
tank etc.
(Internal
surfaces)
Radiator
(external
surfaces)
Blast
cleaning Sa 2
½*
Epoxy
base Zinc
primer
(3040m)
Epoxy high
build
Micaceous
iron oxide (HB
MIO) (75m)
Aliphatic
polyureth
ane (PU)
(Minimu
m 50m)
Blast
cleaning Sa 2
½*
--
Radiator and
pipes upto 80
NB (Internal
surfaces)
Chemical
cleaning, if
required
Control
cabinet /
marshalling
box (outdoor
panels)
Seven tank
process as
per IS:3618
& IS:6005
Hot oil
resistant,
noncorrosive
varnish or
paint or
epoxy
Epoxy
base Zinc
primer
(3040m)
Hot oil
proof,
low
viscosity
varnish
and
flushing
with
transform
er oil
Zinc
chromate
primer
(two
coats)
Chemical /
Blast
cleaning Sa 2
½*
Epoxy base
Zinc primer
(30-40m)
Total dry
film thickness (DFT)
Minimum
155m
Colour shade
--
Minimum
30m
Glossy white for
paint
PU paint
(Minimu
m 50m)
Minimum
100m
Matching shade of
tank/ different
shade
aesthetically
matching to tank
--
--
--
--
EPOXY
paint with
PU top
coat
--
Minimum
80m
697 shade as per
IS-5
RAL 7035 shade
for exterior and
interior
Note: 1. * indicates Sa 2 ½ as per Swedish Standard SIS 055900 of ISO 8501 Part-1.
2. Painting details of RTCC panels shall match with control and relay panels.
ii)
132/33kV transformers with conventional type tank shall also be
acceptable.
iii)
Vector group for 220/132/33kV, 150 MVA transformers given under
clause 6.3.15, Section-Auto transformer of model technical specification
shall be read as YNa0
8. In case of 145kV Current Transformer with 600A current rating, additional ratio
of 150/1 shall be provided for cores-4 & 5 in addition to the ratios given in TableIID, Chapter-INST, Section-Switchgear of Technical specification.
9. In all 220/132/33 kV & 132/33 kV new substations 250 V & 48 V DC batteries
shall be VRLA (Valve Regulated Lead Acid) type. Batteries & Battery chargers
shall be as per Technical specification. Section - Battery & Battery charger –
C/Engg/Spec./Bat rev. 06. Batteries shall be of Exide make.
10. The quantity requirement of portable and wheel/trolley mounted extinguishers has
been given in PRICE SCHEDULE.
11. The quantity requirement of High wall type split AC units of 2 TR capacity has
been given in the PRICE SCHEDULE. Only Control room and battery room
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accommodating Control & Relay panels and Battery shall be air conditioned.
12. i) Section:Control & relay panels, Part-I (Applicable for sub-station) shall be
applicable.
ii) Control, relay and protection panels for 220kV shall be Simplex type; Control,
relay and protection panels for 132kV shall be Simplex / Duplex type as
indicated in the PRICE SCHEDULE; Control, relay and protection panels for
33kV shall be accommodated in a single panel.
iii) 1 no. Under frequency relay (range: 47.5Hz to 52.5Hz) with df/dt feature shall
be provided for each line protection panel for 220kV, 132kV and 33kV.
iv)
One Static type composite meter shall be installed for each line feeder,
HV side &
LV side of each Power transformer even though the same has
not been included in the panel BOQ for 220kV, 132kV and 33kV in the model
specification. The active energy (Wh) measurement shall be carried out on a
3-phase, 4-wire principle with an accuracy as per class 0.2 S of IEC-6205322:2003. For reactive power(VAR) and reactive energy(VARh) measurement,
IEC-62053-23:2003 shall be complied with. The accuracy of measurement of
reactive energy shall be as per class 2. 1 no. data collection device alongwith
necessary software suitable for commonly available PC shall be provided for
each Sub-station.
v) The specification for Relay test kit is given below. Therefore the specification
of Relay test kit given in the model technical specification for C&R Panels is
not applicable.
Relay test kit: One relay test kit shall comprise the equipment detailed below.
(a) Relay tool kits – 3 sets
(b) Portable testing equipment for over current relays – 1 no.
The input rating should be between 200-250V and the current output
range shall be 0.05 – 200Amps with negligible harmonic distortion of
less than 1%. A clock shall be fitted to read 1 to 10 seconds.
(c) Portable testing equipment comprising supply unit, control unit and fault
impedance unit for testing distance relays - 1 no ( omicron make )
(d) Test plugs for use with testing equipment – 2 nos.
(e)
Special type test plugs for using with modular type cases (if
applicable).
13. 132kV Wave traps shall be suspension mounting type. 220kV Wave traps shall
be pedestal mounting type. However, this will be decided during final
engineering.
14. In case of LILO lines, the scope includes shifting of existing PLCC equipment
from one end to the new sub-station as per requirement for one section of the
LILO line and provision of additional carrier terminal and protection coupler as
required for other section.
15. The Quantity of Point Counts for the Remote Terminal Unit(RTU) to be
supplied at new sub-stations is given at Annexure-IX. This supercedes the
quantities given in Annexure-A, Section-RTU & LDMS of technical
specification.
16. (i) Section Lighting system (Rev. 03 ) Clause no 1.3 is deleted and Bidder shall
quote as per lighting BOQ given in s.
(ii) Section Lighting system ( Rev. 03 ) Clause no 3.5.3(a) is amended as under.
All HPSV/HPMV/Metal halide lamp fixtures shall be provided with wirewound ballasts. All fluorescent fixtures shall be provided with high frequency
electronic ballasts. The Ballasts shall be designed, manufactured and supplied
in accordance with relevant standard and function satisfactorily under site
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condition specified. The ballasts shall be designed to have a long service life
and power loss.High frequency electronic ballasts shall be capable of
satisfactory performance in adverse environment like that of EHV substation.
Ballasts shall cosist of AC/DC convertor, high frequency power oscillator and
low pass filter. The ballasts shall be suitable for use of nominal voltage of
240V +/- 10%, 50 Hz supply. The filter circuit shall suppress the feedback of
high frequency signals to the mains. The ballast shall be rated for 36/40W
fluorescent fixtures. The ballasts shall confirm to IEC 68-2-6FC, IEC 929 for
performance, IEC 928 for safety and EN 55015, EN 55022A for RFI and EN
61003.
(iii) Section Lighting system ( Rev. 03 ) Clause no 3.5.5 b ) is amended as under:
Power factor of fluorescent lamp fixtures with HF electronic ballast shall not
be less than 0.90 and that of High pressure Sodium Vapour, Mercury Vapour
and Metal Halide lamp fixtures shall not be less than 0.85.
(iv)The lighting fixtures for switchyard lighting shall be mounted on LMs
wherever LMs are provided. Where LMs are not available, the fixture may be
mounted on Gantry structures.
(v) The description of Lighting Fixtures to be supplied under Lighting system is
given in Annexure-X. Accordingly, clause 2.4, Sec-Lighting system of
Technical specification shall not be applicable.
17. 2 nos. LT transformer of rating 630KVA, 33/0.433kV shall be used to feed the
substation auxiliaries in case of 220/132/33kV new sub-station. The LT
transformer of rating 315KVA, 33/0.433kV shall be used to feed the substation
auxiliaries in case of all 132/33kV new sub-stations. The technical specification
of 250 KVA, 33/0.433kV LT transformer is to be referred to for 315 KVA,
33/0.433kV LT transformer except for the rating which will be 315kVA. These
LT transformers should not be used for construction purpose. The detailed
scheme is shown in the single line diagram.
18. At 132/33kV(new) sub-stations, the Lightning mast height shall be 40m (Lattice
structure: 37.5m; Spike:2.5m) irrespective of the height indicated in the model
specification.
19. Plinth height of gantry and equipment structures in case of extension of existing
sub-stations shall match with the existing foundations.
20. At existing sub-stations which are being extended under present scope, earthmat
design shall be based on measurement of soil resistivity to be taken in the
adjoining / nearby vacant area since correct soil resistivity value cannot be
obtained in the existing switchyard. In case of existing sub-stations, earthmat
design shall be done for entire switchyard area. However, earthmat shall be laid
only in the present bay area based on the design for entire switchyard and should
be connected to the existing earthing system.
21. In case of existing sub-stations, cutting in the floor, provision of channel/angle
frame for installation of C&R and PLCC panels including making good the floor
after the works shall also be in the scope of the contract.
22. Dismantling
of
existing
structures
and
equipment
including
interconnection/stringing wherever required are deemed to be included in the
scope of the contractor without any additional cost implication to JUSNL even
though the same is not specifically mentioned in the bid document. However, for
dismantling of foundations, wherever required, the contractor will be paid at the
unit rate quoted by him in case of other sub-stations of the same package.
23. Wherever quantity and unit are indicated, the actual quantity erected shall be
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considered for payment purpose; Wastage shall not be considered.
i) Civil construction drawings for the following shall be as per JUSNL
ii) 220kV tower, LM and equipment foundations
iii) Fire fighting pump house except Fire water tank
iv) Concrete and Bitumen roads, road culverts
v) Cable trench section and cable trench crossings
vi) Cable trench sump pit
vii) Details of drain
viii) Fence and Gate (Structure & foundation)
ix) Rain water harvesting
x) Control room building for 132/33kV new sub-stations.
xi) Control room building for 220/132kV new sub-station .
All the civil design and drawings are in the scope of contractor.
24. 2 nos. Marshalling kiosks shall be provided for the 33kV switchyard irrespective of
no. of 33kV bays in each new sub-station. In case of extension of existing substations, 1 no. Marshalling kiosk shall be provided for 33kV switchyard extension
irrespective of no. of 33kV bays in each existing sub-station under extension.
25. 50x6mm GS Flat shall be used in case of 33kV column, equipment & auxiliary
structures in place of 75x12mm GS flat specified at clause no. 8.4(b) & (c), SectionSwitchyard erection of model technical specification.
26. 3” IPS (EH type) Aluminium tubular bus conductor shall be used for equipment
interconnection wherever required as per layout drawing. The parameters of 3” IPS
Al.tubular bus conductor is given below.
Size:
3” IPS (EH type)
Outer diameter:
88.90 mm
Thickness:
7.62 mm
Cross-sectional area: 1945.80 sq.mm
Weight:
5.27 kg/metre
27. The HVW spray system shall be designed to have a pressure of 5.5 kg/sq.cm at
180 cu.m/hour (instead of 350 cu.m/hour indicated in the model technical
specification) at the farthest transformer location as per tender drawings. The
total storage capacity of two nos. water storage tanks shall be 320 cu.m above the
pump casing instead of 420 cu.m indicated in the model technical specification.
Only 4 nos. (instead of 10 nos. indicated in the model technical specification)
spare annunciations shall be provided for annunciation panels both in control
room and pump house.The HVW spray pump capacity required shall be 273 cu.m
per hour instead of 410 cu.m per hour indicated in the data sheet for Horizontal
Centrifugal pumps under Section-Fire protection of technical specification.
28. Soak pit capacity for 132/33kV transformers shall be 130% of volume of oil in the
transformer instead of 200% specified in clause 1.0 of Annexure-VI. Further, one 0.5
H.P. pump shall be supplied and installed by the contractor for each transformer
(220/132kV & 132/33kV) soak pit to evacuate firefighting/rain water and oil from
the sump pit to the nearest drain. The estimated quantity of 0.5 H.P. pumps is given
in PRICE SCHEDULE.
29. One 3 H.P. pump for each cable trench sump pit and drain sump pit shall be
supplied and installed by the contractor. The estimated quantity of 3 H.P. pump is
given in PRICE SCHEDULE.
30. Specific descriptions & requirements of various distribution boards of LT
Switchgear is enclosed at Annexure-XI. The contractor shall submit LT
switchgear single line diagrams ,scheme and GA drawings fulfilling the same and
other requirements as per Section-LT Switchgear for Employer’s approval during
detailed Engineering.
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31. Supervision of erection, testing and commissioning of Transformers, Circuit
Breakers, Isolators, Control, relay & protection, PLCC and Remote terminal unit
shall be done by respective manufacturers.
32. Floor details for ACDB, DCDB, toilet and pantry shall be as per details in the
relevant clauses of Technical Specification. Floor details for other areas of control
room building shall be as per the following details:
1. Battery Room – Terrazo Tiles with white cement.
2. C&R Panels and PLCC panel room – 2mm thick Homogeneous PVC Tiles over
25mm thick 1:2:4 cement concrete under bed with neat cement finish.
3. Passage/corridor – Terrazo Tiles with white cement
4. Stair case – Kota Stone
5. Store/Record Room – Terrazo Tiles with white cement
6. Janitor Room – Terrazo Tiles with white cement
7. Sub-station Incharge Room – Terrazo Tiles with white cement
8. Maintenance Staff Room, Electronic Test Lab, Conference Room and Officers Room
- Terrazo Tiles with white cement.
33.
Section-Project(contd…)
Approach to site: The site is located at IN JASIDIH. The land for construction site is
owned by JUSNL.
-The configuration of GSS shall be as below:220 KV Bus System
Main bus –I &II with transfer bus. The Isolator shall be tandem type on transfer bus
side.
132 KV Bus System
Main and transfer bus with high level Isolator with tandem Isolator on transfer bus
side.
33 KV Bus System
Main and transfer bus with High level Isolator with tandem Isolator on transfer bus
side.
TOTAL NO. OF BAYS
(A) 220 KV System
2 Nos. of Transformer bays for 02 nos. of 150 MVA,
220/132KV, 3 Ph Power transformers.
1 No. Transfer Bus Coupler Bay
1 No. Bus Coupler Bay
6 Nos. Line Bays.
Total: 10 Nos.
(B)
-
(C)
132 KV System
2 Nos. of Transformer bays for 132KV side of 02 nos. of 150 MVA,
220/132KV, 3 Ph Power transformers.
2 Nos. of Transformer bays for 02 nos. of 50 MVA, 132/33 KV, 3 Ph
Power transformers.
1 No. Bus Coupler Bay
4 Nos. Line Bays
Total: 9 Nos.
33 KV System
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 12
-
2 Nos. of Transformer bays for 50 MVA, 132/33 KV, 3 Ph Power
transformers.
1 No. Bus Coupler bay
7 Nos. line Bays
Total: 10 Nos.
-The land development work upto Finished ground level (HFL+300 mm) shall be done by agency.
Also boundary wall construction shall be done by agency covering entire switchyard area. However ,
gate of switchyard and colour painting of boundary wall shall be done by turnkey contractor of Grid
Sub Station. The Security Check post and dorimatory for Security guards with 6 bed is covered in
Scope of work.
-The control and relay panel to be supplied will be without synchronising trolley, event logger and
mimic diagrams. The model technical specification of C&R panel contained in Vol-II shall stands
modified to bove content and price of C&R panel is to be quoted accordingly. The communication
protocol for entire substation and automation system shall be IEC-61850.
Sub Station Automation:
The technical specification of SAS is enclosed in volume-II of tender specification. There will be
modification from the given scheme. There will not be KIOSK located in switch yard. All signals
from Sub-Station bays will come to C&R panels housed in the control room. The bay control unit
and other components of automation system will be housed in C&R panel. Necessary networking
and interfacing through electrical and optical network will be done thereafter. The human machine
interface (HMI), server, monitor etc shall be located in separate cubical to be created inside the
control room by glass separation. The air conditioning system of control room is to be designed with
ample adequacy sufficient redundancy (more than 50%) to ensure proper functioning of automation
system in all weather condition with outage of many air conditioning units. The computers and
server to be used for SAS shall be of industrial duty. The monitor shall be of LED type of higher
resolution Guarantee period of SAS shall be 5 Years (Including service assistance part replacement
during during O&M. Mandatory spare shall not be used during Guarantee period. The items and
quantity of mandatory spares are to be specified by bidder and their price should be included in the
offer on lump sum basis. The addition spare for successful operation of SAS for 5 years beyond
guarantee period should also be indicated. This shall include Cards and other electronic components
which undergoes design change quite frequently due to up gradation. However, price of such
addition spares shall not be considered for evaluation purpose. of SAS should include cost of
mandatory spares and shall be considered during tender evaluation. The items and rate for other
spare shall be indicated separately in specified schedule and their cost shall not be considered during
bid evaluation.
It is mandatory on part of bidder to indicate quantity & rate for mandatory spare,
additional spare & other electronics items for replacement. The bid may be rejected on ground of
non submission. The auxiliary supply voltage will be 250V DC and 415V 3phase A.C.
Computer and laptop mentioned in tender specification and shall be supplied in additional of SAS
system. The laptop shall be of business class with latest configuration and industrial use. The
desktop shall also be of same duty cycle and latest configuration.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 13
Annexure-III
33KV SYSTEM PARAMETERS:1.
33kV System Fault current & duration – 25kA for 3 seconds
(This supercedes the duration of short circuit current
& duration given in Sec-GTR)
2.
Min. clearances
(i) Phase to phase
320mm
(ii) Phase to earth
320mm
(iii) Safety working clearance
3000mm
3.
Major Technical Parameters
The major technical parameters of the equipment are given below. For other parameters
and features respective technical sections should be referred.
(A) For 33 kV Vacuum Circuit Breaker and Isolator:
Rated voltage kV (rms)
36
Rated frequency (Hz)
50
No. of Poles
3
Design ambient temperature (°C)
50
Rated insulation levels :
1)
Full wave impulse withstand voltage (1.2/50 micro sec.)
between line
±170 kVp
terminals and ground
between terminals
±170 kVp
with circuit breaker open
between terminals
±170 kVp
with isolator open
2)
One minute power frequency dry and wet withstand voltage
between line
70kV(rms)
terminals and ground
between terminals
70kV(rms)
with circuit breaker open
between terminals
70kV(rms)
with Isolator open
Minimum creepage distance:
Phase to ground (mm)
900
Between CB Terminals (mm)
900
System neutral earthing
Effectively earthed
Seismic acceleration
0.3 g
Rating of Auxiliary Contacts
10 A at 250 V DC
(B)
Breaking capacity of
2 A DC with circuit time
Auxiliary Contacts
constant of not less than 20ms
Auxiliary Switch shall also Comply with other clauses of Section-GTR.
Total break time for 33 KV VCB ---- 60 m sec.
FOR 33kV CT/VT/SA
Rated voltage kV (rms)
36
Rated frequency (Hz)
50
No. of poles
1
Design ambient temperature (°C)
50
Rated insulation levels :
1)
Full wave impulse withstand voltage (1.2/50 micro sec.)
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 14
-
between line
±170 kVp
terminals and ground
for arrester housing
±170 kVp
2)
One minute power frequency dry and wet withstand voltage
between line
70kV rms
terminals and ground
for arrester housing
70kV rms
Minimum creepage distance :
Phase to ground (mm)
900
Between Terminals (mm)
900
System neutral earthing
- Effectively earthed Seismic acceleration
0.3 g
Cantilever strength of bushing
350 kg (minimum)
Class of 33 KV LA
----------III
(C) Technical Parameters of Bushings/Hollow Column Insulators/support
insulators for 33kV:
(a) Rated Voltage (kV)
36
(b) Impulse withstand
±170
voltage (Dry & Wet) (kVp)
(c)
Power frequency
70
withstand voltage
(dry and wet) (kV rms)
(d) Total creepage
900
distance (mm)
(e) Pollution Class-III Heavy (as per IEC 71) and as specified in
Section-2 for all class of equipment.
The requirement of alternate long & short sheds stated in model technical specification shall not be
applicable in case of 33 kV.
4. TECHNICAL PARAMETERS FOR SWITCHGEAR
(In addition to those indicated in 3 above)
A. 33kV Vacuum Circuit Breaker
a)Rated operating duty cycle
0-3min-CO-3 min-CO
b)First pole to clear factor
1.3
c)Rated
line/cable charging interrupting As per IEC
current at 90 deg. Leading power factor angle
(A rms)
(The breaker shall be able to interrupt the rated line/cable charging current with test
voltage immediately before opening equal to the product of U/(root)3 & 1.4 as per IEC
–62271-100)
e)Rated break-time as per IEC (ms)
60 m sec.
f)Total closing time (ms)
Not more than 80
g)Operating mechanism
Spring
h) Max. difference in the instants of 3.3
closing/opening of contacts between poles at
rated control voltage and rated operating and
quenching media pressures (ms).
i) Trip coil & closing coil voltage
250V DC with variation as specified
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 15
j)Noise level at base of CB and upto 50 mtr
distance from base of CB.
k) Rated terminal load
l) Auxiliary contracts
(Auxiliary switch
shall also comply with requirements
stipulated under chapter GTR)
m) No. of Terminals in Common Control
cabinet
140 db (max)
As per IEC
Besides requirement of specification,
the bidder shall wire up to 5 NO + 5
NC contacts for future use of owner.
All Contacts & control circuits to be
wired out upto common control
cabinet plus 24 terminals exclusively
for owners’s use.
n)Rated continuous current at design ambient 1250
temperature (amp).
o)Rated
short circuit current breaking 25 KA with pcercentage DC
capacity at total voltage.
component as per IEC-62271-100
corresponding to minimum opening
time & operating conditions specified.
p) Symmetrical interrupting capability 25
(KA,rms)
q) Rated short circuit making current (KAP)
As per IEC
r)Short time current carrying capability for 3 25
second (KA,rms)
s)Reclosing
Three phase auto reclosing
B. 33kV Isolator
(a) Type
(a) Temperature rise over design
ambient temperature
(b) Rated mechanical terminal load
Outdoor (Double Break)
As per table V of IEC 694
As per table-III of IEC 62271-102
IEC 129(1984) or as per value calculated in
SectionGTR whichever is higher
(c) Number of terminals in control
All contacts and control circuits
cabinet
are to be wired upto control
(Interpole cabling shall be
cabinet plus 24 terminals
Supplied by contractor)
exclusively for Owner’s use.
(d) Rated current at design
1250/1600 Amps(as applicable).
ambient temperature
(e) Rated short time withstand
25 kA for 3 Sec
current of isolator and earthswitch
(f) Rated dynamic short circuit
As per IEC
withstand current of isolator
and earth switch
(g) Operating mechanism for Isolator Manual
and Earth switch
(h) No. of auxiliary contacts on each
5 NO + 5 NC contacts, wired
isolator
to terminal block exclusively
for Owner's use in future.
(i) No. of auxiliary contacts on each
earthing switch
3 NO + 3 NC contacts wired
to terminal block exclusively
for Owner’s use in future.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 16
(j) Moving contacts & fixed contact ---- Shall be HDEC only.
B.1 The porcelain of the 36 kV insulators shall have minimum cantilever strength of
450 kgs
B.2 33 kV Isolator shall be gang operated for main blades and earth switches.
C. Surge Arrester
_________________________________________________________
Equipment to
BIL of the equipment to be protected
be protected
33 kV system (kVp)
____________________________________________________________
Power Transformer
+ 170
Instrument Transformer
+ 170
CB/Isolator
Phase to ground
+ 195
Across open contacts
+ 195
___________________________________________________________
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
Rated arrester voltage
30 kV
Nominal discharge capability 10 kA of 8/20 microsecond wave
Minimum discharge
5kJ/kV (referred to rated
capability
arrester voltage corresponding to
minimum discharge characteristics).
Continuous operating
24 kV rms
voltage at 50 deg.C
Max. switching surge
63 kVp
residual voltage (0.5kA)
Max. residual voltage
(i) 5 kA
80 kVp
(ii) 10 kA nominal
85 kVp
discharge current
Long duration discharge class
High current short duration
test value (4/10 micro second wave)
Current for Pressure Relief test
Low current long duration
test value (2000 micro sec)
Pressure relief class as per IEC-99-1
(k)
D. 33kV Current Transformers
1.
Rated Primary current
2.
Rated Extended Primary current
2.
Rated short time thermal
Current
3.
Rated dynamic current
4.
Maximum temperature rise over
design ambient Temperature
5.
One minute power frequency withstand voltage sec. terminal & earth
6.
Number of terminals
3
100 kAp
40kA rms
As per IEC.
A
600/1000A(as applicable)
120% (on all cores)
25 kA for 3 sec.
As per IEC
As per IEC:44-1
5 kV
All terminals of control
circuits are to be wired upto
marshaling box plus 20%
IN JASIDIH GSS VOL-II
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Page 17
7.
spare terminals evenly
distributed on all TBs.
Class A
Type of insulation
Current transformers shall also comply with requirements of Table – I given below:
TABLE – I
A.
Current Transformer (600A)
_________________________________________________________________
No.of
Cores
Core
No.
3
1
Application
Output
Accuracy
Min. knee Max.CT Max.Excit- Remarks
burden(VA) class as
pt.voltsec.wdg. ation curper IEC:
age Vk
resisrent at Vk
44-1
ance(ohms) (in mA)
___________________________________________________________________________________________________
O/C & E/F
Current
ratio
600300/1
-
P.S.
600/
300
4/2
40 on
600/1 Tap;
80 on
200/1 Tap
2
METERING 600300150/1
20
0.2
-
3
TRANS.
DIFF
PROTN
-
P.S.
600/
300
600300/1
-
-
4/2
40 on
600/1 Tap
80 on
300/1 Tap
___________________________________________________________________________________________________
All relaying CTs shall be of accuracy class PS as per IS:2705.
B. Current Transformer (1200A)
_________________________________________________________________
No.of
Cores
Core
No.
Application
Current
ratio
Output
Accuracy
Min. knee Max.CT Max.Excit- Remarks
burden(VA) class as
pt.voltsec.wdg. ation curper IEC:
age Vk
resisrent at Vk
44-1
ance(ohms) (in mA)
___________________________________________________________________________________________________
3
1
O/C & E/F 1200-600-300/1-1-1-1-1A
2
METERING 1200/600/300/1-1-1-1-1A
-
P.S.
-
0.2
1200/600 12/6
1200/1 Tap;
30 on
1200/1 Tap
60 on 600/1 Tap
3
TRANS. 1200/600/300/1-1-1-1-1A
P.S.
1200/600
30 on
DIFF
12/6
1200/1 Tap
PROTN
___________________________________________________________________________________________________
All relaying CTs shall be of accuracy class PS as per IS:2705.
F.
1.
2.
3.
4.
33 kV POTENTIAL TRANSFORMERS
Rated primary voltage (kV rms)
36
Type
Single phase PT
No. of secondaries
3
Rated voltage factor
1.2 continuous
1.5 - 30 seconds
5. Phase angle error
+/- 20 minutes (for metering core)
6. Standard reference range of
96% to 102% for protection and
frequencies for which the
99% to 102% for measurement
Accuracies are valid
7. One minute power frequency
Withstand voltage:
i) Between LV terminal and earth
10kVrms for exposed terminals and
earth terminal
4kVrms for terminals enclosed in a
weather proof box.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 18
ii) For secondarywinding
8. Maximum temperature rise over
design ambient temperature
9. Number of terminals in control
Cabinet
2 kVrms
As per IEC 186
All terminals of control circuits
are wired upto marshalling box
Plus spare 20% terminals
evenly distributed on all TBs
75 VA
10. Rated total thermal burden
11. .Voltage Ratio
12. Application
13. Accuracy
14. Output burden
(VA) (minimum)
5.
a)
Secondary I
33/0.11
Protection
3P
Secondary II
33/0.11
Protection
3P
SecondaryIII
33/0.11
Metering
0.2
50
50
25
INSULATOR STRING ( 33 KV )
f)
Power frequency withstand
:
voltage of the complete
string with Corona Control
ring (wet) - kV rms
Lightning impulse withstand
:
Voltage of string with corona
control rings (dry) – kVp
Power frequency puncture with- :
stand voltage for a string insulator
Total creepage distance of the
:
complete insulator string (mm)
Total no. of discs per strings
:
6.
a)
b)
33kV Bus Post Insulators.
Type
Voltage class (kV)
b)
c)
d)
75
±170
1.3 times actual wet flashover
voltage of the unit
900
5 ( S/T & S/S )
Solid Core
36
c)
Dry and wet one minute power
70
frequency withstand voltage(kV rms)
d)
Dry lightning impulse
±170
withstand Voltage (kVp)
e)
Total minimum cantilever
450
strength (Kg)
f)
Minimum torsional moment
As per IEC-273
g)
Total height of insulator (mm)
As per requirement
h)
Pollution level as per
Heavy(III)
IEC-815
i)
Minimum creepage distance for
900
Heavy Pollution (mm)
7. CONTROL AND RELAY PANEL
CONFIGURATION OF C&R PANELS
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 19
The following is the general criteria for the selection of the equipments to be provided in each type
of panel.
CONTROL PANEL (33kV)
Various types of control panels shall consist of the following.
a. Ammeter with Selector switch
1 set for each line, TBC and Transformer
b. Wattmeter with transducer
1 set for each line, transformer
c. Varmeter with transducer
1 set for each line, transformer
d. CB Control switch
1 no. for each Circuit breaker
e. Red indicating lamp
1 no. for each Circuit breaker
f. Red indicating lamp
1 no. for each isolator
g. Green indicating lamp
1 no. for each Circuit breaker
h. Green indicating lamp
1 no. for each isolator
i. White indicating lamp
2 nos for each feeder
(DC healthy lamp)
j. Annunciation windows with
6 nos for each feeder
associated annunciation relays
k. Puch button for alarm Accept/
3 nos for each control panel
reset/lamp test
l. Protection transfer
1 no. for each breaker(Except TBC breaker)
m. Mimic to represent SLD
Lot in all control panels
n. Voltmeter with selector switch
1 no for each line, transformer
o. Cut out, mounting and wiring
Lot for transformers
for RWTI and selector switch
Note :
1. For transformer feeders, all equipments of control panel shall be provided separately for HV
and MV sides.
2. The above list of equipments mentioned for control panel is generally applicable unless it is
defined elsewhere and in case of bay extension in existing substations, necessary equipments
for matching the existing control panel shall be supplied.
3. Each line/HV side of transformer/LV side of transformer/TBC shall be considered as one
feeder for above purpose.
LINE PROTECTION PANEL
The Line Protection panel for transmission lines shall consist of following relays and protection
schemes
Sl.No. Description
33KV
1.
3 phase trip relays(Hand reset)
1 no.
2.
Flag relays, carrier receive relays, aux. relays
Lot
Timers etc. as per scheme requirements.
3.
Energy meterStatic type composite meter)
1 no.
(0.2 Class)
4.
Non-Directional back up Over current and
1 set
E/F protection scheme.
5.
Under Frequency relay (with df/dt feature – Separate relay)
1 No.
TRANSFORMER PROTECTION PANEL
I.
The protection panel for 132/33kV Transformer shall consist of the following
equipments.
132kV side
33kV side
1. Transformer Differential protection scheme
1 no.
Nil
2. Restricted Earth fault protection scheme
1 no.
1 no.
3. Directional back up over current and E/F Relay
1 set
Nil
With non directional high set feature
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 20
4. Non-Directional back up over current and E/F
Nil
Relay with non-directional high set feature
5. Over fluxing protection scheme
Nil
6. Over load protection scheme
1 no.
7. Three phase trip relays
2 no.
8. Flag relays, aux. relays, timers etc. as per
Lot
Scheme requirements including transformer
Alarms and trip function
8. Energy meter (Static type composite meter)
1 no.
BREAKER RELAY PANEL
The breaker relay panel for 33kV shall comprise of the following :
Without A/R
1 set
1 no.
Nil
2 no.
Lot
1 no.
1. DC supply supervision relay
2 no.
2.Trip circuit supervision relays
2 nos.
3. Flag relays, aux. relays, timers, trip relays etc.
Lot
As per scheme requirements.
COMMON EQUIPMENTS (for 33kV)
The following common equipments shall be provided for each new substation. These
equipments shall be mounted and wired in the C&R panel offered.
1. Common Annunciation Scheme 1 set
2. Bus voltmeter (Digital)
1 no. for each main bus
3. Bus frequency meter (Digital)
1 no. for each main bus
4. Bus healthy indication lamps
3 nos. for each bus.
Technical Parameters for 50 MVA 132/33 kV,3-Phase Two-winding transformers:
1.1
Rating HV/LV
50MVA/50MVA
(for 50 MVA)
1.2
1.3
Cooling
Rating at different cooling
ONAN/ONAF
80% / 100%
1.4
Type of transformer
Two winding
1.5
Voltage Ratio
132/33 kV
1.6
Frequency
50 Hz
1.7
Phases
Three
1.8
Impedance
i)
HV/LV impedance at 750 C :
- Principal Tap
12.5%
1.9
Service
Outdoor
1.10
1.11
1.12
Duty
Vector Group
Overload capacity
Continuous
YNyn0
As per IS:6600/1972
/ IEC - 354
IN JASIDIH GSS VOL-II
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Page 21
1.13
iv)
v)
vi)
1.15
i)
Temperature rise over
500 C ambient temp.:
Of top oil measured by
Thermometer
Of winding measured by
Resistance method
Max. design ambient
Temperature
Windings
System Fault level(kA)
for 1 sec.
1.2/50 micro sec. impulse
withstand voltage kVp
One minute power freq.
withstand voltage kV(rms)
Winding connection
Neutral
Insulation
Tap Changer
Tap range
ii)
Tap control
1.16
i)
ii)
iii)
Bushing
Rated Voltage(kV)
Rated Current(Amp)
1.2/50 micro sec.
impulse withstand
voltage kVp
One minute power
withstand voltage
kV(rms)
Minimum total
creepage distance
(mm)
Mounting
HV
145
400
650
Tap changer shall be
located at the neutral end
of 132 kV winding for
------- achieving +10% to -10% of -----------HV variation in the step of
1.25%.
It shall be of constant flux
Voltage variation type as per
Cl. 3.2 of IS:2026 Pt-IV/1977
Full capacity – on load tap changer
suitable for group/independent,
------- remote/local electrical and local ---------manual operation and bi-directional
power flow.
LV
Neutral
36
36
1600 1600
170
170
275
70
70
3625
900
900
Tank type
Partial discharge
Level
Conventional
500 pico-coulomb
1.14
1.15
i)
ii)
iii)
iv)
v)
vi)
1.17
1.18
500 C
550 C
500 C
HV
LV
31.5 31.5
(for 1 sec)
550
170
230
25 (for 3 sec)
70
Star Star
Solidily grounded
Graded Uniform
Tank Tank Tank
cover cover side
IN JASIDIH GSS VOL-II
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Page 22
1.19 Noise level
As per NEMA TR-1
Note: 1. In case of parallel operation with existing transformer,the impedance,OLTC connection &
range and the winding configuration (if necessary) is to be matched with the existing.
1.20 Bushing Current transformer Parameters :
1.20.1 Current transformers shall comply with IS : 2705 / IEC-185.
1.20.2 It shall be possible to remove the turret mounted current transformers from the tank without
removing the tank cover. Necessary precautions shall be taken to minimize eddy currents and
local heat generated in the turret.
1.20.3 Current transformer secondary leads shall be brought out to a weatherproof terminal box near
each bushing. These terminals shall be wired out to cooler control cabinet/marshalling box
using separate cables for each core.
1.20.4 Bushing current transformer parameters indicated in this specification are tentative and liable
to change within reasonable limits. The contractor shall obtain Employer’s approval before
proceeding with the design of bushing current transformers.
A) 50 MVA,132 /33 kV Two –winding Transformer :
(on each phase connection)
HV Side
HV Neutral
LV Side
LV Neutral
a) Ratio (A)
Core-1
400/1
Core-2
300/1
b) Min. knee point
Voltage and accuracy
Class:
Core-1
800V
Class PS
400/1
1000/1
1000/1
-
1000/1
-
1000V
Class PS
1000V
Class PS
0.5 Class
30 VA
-
1.5 ohms
1.5 ohms
800V
Class PS
Core-2
0.5 Class
30 VA
c) Max. CT resistance
Core-1
Core-2
1.5 ohms
-
1.5 ohms
-
-
-
-
REF
REF
REF
Metering
-
100 mA
100 mA
d) Application
Core-1
REF
(near the wdg)
Core-2
Metering
-
e) Max. magnetization
Current (at knee point
Voltage)
Core-1
Core-2
100 mA
-
100 mA
-
-
-
IN JASIDIH GSS VOL-II
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Page 23
TECHNICAL REQUIREMENTS FOR MAINTENANCE & TESTING
EQUIPMENTS 1. BDV TEST KIT
i)
The equipment shall be suitable for determination of electrical strength (break
down voltage) of insulating oil confirming to IS-335 up to 100 kV when
measured in accordance with IS:6792. The equipment shall be used in
laboratory.
ii)
The test cell shall be as per IS:6792 and IEC-156-1995 suitable for BDV
up to 100kV without external flash over.
iii)
HV chamber interlocking and zero start interlocking shall be provided.
iv)
The unit shall have motorized drive to increase voltage linearly as per the rate
specified in IS: 6792 . Provision shall also be available for manual increase of
voltage.
v)
The unit shall be complete with motorised test cell stirrer, calibrator and
necessary gauges for adjusting the gap.
vi)
It shall be suitable for 230V, single phase, AC, 50Hz supply with variations of
±10% and ±5% in voltage and frequency respectively.
vii)
Kit shall be supplied along with all accessories operating manual,spare fuses
,indication lamps,power supply chord etc all that is required for carrying out
measurements
It should offer repeatability of test results.
viii) It should have overload and short-circuit protection
--------------2. Megohm meter– 5KV Digital Battery operated.
Sr.NO
6.
Description
Type
Insulation test voltage
Short Circuit Current
Accuracy(test voltage)
Range of
Measurement
Additional features
7.
8.
9.
Accuracy(resistance)
Operation
Display & scale length
10.
11.
12.
13.
14.
15.
16.
Power Supply
Batteries
Battery Charger
Response time
Capacitive Discharge
Guard termination
Accessories
17.
Demonstration
1.
2.
3.
4.
5.
Specifications
5 KV Digital Battery Operated.
5 KV in steps of 0.5,1,2.5,5 KV DC
1.5 mA minimum
±3% of nominal voltages or better
0 to 200 G Ohm minimum
Shall be able to compute and display Polarisation Index
and Dielectric Absorption Ratio as per Indian Standards.
±5% of reading±3 digits or better
Motor Driven by mains/batteries
Digital and Analog in baragraph, with auto switch off
feature
230±10% ,50 Hz
12 V/1.2 AH Rechargeable
Automatic Inbuilt for AC voltage 110 to 240 V
Less than 3 sec
Automatic after insulation test is over,<
To be provided
Test leads,power supply leads, charger leads, Carrying
case,Manual ,etc required for testing
Acceptance of kit subject to successful demonstration in
charged switchyard environment to the satisfaction of
JUSNL
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 24
18.
19.
20.
21.
Calibration Certificate Calibration certificate from/traceable to, NABL
accredited lab or internationally reputed lab, shall be
submitted. Date of calibration shall not be older than one
month from the date of supply of Kit.
Environmental and
Shall conform EMI/EMC and environmental protection
statutory requirement requirement as per relevant International standard.Copy
indicating conformation shall be enclosed .
·
Temp- -5 to 50 deg C.
· Humidity- upto 95% non condensing
Functional
The instrument shall work in charged switchyard
requirement.
environment conditions.
Additional safety
The kit and accessories shall be robust and rugged
requirement
enough, so that it can be transported safely at different
locations .The transportation case and packing of the kit
shall be such that the transportation from one station to
other will not affect the performance and accuracy of
measurement of kit.
Digital Multimeter
i)Heavy Duty, shock proof, splash proof, dust proof.
ii)Measurement Range :
Description
Range
Accuracy
a)
DC Voltage
0 – 1000 Volts
±0.25%
b)
AC Voltage
0 – 750 Volts
±0.75%
c)
DC Current
0 – 10 Amp
±0.75%
d)
AC Current
0 – 10 Amp
±1.5%
e)
Resistance
0 – 30 Mohms min.
±1.0%
f)
Continuity Check
0 – 250 Ohms min
g)
Diode Test Unit
±1%
i)
iv)
Display 3 and ½ digit, LCD,Bar graph.
Polarity Automatic, No indication for positive polarity, Minus (-) sign for
negative polarity. With Capacitance, frequency and Temp.measurement
features
v)
Over range indication – Half digit display with other digits blank.
vi)
Low battery indication
vii)
Power Supply – Single Standard 9 V Battery.
viii) Transient Protection: 2 KV (DCV / ACV and Ohm Ranges).
ix)
Environment: Operating 0 – 55 degree Centigrade, 80% RH at 35 degree C,
Storage –20 to 60 deg.C, 70% RH at 40 deg.C.
x)
Accessories : Test leads set, temp. probe, High Voltage probe, Carrying case,
spare fuses, Manual etc.
xi)
The instrument shall work in charged switchyard environment conditions.
xii)
Instrument shall confirm to International/Indian safety and EMC standards
4. Oil sampling Bottles
-Capacity
- 1 Ltrs
Ø Container
- Made of Stainless Steel.
Ø 2 Nos. of 0.25” of S.S. needle valve with SS T type handle one on each side.
Ø 2 Nos. of SS adopters with end caps one on each side.
Ø The valves should be 100 % leak proof .
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 25
Ø Suitable for Dissolved Gas Analysis Test.
Ø The design of bottle & seal shall be such that loss of Hydrogen shall not be
Exceed 5% per week.Copy of type test report to be enclosed.
Ø Suitable for collecting oil samples from transformers and shunt reactors.
Ø Bottles shall be robust enough ,so that no damage occurs during frequent
transportation of samples from site to laboratory.
5. Portable SF6 Gas Refilling Device
Sr No Description
Specification
1.
Functional Requirement
Equipment shall be able to evacuate and fill the sf6 gas in
breakers, cylinder etc Mobile unit shall be mounted on a
cart provided with wheels for easy movement. The cart
shall have provision for carrying a SF6 gas cylinder.,
2.
Assembly parts
The equipment shall basically consist of a vacuum pump,
vacuum gauge, SF6 gas regulator with H.P and L.P
manometers, Three way valve and hoses of sufficient
length with couplings for connecting to SF6 gas cylinder
and to equipment
3.
Accessories
4.
Vacuum Pump
It shall consist of pressure reducer for SF6, Indicating
instruments (gauge indication in bar),
Hose DN8/ 6 m long,Hose DN8/ 0.7 m long , Coupling
tongue part DN8 and DN20, SF6 bottle connection W21.8
x1/14” ,Power Supply cable with three pin ,Opearting
Instruction manual, Or equivalent accessories that is all
required for carrying out specified work.
Pump 10 m3 /h ( final vacuum<1mbar)
5.
Operating Voltage
230±10% ,50 Hz
6.
Packing
The Cart along with wheels shall be robust and rugged
enough, so that it can be transported safely at different
locations .The transportation case and packing of the kit
shall be such that the transportation from one station to
other will not affect the performance.
Automatic Capacitance and Tan Delta Kit
The equipment shall be suitable to measure capacitance and tan delta of EHV class
transformers (1/2/3 windings), bushings,CT, windings of shunt reactors, bus & line
CVT’s and grading capacitors of CB’s at site in a charged switchyard up to 765kV AC
and 500kV DC. The kit should have the feature of suppression of electrical and
magnetic interference due to line frequency and it should also have the feature of
measuring tan delta and capacitance at different frequencies than line frequency.
The kit shall be capable of measuring capacitance and tan delta of each winding of 315
MVA transformers in suitable switching mode so that capacitance of other windings
does not affect the reading etc.
An optional arrangement if available for measurement of inductance, transformer
turns ratio, transformer leakage reactance and loss ,winding resistance etc may be
included in offer, However the tech/financial evaluation will be made for the basic kit
which have facility of measurement of tan delta and capacitance with induction
suppression feature as detailed above in para-1
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 26
The kit shall be able to measure the ambient temperature and relative humidity with
inbuilt/optional arrangement.
The equipment shall be complete with measuring bridge, HV power supply unit of 12
KV, Standard Capacitor,PC/Video Screen etc. The effects of induced voltage on
instrument during testing for getting final measurement should be compensated
automatically. The kit shall be capable of measuring excitation current of transformer
winding at 12 KV .
The kit should have the facility of generation of test frequency independent of power
line frequency for measurement of tan delta and capacitance
The equipment shall be robust enough to sustain the jerks during the transportation in
local condition.
The kit should be light weight, its packing and transportation cases/trolly shall be such
that the shifting of kit from one substation to other will not affect its performance and
accuracy in measurement of the kit.
Sr,No
Description
Specification
1. 1Output Voltage
and
Current
0 - 12 KV and 100 mA (Min) continues and
200mA&above intermittent @ frequency range 45
Hz max to 70 Hz minimum
2. 2Tan Delta (DF)
Range
- 0 to 100%min
Accuracy -1% or better, of the reading
Resolution - 4 digit or better
3.
Range
- 0 to 100%min
Accuracy - 1% or better of the reading
Resolution - 4 digit or better
Power Factor
4. 3Capacitance
5. 5Power
supply(Input)
6. 6Induction
suppression
7. 7Display/Operati
on
8. 8Data Store
9. 9Safety features
10. 1 Indications
0
Range
- 1pf to 2µf min
Accuracy - 0.5 % min + 0.1 pf of the reading.
Resolution - 6 digit
230V±10% AC, 50Hz±5%
Full automatic
VGA LCD,Front panel/key pad mounted on control
unit.
Facility for data storing in the kit & down loading to
PC
§ Short circuit protection
§ Over voltage protection
§ Interlock for HV output.
§ Reliable ground connections etc.
HV supply ON, Ground open, Power supply ON etc.,
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 27
11. 1 Cablesand
1 accessories
§
§
§
§
§
§
12. 1 Software
2
13. 1 Repeatability
3
14. 1 Environment
4
15. 1 Operating
5 conditions
16. 1 Demonstration/I
6 nspection
17. Calibration
HV/LV screened cable set – 20 meters (min) with
clamps & connectors.
Power supply cable
Grounding cable with clamps
One set of interconnecting cables.
Other cables and accessories required for
carrying out measurement.
One set of fuses and indicating lamps and other
consumables shall be supplied with kit.
Data analysis software in windows 98/2000/latest
version with the features of
§ Storing and downloading of files in data base for
further analysis in PC.
§ Facility of drawing graphs between voltages
tan δ with temperature correction of tan δ
values,frequencies etc.
§ Comparing of different value of same parameter
at different period/time
It should offer repeatability of test results in charged
switchyard.
The kit shall be compatible for EMI / EMC
requirement as per relevant IEC .
Shall operate at Temperature -5 to 50 deg C,
Humidity not condensing up to 95%,
Acceptance of the kit shall be subjected to the
arrangement of successful demonstration by supplier
to the satisfaction of Power grid at prescribed site.
Calibration certificate from/traceable to, NABL
accredited lab or internationally reputed lab, shall be
submitted. Date of calibration shall not be older than
one month from the date of supply of Kit.
7. Dew Point Kit for SF6 gas
Sr.No
1.
2.
3.
4.
5.
6.
7.
Item
Functional
Requirement
Measuring Range
Display
Accessories
Specification
The Instrument shall be able to measure the dew point of SF6 and
Nitrogen available in the electrical equipment or Cylinders.
-80 to 0 ˚C minimum @ +/-2% or better accuracy
Digital
Compatible inlet and out let couplings,Hoses, carrying
case,Instrution manual,Power supply chord,Charger, The
accessories shall be suitable to the equipments in Powergrid,
during Atmospheric to 30 Mpa max
Pressure
measurement
Flow Rate during 0.5 to 5 L/min
Measurement
Power Supply
Internal rechargeable battery pack with charger.To be operated on
220 +/- 10% V AC ,50+/-10% Hz.Or Equivalent
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 28
8.
9.
Operating
Temperature
Calibration
10. Demonstration.
-20 to 50 deg C.
Calibration certificate from/traceable to, NABL accredited lab
or internationally reputed lab, shall be submitted. Date of
calibration shall not be older than one month from the date of
supply of Kit.
Acceptance of kit subject to successful demonstration in
charged switchyard environment to the satisfaction of Power
grid
11. Packing and transport The kit and accessories shall be robust and rugged enough, so
cases
that it can be transported safely at different locations .The
transportation case and packing of the kit shall be such that
the transportation from one station to other will not affect the
performance and accuracy of measurement of kit.
8. Transformer Oil Filtration Plant
8.1
Performance Requirements
8.1.1
The ultra High Vacuum type oil treatment plant of capacity 2KL/4KL per hour will be
mobile and will be suitable for treatment of new oil and reconditioning of used oil in
EHV class transformer, shunt reactor and other oil filled equipments in order to
achieve properties of treated oil within specified limits at the rated capacity.
8.1.2
The plant will be capable of treatment of new oil (as per IEC
296/IS:335 and
reconditioning of used oil as per IS: 1865/IEC:422 for oil in service) at rated capacity
on single pass basis as follows:
(i)
Removal of moisture from 100 ppm to 3 ppm (maxm.)
(ii)
Removal of dissolved gas content from 10% by vol to 0.1% by vol.
(iii) Improvement of dielectric strength break down voltage from 20 KV to 70
KV (min)
(iv)
Vacuum level of degassing Not more than 0.15 torr (0.2mbar) Chamber at
rated flow and max. At final stage.
(v)
(vi)
(degassing chambers of different degree of vacuum will have efficient
surface areas to achieve the final parameters. A detailed justification as to
how end parameters will be met with detailed calculations and test reports in
support of the same will be submitted along with the offer.
Filtering capacity : Max. particle size less than 0.5 micron in the filtered oil.
(a)
Processing temperature
(b) Maximum allowed temp.
in oil to prevent oxidation
(when oil is at atmospheric
pressure)
8.1.3
400C to 600C
600C
Contractor shall furnish detailed calculation to establish the sizing and capability of
the vacuum pumping system with respect to moisture and gas removal as above.
8.1.4 Contractor shall submit test reports, test methodology to prove the capability of the plant
offered.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 29
8.1.5 The plant will also have two independent vacuum pumping systems one for
evacuating the transformer for vacuum filling of oil in transformer and the other for
degassing chamber. The blank off vacuum of each pumping system will be 10-3 torr
or less.
8.1.6 The plant will be provided with control and indication panel with full automation.
8.1.7 The plant will be fitted with hoses for connection of oil lines and vacuum lines to
transformers and reactors. Hoses will have leakage rate of 10-12 torr ltr/ sec (max.)
8.1.8 The plant will be suitable for cleaning and degassing of the oil
tanks.
stored in the storage
8.1.9 All equipments required as above will be mounted on a towable road worthy trailer
unit with 04 nos. pneumatic tyres.
8.2 Design & Construction
8.3 The features and construction details of each 2KL/4KL per hour capacity mobile outdoor
type oil filteration & purification plant will be in accordance with the requirements stated
hereunder.
8.2.1 Oil Pump (Inlet Side)
8.2.1.1
Two (2) nos. electrically driven oil pumps with one (1) working and One (1)
standby will be provided. Selection switch will be provided for selection of either
of pumps. The pumps will be single stage positive displacement gear type.
Suitable mechanical seals will be provided to ensure vacuum tightness. A built in
pressure relief valve to recirculate the oil to suction side in case of accidental
pressure rise will be provided. Suction lift of the pump will be atleast 5 meters of
transformer oil at atmospheric pressure and temperature. A seperate by pass
valve is provided across the gear pump so that the flow rate through the filter can
be adjusted as required. The pump should be controlled by frequency drive .This
should help to set the the flow rating of filter pLant from 1000-200LPH / 20004000 LPH .
8.2.1.2 The pumps will be provided with an interlock with delay such that if there is no oil
flow for 30 sec. through the heater, the pump will trip automatically and also if the
pump is not operating the heater will not be energized.
8.2.2
Magnetic Strainer
8.2.2.1 The plant will be provided with a suitable magnetic strainer with wire mesh to filter
all particles of sizes above 0.5 mm and all magnetic particles. The strainer will be installed at
the suction of the oil pump described above.
8.2.3 Heater
8.2.3.1.
An oil heater for heating up inlet oil will be provided at the discharge side of the
oil pump.
8.2.3.2.
The oil heater vessel will be of Mild Steel welded construction
and insulated with glass/ mineral wool.
The vessel will be constructed for ultra high vacuum and pressure application.
8.2.3.3
Electric heater will be provided inside the heater vessel to heat up oil from lowest
ambient temperature to temperature required for filtration / degasification
operation in single pass. The heater will also be rated for heating the inlet oil
from lowest ambient temperature to 700C in single pass during filling up of
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 30
transformers. Two separate temperature setting with thermostatic controllers will
be provided for this purpose.
8.2.3.4
The heating will be indirect type and specific heat load will not exceed 2.0 watt/
cm2 in order t avoid local overheating.
8.2.3.5
The total heating capacity will be divided into three independent thermostatically
controlled heating stages evenly balancing the three phases of power supply. The
control switches and knobs will be housed on a control panel.
8.2.3.6
An additional preset temper proof safety thermostat set at the highest temperature
will be provided on the heater to put off the heater and give audio and visual
alarm to take care of accidential overheating.
8.2.3.7
The heater body will be so designed as to follow replacement of heating elements
without draining of oil. Suitable pressure relief valve, vent and drain valves and
two (2) dial type temperature gauges at inlet and outlet of the heater will be
provided.
8.2.4
Filter
8.2.4.1
Cartridge filter as may be required to ensure maximum particle size of less than
0.5 micron in the filtered oil will be provided.
8.2.4.2
The filter body will be fabricated of mild steel and designed for leak tightness at
full vacuum and high pressures. The oil will flow from dirty oil chamber to clean
oil chamber through filter elements.
8.2.4.2.1
Cartridge type element used will be suitable for transformer oil in service and submicronic
filtration, the media will be non hygroscopic and of high dirt holding capacity.
8.2.4.3
The filter elements will be easily removable for replacement when required. Compound
gauge to indicate pressure across the filter vent and drain with valves and other necessary
accessories.
8.2.5 Coarse Filter
8.2.5.1
For treating dirty oil, coarse filter of adequate rating may be supplied for supplementing the
capacity of filter elements. These units will be designed for quick and easy replacement of
media. A sludge outlet for receiving the solid impurities and cleaning the filter plate without
opening the unit will be provided. The unit will also be provided with vent and drain valves,
pressure gauges at inlet and outlet and other necessary accessories.
8.2.6
External Solenoid Operated valves
8.2.6.1
8.2.7
Two valves will be provided at the inlet and outlet of the plant. The moment inlet
and outlet pumps are switched on these valves open thus making way for oil to
pass. In case of power failure, oil from the transformer will not enter the plant and
the vacuum system.
Degassing chamber
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 31
8.2.7.1
The degassing chamber will be of welded construction and will be suitable for
operation under full vacuum. The fill of raschig rings and trays for distribution
will be designed for efficient distribution of oil over large areas. Incoming
transformer oil will be spread over these rings in the from of film and over a
longer surface area thus achieving better degassing and dehumidification.
8.2.7.2
The degassing chamber will be either single stage or multi stage type suitable for
ensuring the desired oil properties. Arrangement for condensing back lighter
fraction (Aromatics) of the insulating oil into the system will be provided.
8.2.7.3
The degassing channels will have adequate height to allow long enough free fall
for complete degassing. Design will be such as to minimize foam formation.
8.2.7.4
The degassing chambers will be provided with suitable level monitor for oil or
foam level in the chamber and will trip the inlet gear pump when the level rises
above the designed maximum level in order to prevent foam/ oil to enter the
vacuum pumping system. The oil inlet pump starts again automatically once the
oil level in the degassing chamber falls below the preset oil level.
8.2.7.5
Necessary illuminated sight glass will be provided through which oil flow
through the degasser can be viewed clearly.
The degasser will be provided with vacuum gauges, vacuum breaking valves, main
and auxiliary vacuum connections and other necessary accessories.
8.2.8
8.2.8.1
8.2.8.2
Vacuum Pumping System
The pump will be provided with a suitable vacuum pumping system for creating
adequate high vacuum in the degassing chambers. The pumping system will
consist of suitable combination of Roots Blowers and Rotary vane vacuum pumps
with interstage condensing units.
The Roots blowers will be of reputed make. Suitable built in labyrinth packing system,
slinger rings, oil return chambers will be provided between bearings and working chambers to
prevent penetration of lubricating oil to the working chamber. The pumps motor will be
dynamically balanced. The pumps will be suitable for starting evacuation from atmospheric
pressure and will be applied with necessary overflow valve.
8.2.8.3
The rotary vane vacuum pumps will be installed after the roots blower. An
automatic by pass valve across the roots blower will permit operation of rotary
vane pump alone to operate when so required. The rotary vane pumps are
provided with gas ballast valve to prevent contamination of vacuum pump oil
with moisture. The vacuum pump will also be provided with suitable non-return
valve device such that in the event of power failure the vacuum in the degassing
chamber will be maintained and the vacuum pump oil is not sucked back into the
degassing chamber. A high vacuum safety valve (piston type) to prevent back
streaming of oil and air intrusion will be provided. The pump motors will have
return stop device.
8.2.8.4
Necessary water cooled condensing units to condense the lighter faction
(Aromatics) and return the same to the transformer oil will be provided to reduce
the loss of aromatics. Condensing units will also be suitable for operation with
broken ice for remote location operation where cooling water connection is not
available.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 32
8.2.8.5
Vacuum Pumping System for Transformer Evacuation
8.2.8.5.1 An independent vacuum pumping system will be provided for evacuating the
transformer for oil filling. The vacuum level required for transformer evacuation
for oil transfer is about 0.76 torr (1 m bar) for transformer oil heated to 70-800C.
The pumping system will be identical to that of the degassing vacuum system.
The capacity will be adequate for evacuation of transformer in one hour. The
vacuum systems for degasser and transformer evacuation will be inter connected
in such a way that it will be possible to use either or both the systems for any of
the purpose. A reinforced of 10 mts. Length will be provided. The hoses will be
for vacuum leakage rate of 10-2 torr litre/ sec.
8.2.9
8.2.9.1
Oil Extraction Pump
Suitable pumping system will be provided for extracting oil from degasser under
vacuum and supplying to transformer/ reactor etc., at discharge pressure of 1.5
Kg/ cm2 at the outlet hose nozzle of the plant, the pump will be either glandless
centrifugal type with canned motors or a combination of gear pump and
centrifugal pump with mechanical seals suitable for extracting oil from high
vacuum degassing chamber. The oil extraction pump will be located at a suitable
level below the degasser chamber so as to ensure adequate suction head for the
pump. The pump will be supplied with double check valve assembly and
solenoid operated non-return valve. In order to stop reverse flow of the oil in
case of power failure, the pumping system will preferably be self priming type
alternatively priming device with safety interlock to protect pump against dry
running will be provided. Sampling valves will be provided at the discharge of
extraction pump for testing of oil properties. A recirculation line with valves will
be provided to recirculate a part of the purified oil to the inlet point if necessary
during operation.The outlet pump should be control by frequency drive to give
controlled output from range 1000-2000 LPH/2000 – 4000 LPH .
9. Circuit Breaker Test Kit
Sr.no
1
Description
Functional
Requirement
Specifications
This instrument shall have microprocessor-based operation with LCD display
for testing of EHV Circuit Breakers in the charged switchyard
environment.(420 kV AC and 500 kV DC).
To measure the CB contact movement during opening, closing, auto-reclosing
and make/break operation, contact speed at various stages of operation, travel
of contacts, Main and auxiliary contacts (wet and dry), opening time, closing
time and make break time, closing resistor pre-insertion time etc.
Dynamic contact resistance measurement of Arcing and Main Contact with
minimum 100 Amp DC current while closing/opening of CB. The kit should
also be capable of indicating trip/closing coil currents (analogue values).DCR
measurements shall be shall be carried out for minimum one pole(two breaks)
at a time.
In case, to meet the functional requirements as mentioned above if more than
one units are required, the facility to co-relate/interface various parameters,
shall be supplied along with the kit.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 33
2
Channels
3.1
3.2
3.3
3.4
4
5
6
7
8
9
10
11
12
Contact channels
Auxiliary contacts
:24 ( 4 each for main and PIR)
: 2 dry + 2 wet
Current and Voltage
: 3 each .
Ranges
& Main/Auxiliary Contacts
: 0 to 4000 ms minimum
Accuracy
Accuracy
: ± 0.1 % or better
Resolution
: ± 0.1 ms at 10 Kc.
Contact Travel
: 0 to 10 m/s speed, 350 mm minimum
Accuracy
: ± 0.1 % or better
Resolution
: ± 2mm or better
Dynamic Contact Resistance : 0 to 2000 microhm
Accuracy
: ± 2 % or better
Coil currents
: 0 to 25 Amps
Accuracy
: ± 1 % or better
Sampling rate
Selectable – 100 Hz,1 Khz,10 KHz or better.
Power Supply
230VAC±10%, 50Hz±5% with variations in voltage and frequency
respectively.
Software
Window based software for analysis of data shall be supplied along with the
equipment.
Data Storage
The kit should have enough data storage capacity not less than 2 MB with
battery backup.
Repeatability
The instrument should have proven for repeatability of test results in charged
switchyard conditions. Documentary evidence for this should be furnished
along with the bid.
Kit output
Rs 232 port to down load data to external PC .The kit should have facility to
get hard copy through plain paper printer by directly connecting printer to test
kit
Travel Adapter Travel adapter and Transducers (Rotary/Linear) along with various
and Transducer clamps/fixtures to suit any type of model of CB. The details of CB existing at
Power grid S/Stn will be furnished to the successful bidder
Accessories
All standard accessories including test leads of 15 meters with
suitableclamps,connectors,cables,power
supply
cords,printer,travel
transducers, fuses, carrying case ,manual etc all those required for carrying
out testing of CB and DCRM
Environment
Temp- 0 to 50 Deg C.
Humidity – 95 % non Condensing
The test kit shall be compatible for EMI / EMC environment as per
relevant IEC
13
Demonstration
The acceptance of kit is subjected to successful demo to the satisfaction
of Power grid at prescribed site of Power grid.
14
Calibration
certificate
Calibration certificate from/traceable to, international/ govt/ govt
approved lab shall be submitted.
10. Primary Injection Kit
i)
Ranges
a)
0 – 500 Amps.AC
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 34
b)
0 – 1000 Amps.AC
ii)
Open circuit Voltage-
iii)
Ranges selectable by change of link connections.
ii)
iii)
iv)
v)
vi)
vii)
Continuous Current control by variable Auto Transformer
Current measurement by Ammeter of accuracy 1%
Input Power Supply 230 V±10% ac 50 ± 5%Hz
Provided with metallic enclosure.
Mobility – Kit should be sturdy and mobile on metal surface in switchyard.
Kit shall be supplied along with all accessories and cable set (15 mtr length),
clamps ,connectors, spare fuses ,indication lamps,power supply cable, etc.all that
is required for carrying out measurement for one unit.
Kit shall have safety features like fuses/MCBs,ON indications etc
--------------------------------
viii)
0 to 6 Volts(minimum) at 1000 Amp.
11) SECONDARY INJECTION KIT
i)
Ranges
a)
0 – 1 Amps.AC
b)
0 – 5 Amps.AC
c)
0 – 10 Amps.AC
d)
0 - 30 Amps AC
-
0.01Amp
ii)
Resolution
iii)
iv)
v)
vi)
vii)
viii)
ix)
Should have digital time interval meter 0 to 99.99 sec with 1 ms resolution.
Continuous Current control by variable Auto Transformer
Current & Voltage measurement by Digital Ammeter and Voltmeter.
Input power supply 230 V±10% ac 50 ± 5%Hz
Output variable voltages 0 –250 V AC
Provided with metallic enclosure.
Kit shall be supplied along with all accessories and cable set(3 mtr length),spare
fuses ,indication lamps,power supply chord etc all that is required for carrying
out measurements.
Kit shall have safety features like fuses/MCBs,ON indications etc
It should have overload and short-circuit protection
x)
xi)
12. DIGITAL LEVEL METER
Sr.no Description
Specification
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 35
1.
Functional
requirement
2.
Frequency
3.
4.
5.
Input Impedance’s
Min readable level
Sensitivity in step of
10 db
6.
Automatic tuning
7.
Power supply
8.
Error of level
measurement
9. Resolution
10. Impedence
Measurement
Equipment shall be used for measurement of
strength of PLCC signal
It should include impedance & return loss
measuring attachment compatible with level
generator
The kit and accessories shall be robust and
rugged enough, so that it can be transported
safely at different locations .The
transportation case and packing of the kit
shall be such that the transportation from
one station to other will not affect the
performance and accuracy of measurement
of kit.
200 Hz to 620 kHz (balanced)
50Hz to 620 kHz (unbalanced)
75, 125, 150, 600 ohm
-90db/dbm
Sensitivity in step of 10 db :
with balanced input
–60 to +20 db/dbm
with unbalanced input –70 to +10 db/dbm
Between level meter and generator to be
provided
230 V, single phase, AC 50Hz supply with
variations of ±10% and ±5% in voltage &
frequency respectively.
< 0.1 db at
0 db level at 0 scale division.
1Hz
i)Frequency Range : 300Hz to 600 kHz
ii)Measuring Range : 50 to 3000 ohms
iii)Accuracy
: ±10%
11. Balance & return loss i)Frequency Range : 300Hz to 600 kHz
measurement
ii)Impedance Limits : 60 to 1200 ohms
iii)Return loss
: 40 db
iv)Accuracy
: ±1 db
12. Accessories
Measuring cable, power cable, synchroniser
cable, Battery connecting
cable,fuse,operating manual, and any other
accessories required for use of the specified
equipment.
13. Calibration
Calibration certificate from/traceable to,
Certificate
NABL accredited lab or internationally
reputed lab, shall be submitted. Date of
calibration shall not be older than one month
from the date of supply of Kit.
13. DIGITAL LEVEL GENERATOR
Sr.no
Description
Specification
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 36
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Functional
Requirement
Signal generation
freq. Range
Compatibility
Output impedances
Output level
Frequency display
Frequency accuracy
Spurious signals at 0
db (dbm)
Supply for mains &
supply
from battery
Accuracy of level
indicator:
Harmonic distortion
Automatic tuning/
Synchronisation of
generator
Accessories
Calibration
Certificate
Equipment shall be used along with the level
meter for measurement of strength of PLCC
signal
The kit and accessories shall be robust and
rugged enough, so that it can be transported
safely at different locations .The
transportation case and packing of the kit
shall be such that the transportation from
one station to other will not affect the
performance and accuracy of measurement
of kit.
200 Hz to 620 kHz
Compatible with level Meter
75, 125, 150, 600 ohms
-60 to + 10 db/dbm
6 digit
2x10-5 ±1 digits
> 60 below fundamental
230 V, single phase, AC 50Hz supply with
variations of ±10% and ±5% in voltage&
frequency respectively.
±0.15 db at an output level of o dbm
2nd & 3 rd product
50 db below fundamental frequency
To be provided.
Measuring cable, power cable, synchroniser
cable, Battery connecting
cable,fuse,operating manual etc. and any
other accessories those required for use of
the specified equipment.
Calibration certificate from/traceable to,
NABL accredited lab or internationally
reputed lab, shall be submitted. Date of
calibration shall not be older than one month
from the date of supply of Kit.
14. AUTOMATIC TRANSFORMER TURNS RATIO TESTER
The equipment offered shall be used for measurement of turns ratio of various power and
distribution transformers automatically displaying the ratio without requiring any manual balancing
of decades.
Technical Requirement
Input Supply Voltage: 230 Volts, 50 Hz, single phase a.c. with variations of +-15 % &
+-5 % in voltage and frequency.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 37
Measuring Principle
It should display actual turns ratio of different vector groups in three phase transformers without
conversion.
Measuring range
Accuracy
1 to 200
+-5 % of FSD
The kit should be supplied with 15m of test lead.
General Requirements
It should offer repeatability of test results.
The test kit shall be compatible for EMI/EMC environment as per IEC 1000.
As per requirement of ISO-9001, calibration certificate for each testing instrument covering entire
range shall be supplied with the test kit at the time of supply.
The testing equipments are generally meant for carrying out testing at site and movement from one
place to another is unavoidable. Therefore equipment shall be robust in design so that it gives
desired performance even in adverse site conditions.
Environmental conditions such as temperature, humidity, vibration, bump etc. shall be as per IS9000 and IS 9001 or equivalent standards. Required certificates confirming to above standards shall
be furnished along with he offer.
Necessary transport packing arrangement shall be supplied along with the equipment.
The equipment shall generally comply with the requirement of relevant Indian standard or equivalent
International standard such as IEC, BS, ASTM, ISO, etc.
The supplier should have adequate “After Sales Service” facility in India.
15. TRANSFORMER DC WINDING RESISTANCE MEASUREMENT
The instrument shall be used for measuring DC winding resistance of the large 400kV class transformer/reacto
high inductance is present.
The test kit shall be able to withstand inductive kicks from transformer winding.
Variation in test current shall not result in loss of accuracy.
The display or resistance should be through LED/LCD without requiring any balancing of decades
to obtain stable readings.
It should employ four wire method and no lead compensation shall be required for the measurement.
Built-in-discharge circuit should be provided to discharge the specimen when test is
completed or when current lead accidentally disconnects or when instrument power supply is lost.
Technical Parameter
Test current
Resolution
Min 25 Amp DC in range of 0-2000 milliohm
1 milliohm
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 38
Range
Accuracy
0 to 10 ohms
+-0.5 % of full scale reading or better
Open circuit voltage minimum 30 volts DC.
The instrument shall contain all standard accessories including test leads of 20m with suitable
clamps/connectors and carrying case.
It shall be suitable for 230V, single phase AC, 50 Hz supply with variations of +-15 % and +-5 % in
voltage and frequency respectively.
General Requirements
It should offer repeatability of test results in charged switchyard.
The test kit shall be compatible for EMI/EMC environment as per IEC 1000.
As per requirement of ISO-9001, calibration certificate for each testing instrument covering entire
range shall be supplied with the test kit at the time of supply.
The testing equipments are generally meant for carrying out testing at site and movement from one
place to another is unavoidable. Therefore equipment shall be robust in design so that it gives
desired performance even in adverse site conditions.
Environmental conditions such as temperature, humidity, vibration, bump etc. shall be as per IS9000 and IS 9001 or equivalent standards. Required certificates confirming to above standards shall
be furnished along with he offer.
Necessary transport packing arrangement shall be supplied along with the equipment.
The equipment shall generally comply with the requirement of relevant Indian standard or equivalent
International standard such as IEC, BS, ASTM, ISO, etc.
The supplier should have adequate “After Sales Service” facility in India.
16. SF6 GAS FILTERING, EVACUATING AND DRYING PLANT
The capacity of this plant shall be such that it shall not take appreciable time for filling or evacuating
of the breaker. The required vacuum for complete evacuation shall be attained with the help of this
plant.
-
This shall include all the necessary devices for measurement of purity, moisture content,
decomposition products etc. of SF6 gas. Mixing with air/oil/moisture during above process
should be proved to be Nil during testing. The storage capacity of the reservoir should be
sufficient for storing complete SF6 gas for at least one 420kV Circuit Breaker (3 poles) or
105 kgs whichever is higher.
-
The plant shall be complete with accessories and fittings so that SF6 gas from the breaker
can be directly filled in the plant storage reservoir.
-
In case purging of the equipment before filling with SF6 gas is desirable, then the required
equipment for dry gases etc. shall be furnished as a part of the plant.
-
For heavy items within the plant, the lifting hooks shall be provided for lifting and moving
with the overhead cranes.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 39
The SF6 gas handling plants shall comply with following requirements:
i)
ii)
iii)
The plant shall be complete with all the necessary pipes, couplings, flexible tubes and
valves for coupling to the equipment for the filling or evacuating SF6 gas to be used with
all necessary instructions for storage and handling of the plant.
The design and construction of the plant, valves, couplings, and connections shall be such
that leakage of SF6 gas shall be minimum. Similarly valves, couplings and pipe work
shall be so arranged that accidental loss of gas to the atmosphere shall be minimum.
Facilities shall be provided to reduce the gas pressure within the Circuit Breaker to a
value not less than 8 mill bars.
SF6 gas composition analyzing equipment and instruments for the following functions shall be
provided:
a) The moisture content measurement or alternatively dew point measurement.
17. Relay Operation Timer
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Range
Resolution
: 1 m Sec. To 999.9 Sec.
: 1 mSec (Range – 1 mS to 9.999 Sec.)
: 10 mSec (Range– 10 mS to 99.99 Sec.)
: 100 mSec (Range – 100 mS to 999.9 Sec.)
Time base Accuracy : +/- 0.1%
Accuracy
: +/- 1 count +/- Time base accuracy
Display
: 4 digit LED/ LCD
Power supply
: 230 VAC +/- 10% at 50 Hz.
Suitable for use in EHV S/S.
Operating Modes:
By Potential free open contact closing (Start/Stop)
By Potential free close contact opening (Start/Stop)
By step +ve voltage application (50 V to 250 V DC)
By step +ve voltage removal (50 V to 250 V DC)
Should have latching facility and reset facility.
Calibration Certificate- Calibration certificate from/traceable to, NABL
accredited lab or internationally reputed lab, shall be submitted. Date of
calibration shall not be older than one month from the date of supply of
Kit.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 40
Annexure-VI
1.0
AUTOTRANSFORMER / REACTOR FOUNDATION, RAIL TRACK/ ROAD
CUM RAIL TRACK
The Contractor shall provide a RCC Rail cum road system integrated with the
Autotransformer / Reactor foundation to enable installation and the replacement of any failed unit
. The transfer track system shall be suitable to permit the movement of any failed unit fully
assembled (including OLTC, bushings) with oil. This system shall enable the removal of any
failed unit from its foundation to the nearest road. If trench/drain crossings are required then
suitable R.C.C. culverts shall be provided in accordance with I.R.C. standard / relevant IS.
The Contractor shall provide a pylon support system for supporting the fire fighting
system.
Each Autotransformer/Reactor including oil conservator tank and cooler banks etc.
shall be placed in a self-sufficient pit surrounded by retaining walls (Pit walls). The
clear distance of the retaining wall of the pit from the Autotransformer/Reactor shall
be 20% of the Autotransformer/Reactor height or 0.8m whichever is more. The oil
collection pit thus formed shall have a void volume equal to 200% volume of total oil
in the Autotransformer/Reactor. The minimum height of the retaining walls shall be
15 cm above the finished level of the ground to avoid outside water pouring inside the
pit. The bottom of the pit shall have an uniform slope towards the sump pit. While
designing the oil collection pit, the movement of the autotransformer must be taken
into account.
The grating shall be made of MS flat of size 40mmx 5mm placed at 30mm center to
center and 25mmx5mm MS flat at an spacing of 150mm at right angle to each other.
Maximum length of grating shall be 2000mm and width shall not be more than
500mm. The gratings, supported on ISMB 150mm, shall be placed at the formation
level and will be covered with 100mm thick layer of broken/crushed/non-crushed
stone having size 40mm to 60mm which acts as an extinguisher for flaming oil.
Each oil collection pit shall be drained towards a sump pit within the collection pit
whose role is to drain water and oil due to leakage within the collection pit so that
collection pit remains dry.
1.1
MATERIALS
Complete foundation shall be made of reinforced cement concrete and shall be
designed as per guidelines for design of foundations given in clause 10.0 in the
specification.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 41
1.2
DRAINAGE
One 0.5 H.P pump for each pit shall be supplied and installed by the Contractor to
evacuate the fire fighting & rain water from the sump pit in to the nearest drain.
2.0
FIRE PROTECTION WALLS
2.1
GENERAL
Fire protection walls shall be provided,if rerquired, in accordance with Tariff
Advisory Committee (TAC) recommendations.
2.2
FIRE RESISTANCE
The firewall shall have a minimum fire resistance of 3 hours. The partitions, which
are made to reduce the noise level, shall have the same fire resistance. The walls of
the building, which are used as firewalls, shall also have a minimum fire resistance of
3 hours.
The firewall shall be designed to protect against the effect of radiant heat and flying debris
from an adjacent fire.
2.3
DIMENSIONS
The firewall shall extend 600 mm on each side of the Autotransformer/Reactors and
600 mm above the conservator tank or safety vent.
These dimensions might be reduced in special cases, as per the approval of owner
where there is lack of space. A minimum of 2.0meter clearance shall be provided
between the equipments e.g. Autotransformer/Reactors and firewalls.
The building walls, which act as firewalls, shall extend at least 1 m above the roof in
order to protect it.
2.4
MATERIALS
The firewall will be made of reinforced concrete (M-20 grade), as per the system
requirements.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 42
Annexure-VII
245kV CURRENT TRANSFORMERS
Rated primary current: 1200A
Rated extended primary current: 120% on all cores
No.of Core
Appli- Current
Output
Accuracy
Min. knee
Max. CT
Max.
cation
ratio
burden
class as
pt.volt-
sec.wdg.
ation cur-
Remarks
(VA)
per IEC:
resist-
rent at Vk
44-1
ance(ohms) (in
ExcitCores No.
Vk
age
mA)
5
1
1200/
BUS DIFF
12006/3
P.S.
20 on
600/1
1200/1
of dead tank
In
case of
CHECK
600
on
Tap;
current transf-
40 on
ormers 3 cores
600/1
shall be fix-
Tap
ed on one side
BUS DIFF
P.S.
ing two cores
MAIN
600
& the remain- 2
12001200/
6/3
600/1
1200/1
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
20
shall be fixed
Page 43
Tap;
on the other
40 on
side.
600/1
Tap
3
-
METERING
-
1200-
20
0.2
-
P.S.
600300/1
4
1200/
TRANS.
6/3/1.5
BACK UP/
120020 on
6001200/1
600/
LINE PROTN. 300/1
300
Tap;
40 on
600/1
Tap;
80 on
300/1
Tap;
5
1200/
600/
300
TRANS.
6/3/1.5
DIFF/LINE
1200/1
PROTN
Tap;
120020 on
600-
-
P.S.
300/1
40 on
600/1
Tap;
80 on
300/1
Tap
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 44
-
All relaying CTs shall be of accuracy class PS as per IS: 2705.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 45
Annexure-IX
A.
Points counts for the Remote Terminal Unit (RTU)
(Applicable for each 132/33 kV new sub-station)
Sl. No. Type of Telemetry point
Qty.
Remarks
1
Analogue Input
21
(a) P,Q for each feeder/transformer.
(b) Bus V, F for each bus.
( c) OLTC position for each transformer
2
Digital Input
56
(a) Dual status contacts : (1 No & 1 NC) for
each breaker.
(b) Single status contact : Protection contact 1
per feeder/transformer/BUS.
( c) Single status contact : 1 per isolator.
3
Digital control output
(with interposing relays)
74
(a) TRIP/CLOSE of circuit breakers.
(b) OPEN/CLOSE of Isolators.
Note : 1. Cabling with control and relay panels shall be carried out for current bays(132kV) as per
single line diagram of the substation, however all analogue and digital points shall be wired
to terminal blocks in the RTU for external interface.
2. Except isolator contact all other contacts shall be initially defined as SOE.
B.
Points counts for the Remote Terminal Unit (RTU)
(Applicable for 220/132/33 kV Sipara (new) sub-station):
Sl. No. Type of Telemetry point
Qty.
Remarks
1
Analogue Input
53
(a) P,Q for each feeder/transformer.
(b) Bus V, F for each bus.
( c) OLTC position for each transformer
2
Digital Input
148
(a) Dual status contacts : (1 No & 1 NC) for
each breaker.
(b) Single status contact : Protection contact 1
per feeder/transformer/BUS.
( c) Single status contact : 1 per isolator.
3
Digital control output
(with interposing relays)
198
(a) TRIP/CLOSE of circuit breakers.
(b) OPEN/CLOSE of Isolators.
Note : 1. Cabling with control and relay panels shall be carried out for current bays(220kV and
132kV) as per single line diagram of the substation, however all analogue and digital points
shall be wired to terminal blocks in the RTU for external interface.
2. Except isolator contact all other contacts shall be initially defined as SOE.
3. The total point counts shall be minimum 512 nos.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 46
Annexure-X
Description of Lighting Fixtures
Sl. No. Type
of
Lighti
ng
Fixtur
e
1.
FI
2.
FB
3.
FF
4.
IF
5.
6.
DSM
CL
7.
PF
8.
SF1
9.
SF2
10.
SF3
11.
SF4
12.
SC
13.
MP
14.
BL
15.
DLR
Description
2x36W fluorescent lamps in fixture, complete with HF Electronic Ballast
and suitable for pendent /surface Mounting, similar to Philips Cat. No.
TCW097/236 / CGL cat IPFC24HSB236/ Bajaj cat. No. BJP 236
9W CFL lamp in Bulkhead fixtures. Philips Cat. No. FXC 101/Bajaj Cat.
No. BJBE-19/ CGL Cat. No. CBH9
2x36W fluorescent lamp with mirror optics in surface mounting type
decorative fluorescent fitting with HF Electronic Ballast and excellent
glare control Philips TCS398/236 / Crompton Greaves Cat. No.
T8CX236HSB-236 EB/ Bajaj Cat.BLSM236CFLP2
Incandescent GLS lamp in recessed down light having high purity
aluminum reflector electrochemically brightened and anodized. Stainless
steel leaf springs and pressure die cast ceiling Philips Cat. No. Philips
FCS 100 with 60W incandescent lamp.
1X13 WATT surface mounted CFL , Philips FCS 100 or Equivalent
3X 36W CFL Decorative ceiling mounted luminaire. Philips Cat. No.
FBS 300 P5/ CGL Cat. No. TTL 336 cat-II/ Bajaj cat. BMMS 336 CFL
1x11 W CFL Lamp emergency light with Battery operated portable
fixture with built in chargeable Batteries and battery charger suitable for
a lighting period of six hours similar to ALPHA DELUX of M/s DELTA
FLASH LITE/ MICRO LITE OF M/s MICRO / BPL MAKE
1 X 400W HPSV lamps in high flood lighting fixture mounted on Swivel
support, integral control gear: similar to Phillips cat. No. SWF 330/ CGL
Cat. No. FAI40IHSV/ Bajaj Cat. No. BJEFL 14.
2 X 400W HP sodium Vapour lamps in high flood lighting, non-integral
control gear: similar to Phillips cat. No. RVP301/ CGL Cat.
No.FHD1424 / Bajaj Cat. No. BJHM 22 SS
1 X 250W HPSV lamps in high flood lighting fixture mounted on Swivel
support, integral control gear: similar to Phillips cat. No. SWF 330/ CGL
Cat. No. FAI25IHSV/ Bajaj Cat. No. BJEFL 14.
2 X 250W HP sodium Vapour lamps in high flood lighting, non-integral
control gear: similar to Phillips cat. No. RVP301/ CGL Cat.
No.FHD1424 / Bajaj Cat. No. BJHM 22 SS
150W SON-T Tubular Sodium Vapour lamp in street lighting luminare
Philips Cat No. SRX-51 and Bajaj Cat No. BJMSDT/150 / Crompton
Greaves Cat No. SSG 23151H.
125 HP MV Lamp in weather proof post top lantern for mounting on pole
top, philips Cat. No. HPC-101/ Bajaj Cat. No. BJDPTI / Crompton
Greaves Cat No. MPT12IH/BC
2X9 or 1x18 watt CFL bollard light for landscape lighting having
FRP/LLDPE housing, Philips FGC202 /Crompton Greaves Cat No
CFBL1129
2 X 18 watts CFL down light- Philips FBH 225/2X18/ Crompton
Greaves Cat no. DDLH218TG
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 47
16.
IB
100 watts GLS lamp in Bulkhead fixtures- Philips Cat no. NXC 101/
Crompton Greaves IBH1110/BC/ Bajaj Cat no. BJDB 100
Annexure-XI
LT SWITCHGEAR
LT switchgear shall essentially consist of following distribution boards conforming to technical
specifications :
415V, Main Switchboard (1 no.) :
This board shall consist of two (2) nos. – ACB Incomers, one (1) no. – ACB Bus –coupler and
required number of MCCB outgoing feeders. Both incomers and bus coupler shall have same
current rating. The board shall receive two incoming supplies through 630 KVA 33/0.433 KV LT
Transformers .The board shall have 2 sections and all major loads e.g. indoor lighting, outdoor
switchyard lighting including receptacles,Street lighting,Air Conditioning units,HVW motor for fire
fighting,exhaust fans,oil filtration, supply to ACDBs etc. shall be fed from each section(feeds to be
duplicated)through MCCB units of appropriate rating. Both Incomers and bus-coupler shall have
mechanical (castle key) as well as electrical interlock to prevent paralleling of incomers. The
switchboard shall have all necessary metering, indications and protections (U/V, E/F, Instantaneous
O/C relays). The contractor shall furnish details of no. of feeders and calculations for feeder ratings
during detailed engineering for Employer’s approval.
415V, AC distribution board (1 no.) :
This board shall have three MCCB incomers, two through Main Switchboard and one through DG
set/alternate source with all necessary mechanical/electrical interlocks for preventing parallel
operation. This board shall have 2 sections and bus coupler of adequate rating. All essential loads of
substations including all MB’s supply, Chargers supply,Fire Fighting,ACDB and Annunciation
panels,Jockey Pump,DG set AMF panel,all control supplies, emergency lighting etc. shall be fed
from each section (feeds to be duplicated) through MCCBs of adequate rating.The board shall have
all necessary metering, indications and protections. The contractor shall furnish details of no. of
feeders and calculations for feeder ratings during detailed engineering for Employer’s approval.
415V, AMF panel (1 no.) :
Details of AMF (Automatic Main’s Failure) panel are mentioned in technical specification. This
panel shall be supplied to start DG set in case of AC failure.
250/220V DC DISTRIBUTION BOARD (1 NO.):
250/220 V DCDB shall be suitable for connection with two sets of battery & two sets chargers in
case of new substations & 1 set battery & 1 set charger in case of extension substations. 250V/220V
DCDB shall feed all loads for control and protection purposes including emergency DC lighting
RTCC supply etc.through 2 Pole MCB feeders of appropriate rating. The board shall have all
necessary, metering, indications & protections (U/V, O/V, E/F).
48V DCDB (1 no.) :
48V DCDB shall be suitable for connection with two sets of battery & two sets chargers in case of
Saharsa/Madhepura(new) 220/132/33 kV new substation and one sets of battery & two sets chargers
in case of all 132/33 kV new substations & 220/132 kV extension substatons and 1 set battery & 1
set charger in case of 132/33 kV extension substations. 48V DCDB shall feed all loads for PLCC
purposes including EPAX,Telemetery,Event logger etc.through 2 pole MCB feeders of appropriate
rating. The board shall have all necessary metering, indications & protections (U/V, O/V).
Common requirement for all boards
The bidder shall make his own estimation for all present and future feeders required as per
Substation single line diagram and GA/Layout. 20% spare outgoing feeders of each
rating shall
be provided in each board.
The other Technical requirements as per Section – L.T. Switchgear are to be met except for the
above.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 48
2.0 GENERAL TECHNICAL REQUIREMENT
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 49
GENERAL TECHNICAL REQUIREMENT
1.0
FOREWORD
1.1
The provisions under this section are intended to supplement general
requirements for the materials, equipments and services covered under other
sections of tender documents and is not exclusive.
2.0
GENERAL REQUIREMENT
2.1
The bidders shall submit the technical requirements, data and information as per
the technical data sheets provided in the bid documents.
2.2
The bidders shall furnish catalogues,
engineering data, technical
information, design documents, drawings etc., fully in conformity with the
technical specification.
2.3
It is recognized that the Contractor may have standardized on the use of certain
components, materials, processes or procedures different from those specified
herein.
Alternate proposals offering similar equipment based
on the manufacturer’s standard practice will also be considered provided such
proposals meet the specified designs, standard and performance requirements
and are acceptable to the Purchaser’s. Unless brought out clearly, the Bidder
shall be deemed to conform to this specification scrupulously. All deviations
from the specification shall be clearly brought out in the respective schedule
of deviations. Any discrepancy between the specification and the catalogues or the
bid, if not clearly brought out in the specific requisite schedule, will not be
considered as valid deviation.
2.4
Except for lighting fixtures, wherever a material or article is specified or defined
by the name of a particular brand, Manufacturer or Vendor, the specific name
mentioned shall be understood as establishing type, function and quality and
not as limiting competition. For lighting fixtures, makes shall be as defined in
Section- Lighting System.
2.5
Equipment furnished shall be complete in every respect with all
mountings, fittings, fixtures and standard accessories normally provided with such
equipment and/or needed for erection, completion and safe operation of the
equipment as required by applicable codes though they may not have been
specifically detailed in the Technical Specifications unless included in the list of
exclusions. Materials and components not specifically stated in the specification
but which are necessary for commissioning and satisfactory operation of the
switchyard/substation unless specifically excluded shall be deemed to be included
in the scope of the specification and shall be supplied without any extra cost. All
similar standard components/parts of similar standard equipment provided, shall be
inter-changeable with one another.
3.0
STANDARDS
3.1
The works covered by the specification shall be designed, engineered,
manufactured, built, tested and commissioned in accordance with the Acts,
Rules, Laws and Regulations of India.
3.2
The equipment to be furnished under this specification shall conform to latest
issue with all amendments (as on the date of bid opening) of standard
specified unless specifically mentioned in the specification.
3.3
The Bidder shall note that standards mentioned in the specification are not
mutually exclusive or complete in themselves, but intended to compliment
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each other.
3.4
The Contractor shall also note that list of standards presented in this
specification is not complete. Whenever necessary the list of standards shall be
considered in conjunction with specific IS/IEC.
3.5
When the specific requirements stipulated in the specifications exceed or differ than
those required by the applicable standards, the stipulation of the specification shall
take precedence.
3.6
Other internationally accepted standards which ensure equivalent or better
performance than that specified in the standards specified / individual sections
for various equipments shall also, be accepted, however the salient points of
difference shall be clearly brought out in additional information schedule of
Vol. III along with English language version of such standard. The
equipment conforming to standards other than specified / individual sections for
various equipments shall be subject to Purchaser’s approval.
3.7
The bidder shall clearly indicate in his bid the specific standards in
accordance with which the works will be carried out.
4.0
SERVICES TO BE PERFORMED BY THE EQUIPMENT BEING
FURNISHED
4.1
The equipment furnished under this specification shall perform all its functions and
operate satisfactorily without showing undue strain, restrike etc under such over
voltage conditions.
4.2
All equipments shall also perform satisfactorily under various other electrical,
electromechanical and meteorological conditions of the site of installation.
4.3
All equipment shall be able to withstand all external and internal
mechanical, thermal and electromechanical forces due to various factors like wind
load, temperature variation, ice & snow, (wherever applicable) short circuit etc for
the equipment.
4.4
The bidder shall design terminal connectors of the equipment taking into account
various forces that are required to withstand.
4.5
The equipment shall also comply to the following:
a)
To facilitate erection of equipment, all items to be assembled at site shall be
“match marked”.
b)
All piping, if any between equipment control cabinet/ operating
mechanism to marshalling box of the equipment, shall bear proper
identification to facilitate the connection at site.
4.6
EHV equipments and system shall be designed to meet the following
major technical parameters as brought out hereunder.
4.6.1
System Parameter
SL
No
Description of parameters
220 KV
System
132 kV
System
33 kV
System
1.
System operating voltage
220 KV
132kV
33kV
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2.
Maximum operating voltage of the
system(rms)
245 KV
145kV
36kV
3.
4.
5.
Rated frequency
No. of phase
Rated Insulation levels
50 Hz
3
50Hz
3
50Hz
3
i)
Full wave impulse withstand voltage 1050 KVp
(1.2/50 microsec.)
650 kVp
170 kVp
ii)
Switching impulse withstand voltage
(250/2500 micro sec.) dry and wet
-
-
-
iii)
One minute power frequency dry
withstand voltage (rms)
-
-
-
iv)
One minute power frequency dry
and wet withstand voltage (rms)
460 kV
275kV
6.
Corona extinction voltage
156 kV
105kV
7.
Max. radio interference voltage for
frequency between 0.5 MHz and 2
MHz at
508 kV rms for
765kV, 320KV rms for 400KV
system and 156KV rms for
220KV system &
92 KV rms for
132KV system
1000 microvolts
500 microvolts
-
8.
Minimum
distance
25 mm/KV
25 mm/KV
(3625 mm)
25 mm/KV
(900 mm)
i.
Phase to phase
2100 mm
1300 mm
320 mm
creepage
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-
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ii.
Phase to earth
2100 mm
1300 mm
320 mm
iii)
Sectional clearances
5000
4000 mm
3000 mm
10.
Rated short circuit current for 1 sec.
duration
40 KA
31.5 KA
25 KA
11.
System neutral earthing
Effectiv ely
Earthed
Effectiv ely
Earthed
Effectiv ely
Earthed
12
i.
Phase to phase
1220 mm (for
530
mm (for BIL-
BIL-550
kVp)
250 kVp)/
350
mm (for BIL170 kVp)
ii.
Phase to earth
480
mm (for BIL-
1050 mm (for
BIL-550
kVp)
250 kVp)/
320mm
(for BIL170 kVp)
The insulation and RIV levels of the equipments if applicable shall be as per values given in
Note : the
respective chapter of the equipments.
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4.6.2 Major technical parameters of bushings / hollow column / support insulators are
given below:
4.6.3
(A)
S.N.
Parameters
245 KV
145 kV
(a)
Max. System voltage
Um(kV)
245
145
(b)
Impulse withstand voltage (dry
& wet)
(kVp)
1050
+ 650
(c)
Switching surge withstand
voltage
(dry & wet) (kVp)
-
-
(d)
Power frequency withstand
voltage (dry and wet) (kV
rms)
460
+ 275
(e)
Total creepage
distance (min) (mm)
6125
3625
Major Technical Parameters
The major technical parameters of the equipments are given below. For
other parameters and features respective technical sections should be
referred.
For 245 KV & 145 kV Circuit Breaker and Isolator
Rated voltage kV (rms)
245
145
Rated frequency (Hz)
50
50
No. of Poles
Design ambinet
temperature (°C)
3
3
50
50
Rated insulation levels :
1)
-
Full wave impulse withstand voltage (1.2/50 micro sec.)
±1050 kVp ±650 kVp
between line terminals
and ground
±1050 kVp ±650 kVp
between terminals
with circuit breaker open
±1200 kVp ±750 kVp
between terminals
with isolator open
2)
One minute power frequency dry and wet withstand voltage
-
between line
400 kV (rms)
275 kV (rms)
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terminals and ground
-
between terminals
with circuit breaker open
460 Kv (rms)
275 kV (rms)
-
between terminals
with Isolator open
530 kV (rms)
315kV (rms)
Max. radio interference
1000
voltage (microvolts) for
(at 156
kV
frequency between 0.5 MHz
Kv rms)
rms)
and 2 MHz in all positions of the
equipments.
500
(at 92
Minimum creepage distance :Phase to ground (mm)
6125
3625
6125
3625
Between CB Terminals (mm)
System neutral earthing
Effectivey
earthed
Seismic acceleration
Rating of Auxiliary
Contacts
Breaking capacity of
Auxiliary Contacts
2 A DC with circuit time
constant of not less than20ms.
Phase to phase spacing (mm)
4500
3000 or 2700
Auxiliary Switch shall also comply with other clauses of this chapter.
(B)
FOR 245 kV & 145 kV CT/CVT/SA
Rated voltage kV (rms)
245
145
Rated frequency (Hz)
50
50
No. of poles
1
1
Design ambient temperature (°C)
50
50
Rated insulation levels :
1)
Full wave impulse withstand voltage (1.2/50 micro sec.)
-
between line terminals
±1050 kVp
±650kVp and ground for CT and CVT
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-
for arrester housing
±1050 kVp
±650 kVp
2)
One minute power frequency dry and wet withstand voltage
-
between line terminals
and ground for CT and CVT
-
for arrester housing
460 kV rms
275 kV rms
460 kV rms
Max. radio interference
voltage (microvolts) for
frequency between 0.5 MHz
1000
275kV rms
500
(at 92 kV
and 2 MHz in all positions
of the equipment.
rms)
Minimum creepage distance :Phase to ground (mm)
System neutral earthing
6125
3625
- Effectively earthed -
Seismic acceleration
- 0.3g horizontal -
Partial discharge for :-
(C)
-
Surge arrester at
1.05 COV
- Not exceeding 50 pc. -
-
for CT/CVT
- Not exceeding 10 pc. –
For 36 kV EQUIPMENTS
Rated Voltage KV (rms)
36
Rated frequency (Hz)
50
No. of Poles
3
Design ambinet
temperature (°C)
50
Rated insulation levels :
1)
Full wave impulse withstand voltage (1.2/50 micro sec.)
-
between line terminals
and ground
± 170 kVp
-
between terminals
with Isolator open
± 180 kVp
2)
One minute power frequency dry and wet withstand
voltage
-
between line terminals
and ground
70 kV (rms)
-
between terminals
with Isolator open
80 kV (rms)
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Minimum creepage distance :Phase to ground (mm)
900
Seismic acceleration
-- 0.3g horizontal --
Rating of Auxiliary Contacts
10A at 220/ DC (As applicable)
Breaking capacity of
Auxiliary Contacts
2 A DC with circuit
time constant of
not less than 20 ms.
Phase to phase spacing (mm)
1500
Auxiliary Switch shall also comply with other clauses of this chapter.
(D)
36 KV SURGE ARRESTOR WITHOUT SURGE MONITOR
1.
2.
3.
4.
5.
6.
7.
8.
(E)
Rated voltage of arrestor
Maximum continuous
operating voltage (COV) at
design ambient temperature
Standards
Normal discharge current (8/20
msec)
Minimum discharge capability
(FJ/KV) referred
One minute Power Frequency
(dry) withstand voltage of
arrestor
Line discharge class as per
IEC
Maximum residual voltage at
S.No. 4 above
30 KV
25 kv
IEC 60099-4
10 KA
5.0 KJ/KV
80 KV rms
3
85 KVp
36 KV ISOLATOR
1.
2.
3.
4.
Rated voltage
Rated current
Standards
Rated short time withstand (inKA)
36 KV
As per price sehedule
IS 9921/IEC 129
25 KA for 1 sec.
5.
Operating drive
Manual operating mechanism
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6.
Type
7.
Constructed detail
8.
Terminal Connector
Double break Isolator w/o E/S
3 pole, outdoor, Gang
operated.
All ferrous parts to be galvanized
except nuts and bolts which shall
be electroplated as per relevant
IS.
To suit site conditions and
layout requirements.
5.0
ENGINEERING DATA AND DRAWINGS
5.1
The engineering data shall be furnished by the Contractor in accordance with the
Schedule for each set of equipment as specified in the Technical Specifications.
5.2
The list of drawings/documents which are to be submitted to the
Purchaser shall be discussed and finalised by the Purchaser at the time of award.
The Contractor shall necessarily submit all the drawings/ documents unless
anything is waived.
The Contractor shall submit 4 (four) sets of drawings/ design documents
/data/ test reports as may be required for the approval of the Purchaser.
5.3
Drawings
5.3.1
All drawings submitted by the Contractor including those submitted at the time
of bid shall be in sufficient detail to indicate the type, size, arrangement,
material description, Bill of Materials, weight of each component, break-up
for packing and shipment, dimensions, internal & the external connections,
fixing arrangement required and any other information specifically requested
in the specifications.
5.3.2
Each drawing submitted by the Contractor shall be clearly marked with the name
of the Purchaser, the unit designation, the specifications title, the specification
number and the name of the Project. If standard catalogue pages are submitted,
the applicable items shall be indicated therein. All titles, noting, markings and
writings on the drawing shall be in English. All the dimensions should be in
metric units.
5.3.3
Further work by the Contractor shall be in strict accordance with these
drawings and no deviation shall be permitted without the written approval of the
Purchaser, if so required.
5.4
The review of these data by the Purchaser will cover only general
conformance of the data to the specifications and documents, interfaces with the
equipment
providedunder
the specifications,
external
connections and of the dimensions which might affect substation layout. This
review by the Purchaser may not indicate a thorough review of all dimensions,
quantities and details of the equipment, materials, any devices or items
indicated or the accuracy of the information submitted. This review and/or
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approval by the Purchaser shall not be considered by the Contractor, as limiting
any of his responsibilities and liabilities for mistakes and deviations from the
requirements, specified under these specifications and documents.
5.5
All manufacturing and fabrication work in connection with the equipment prior
to the approval of the drawings shall be at the Contractor’s risk. The Contractor
may make any changes in the design which are necessary to make the
equipment conform to the provisions and intent of the Contract and such
changes will again be subject to approval by the Purchaser. Approval of
Contractor’s drawing or work by the Purchaser shall not relieve the
contractor of any of his responsibilities and liabilities under the Contract.
5.6
All engineering data submitted by the Contractor after final process
including review and approval by the Purchaser shall form part of the
Contract Document and the entire
works
Performed under these specifications shall be performed in strict conformity,
unless otherwise expressly requested by the Purchaser in Writing.
5.7
Approval Procedure
The scheduled dates for the submission of the drawings as well as for, any
data/information to be furnished by the Purchaser would be discussed and
finalised at the time of award.
NOTE :
(1)
The contractor may please note that all resubmissions must
incorporate all comments given in the earlier submission by the
Purchaser or adequate justification for not incorporating the same must be
submitted failing which the submission of documents is likely to be
returned.
(2)
All major drawings should be submitted in Auto Cad Version 2004 or
better.
(3)
The instruction Manuals shall contain full details of drawings of all
equipment
being supplied under this contract, their exploded
diagrams with complete instructions for storage, handling, erection,
commissioning, testing, operation,
trouble shooting, servicing and
overhauling procedures.
(4)
If after the commissioning and initial operation of the substation, the
instruction manuals require any modifications/ additions/changes, the
same shall be incorporated and the updated final instruction manuals
shall be submitted by the Contractor to the Purchaser.
(5)
The Contractor shall furnish to the Purchaser catalogues of spare parts.
5.8
The contractor shall have to furnish details and documents required as per
specifications for release of advance.
6.0
MATERIAL/ WORKMANSHIP
6.1
General Requirement
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6.1.1
Where the specification does not contain references to workmanship,
equipment, materials and components of the covered equipment, it is essential
that the same must be new, of highest grade of the best quality of their kind,
conforming to best engineering practice and suitable for the purpose for which
they are intended.
6.1.2
Incase where the equipment, materials or components are indicated in the
specification as “similar” to any special standard, the Purchaser shall decide
upon the question of similarity. When required by the specification or when
required by the Purchaser the Contractor shall submit, for approval, all the
information concerning the materials or components to be used in manufacture.
Machinery, equipment, materials and components supplied, installed or used
without such approval shall run the risk of subsequent rejection, it being
understood that the cost as well as the time delay associated with the rejection
shall be borne by the Contractor.
6.1.3
The design of the Works shall be such that installation, future expansions,
replacements and general maintenance may be undertaken with a minimum
of time and expenses. Each component shall be designed to be consistent with its
duty and suitable factors of safety, subject to mutual agreements. All joints and
fastenings shall be devised, constructed and documented so that the component
parts shall be accurately positioned and restrained to fulfill their required
function. In general, screw threads shall be standard metric threads. The use of
other thread forms will only be permitted when prior approval has been obtained
from the Purchaser.
6.1.4
Whenever possible, all similar part of the Works shall be made to gauge and
shall also be made interchangeable with similar parts. All spare parts shall also
be interchangeable and shall be made of the same materials and workmanship
as the corresponding parts of the Equipment supplied under the Specification.
Where feasible, common component units shall
be employed in different pieces of equipment in order to minimize spare parts
stocking requirements. All equipment of the same type and rating shall be
physically and electrically interchangeable.
6.1.5
All materials and equipment shall be installed in strict accordance with the
manufacturer’s recommendation(s).
Only first-class work in accordance with
the best modern practices will be accepted.
Installation shall be considered as
being the erection of equipment at its permanent location. This, unless otherwise
specified, shall include unpacking, cleaning and lifting into position, grouting,
levelling, aligning, coupling of or bolting down to previously installed equipment
bases/foundations, performing the alignment check and final adjustment prior to
initial operation, testing and commissioning in accordance with the manufacturer’s
tolerances, instructions
and the
Specification.
All
factor
assembled
rotating machinery shall be checked for alignment
and adjustments made as necessary to re-establish the manufacturer’s limits
suitable guards shall be provided for the protection of personnel on all exposed
rotating and / or moving machine parts and shall be designed for easy
installation and removal for maintenance purposes.
The
spare
equipment(s) shall be installed at designated locations and tested for healthiness.
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6.1.6
The Contractor shall apply oil and grease of the proper specification to suit the
machinery, as is necessary for the installation of the equipment. Lubricants used
for installation purposes shall be drained out and the system flushed through
where necessary for applying the lubricant required for operation. The
Contractor shall apply all operational lubricants to the equipment installed by him.
6.1.7
All oil, grease and other consumables used in the Works/ Equipment shall be
purchased in India unless the Contractor has any special requirement for the
specific application of a type of oil or grease not available in India. In such is the
case he shall declare in the proposal, where such oil or grease is available.He
shall help Purchaser in establishing equivalent Indian make and Indian
Contractor. The same shall be applicable to other consumables too.
6.1.8
Corona and radio interference voltage test and seismic withstand test
procedures
for
equipments shall be in line with the procedure a s
applicable.
6.2
Provisions For Exposure to Hot and Humid climate
Outdoor equipment supplied under the specification shall be suitable for service
and storage under tropical conditions of high temperature, high humidity, heavy
rainfall and environment favourable to the growth of fungi and mildew. The
indoor equipments located in non-airconditioned areas shall also be of same type.
6.2.1
Space Heaters
6.2.1.1
The heaters shall be suitable for continuous operation at 240 V as supply voltage.
On-off switch and fuse shall be provided.
6.2.1.2
One or more adequately rated thermostatically connected heaters shall be supplied
to prevent condensation in any compartment. The heaters shall be installed in
the compartment and electrical connections shall be made sufficiently away
from below the heaters to minimize deterioration of supply wire insulation.
The heaters shall be suitable to maintain the
compartment temperature to prevent condensation.
6.2.1.3
Suitable anti condensation heaters with the provision of thermostat
shall be provided.
6.2.2
FUNGI STATIC VARNISH
Besides the space heaters, special moisture and fungus resistant varnish shall be
applied on parts which may be subjected or predisposed to the formation of
fungi due to the presence or deposit of nutrient substances. The varnish shall
not be applied to any surface of part where the treatment
will
interfere
with the operation or performance of the
equipment.
Such surfaces or parts shall be protected against the
application of the varnish.
6.2.3
Ventilation opening
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Wherever ventilation is provided, the compartments shall have ventilation
openings with fine wire mesh of brass to prevent the entry of insects and to
reduce to a minimum the entry of dirt and dust. Outdoor compartment openings
shall be provided with shutter type blinds and suitable provision shall be made so
as to avoid any communication of air / dust with any part in the enclosures of the
Control Cabinets, Junction boxes and Marshalling Boxes, panels etc.
6.2.4
Degree of Protection
The enclosures of the Control Cabinets, Junction boxes and Marshalling Boxes,
panels etc. to be installed shall provide degree of protection as detailed here
under:
a)
Installed out door: IP- 55
b)
Installed indoor in air conditioned area: IP-31 c) Installed in covered area: IP-
52
d)
Installed indoor in non air conditioned area where possibility of entry of
water is limited: IP-41.
e)
For LT Switchgear (AC & DC distribution Boards) : IP-52
The degree of protection shall be in accordance with IS:13947 (Part-I) / IEC60947 (Part-I) / IS 12063 / IEC-60529. Type test report for degree of protection
test, on each type of the box shall be submitted for approval.
6.3
RATING PLATES, NAME PLATES AND LABELS
6.3.1
Each main and auxiliary item of substation is to have permanently
attached to it in a conspicuous position a rating plate of non-corrosive material
upon which is to be engraved manufacturer’s name, year of manufacture,
equipment name, type or serial number together with details of the loading
conditions under which the item of substation in question has been designed to
operate, and such diagram plates as may be required by the Purchaser. The
rating plate of each equipment shall be according to IEC requirement.
6.3.2
All such nameplates, instruction plates, rating plates of transformers,
reactors, CB, CT, CVT, SA, Isolators, C & R panels and PLCC
equipments shall be bilingual with Hindi inscription first followed by
English. Alternatively two separate plates one with Hindi and the other with
English inscriptions may be provided.
6.4
FIRST FILL OF CONSUMABLES, OIL AND LUBRICANTS
All the first fill of consumables such as oils, lubricants, filling compounds, touch
up paints, soldering/brazing material for all copper piping of circuit breakers
and essential chemicals etc. which will be required to put the equipment
covered under the scope of the specifications, into successful Operation, shall
be furnished by the Contractor unless specifically excluded under the
exclusions in these specifications and documents.
7.0
DESIGN IMPROVEMENTS / COORDINATION
7.1
The bidder shall note that the equipment offered by him in the bid only shall be
accepted for supply. However, the Purchaser or the Contractor may propose
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changes in the specification of the equipment or quality thereof and if the
Purchaser & contractor agree upon any such changes, the specification shall be
modified accordingly.
7.2
If any such agreed upon change is such that it affects the price and schedule
of completion, the parties shall agree in writing as to the extent of any change
in the price and/or schedule of completion before the Contractor proceeds
with the change.
Following such agreement, the
provision thereof, shall be deemed to have been amended accordingly.
7.3
The Contractor shall be responsible for the selection and design
appropriate equipments to provide the best co-ordinated performance of
entire system. The basic design requirements are detailed out in
Specification. The design of various
components, sub-assemblies
assemblies shall be so done that it facilitates easy field assembly
maintenance.
7.4
The Contractor has to coordinate designs and terminations with the
agencies (if any) who are Consultants/Contractor for the Purchaser. The names
of agencies shall be intimated to the successful bidders.
7.5
The Contractor will be called upon to attend design co-ordination
meetings with the Engineer, other Contractor’s and the Consultants of the
Purchaser (if any) during the period of Contract. The Contractor shall attend
such meetings at his own cost at Ranchi or at mutually agreed venue as and
when required and fully cooperate with such persons and agencies involved
during those discussions.
8.0
QUALITY ASSURANCE PROGRAMME
8.1
of
the
this
and
and
To ensure that the equipment and services under the scope of this Contract
whether manufactured or performed within the Contractor’s Works or at his
Sub-contractor’s premises or at the Purchaser’s site or at any other place of
Work are in accordance with the specifications, the Contractor shall adopt
suitable quality assurance programme to control such activities at all points
necessary. Such programme shall be broadly outlined by the contractor and
finalised after discussions. The detailed programme shall be submitted by the
contractor after the award of contract and finally accepted by C h i e f
E n g i n e e r ( T r a n s m i s s i o n ) after discussion. However, in case detailed
valid programme approved by Chief Engineer(Transmission) for the equipment
already exist, same would be followed till its validity. A quality assurance
programme of the contractor shall generally cover the following:
(a)
His organisation structure for the management and implementation of the
proposed quality assurance programme:
(b)
Documentation control system;
(c)
Qualification data for bidder’s key personnel;
(d)
The procedure for purchases of materials, parts components and selection
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of sub-Contractor’s services including vendor analysis, source
inspection, incoming raw material inspection, verification of material
purchases etc.
(e)
System for shop manufacturing and site erection controls including
process controls and fabrication and assembly control;
(f)
Control of non-conforming items and system for corrective actions;
(g)
Inspection
activities.
(h)
Control of calibration and testing of measuring instruments and field
activities;
(i)
System for indication and appraisal of inspection status;
(j)
System for quality audits;
(k)
System for
Purcahser.
(l)
System for maintenance of records;
and
test
procedure
authorising
release
both
of
for
manufacture
manufactured
and
product
field
to
the
(m) System for handling storage and delivery; and
(n)
A quality plan detailing out the specific quality control measures and
procedures adopted for controlling the quality characteristics relevant to each
item of equipment furnished and/or services rendered.
The Purchaser or his duly authorised representative reserves the right to carry
out quality audit and quality surveillance of the system and procedure of
the Contractor/his vendor’s quality management and control activities.
8.2
Quality Assurance Documents
The contractor would be required to submit all the Quality Assurance
Documents as stipulated in the Quality Plan at the time of purchaser’s
inspection of equipment/material
9.0
TYPE
TESTING,
CERTIFICATE
9.1
All equipment being supplied shall conform to type tests including
additional type tests as per technical specification and shall be subject to routine
tests in accordance with requirements stipulated under respective sections.
Purchaser reserves the right to witness any or all the type tests. The Contractor
shall intimate the Purchaser the detailed program about the tests atleast three
(3) weeks in advance in case of domestic supplies& six (6) weeks in advance in
case of foreign supplies. This shall conform to the details provided in the volume
III of the Board’s specifications.
10.0
TESTS
10.1
Pre-commissioning Tests
INSPECTION,
TESTING&
INSPECTION
On completion of erection of the equipment and before charging, each item of
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the equipment shall be thoroughly cleaned and then inspected jointly by the
Purchaser and the Contractor
for
correctnessand completeness of installation and acceptability for charging,
leading to initial pre-commissioning tests at Site. The list of pre-commissioning
tests to be performed are given in respective chapters and shall be included in
the Contractor’s quality assurance programme.
10.2
Commissioning Tests
10.2.1
The available instrumentation and control equipment will to be used during such
tests and the Purchaser will calibrate, all such measuring equipment and devices
as far as practicable.
10.2.2
Any special equipment, tools and tackles required for the successful
completion of the Commissioning Tests shall be provided by the
Contractor, free of cost.
10.2.3
The specific tests requirement on equipment have been brought out in the
respective chapters of the technical specification.
10.3
The Contractor shall be responsible for obtaining statutory clearances from the
concerned authorities for commissioning the equipment and the switchyard.
However necessary fee shall be reimbursed by POWERGRID on production of
requisite documents.
11.0
PACKAGING & PROTECTION
11.1
All the equipments shall be suitably protected, coated, covered or boxed and
crated to prevent damage or deterioration during transit, handling and storage at
Site till the time of erection. On request of the Purchaser, the Contractor shall
also submit packing details/associated drawing for any equipment/material under
his scope of supply, to facilitate the Purchaser to repack any equipment/material at
a later date, in case the need arises. While packing all the materials, the
limitation from the point of view of availability of Railway wagon sizes in
India should be taken into account. The Contractor shall be responsible for
any loss or damage during transportation, handling and storage due to
improper packing. Any demurrage, wharfage and other such charges claimed by
the transporters, railways etc. shall be to the account of the Contractor. Purchaser
takes no responsibility of the availability of the wagons.
11.2
All coated surfaces shall be protected against abrasion, impact,
discolouration and any other damages. All exposed threaded portions shall be
suitably protected with either a metallic or a non-metallic protecting device.
All ends of all valves and pipings and conduit equipment connections
shall be properly sealed with suitable devices to protect them from damage.
12.0
FINISHING OF METAL SURFACES
12.1
All metal surfaces shall be subjected to treatment for anti-corrosion
protection. All ferrous surfaces for external use unless otherwise stated
elsewhere in the specification or specifically agreed, shall be hot-dip
galvanized after fabrication. High tensile steel nuts & bolts and spring washers
shall be electro galvanized to service condition 4. All steel conductors
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including those used for earthing/grounding (above ground level) shall also be
galvanized according to IS: 2629.
12.2
HOT DIP GALVANISING
12.2.1
The minimum weight of the zinc coating shall be 610 gm/sq. m and
minimum thickness of coating shall be 85 microns for all items thicker than
6mm. For items lower than 6mm thickness requirement of coating
thickness shall be as per relevant ASTM. For surface which shall be
embedded in concrete, the zinc coating shall be 610 gm/sq. m minimum.
12.2.2
The galvanized surfaces shall consist of a continuous and uniform thick coating
of zinc, firmly adhering to the surface of steel. The finished surface shall
be clean and smooth and shall be free from defects like discoloured patches,
bare spots, unevenness of coating, spelter which is loosely attached to the steel
globules, spiky deposits, blistered surface, flaking or peeling off, etc. The
presence of any of these defects noticed on visual or microscopic inspection
shall render the material liable to rejection.
12.2.3
After galvanizing. no drilling or welding shall be performed on the
galvanized parts of the equipment excepting that nuts may be threaded after
galvanizing. Sodium dichromate treatment shall be provided to avoid formation of
white rust after hot dip galvanization.
12.2.4
The galvanized steel shall be subjected to six one minute dips in copper sulphate
solution as per IS-2633.
12.2.5
Sharp edges with radii less than 2.5 mm shall be able to withstand four
immersions of the Standard Preece test. All other coatings shall withstand six
immersions. The following galvanizing tests should essentially be performed
as per relevant Indian Standards.
-
Coating thickness
-
Uniformity of zinc
-
Adhesion test
-
Mass of zinc coating
12.2.6
Galvanised material must be transported properly to ensure that
galvanised surfaces are not damaged during transit. Application of zinc rich
paint at site shall not be allowed.
12.3
PAINTING
12.3.1
All sheet steel work shall be degreased,
pickled, phosphated
in
accordance with the IS-6005 “Code of practice for phosphating iron and sheet”.
All surfaces, which will not be easily accessible after shop assembly, shall
beforehand be treated and protected for the life of the equipment.
The surfaces, which are to be finished painted after installation or
require corrosion protection until installation, shall be shop painted with at least
two coats of primer. Oil, grease, dirt and swaf shall be thoroughly removed by
emulsion cleaning. Rust and scale shall be removed by pickling with dilute
acid followed by washing with running water, rinsing with slightly alkaline hot
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water and drying.
12.3.2
After phosphating, thorough rinsing shall be carried out with clean water
followed by final rinsing with dilute dichromate solution and oven drying. The
phosphate coating shall be sealed with application of two coats of ready mixed,
stoving type zinc chromate primer. The first coat may be “flash dried” while the
second coat shall be stoved.
12.3.3
After application of the primer, two coats of finishing synthetic enamel paint
shall be applied, each coat followed by stoving. The second finishing coat shall be
applied after inspection of first coat of painting.
12.3.4
The exterior and interior colour of the paint in case of new substations shall be
RAL 7032 for all equipment, marshalling boxes, junction boxes, control
cabinets, panels etc.
unless specifically mentioned
under
respective
sections
of
the
equipments. Glossy white colour inside the equipments
/boards
/panels/junction boxes is also acceptable. The exterior colour for panels
shall be matching with the existing panels in case of extension of a substation.
Each coat of primer and finishing paint shall be of slightly different shade to
enable inspection of the painting. A small quantity of finishing paint shall be
supplied for minor touching up required at site after installation of the
equipments.
12.3.5
In case the Bidder proposes to follow his own standard surface finish and
protection procedures or any other established painting procedures, like
electrostatic painting etc., the procedure shall be submitted alongwith the Bids for
Purchaser’s review & approval.
12.3.6
The colour scheme as given below shall be followed for Fire Protection and
Air Conditioning systems
S.No.
PIPE LINE
Fire Protection System
1
Hydrant and Emulsifier system
pipeline
2
Emulsifier system detection line
– water
3
Emulsifier system detection line
–Air
4
Pylon support pipes
Air Conditioning System
5
Refrigerant gas pipeline – at
compressor suction
6
Refrigerant gas pipeline – at
compressor discharge
7
Refrigerant liquid pipeline
Base colour
Band
colour
FIRE RED
-
FIRE RED
Sea
Green
Sky Blue
FIRE RED
FIRE RED
Canary
Yellow
Canary
Yellow
Dark
Admiralty
Green
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-
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8
9
Chilled water pipeline
Condenser water pipeline
Sea Green
Sea Green
Dark Blue
The direction of flow shall be marked by → (arrow) in black colour.
Base Colour Direction of flow Band Colour
12.3.7
For aluminium casted surfaces, the surface shall be with smooth
Finish.
Further, in case of aluminium enclosures the surface shall be coated with power
(coating thickness of 60 microns) after surface preparation for painting.
13.0
HANDLING, STORING AND INSTALLATION
13.1
In accordance with the specific installation instructions as shown on
manufacturer’s drawingsoras directed by the Purchaser or
his
representative, the Contractor shall unload, store, erect, install, wire, test and
place into commercial use all the equipment included in the contract. Equipment
shall be installed in a neat, workmanlike manner so that it is level, plumb,
square and properly aligned and oriented. Commercial use of switchyard
equipment means completion of all site tests specified and energisation at rated
voltage.
13.2
Contractor may engage manufacturer’s Engineers to supervise the
unloading, transportation to site, storing, testing and commissioning of the various
equipment being procured by them separately. Contractor shall unload,
transport, store, erect, test and commission the equipment as per instructions of
the manufacturer’s supervisory Engineer(s) and shall extend full cooperation
to them.
13.3
In case of any doubt/misunderstanding as to the correct interpretation of
manufacturer’s drawings or instructions, necessary clarifications shall be
obtained from the Purchaser. Contractor shall be held responsible for any damage
to
the
equipment
consequent
to
not
following
manufacturer’s
drawings/instructions correctly.
13.4
Where assemblies are supplied in more than one section, Contractor shall make
all
necessary mechanical and electrical connections between sections
including the connection between buses. Contractor shall also do necessary
adjustments/alignments necessary for proper operation of circuit breakers,
isolators and
their
operating
mechanisms. All components
shall
be
protected
against
damage during
unloading,
transportation, storage,
installation, testing and commissioning. Any
equipment damaged due to negligence or carelessness or otherwise shall be
replaced by the Contractor at his own expense.
13.5
Contractor shall be responsible for examining all the shipment and notify the
Purchaser immediately of any damage, shortage, discrepancy etc. for the purpose
of Purchaser’s information only. The Contractor shall submit to the Purchaser
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every week a report detailing all the receipts during the weeks. However, the
Contractor shall be solely responsible for any shortages or damages in
transit, handling and/or in storage and erection of the equipment at Site. Any
demurrage, wharfage and other such charges claimed by the transporters,
railways etc. shall be to the account of the Contractor.
13.6
The Contractor shall be fully responsible for the equipment/material until the
same is handed over to the Purchaser in an operating condition after
commissioning. Contractor shall be responsible for the maintenance of the
equipment/material while in storage as well as after erection until taken
over by Purchaser, as well as protection of the same against theft, element
of nature, corrosion, damages etc.
13.7
Where material / equipment is unloaded by Purchaser before the
Contractor arrives at site or even when he is at site, Purchaser by right can
hand over the same to Contractor and there upon it will be the responsibility
of Contractor to store the material in an orderly and proper manner.
13.8
The Contractor shall be responsible for making suitable indoor storage
facilities, to store all equipment which requires indoor storage.
13.9
The words ‘erection’ and ‘installation’ used in the specification are
synonymous.
13.10
Exposed live parts shall be placed high enough above ground to meet the
requirements of electrical and other statutory safety codes.
13.11
The design and workmanship shall be in accordance with the best
engineering practices to ensure satisfactory performance throughout the service
life. If at any stage during the execution of the Contract, it is observed that
the erected equipment(s) do not meet the above minimum clearances as given
in clause 4.7.1 the Contractor shall immediately proceed to correct the
discrepancy at his risks and cost.
13.12
EQUIPMENT BASES
A cast iron or welded steel base plate shall be provided for all rotating
equipment which is to be installed on a concrete base unless otherwise agreed
to by the Purchaser. Each base plate shall support the unit and its drive assembly,
shall be of a neat design with pads for anchoring the units, shall have a raised
lip all around, and shall have threaded drain connections.
14.0
TOOLS AND TACKLES
The Contractor shall supply with the equipment one complete set of all special
tools and tackles for the erection, assembly, dis-assembly and maintenance of
the equipment. However, these tools and tackles shall be separately, packed and
brought on to Site.
15.0
AUXILIARY SUPPLY
15.1
The sub-station auxiliary supply is normally met through a system
indicated under section “Electrical & Mechanical Auxiliaries” having the
following parameters. The auxiliary power for station supply, including the
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equipment drive, cooling system of any equipment, air-conditioning,
lighting etc shall be designed for the specified Parameters as under. The DC
supply for the instrumentation and PLCC system shall also conform the
parameters as indicated in the following.
Normal
Voltage
Variation in
Voltage
Frequency
in HZ
Phase/
Wire
Neutral
connection
415V
+ 10%
50 + 5%
3/4 Wire
Solidly
Earthed.
240V
+ 10%
50 + 5%
1/2 Wire
Solidly
Earthed.
220V
190V to 240V
DC
-
Isolated 2 wire
System
110V
95V to 120V
DC
-
Isolated 2 wire
System
50V
_
DC
_
2 wire
system (+)
earthed
Combined variation of voltage and frequency shall be limited to + 10%.
16.0
SUPPORT STRUCTURE
16.1
The equipment support structure shall be suitable for equipmentconnection at first
level.All equipment support structure supplied alongwith brackets, angels, stools, etc.
for attaching the operating mechanism, control cabinets & marshelling box (wherever
applicable) etc.
16.2
The support structures should be hot dip galvanised with minimum 610
gram/sq.m net of zinc.
16.3
In case of any deviation in this regard the bid is liable to be considered
technically non responsive and shall be liable to be rejected.
16.4
Support structure shall meet the following mandatory requirements:
16.4.1
The minimum vertical distance from the bottom of the lowest porcelain part of
the bushing, porcelain enclosures or supporting insulators to the bottom of the
equipment base, where it rests on the foundation pad shall be 2.55 metres.
17.0
CLAMPS AND CONNECTORS INCLUDING TERMINAL CONNECTORS
17.1
All power clamps and connectors shall conform to IS:5561 & NEMA CC1 and
shall be made of materials listed below :
a)
For connecting
conductors
Aluminum alloy casting, ACSR
conforming to
designation A6
of IS:617 and all test shall
conform to IS:617
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b)
For connecting
equipment
made of
with
conductors
Bimetallic connectors made
from aluminum alloy terminals
casting conforming to copper
designation A6 of thick ACSR
IS:617 with 2mm
bimetallic liner and all test shall conform
to IS:617
c)
For connecting G.I
wire
Galvanised mild steel shield
d)
i)
Bolts, nuts &
Plain, washers
i)
Electrogalvanised for sizes
below M12, for others hot dip
galvanised.
ii)
Spring washers
for items
‘a’ to ‘c’
ii)
Electro-galvanised mild
steel suitable for atleast
service condition-3 as per
IS:1573
17.2
Each equipment shall be supplied with the necessary terminals and
connectors, as required by the ultimate design for the particular
installation. The conductor terminations of equipment shall be either
expansion, sliding or rigid type suitable for a) If corona rings are required to
meet these requirements they shall be considered as part of that equipment and
included in the scope of work.
17.3
Where copper to aluminum connections are required, bi-metallic clamps shall
be used, which shall be properly designed to ensure that any deterioration
of the connection is kept to a minimum and restricted to parts which are not
current carrying or subjected to stress. The design details of the joint shall be
furnished to the Purchaser by the Contractor.
17.4
Low voltage connectors, grounding connectors and accessories for
grounding all equipment as specified in each particular case, are also included
in the scope of Work.
17.5
No current carrying part of any clamp shall be less than 10 mm thick. All
ferrous parts shall be hot dip galvanised. Copper alloy liner of minimum 2 mm
thickness shall be cast integral with aluminum body for Bi-metallic clamps.
17.6
All casting shall be free from blow holes, surface blisters, cracks and cavities.
All sharp edges and corners shall be blurred and rounded off.
17.7
Flexible connectors, braids or laminated straps made for the terminal clamps
for bus posts shall be .
17.8
Clamp shall be designed to carry the same current as the conductor and the
temperature rise shall be equal or less than that of the conductor at the
specified ambient temperature. The rated current for which the
clamp/connector is designed with respect to the specified reference
ambient temperature, shall also be indelibly marked on each component of the
clamp/connector, except on the hardware.
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17.9
All current carrying parts shall be designed and manufactured to have
minimum contact resistance.
17.10
Clamps and connectors shall be designed as per IEC/ISS & JUSNL’s requirement.
17.11
Tests
17.11.1
Clamps and connectors should be type tested as per IS:5561 and shall also be
subjected to routine tests as per IS:5561. Following type test reports on
samples of similar type shall be submitted for approval
i)
Temperature rise test (maximum temperature rise allowed is
over 50°C ambient)
ii)
Short time current test
Iii)
iv)
35°C
Corona (dry) and RIV (dry) test for 220 KV and above voltage
And clamp
Resistance test and tensile test
18.0
CONTROL CABINETS, JUNCTION BOXES, TERMINAL BOXES &
MARSHALLING BOXES FOR OUTDOOR EQUIPMENT
18.1
All types of boxes, cabinets etc. shall generally conform to & be tested in
accordance with IS-5039/IS-8623, IEC-60439, as applicable, and the clauses
given below:
18.2
Control cabinets, junction boxes, Marshalling boxes & terminal boxes shall be
made of sheet steel or aluminum enclosure and shall be dust, water and vermin
proof. Sheet steel used shall be atleast 2.0 mm thick cold rolled. The box shall
be properly braced to prevent wobbling. There shall be sufficient reinforcement to
provide level surfaces, resistance to vibrations and rigidity during transportation
and installation. In case of aluminum enclosed box the thickness of aluminum
shall be such that it provides adequate rigidity and long life as comparable with
sheet steel of specified thickness.
18.3
Cabinet/boxes shall be free standing floor mounting type, wall mounting type or
pedestal mounting type as per requirements. A canopy and sealing
arrangements for operating rods shall be provided in marshalling boxes / Control
cabinets to prevent ingress of rain water.
18.4
Cabinet/boxes shall be provided with double hinged doors with padlocking
arrangements. The distance between two hinges shall be adequate to ensure
uniform sealing pressure against atmosphere. The quality of the
gasket shall be such that it does not get damaged/cracked during the operation
of the equipment.
18.5
All doors, removable covers and plates shall be gasketed all around with suitably
profiled EPDM/Neoprene gaskets. The gasket shall be tested in accordance with
approved quality plan, IS:11149 and IS:3400. The quality of gasket shall be such
that it does not get damaged/ cracked during the ten years of operation of the
equipment or its major overhaul whichever is earlier. All gasketed surfaces shall
be smooth straight and reinforced if necessary to minimize distortion and to
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make a tight seal. Ventilating Louvers, if provided, shall have screen and filters.
The screen shall be fine wire mesh made of brass.
18.6
All boxes/cabinets shall be designed for the entry of cables from bottom by
means of weather proof and dust-proof connections. Boxes and cabinets
shall be designed with generous clearances to avoid interference between the
wiring entering from below and any terminal blocks or accessories mounted
within the box or cabinet. Suitable cable gland plate projecting at least 150 mm
above the base of the marshalling kiosk/box shall be provided for this purpose
along with the proper blanking plates. Necessary number of cable glands shall
be supplied and fitted on this gland plate. Gland plate shall have provision for
some future glands to be provided later, if required. The Nickel plated glands
shall be dust proof, screw on & double compression type and made of brass. The
gland shall have provision for securing armour of the cable separately and shall
be provided with earthing tag. The glands shall conform to BS:6121.
18.7
A 240V, single phase, 50 Hz, 15 amp AC plug and socket shall be
provided in the cabinet with ON-OFF switch for connection of hand lamps. Plug
and socket shall be of industrial grade.
18.8
For illumination, a 20 Watts fluorescent tube or 15 watts CFL shall be
provided. The switching of the fittings shall be controlled by the door switch.
For junction boxes of smaller sizes such as lighting junction box, manual
operated earth switch mechanism box etc., plug socket, heater and
illumination is not required to be provided.
18.9
All control switches shall be of rotary switch type and Toggle/piano
switches shall not be accepted.
18.10
Positive earthing of the cabinet shall be ensured by providing two
separate earthing pads. The earth wire shall be terminated on to the earthing
pad and secured by the use of self etching washer. Earthing of hinged door shall
be done by using a separate earth wire.
18.11
The bay marshalling kiosks shall be provided with danger plate and a diagram
showing the numbering/connection/feruling by pasting the same on the inside of
the door. The bus bar in marshalling kiosks shall be suitably covered to guard
against unintentional contact.
18.12
a)
b)
19.0
The following routine tests alongwith the routine tests as per IS:5039 shall
also be conducted:
i)
Check for wiring
ii)
Visual and dimension check
The enclosure of bay marshalling kiosk, junction box, terminal box shall
conform to IP-55 as per IS:13947 including application of, 2.5
KV rms for 1 (one) minute, insulation resistance and functional test after
IP-55 test.
Auxiliary Switches (Applicable for isolators and circuit breakers)
The following type test reports on auxiliary switches shall be submitted for
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approval:
(a)
Electrical endurance test - A minimum of 2000 operation for 2A D. C. with
a time constant greater than or equal to 20 millisecond with a subsequent
examination of mV drop/visual defects/temperature rise test.
(b)
Mechanical endurance test. A minimum of 1,00,000 operations with a
subsequent checking of contact pressure test/visual examination.
(c)
Heat run test on contacts. (d)
IR/HV test etc.
20.0
TERMINAL BLOCKS AND WIRING
20.1
Control and instrument leads from the switchboards or from other
equipment will be brought to terminal boxes or control cabinets in
conduits. All interphase and external connections to equipment or to control
cubicles will be made through terminal blocks.
20.2
Terminal blocks shall be 650 V grade and have continuous rating to carry the
maximum expected current on the terminals and non breakable type. These shall
be of moulded piece, complete with insulated barriers, stud type terminals,
washers, nuts and lock nuts. Screw clamp, overall insulated, insertion type,
rail mounted terminals can be used in place of stud type terminals. But
preferably the terminal blocks shall be non- disconnecting stud type of Elmex
or Phoenix or Wago or equivalent make.
20.3
Terminal blocks for current transformer and voltage transformer
secondary leads shall be provided with test links and isolating facilities. The
current transformer secondary leads shall also be provided with short circuiting
and earthing facilities.
20.4
The terminal shall be such that maximum contact area is achieved when a cable is
terminated. The terminal shall have a locking characteristic to prevent cable
from escaping from the terminal clamp unless it is done intentionally.
20.5
The conducting part in contact with cable shall preferably be tinned or silver
plated however Nickel plated copper or zinc plated steel shall also be acceptable.
20.6
The terminal blocks shall be of extensible design.
20.7
The terminal blocks shall have locking arrangement to prevent its escape from the
mounting rails.
20.8
The terminal blocks shall be fully enclosed with removable covers of
transparent, non-deteriorating type plastic material. Insulating barriers shall be
provided between the terminal blocks. These barriers shall not hinder the
operator from carrying out the wiring without removing the barriers.
20.9
Unless otherwise specified terminal blocks shall be suitable for connecting the
following conductors on each side.
a)
All circuits except
CT circuits
Minimum of two of 2.5 sq mm
copper flexible.
b)
All CT circuits
Minimum of 4 nos. of 2.5 sq mm
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copper flexible.
20.10
The arrangements shall be in such a manner so that it is possible to safely connect
or disconnect terminals on live circuits and replace fuse links when the cabinet
is live.
20.11
Atleast 20 % spare terminals shall be provided on each panel/cubicle/box and
these spare terminals shall be uniformly distributed on all terminals rows.
20.12
There shall be a minimum clearance of 250 mm between the First/bottom row of
terminal block and the associated cable gland plate. Also the clearance
between two rows of terminal blocks shall be a minimum of 150 mm.
20.13
The Contractor shall furnish all wire, conduits and terminals for the
necessary interphase electrical connections (where applicable) as well as between
phases and common terminal boxes or control cabinets. For equipments rated
for 400 kV and above the wiring required in these items shall be run in metallic
ducts or shielded cables in order to avoid surge overvoltages either transferred
through the equipment or due to transients induced from the EHV circuits.
20.14
All input and output terminals of each control cubicle shall be tested for surge
withstand capability in accordance
the
relevant
IEC Publications, in both longitudinal and transverse
modes. The Contractor shall also provide all necessary filtering, surge protection,
interface relays and any other measures necessary to achieve an impulse
withstand level at the cable interfaces of the equipment.
with
21.0
LAMPS AND SOCKETS
21.1
Lamps
All incandescent lamps shall use a socket base as per IS-1258, except in the case
of signal lamps.
21.2
Sockets
All sockets (convenience outlets) shall be suitable to accept both 5 Amp &
15 Amp pin round Standard Indian plugs. They shall be switched sockets with
shutters.
21.3
Hand Lamp:
A 240 Volts, single Phase, 50 Hz AC plug point shall be provided in the
interior of each cubicle with ON-OFF Switch for connection of hand lamps.
21.4
Switches and Fuses:
21.4.1
Each panel shall be provided with necessary arrangements for receiving,
distributing, isolating and fusing of DC and AC supplies for various control,
signalling, lighting and space heater circuits. The incoming and sub- circuits
shall be separately provided with miniature circuit breaker / switchfuse
units. Selection of the main and Sub-circuit fuse ratings shall be such as to
ensure selective clearance of sub-circuit faults. Potential circuits for relaying and
metering shall be protected by HRC fuses.
21.4.2
All fuses shall be of HRC cartridge type conforming to IS:9228 mounted on
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plug-in type fuse bases. Miniature circuit breakers with thermal protection
and alarm contacts will also be accepted. All accessible live connection to fuse
bases shall be adequately shrouded. Fuses shall have operation indicators for
indicating blown fuse condition. Fuse carrier base shall have imprints of the fuse
rating and voltage.
22.0
Bushings, Hollow Column Insulators, Support Insulators:
22.1
Bushings shall be manufactured and tested in accordance with IS: 2099 & IEC60137 while hollow column insulators shall be manufactured and tested in
accordance with IEC-60233/IS:5621. The support insulators shall be manufactured
and tested as per IS:2544/IEC-60168 and IEC-60273. The insulators shall also
conform to IEC-60815 as applicable.
The bidder may also offer composite silicon rubber insulator, conforming to
IEC-61109.
22.2
Support insulators, bushings and hollow column insulators shall be
manufactured from high quality porcelain. Porcelain used shall be
homogeneous,
free from laminations, cavities and other flaws or
imperfections that might affect the mechanical or dielectric quality and shall be
thoroughly vitrified tough and impervious to moisture.
22.3
Glazing of the porcelain shall be uniform brown in colour, free from
blisters, burrs and similar other defects.
22.4
Support insulators/bushings/hollow column insulators shall be designed to have
ample insulation, mechanical strength and rigidity for the conditions under which
they will be used.
22.5
When operating at normal rated voltage there shall be no electric
discharge between the conductors and bushing which would cause
corrosion or injury to conductors, insulators or supports by the formation of
substances produced by chemical action. No radio interference shall be caused
by the insulators/bushings when operating at the normal rated voltage.
22.6
Bushing porcelain shall be robust and capable of withstanding the internal
pressures likely to occur in service design and location of clamps and the shape
and the strength of the porcelain flange securing the bushing to the tank
shall be such that there is no risk of fracture.
All
portions of the assembled porcelain enclosures and supports other than gaskets,
which may in any way be exposed to the atmosphere shall be composed of
completely non hygroscopic material such as metal or glazed porcelain.
22.7
All iron parts shall be hot dip galvanised and all joints shall be air tight.
Surface of joints shall be trued up porcelain parts by grinding and metal parts
by machining. Insulator/bushing design shall be such as to ensure a uniform
compressive pressure on the joints.
22.8
Tests
In bushing, hollow column insulators and support insulators shall conform to type
tests and shall be subjected to routine tests in accordance with IS:
2099 & IS: 2544 & IS : 5621. The type test reports shall be submitted for
IN JASIDIH GSS VOL-II
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approval.
23.0
MOTORS
Motors shall be “Squirrel Cage” three phase induction motors of sufficient size
capable of satisfactory operation for the application and duty as required for
the driven equipment and shall be subjected to routine tests as per applicable
standards. The motors shall be of approved make.
23.1
23.2
23.3
Enclosures
a)
Motors to be installed outdoor without enclosure shall have hose proof
enclosure equivalent to IP-55 as per IS: 4691. For motors to be installed
indoor i.e. inside a box, the motor enclosure, shall be dust proof equivalent
to IP-44 as per IS: 4691.
b)
Two independent earthing points shall be provided on opposite sides of the
motor for bolted connection of earthing conductor.
c)
Motors shall have drain plugs so located that they will drain water
resulting from condensation or other causes from all pockets in the motor
casing.
d)
Motors weighing more than 25 Kg. shall be provided with eyebolts, lugs
or other means to facilitate lifting.
Operational Features
a)
Continuous motor rating (name plate rating) shall be at least ten (10) percent
above the maximum load demand of the driven equipment at design duty
point and the motor shall not be over loaded at any operating point of
driven equipment that will rise in service.
b)
Motor shall be capable at giving rated output without reduction in the
expected life span when operated continuously in the system having the
particulars as given in Clause 15.0 of this Section.
Starting Requirements:
a)
All induction motors shall be suitable for full voltage direct-on-line
starting. These shall be capable of starting and accelerating to the rated
speed alongwith the driven equipment without exceeding the
acceptable winding temperature even when the supply voltage drops down to
80% of the rated voltage.
b)
Motors shall be capable of withstanding the electrodynamic stresses and
heating imposed if it is started at a voltage of 110% of the rated value.
c)
The locked rotor current shall not exceed six (6) times the rated full load
current for all motors, subject to tolerance as given in IS:325.
d)
Motors when started with the driven equipment imposing full starting torque
under the supply voltage conditions specified under Clause
15.0 shall be capable of withstanding atleast two successive starts from
cold condition at room temperature and one start from hot condition
without injurious heating of winding. The motors shall also be suitable for
three equally spread starts per hour under the above
IN JASIDIH GSS VOL-II
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referred supply condition.
e)
23.4
23.5
The locked rotor withstand time under hot condition at 110% of rated
voltage shall be more than starting time with the driven equipment of
minimum permissible voltage by at least two seconds or 15% of the
accelerating time whichever is greater. In case it is not possible to meet
the above requirement, the Bidder shall offer centrifugal type speed switch
mounted on the motor shaft which shall remain closed for speed lower than
20% and open for speeds above 20% of the rated speed. The speed
switch shall be capable of withstanding
120% of the rated speed in either direction of rotation.
Running Requirements:
a)
The maximum permissible temperature rise over the ambient
temperature of 50 degree C shall be within the limits specified in IS:325
(for 3 - phase induction motors) after adjustment due to increased
ambient temperature specified.
b)
The double amplitude of motor vibration shall be within the limits
specified in IS: 4729. Vibration shall also be within the limits
specified by the relevant standard for the driven equipment when
measured at the motor bearings.
c)
All the induction motors shall be capable of running at 80% of rated
voltage for a period of 5 minutes with rated load commencing from hot
condition.
TESTING AND COMMISSIONING
An indicative list of tests is given below. Contractor shall perform any
additional test based on specialities of the items as per the field
Q.P./Instructions of the equipment Contractor or Purchaser without any extra
cost to the Purchaser. The Contractor shall arrange all instruments required for
conducting these tests alongwith calibration certificates and shall furnish the list
of instruments to the Purchaser for approval.
(a)
Insulation resistance.
(b)
Phase sequence and proper direction of rotation.
(c)
Any motor operating incorrectly shall be checked to determine the cause
and the conditions corrected.
24.0
TECHNICAL REQUIREMENT OF EQUIPMENTS
24.1
Circuit Breakers (Applicable for 220 Kv & 132 kV)
24.1.(i)
The manufacturer(s) whose SF6 Circuit Breaker are offered should have
designed, manufactured tested as per IEC/IS or equivalent standard supplied
the same for the specified system voltage which are in satisfactory operation
for at least 2 (two) years as on the date of bid opening
OR
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24.1(ii)
24.1.(iii)
The manufacturer(s) whose SF6 Circuit Breaker are offered who have recently
established production line in India for the specified system voltage or
above class, based on technological support of a parent company or
collaborator for the respective equipment(s) can also be considered provided
the parent company (Principal) or collaborator meets qualifying requirements
stipulated under clause no 24.4. (a) & (b) given below.
AND
Furnishes (jointly with parent company or collaborator) a
legally enforceable undertaking to guarantee quality, timely supply, performance
and warranty obligations as specified for the equipment(s)
AND
24.1.(iv)
24.2
24.2.(i)
Furnishes a confirmation letter from the parent company or collaborator
alongwith the bid stating that parent company or collaborator shall furnish
performance guarantee for an amount of 10% of the cost of such
equipment(s). This performance guarantee shall be in addition to contract
performance guarantee to be submitted by the Bidder
Isolators (Applicable for 220 KV & 132 kV)
The manufacturer whose isolator are offered, should have designed,
manufactured & tested as per IS/IEC or equivalent standard and supplied the
isolator for the specified system voltage and should be in satisfactory
operation for at least 2 (two) years as on the date of bid opening
OR
The manufacturer(s) whose Isolator are offered who have recently
established production line in India for the specified system voltage or above
class, based on technological support of a parent company or collaborator
for the respective equipment(s) can also be considered provided
the
parent
company
(Principal) or
collaborator
meets
qualifying requirements stipulated under clause no 24.2.(i) (a) & (b) given
above.
AND
24.2.(ii)(b)
Furnishes (jointly with parent company or collaborator) a legally
enforceable
undertaking
to guarantee
quality, timely supply,
performance and warranty obligations as specified for the equipment(s)
AND
24.2.(ii)(c)
Furnishes a confirmation letter from the parent company or collaborator
alongwith the bid stating that parent company or collaborator shall furnish
performance guarantee for an amount of 10% of the cost of such
equipment(s). This performance guarantee shall be in addition to contract
performance guarantee to be submitted by the Bidder
24.3
Instrument Transformers (Applicable for 220 KV & 132 kV)
24.2.(ii)(a)
24.3.(i) (a)
The manufacturer whose instrument transformers are offered, should have
designed, manufactured & tested as per IS/IEC or equivalent standard and
supplied the same for the specified system voltage for CT
IN JASIDIH GSS VOL-II
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& CVT and should be in satisfactory operation for at least 2 (two) years as on
the date of bid opening
OR
24.3.(ii)(a)
The manufacturer(s) whose Instrument Transformer are offered who have recently
established production line in India for the specified system
voltage or above class, based on technological support of a parent
company or collaborator for the respective equipment(s) can also be
considered provided the parent company (Principal) or collaborator meets
qualifying requirements stipulated under clause no 24.6.(i) given above.
AND
24.3.(ii)(b)
Furnishes (jointly with parent company or collaborator) a legally
enforceable undertaking to guarantee quality, timely supply, performance and
warranty obligations as specified for the equipment(s)
AND
24.3.(ii)(c)
Furnishes a confirmation letter from the parent company or collaborator
alongwith the bid stating that parent company or collaborator shall furnish
performance guarantee for an amount of 10% of the cost of such
equipment(s). This performance guarantee shall be in addition to contract
performance guarantee to be submitted by the Bidder
24.4
Surge Arresters (Applicable for 132 kV)
(a) The manufacturer whose Surge Arresters are offered should have designed,
manufactured and tested as per IEC/IS or equivalent standard and
supplied the Surge Arrester for the specified energy capability with rated
system voltage and which are in satisfactory operation for at least 2 (two)
years as on the date of bid opening.
OR
(b) The manufacturer(s) whose Surge Arrestors are offered who have recently
established production line in India for the specified system voltage or
above class, based on technological support of a parent company or
collaborator for the respective equipment(s) can also be considered provided
the parent company
(Principal) or collaborator meets qualifying
requirements stipulated under clause no (a) given above.
AND
Furnishes (jointly with parent company or collaborator) a legally
enforceable undertaking to guarantee quality, timely supply, performance and
warranty obligations as specified for the equipment(s)
AND
Furnishes a confirmation letter from the parent company or collaborator
alongwith the bid stating that parent company or collaborator shall furnish
performance guarantee for an amount of 10% of the cost of such
equipment(s). This performance guarantee shall be in addition to contract
performance guarantee to be submitted by the Bidder.
24.5
24.5.1
1.1 KV Grade Power & Control Cables
Applicable for PVC Control Cable
The manufacturers, whose PVC control cables are offered, should have
designed, manufactured, tested and supplied in a single contract at least
100 Kms of 1.1 KV grade PVC insulated control cables as on the date of bid
IN JASIDIH GSS VOL-II
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opening. Further the manufacturer should also have designed, manufactured,
tested and supplied at least 1 km of 27C x 2.5 Sq.mm or higher size as on the
date of bid opening.
24.5.2
Applicable for PVC Power Cable
The manufacturer, whose PVC Power Cables are offered, should have designed,
manufactured, tested and supplied in a single contract atleast
100 Kms of 1.1 KV or higher grade PVC insulated power cables as on the date of
bid opening. Further the manufacturer should also have designed, manufactured,
tested and supplied at least 1 km of 1C x 150 Sq. mm or higher size as on the
date of bid opening.
24.5.3
Applicable for XLPE Power Cables
The Manufacturer, whose XLPE Power cables are offered, should have
designed, manufactured, tested and supplied in a single contract atleast
25 Kms of 1.1 KV or higher grade XLPE insulated power cables as on the date of
bid opening. Further the manufacturer should also have designed, manufactured,
tested and supplied at least 1 km of 1C x 630 Sq. mm or higher size as on the
date of bid opening.
24.6
LT Switchgear
24.6.1
The Manufacturer whose LT Switchgear are offered, should be a
manufacturer of LT Switchboards of the type and rating being offered. He should
have designed, manufactured, tested and supplied at least 50 nos. draw out circuit
breaker panels, out of which at least 5 nos. should have been with relay and
protection schemes with current transformer. He should have also
manufactured at least 50 nos. motor control center panels of the type and
rating being offered which should be in successful operation as on date of bid
opening.
24.6.2
The Switchgear items (such as
contactors etc.), may be of his own
manufacturers and of proven design.
the make and type being offered
of bid opening.
24.7
Battery and Battery Charger
24.7.1
Requirements for Battery Manufacturers
circuit breakers, fuse switch units,
make or shall be procured from reputed
At least one hundred circuit breakers of
shall be operating satisfactory as on date
The manufacturer whose Batteries are offered should have designed,
manufactured and supplied DC Batteries of the type specified and being offered,
having a capacity of at least 500 AH and these shall be operating satisfactorily for
two years in power sector and/or industrial installations as on date of bid opening.
24.7.2
Requirements for Battery Charger Manufacturers
The manufacturer, whose Battery Chargers are offered, should have
designed, manufactured and supplied Battery Chargers generally of the
type offered, with static automatic voltage regulators and having a
continuous output of atleast ten (10) KW and these should be in
successful operation as on the date of bid opening.
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Page 81
24.8
LT Transformers
The manufacturer, whose transformers are offered should have designed,
manufactured, type tested including short circuit test as per IEC/IS or
equivalent standards and supplied transformers of at least 33 kV class of
3 1 5 KVA or higher. The transformer should have been in successful
operation for at least 2 years as on the date of bid opening.
24.9
Fire Fighting System
The bidder or his sub-vendor should have designed, tested and similar
equipments.
24.10
Control and Relay Panels
24.10.1
The manufacturer whose C&R panels and protective relay are offered should
have designed, manufactured, tested, installed and commissioned C&R panels
including protection relays which must be in satisfactory operation on
specified voltage level or above [for 400 kV & below substation] for atleast 2
(two) years on the date of bid opening.
24.10.2
The C&R Panel from a manufacturer who has designed, manufactured, tested,
installed and commissioned C&R panels which are in satisfactory operation on
220 kV system or above for atleast 2 (two) years on the date of bid opening
can also be offered, provided the protective relay schemes should be offered
from a Contractor who fully meets the requirements stipulated under
specifications.
Further, in such an event the manufacturer shall furnish an undertaking jointly
executed by him and his protective relay schemes Supplier, as per the format
enclosed in the bid documents for successful performance of the protection
system offered.
24.11
PLCC
24.11.1
The manufacturer whose PLCC panels are offered should have designed,
manufactured, tested, supplied and commissioned PLCC panels for 132 kV
system or above [for 132 kV substation] and the same should be in successful
operation for atleast 2 (two) years as on the date of bid opening.
24.11.2
The manufacturer whose line traps are offered should have designed,
manufactured tested, supplied and commissioned similar line traps for specified
voltage level or above and specified fault level and should be in successful
operation for atleast 2 (two) years as on the date of bid opening.
24.11.3
PLCC Panels/line traps manufactured by the manufacturer meeting the
requirements
except that the PLCC Panels/line traps manufactured, tested
and supplied by them is not in operation for the stipulated period can also
be offered provided the manufacturer furnishes an undertaking jointly
executed by him and his collaborator, who in turn fully meets the
requirement specified above as per the format enclosed in the bid document for
successful performance of the equipment offered.
24.11.4
The manufacturer(s) whose PLCC Panels/Line traps are offered who have recently
established production line in India for the specified system voltage or
IN JASIDIH GSS VOL-II
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Page 82
above class, based on technological support of a parent company or
collaborator for the respective equipment(s) can also be considered provided
the parent company (Principal) or collaborator meets qualifying requirements
stipulated under clause no 24.14.1/24.14.2 given above.
And
Furnishes (jointly with parent company or collaborator) a
legally enforceable undertaking to guarantee quality, timely supply, performance
and warranty obligations as specified for the equipment(s)
And
Furnishes a confirmation letter from the parent company or collaborator
alongwith the bid stating that parent company or collaborator shall furnish
performance guarantee for an amount of 10% of the cost of such
equipment(s). This performance guarantee shall be in addition to contract
performance guarantee to be submitted by the Bidder.
ANNEXURE - A
LIST OF SPECIFICATIONS GENERAL STANDARDS AND CODES
India Electricity Rules
Indian Electricity Act
Indian Electricity (Supply) Act
Indian Factories Act
IS-5,
-
Colors for Ready Mixed Paints and Enamels. IS-335,
New Insulating Oils.
IS-617,
-
Aluminium and Aluminium Alloy Ingots and
Castings for General Engineering Purposes
IS-1448 (P1 to P 145)
-
Methods of Test for Petroleum and its Products. IS-2071
(P1 to P3)
-
Methods of High Voltage Testing.
IS-12063
-
Classification of degrees of protection provided by
enclosures of electrical equipment.
P1:1997
-
Insulation Coordination. P2:1983
IS-3043
-
Code of Practice for Earthing
IS-6103
-
Method of Test for Specific Resistance
(Resistivity) of Electrical Insulating Liquids
IS-2165
IS-6104
-
Method of Test for Interfacial Tension of Oil
against Water by the Ring Method
IS-6262
-
Method of test for Power factor & Dielectric
Constant of Electrical Insulating Liquids.
IS-6792
-
Method for determination of electric strength of
IN JASIDIH GSS VOL-II
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Page 83
-
insulating oils.
IS-5578
-
Guide for marking of insulated conductors. IS-11353
-
Guide for uniform system of marking &
identification of conductors & apparatus terminals.
IS-8263
-
Methods for Radio Interference Test on High
voltage Insulators.
IS-9224 (Part 1,2&4)
-
Low Voltage Fuses
IEC-60060 (Part 1 to P4)
-
High Voltage Test Techniques
IEC 60068
-
Environmental Test
IEC-60117
-
Graphical Symbols
IEC-60156,
-
Method for the Determination of the Electrical
Strength of Insulation Oils.
IEC-60270,
-
Partial Discharge Measurements.
IEC-60376
-
Specification and Acceptance of New Sulphur
Hexafloride
IEC-60437
-
Radio Interference Test on High Voltage
Insulators.
IEC-60507
-
Artificial Pollution Tests on High Voltage
Insulators to be used on AC Systems.
IEC-60694
-
Common Specification for High Voltage
Switchgear & Controlgear Standards.
IEC-60815
-
Guide for the Selection of Insulators in respect of Polluted
Conditions.
IEC-60865 (P1 & P2)
-
Short Circuit Current - Calculation of effects. ANSI-
C.1/NFPA.70
-
National Electrical Code
ANSI-C37.90A
-
Guide for Surge Withstand Capability (SWC)
Tests
ANSI-C63.21,
-
Specification for Electromagnetic Noise and C63.3
-
Field Strength Instrumentation 10 KHz to 1 GHZ
C36.4ANSI-C68.1
-
Techniquest for Dielectric Tests
ANSI-C76.1/EEE21
-
Standard General Requirements and Test
Procedure for Outdoor Apparatus Bushings. ANSI-SI-4 -
Specification for Sound Level Metres
ANSI-Y32-2/C337.2
-
Drawing Symbols
ANSI-Z55.11
-
Gray Finishes for Industrial Apparatus and
Equipment No. 61 Light Gray
NEMA-107T
-
Methods of Measurements of RIV of High Voltage
IN JASIDIH GSS VOL-II
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Page 84
Apparatus
NEMA-ICS-II
-
General Standards for Industrial Control and
Systems Part ICSI-109
CISPR-1
-
Specification for CISPR Radio Interference
Measuring Apparatus for the frequency range
0.15 MHz to 30 MHz
CSA-Z299.1-1978h
-
Quality Assurance Program Requirements CSA-Z299.2-
1979h
-
Quality Control Program Requirements
CSA-Z299.3-1979h
-
Quality Verification Program Requirements CSA-Z299.4-
1979h
-
Inspection Program Requirements
TRANSFORMERS AND REACTORS
IS:10028 (Part 2 & 3)
-
Code of practice for selection, installation & maintenance
of Transformers (P1:1993), (P2:1991), (P3:1991)
IS-2026 (P1 to P4)
-
Power Transformers
IS-3347 (part 1 to Part 8)
-
Dimensions for Porcelain transformer Bushings for
use in lightly polluted atmospheres.
IS-3639
-
Fittings and Accessories for Power Transformers
IS-6600
-
Guide for Loading of OIl immersed Transformers.
IEC-60076 (Part 1 to 5)
-
Power Transformers
IEC-60214
-
On-Load Tap-Changers. IEC-60289
-
Reactors.
IEC- 60354
-
Loading Guide for Oil - Immersed power trans formers
IEC-60076-10
-
Determination of Transformer and Reactor Sound
Levels
ANSI-C571280
-
General requirements for
Regulating Transformers
ANSI-C571290
-
Test Code for Distribution, Power and Regulation
Transformers
ANSI-C5716
-
Terminology & Test Code for Current Limiting
Reactors
ANSI-C5721
-
Requirements, Terminology and Test Code for
Shunt Reactors Rated Over 500 KVA
ANSI-C5792
-
Guide for Loading Oil-Immersed Power Transformers
upto and including 100 MVA with 55 deg C or 65 deg C
Winding Rise
ANSI-CG,1EEE-4
-
Standard Techniques for High Voltage Testing
Distribution,
IN JASIDIH GSS VOL-II
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Power
Page 85
and
CIRCUIT BREAKERS
IEC-62271-100
-
High Voltage Alternating Current Circuit Breakers
IEC-60427
-
Synthetic Testing of High Voltage alternating
current circuit Breakers.
IEC-61264
-
Pressurised Hollow Column Insulators
CURRENT TRANSFORMERS, VOLTAGE TRANSFORMERS AND COUPLING
CAPACITOR VOLTAGE TRANSFORMERS
IS-2705- (P1 to P4)
-
Current Transformers. IS:3156-
(P1 to P4)
-
Voltage Transformers.
IS-4379
Cylinders
-
Identification of the Contents of Industrial Gas
IEC-60044-1
-
Current transformers.
IEC-60044-2
-
Voltage Transformers.
IEC-60358
-
Coupling capacitors and capacitor dividers.
IEC-60044-4
-
Instrument Transformes : Measurement of Partial
Discharges
IEC-60481
-
Coupling Devices for power Line Carrier Systems. ANSI-
C5713
-
Requirements for Instrument transformers ANSIC92.2
-
Power Line Coupling voltage Transformers
ANSI-C93.1
-
Requirements for Power Line Carrier Coupling
Capacitors
-
Bushings for Alternating Voltages above 1000V IEC-60137
-
Insulated Bushings for Alternating Voltages
above 1000V
IS-3070 (PART2)
-
Lightning arresters for alternating current systems
: Metal oxide lightning arrestors without gaps. IEC-60099-
4
-
Metal oxide surge arrestors without gaps
IEC-60099-5
-
Selection and application recommendation ANSI-C62.1 -
BUSHING
IS-2099
SURGE ARRESTERS
IEE Standards for S A for AC Power Circuits NEMA-LA 1
Surge Arresters
CUBICLES AND PANELS & OTHER RELATED EQUIPMENTS
IS-722, IS-1248,
-
IS-3231, 3231 (P-3)
IS:5039
Electrical relays for power system
protection
-
Distributed pillars for Voltages not Exceeding
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-
1000 Volts.
IEC-60068.2.2
-
Basic environmental testing procedures Part 2: Test
B: Dry heat
IEC-60529
-
Degree of Protection provided by enclosures. IEC-60947-4-
1
-
Low voltage switchgear and control gear.
IEC-61095
-
Electromechanical Contactors for household and
similar purposes.
IEC-60439 (P1 & 2)
-
Low Voltage Switchgear and control gear
assemblies
ANSI-C37.20
-
Switchgear Assemblies, including metal enclosed bus.
ANSI-C37.50
-
Test Procedures for Low Voltage Alternating
Current Power Circuit Breakers
ANSI-C39
-
Electric Measuring instrument
ANSI-C83
-
Components for Electric Equipment
IS: 8623: (Part I to 3)
-
Specification for Switchgear & Control
Assemblies.
NEMA-AB
-
Moulded Case Circuit and Systems
NEMA-CS
-
Industrial Controls and Systems
NEMA-PB-1
-
Panel Boards
NEMA-SG-5
-
Low voltage Power Circuit breakers
NEMA-SG-3
-
Power Switchgear Assemblies
NEMA-SG-6
-
Power switching Equipment
NEMA-5E-3
-
Motor Control Centers
1248 (P1 to P9)
-
Direct acting indicating analogue electrical
measuring instruments & their accessories.
IEC-60129
-
Alternating Current Disconnectors (Isolators) and
Earthing switches
IEC-1129
-
Alternating Current Earthing Switches Induced
Current switching
IEC-60265 (Part 1 & 2)
-
High Voltage switches
ANSI-C37.32
-
Schedule of preferred Ratings, Manufacturing
Specifications and Application Guide for high
voltage Air Switches, Bus supports and switch
accessories
ANSI-C37.34
-
Test Code for high voltage air switches
NEMA-SG6
-
Power switching equipment
Disconnecting switches
IN JASIDIH GSS VOL-II
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PLCC and line traps
IS-8792
-
Line traps for AC power system.
IS-8793
-
Methods of tests for line traps.
IS-8997
-
Coupling devices for PLC systems.
IS-8998
-
Methods of test for coupling devices for PLC
systems.
IEC-60353
-
Line traps for A.C. power systems.
IEC-60481
-
Coupling Devices for power line carrier systems. IEC-
60495
-
Single sideboard power line carrier terminals
IEC-60683
-
Planning of (single Side-Band) power line carrier
systems.
CIGRE
-
Teleprotection report by Committee 34 & 35.
CIGRE
-
Guide on power line carrier 1979.
CCIR
-
International Radio Consultative Committee
CCITT
-
International Telegraph & Telephone Consultative
Committee
EIA
-
Electric Industries Association
Protection and control equipment
IEC-60051 : (P1 to P9)
-
Recommendations for Direct Acting indicating
analogue electrical measuring instruments and their
accessories.
IEC-60255 (Part 1 to 23)
-
Electrical relays. IEC-60297
(P1 to P4)
-
Dimensions of mechanical structures of the
482.6mm (19 inches) series.
IEC-60359
-
Expression of the performance of electrical &
electronic measuring equipment.
IEC-60387
-
Symbols for Alternating-Current Electricity meters. IEC-60447
-
Man machine interface (MMI) - Actuating
principles.
IEC-60521
-
Class 0.5, 1 and 2 alternating current watt hour
metres
IEC-60547
-
Modular plug-in Unit and standard 19-inch rack
mounting unit based on NIM Standard (for
electronic nuclear instruments)
ANSI-81
-
Screw threads
ANSI-B18
-
Bolts and Nuts
ANSI-C37.1
-
Relays, Station Controls etc.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 88
ANSI-C37.2
-
Manual and automatic station control, supervisory and
associated telemetering equipment
ANSI-C37.2
-
Relays and relay systems associated with electric power
apparatus
ANSI-C39.1
-
Requirements for electrical analog indicating
instruments
IS-325
-
Three phase induction motors.
IS-4691
-
Degree of protection provided by enclosure for
rotating electrical machinery.
IEC-60034 (P1 to P19:)
-
Rotating electrical machines
IEC-Document 2
-
Three phase induction motors
MOTORS
(Central Office) NEMA-MGI
Motors and Generators
Electronic equipment and components
MIL-21B, MIL-833 & MIL-2750
IEC-60068 (P1 to P5)
-
Environmental testing
IEC-60326 (P1 to P2)
-
Printed boards
Material and workmanship standards
IS-1363 (P1 to P3)
-
Hexagon headbolts, screws and nuts of product grade
C.
IS-1364 (P1 to P5)
-
Hexagon head bolts, screws and nuts of products grades
A and B.
IS-3138
-
Hexagonal Bolts and Nuts (M42 to M150)
ISO-898
-
Fasteners: Bolts, screws and studs
ASTM
-
Specification and tests for materials
IS-5561
-
Electric power connectors.
NEMA-CC1
-
Electric Power connectors for sub station
NEMA-CC 3
-
Connectors for Use between aluminium or
aluminum-Copper Overhead Conductors
Clamps & connectors
Bus hardware and insulators
IS: 2121
-
Fittings for Aluminum and steel cored Al conductors for
overhead power lines.
IS-731
-
Porcelain insulators for overhead power lines with a
nominal voltage greater than 1000 V.
IS-2486 (P1 to P4)
-
Insulator fittings for overhead power lines with a
nominal voltage greater than 1000 V.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 89
IEC-60120
-
Dimensions of Ball and Socket Couplings of string
insulator units.
IEC-60137
-
Insulated bushings for alternating voltages above
1000 V.
IEC-60168
-
Tests on indoor and outdoor post insulators of
ceramic material or glass for Systems with Nominal
Voltages Greater than 1000 V.
IEC-60233
-
Tests on Hollow Insulators for use in electrical
equipment.
IEC-60273
-
Characteristices of indoor and outdoor post
insulators for systems with nominal voltages
greater than 1000V.
IEC-60305
-
Insulators for overhead lines with nominal voltage
above 1000V-ceramic or glass insulator units for
a.c. systems Characteristics of String Insulator
Units of the cap and pintype.
IEC-60372 (1984)
-
Locking devices for ball and socket couplings of
string insulator units : dimensions and tests.
IEC-60383 (P1 and P2)
-
Insulators for overhead lines with a nominal
voltage above 1000 V.
IEC-60433
-
Characteristics of string insulator units of the long rod
type.
IEC-60471
-
Dimensions of Clevis and tongue couplings of
string insulator units.
ANSI-C29
-
Wet process proelain insulators
ANSI-C29.1
-
Test methods for electrical power insulators
ANSI-C92.2
-
For insulators, wet-process porcelain and
toughened glass suspension type
ANSI-C29.8
-
For wet-process porcelain insulators apparatus, posttype
ANSI-G.8
-
Iron and steel hardware
CISPR-7B
-
Recommendations of the CISPR, tolerances of form
and of Position, Part 1
ASTM A-153
-
Zinc Coating (Hot-Dip) on iron and steel hardware
Strain and rigid bus-conductor
IS-2678
-
Dimensions & tolerances for Wrought Aluminum and
Aluminum Alloys drawn round tube.
IS-5082
-
Wrought Aluminum and Aluminum Alloy Bars.
Rods, Tubes and Sections for Electrical purposes.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 90
ASTM-B 230-82
-
Aluminum 1350 H19 Wire for electrical purposes
ASTM-B 231-81
-
Concentric - lay - stranded, aluminum 1350
conductors
ASTM-B 221
-
Aluminum - Alloy extruded bar, road, wire, shape
ASTM-B 236-83
-
Aluminum bars for electrical purpose (Bus-bars)
ASTM-B 317-83
-
Aluminum-Alloy extruded bar, rod, pipe and
structural shapes for electrical purposes (Bus
Conductors)
Batteries and batteries charger
Battery
IS:1651
-
Stationary Cells and Batteries, Lead-Acid Type
(with Tubular Positive Plates)
IS:1652
-
Stationary Cells and Batteries, Lead-Acid Type
(with Plante Positive Plates)
IS:1146
-
Rubber and Plastic Containers for Lead-Acid
Storage Batteries
IS:6071
-
Synthetic Separators for Lead-Acid Batteries
IS:266
-
Specification for Sulphuric Acid
IS:1069
-
Specification for Water for Storage Batteries
IS:3116
-
Specification for Sealing Compound for Lead-Acid
Batteries
IS:1248
-
Indicating Instruments
IS:10918
-
Vented type nickel Cadmium Batteries
IEC:60896-21&22
-
Lead Acid Batteries Valve Regulated types –
Methods of Tests & Requirements
IEC: 60623
-
Vented type nickel Cadmium Batteries
IEC:60622
-
Secondary Cells & Batteries – Sealed Ni-Cd
rechargeable single cell
IEC:60623
-
Secondary Cells & Batteries – Vented Ni-Cd
rechargeable single cell
IEC:60896-11
-
Stationary Lead Acid Batteries – Vented Type –
General requirements & method of tests
IEEE-485
-
Recommended practices for sizing of Lead Acid
Batteries
IEEE-1115
-
Sizing of Ni-Cd Batteries
IEEE-1187
-
Recommended practices for design & installation of
VRLA Batteries
IEEE-1188
-
Recommended practices for design & installation of
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 91
VRLA Batteries
IEEE-1189
-
Guide for selection of VRLA Batteries
IS:3895
-
Mono-crystalline Semiconductor Rectifier Cells and
Stacks
IS:4540
-
Mono-crystalline Semiconductor Rectifier
Assemblies and Equipment.
IS:6619
-
Safety Code for Semiconductor Rectifier
Equipment
IS:2026
-
Power Transformers
IS:2959
-
AC Contactors for Voltages not Exceeding 1000
Volts
IS:1248
-
Indicating Instruments
IS:2208
-
HRC Fuses
IS:13947 (Part-3)
-
Air break switches, air break disconnectors & fuse
combination units for voltage not exceeding 1000V AC or
1200V DC
IS:2147
-
Degree of protection provided by enclosures for low
voltage switchgear and controlgear.
IS:6005
IS:5
Code of practice for phosphating of Iron and Steel IS:3231
Electrical relays for power system protection IS:3842
Electrical relay for AC Systems
Colours for ready mix paint
IEEE-484
-
Recommended Design for installation design and
installation of large lead storage batteries for
generating stations and substations.
IEEE-485
-
Sizing large lead storage batteries for generating
stations and substations
ASTMD-2863
-
Measuring the minimum oxygen concentration to
support candle like combustion of plastics (oxygen
index)
IS-694
-
PVC insulated cables for working voltages upto and
including 1100 Volts.
IS-1255
-
Code of practice for installation and maintenance of
power cables, upto and including 33 kV rating
IS-1554 (P1 and P2)
-
PVC insulated (heavy duty) electric cables (part 1)
for working voltage upto and including 1100 V.
Battery Charger
Wires and cables
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 92
-
Part (2) for working voltage from 3.3 kV upto and
including 11kV.
IS:1753
-
Aluminium conductor for insulated cables
IS:2982
-
Copper Conductor in insulated cables.
IS-3961 (P1 to P5)
-
Recommended current ratings for cables.
IS-3975
-
IS-5831
IS-6380
-
Mild steel wires, formed wires and tapes for
armouring of cables.
PVC insulating and sheath of electric cables.
Elastometric insulating and sheath of electric
cables.
IS-7098
-
Cross linked polyethylene insulated PVC sheathed
cables for working voltage upto and including
1100 volts.
IS-7098
-
IS-8130
-
Cross-linked polyethyle insulated PVC sheathed
cables for working voltage from 3.3kV upto and
including 33 kV.
Conductors for insulated electrical cables and
flexible cords.
IS-1753
-
Aluminum Conductors for insulated cables.
IS-10418
-
Specification for drums for electric cables.
IEC-60096 (part 0 to p4)
-
Radio Frequency cables.
IEC-60183
-
Guide to the Selection of High Voltage Cables.
IEC-60189 (P1 to P7)
-
Low frequency cables and wires with PVC
insulation and PVC sheath.
IEC-60227 (P1 to P7)
-
Polyvinyl Chloride insulated cables of rated
voltages up to and including 450/750V.
IEC-60228
-
Conductors of insulated cables
IEC-60230
-
Impulse tests on cables and their accessories. IEC-60287
(P1 to P3)
-
Calculation of the continuous current rating of
cables (100% load factor).
IEC-60304
-
Standard colours for insulation for low-frequency
cables and wires.
IEC-60331
-
Fire resisting characteristics of Electric cables. IEC-60332
(P1 to P3)
-
Tests on electric cables under fire conditions.
IEC-60502
-
Extruded solid dielectric insulated power cables for rated
voltages from 1 kV upto to 30 kV
IEC-754 (P1 and P2)
-
Tests on gases evolved during combustion of electric
cables.
AIR conditioning and ventilation
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 93
IS-659
-
Safety code for air conditioning
IS-660
-
Safety code for Mechanical Refrigeration
ARI:520
-
Standard for Positive Displacement
RefrigerationCompressor and Condensing Units
IS:4503
-
Shell and tube type heat exchanger
ASHRAE-24
-
Method of testing for rating of liquid coolers ANSI-B-31.5
-
Refrigeration Piping
IS:2062
-
Steel for general structural purposes
IS:655
-
Specification for Metal Air Dust
IS:277
-
Specification for Galvanised Steel Sheets
IS-737
-
Specification for Wrought Aluminium and
Aluminium Sheet & Strip
IS-1079
-
Hot rolled cast steel sheet & strip
IS-3588
-
Specification for Electrical Axial Flow Fans
IS-2312
-
Propeller Type AC VentilationFans
BS-848
-
Methods of Performance Test for Fans
BS-6540 Part-I
-
Air Filters used in Air Conditioning and General
Ventilation
BS-3928
-
Sodium Flame Test for Air Filters (Other than for
Air Supply to I.C. Engines and Compressors) US-PED-
2098
-
Method of cold DOP & hot DOP test
MIL-STD-282
-
DOP smoke penetration method
ASHRAE-52
-
Air cleaning device used in general ventilation for
removing particle matter
IS:3069
-
Glossary of Terms, Symbols and Units Relating to
Thermal Insulation Materials.
IS:4671
-
Expanded Polystyrene for Thermal Insulation
Purposes
IS:8183
-
Bonded Mineral Wool
IS:3346
-
Evaluation of Thermal Conductivity properties by
means of guarded hot plate method
ASTM-C-591-69
-
Standard specification for rigid preformed cellular
urethane thermal insulation
IS:4894
-
Centrifugal Fans
BS:848
-
Method of Performance Test for Centrifugal Fans
IS:325
-
Induction motors, three-phase
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 94
IS:4722
-
Rotating electrical machines
IS:1231
-
Three phase foot mounted Induction motors,
dimensions of
IS:2233
-
Designations of types of construction and
mounting arrangements of rotating electrical
machines
IS:2254
-
Vertical shaft motors for pumps, dimensions of
IS:7816
-
Guide for testing insulation resistance of rotating
machines
IS:4029
-
Guide for testing three phase induction motors
IS:4729
-
Rotating electrical machines, vibration of,
Measurement and evaluation of
IS:4691
-
Degree of protection provided by enclosures for
rotating electrical machinery
IS:7572
-
Guide for testing single-phase a.c. motors
IS:2148
-
Flame proof enclosure for electrical apparatus
BS:4999
-
Noise levels
IS-209
-
Zinc Ingot
IS-2629
-
Recommended Practice for Hot-Dip galvanizing on
iron and steel.
IS-2633
-
Methods for testing uniformity of coating of zinc
coated articles.
ASTM-A-123
-
Specification for zinc (Hot Galavanizing) Coatings, on
products Fabricated from rolled, pressed and forged
steel shapes, plates, bars and strips.
ASTM-A-121-77
-
Zinc-coated (Galvanized) steel barbed wire
IS-6005
-
Code of practice for phosphating of iron and steel.
ANSI-Z551
-
Gray finishes for industrial apparatus and
equipment
SSPEC
-
Steel structure painting council
(Part-51)
Galvanizing
Painting
Fire protection system
Fire protection manul issued by tariff advisory committee (TAC) of India
HORIZONTAL CENTRIFUGAL PUMPS
IS:6595(Part 2)
-
Horizontal centrifugal pumps for clear, cold water
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 95
IS:9137
-
Code for acceptance test for centrifugal & axial
pumps
IS:5120
-
Technical requirement - Rotodynamic special
purpose pumps
API-610
-
Centrifugal pumps for general services
-
Hydraulic Institutes Standards
BS:599
-
Methods of testing pumps
PTC-8.2
-
Power Test Codes - Centrifugal pumps
IS:10000
-
Methods of tests for internal combustion engines
IS:10002
-
Specification for performance requirements for constant
speed compression ignition engines for general purposes
(above 20 kW)
BS:5514
-
The performance of reciprocating compression ignition
(Diesel) engines, utilising liquid fuel only, for general
purposes
ISO:3046
-
Reciprocating internal combustion engines
performance
IS:554
-
Dimensions for pipe threads where pressure tight joints
are required on threads
ASME Power Test Code
-
Internal combustion engine PTC-17
-
Codes of Diesel Engine Manufacturer’s
Association, USA
DIESEL ENGINES
PIPING VALVES & SPECIALITIES
IS:636
-
Non percolating flexible fire fighting delivery hose
IS:638
-
Sheet rubber jointing and rubber inserting jointing
IS:778
-
Gun metal gate, globe and check valves for general purpose
IS:780
-
Sluice valves for water works purposes (50 to 300 mm)
IS:901
-
Couplings, double male and double female
instantaneous pattern for fire fighting
IS:902
-
Suction hose couplings for fire fighting purposes
IS:903
-
Fire hose delivery couplings branch pipe nozzles and
nozzle spanner
IS:1538
-
Cast iron fittings for pressure pipes for water, gas and
sewage
IS:1903
-
Ball valve (horizontal plunger type) including floats for
water supply purposes
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 96
IS:2062
-
SP for weldable structural steel
IS:2379
-
Colour Code for the identification of pipelines
IS:2643
-
Dimensions of pipe threads for fastening
purposes
IS:2685
-
Code of Practice for selection, installation and maintenance
of sluice valves
IS:2906
-
Sluice valves for water-works purposes (350 to
1200 mm size)
IS:3582
-
Basket strainers for fire fighting purposes
(cylindrical type)
IS:3589
-
Electrically welded steel pipes for water, gas and sewage
(150 to 2000 mm nominal diameter)
IS:4038
-
Foot valves for water works purposes IS:4927
Unlined flax canvas hose for fire fighting IS:5290 -
Landing
valves (internal hydrant)
IS:5312
-
Swing check type reflex (non-return) valves
IS:5306
-
Code of practice for fire extinguishing installations and
equipment on premises
Part-I
-
Hydrant systems, hose reels and foam inlets
Part-II
-
Sprinkler systems
BS:5150
-
Specification for cast iron gate valves
(Part-I)
MOTORS & ANNUNCIATION PANELS
IS:325
-
Three phase induction motors
IS:900
-
Code of practice for installation and maintenance of
induction motors
IS:996
-
Single phase small AC and universal electric
motors
IS:1231
-
Dimensions of three phase foot mounted
induction motors
IS:2148
-
Flame proof enclosure of electrical apparatus
IS:2223
-
Dimensions of flange mounted AC induction
motors
IS:2253
-
Designations for types of construction and
mounting arrangements of rotating electrical
machines
IS:2254
-
Dimensions of vertical shaft motors for pumps
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 97
IS:3202
-
Code of practice for climate proofing of electrical
equipment
IS:4029
-
Guide for testing three phase induction motors
IS:4691
-
Degree of protection provided by enclosure for
rotating electrical machinery
IS:4722
-
Rotating electrical machines
IS:4729
-
Measurement and evaluation of vibration of
rotating electrical machines
IS:5572
-
Classification of hazardous areas for electrical
(Part-I) installations (Areas having gases and
vapours)
IS:6362
-
Designation of methods of cooling for rotating
electrical machines
IS:6381
-
Construction and testing of electrical apparatus with
type of protection ‘e’
IS:7816
-
Guide for testing insulation for rotating machine
IS:4064
-
Air break switches
IEC DOCUMENT 2
-
Three Phase Induction Motor
VDE 0530 Part I/66
-
Three Phase Induction Motor
IS:9224
-
HRC Fuses
IS:6875
-
Push Button and Control Switches
IS:694
-
PVC Insulated cables
IS:1248
-
Indicating instruments
IS:375
-
Auxiliary wiring & busbar markings
IS:2147
-
Degree of protection
IS:5
-
Colour Relay and timers
IS:2959
-
Contactors
NFPA-13
-
Standard for the installation of sprinkler system
NFPA-15
-
Standard for water spray fixed system for the fire
protection
NFPA-12A
-
Standard for Halong 1301 Fire Extinguishing
System
NFPA-72E
-
Standard on Antomatic Fire Detectors
(Control Office) 432
(Part-II)
PG Test Procedures
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 98
Fire Protection Manual by TAC (Latest Edition)
NFPA-12
-
Standard on Carbon dioxide extinguisher systems
IS:3034
-
Fire of industrial building: Electrical generating and
distributing stations code of practice
IS:2878
-
CO2 (Carbon dioxide) Type Extinguisher
IS:2171
-
DC (Dry Chemical Powder) type
IS:940
-
Pressurised Water Type
IS:10002
-
Specification for performance requirements for constant
speed compression ignition (diesel engine) for general
purposes
IS:10000
-
Method of tests for internal combustion engines IS:4722
-
Rotating electrical machines-specification IS:12063
D.G. SET
-
Degree of protection provided by enclosures
IS:12065
-
Permissible limit of noise levels for rotating
electrical machines.
-
Indian Explosive Act 1932
IS-228 (1992)
-
Method of Chemical Analysis of pig iron, cast iron and
plain carbon and low alloy steels.
IS-802 (P1 to 3:)
-
Code of practice for use of structural steel in overhead
transmission line towers.
IS-806
-
Code of practice for use of steel tubes in general
building construction
IS-808
-
Dimensions for hot rolled steel beam, column
channel and angle sections.
IS-814
-
Covered electrodes for manual arc welding of carbon of
carbon manganese steel.
IS-816
-
Code of Practice for use of metal arc welding for general
construction in Mild steel
IS-817
-
Code of practice for training and testing of metal arc
welders. Part 1 : Manual Metal arc welding.
IS-875 (P1 to P4)
-
Code of practice for design loads (other than earthquake) for
buildings and structures.
IS-1161
-
Steel tubes for structural purposes.
IS-1182
-
Recommended practice for radiographic examination of
fusion welded butt joints in steel plates.
Steel structures
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 99
IS-1363 (P1 to P3)
-
Hexagonal head bolts, screws & nuts of products grade
C.
IS-1364
-
Hexagon headbolts, screws and nuts of product
grades A and B.
IS-1367 (P1 to P18)
-
Technical supply condition for threaded steel fasteners.
IS-1599
-
Methods for bend test.
IS-1608
-
Method for tensile testing of steel products.
IS-1893
IS-1978
-
Criteria for earthquake resistant design of structures.
Line Pipe.
IS-2062
-
Steel for general structural purposes.
IS-2595
-
Code of practice for Radiographic testing.
IS-3063
-
Single coil rectagular section spring washers for
bolts, nuts and screws.
IS-3664
-
Code of practice for ultrasonic pulse echo testing by
contact and immersion methods.
IS-7205
-
Safety code for erection of structural steel work. IS-9595 -
Recommendations for metal arc welding of
carbon and carbon manganese steels.
ANSI-B18.2.1
-
Inch series square and Hexagonal bolts and
screws
ANSI-B18.2.2
-
Square and hexagonal nuts
ANSI-G8.14
-
Round head bolts
ASTM-A6
-
Specification for General Requirements for rolled steel
plates, shapes, sheet piling and bars of structural use
ASTM-A36
-
Specifications of structural steel
ASTM-A47
-
Specification for malleable iron castings
ASTM-A143
-
Practice for safeguarding against embilement of Hot
Galvanized structural steel products and procedure
for detaching embrilement
ASTM-A242
-
Specification for high strength low alloy structural
steel
ASTM-A283
-
Specification for low and intermediate tensile strength
carbon steel plates of structural quality
ASTM-A394
-
Specification for Galvanized steel transmission
tower bolts and nuts
ASTM-441
-
Specification for High strength low alloy structural
manganese vanadium steel.
ASTM-A572
-
Specification for High strength low alloy colombiumIN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 100
Vanadium steel of structural quality
AWS D1-0
-
Code for welding in building construction welding
inspection
AWS D1-1
-
Structural welding code
AISC
-
American institute of steel construction NEMA-CG1
-
Manufactured graphite electrodes
Piping and pressure vessels
IS-1239 (Part 1 and 2)
-
Mild steel tubes, tubulars and other wrought steel
fittings
IS-3589
-
Seamless Electrically welded steel pipes for
water, gas and sewage.
IS-6392
-
Steel pipe flanges
ASME
-
Boiler and pressure vessel code
ASTM-A120
-
Specification for pipe steel, black and hot dipped, zinccoated (Galvanized) welded and seamless steel pipe
for ordinary use
ASTM-A53
-
Specification for pipe, steel, black, and hotdipped, zinc coated welded and seamless
ASTM-A106
-
Seamless carbon steel pipe for high temperature
service
ASTM-A284
-
Low and intermediate tensile strength carbon- silicon
steel plates for machine parts and general construction.
ASTM-A234
-
Pipe fittings of wrought carbon steel and alloy steel
for moderate and elevated temperatures
ASTM-S181
-
Specification for forgings, carbon steel for general
purpose piping
ASTM-A105
-
Forgings, carbon steel for piping components
ASTM-A307
-
Carbon steel externally threated standard
fasteners
ASTM-A193
-
Alloy steel and stainless steel bolting materials for high
temperature service
ASTM-A345
-
Flat rolled electrical steel for magnetic
applications
ASTM-A197
-
Cupola malleable iron
ANSI-B2.1
-
Pipe threads (Except dry seal)
ANSI-B16.1
-
Cast iron pipe flangesand glanged fitting. Class
25, 125, 250 and 800
ANSI-B16.1 -
Malleable iron threaded fittings, class 150 and 300
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 101
ANSI-B16.5
-
Pipe flanges and flanged fittings, steel nickel alloy and
other special alloys
ANSI-B16.9
-
Factory-made wrought steel butt welding fittings
ANSI-B16.11
-
Forged steel fittings, socket-welding and threaded
ANSI-B16.14
-
Ferrous pipe plug, bushings and locknuts with
piplethreads
ANSI-B16.25
-
Butt welding ends
ANSI-B18.1.1
-
Fire hose couplings screw thread.
ANSI-B18.2.1
-
Inch series square and hexagonal bolts and screws
ANSI-B18.2.2
-
Square and hexagonal nuts
NSI-B18.21.1
-
Lock washers ANSI-
B18.21.2
-
Plain washers ANSI-B31.1
-
Power piping
ANSI-B36.10
-
Welded and seamless wrought steel pipe
ANSI-B36.9
-
Stainless steel pipe
IS-269
-
33 grade ordinary portland cement.
IS2721
-
Galvanized steel chain link fence fabric
IS-278
-
Galvanized steel barbed wire for fencing.
IS-383
-
Coarse and fine aggregates from natural sources for
concrete.
IS-432 (P1 and P2)
-
Mild steel and medium tensile steel bars and harddawn steel wire for concrete reinforcement.
IS-456
-
Code of practice for plain and reinforced concrete. IS-516 -
Other civil works standards
Method of test for strength of concrete.
IS-800
-
Code of practice for general construction in steel. IS-
806
-
Steel tubes for structural purposes.
IS-1172
-
Basic requirements for water supply, drainage and
sanitation.
IS-1199
-
Methods of sampling and analysis of concrete. IS-
1566
-
Hard-dawn steel wire fabric for concrete
reinforcement.
IS-1742
-
Code of Practice for Building drainage.
IS-1785
-
Plain hard-drawn steel wire for prestressed
concrete.
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 102
IS-1786
-
High strength deformed Steel Bars and wires for
concrete reinforcement.
IS-1811
-
Methods of sampling Foundry sands.
IS-1893
-
Criteria for earthquake resistant design of
structures.
IS-2062
-
Steel for general structural purposes.
IS-2064
-
Selection, installation and maintenance of sanitary
appliances-code of practices.
IS-2065
-
Code of practice for water supply in buildings. IS-2090
-
High tension steel bars used in prestressed
concrete.
IS-2140
-
Standard Galvanized steel wire for fencing.
IS-2470 (P1 & P2)
-
Code of practice for installation of septic tanks. IS-2514 -
Concrete vibrating tables.
IS-2645
-
Integral cement waterproofing compounds.
IS-3025 (Part 1 to Part 48)
-
Methods of sampling and test (Physical and chemical) for
water and waste water.
IS-4091
-
Code of practice for design and construction of
foundations for transmission line towers and poles.
(Part 1 to P5)
-
Code of practice for ancillary structures in
sewerage system.
IS-4990
-
Plywood for concrete shuttering work. IS-5600
IS-4111
-
Sewage and drainage pumps. National buiding code of
India 1970
USBR E12
-
Earth Manual by United States Department of the
interior Bureau of Reclamation
ASTM-A392-81
-
Zinc/Coated steel chain link fence fabric
ASTM-D1557-80
-
test for moisture-density relation of soils using 10- lb
(4.5 kg) rame land 18-in. (457 mm) Drop.
ASTM-D1586
-
Penetration Test and Split-Barrel
(1967)
-
Sampling of Soils
ASTM-D2049-69
-
Test Method for Relative Density of Cohesionless Soil
ASTM-D2435
-
Test method for Unconsolidated, (1982) Undrained
Strengths of Cohesive Soils in Triaxial Compression.
BS-5075
-
Specification for accelerating Part I Admixtures,
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 103
Retarding Admixtures and Water Reducing
Admixtures.
CPWD
-
Latest CPWD specifications
ACSR MOOSE CONDUCTOR
IS:6745
Methods for Determination of
Mass of zinc coating on zinc
coated Iron and Steel Articles
BS:443-1969
IS:8263
Methods for Radio Interference
IEC:437-1973
Test on High Voltage Insulators NEMA:107-1964 CISPR
IS:209
Zinc Ingot BS:3436-1961
IS:398
Aluminum Conductors for IEC:209-1966
Part - V
Overhead Transmission Purposes
BS:215(Part-II)
Aluminium Conductors galvanized IEC:209-1966 steel
reinforced extra high
BS:215(Part-II)
voltage (400 kV and above)
IS:1778
Reels and Drums forBS:1559-1949
Bare Conductors
IS:1521
Method for Tensile Testing ISO/R89-1959of steel wire
IS:2629
Recommended practice for Hot dip Galvanising on Iron and Steel.
IS:2633
Method for Testing Uniformity of coating of zinc Coated Articles.
IS:4826
Hot dip galvanised coatings
on round steel wiresASTMA-472-729
GALVANISED STEEL EARTHWIRE
IS:1521
Method for Tensile Testing ISO/R:89-1959 of
Steel Wire
IS:1778
Reels and Drums for Bare Conductors
IS:2629
Recommended practice for Hot Dip Galvanising on Iron and
Steel.
IS:2633
Methods for testing Uniformity of Coating of Zinc Coated Articles.
IS:4826
Hot dip Galvanised Coatings ASTM:A 475-72a on Round Steel
Wires BS:443-1969
IS:6745
Method for Determination BS:443-1969of mass of Zinc
Coating on Zinc coated Iron and Steel Articles. IS:209
Zinc ingot
BS:3463-1961
IS:398 (Pt. I to
Aluminum Conductors for BS:215 (Part-II)
P5:1992)
overhead transmission purposes.
Lighting Fixtures and Accessories
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 104
IS:1913
General and safety requirements for electric lighting
fittings.
IS:3528
Water proof electric lighting fittings. IS:4012
Dust proof electric lighting fittings.
IS:4013
Dust tight proof electric lighting fittings.
IS:10322
Industrial lighting fittings with metal reflectors. IS:10322
Industrial lighting fittings with plastic reflectors.
IS:2206
IS:10322
Well glass lighting fittings for use under ground in mines (nonflameproof type).
Specification for flood light.
IS:10322
Specification for decorative lighting outfits.
IS:10322
Luminaries for street lighting
IS:2418
Tubular fluorescent lamps
IS:9900
High pressure mercury vapour lamps.
IS:1258
Specification for Bayonet lamp fluorescent lamp. IS:3323 Bi-
pin lamp holder tubular fluorescent lamps.
IS:1534
Ballasts for use in fluorescent lighting fittings.
(Part-I)
IS:1569
Capacitors for use in fluorescent lighting fittings. IS:2215
Starters for fluorescent lamps.
IS:3324
Holders for starters for tubular fluorescent lamps
IS:418
GLS lamps
IS:3553
Water tight electric fittings
IS:2713
Tubular steel poles
IS:280
MS wire for general engg. purposes
Conduits, Accessories and Junction Boxes
IS:9537
Rigid steel conduits for electrical wiring
IS:3480
Flexible steel conduits for electrical wiring
IS:2667
Fittings for rigid steel conduits for electrical wiring IS:3837
Accessories for rigid steel conduits for electrical wiring IS:4649
Adaptors for flexible steel conduits.
IS:5133
Steel and Cast Iron Boxes
IS:2629
Hot dip galvanising of Iron & Steel.
Lighting Panels
IN JASIDIH GSS VOL-II
IN JASIDIH GSS VOL-II
Page 105
IS:13947
LV Switchgear and Control gear(Part 1 to 5)
IS:8828
Circuit breakers for over current protection for house hold and
similar installations.
IS:5
Ready mix paints IS:2551
Danger notice plates IS:2705 Current transformers
IS:9224
HRC Cartridge fuse links for voltage above 650V(Part-2)
(7)IS:5082
Wrought aluminium and Al. alloys, bars, rods, tubes and
sections for electrical purposes.
(8)IS:8623
Factory built Assemblies of Switchgear and Control Gear for
voltages upto and including 1000V AC and 1200V DC.
(9)IS:1248
Direct Acting electrical indicating instruments
Electrical Installation
IS:1293
3 pin plug
IS:371
Two to three ceiling roses
IS:3854
Switches for domestic and similar purposes
IS:5216
Guide for safety procedures and practices in electrical work.
IS:732
Code of practice for electrical wiring installation (system
voltage not exceeding 650 Volts.)
IS:3043
Code of practice for earthing.
IS:3646
Code of practice of interior illumination part II & III. IS:1944
Code of practice for lighting of public through fares.
IS:5571
Guide for selection of electrical equipment for hazardous areas.
IS:800
Code of practice for use of structural steel in general
building construction.
IS:2633
Methods of Testing uniformity of coating on zinc coated
articles.
IS:6005
Code of practice for phosphating iron and steel.
INDIAN ELECTRICITY ACT INDIAN ELECTRICITY
RULES
LT SWITCHGEAR
IS:8623 (Part-I)
Specification for low voltage switchgear and control gear
assemblies
IS:13947 (Part-I)
Specification for low voltage switchgear and control gear, Part
1 General Rules
IN JASIDIH GSS VOL-II
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Page 106
IS:13947 (part-2)
Specification for low voltage switchgear and control gear, Part
2 circuit breakers.
IS:13947 (part-3)
Specification for low voltage switchgear and control gear.
Part 3 Switches, Disconnectors, Switch-disconnectors and
fuse combination units
IS:13947 (part-4)
Specification for low voltage switchgear and control gear.
Part 4 Contactors and motors starters.
IS:13947 (part-5)
Specification for low voltage switchgear and control gear.
Part 5 Control-circuit devices and switching elements
IS:13947 (part-6)
Specification for low voltage switchgear and control gear.
Part 6 Multiple function switching devices.
IS:13947 (part-7)
Specification for low voltage switchgear and control gear.
Part 7 Ancillary equipments
IS:12063
Degree of protection provided by enclosures
IS:2705
Current Transformers
IS:3156
Voltage Transformers
IS:3231
Electrical relays for power system protection
IS:1248
Electrical indicating instruments
IS:722
AC Electricity meters
IS:5578
Guide for Marking of insulated conductors of
apparatus terminals
IS:13703 (part 1)
Low voltage fuses for voltage not exceeding 1000V AC or
1500V DC Part 1 General Requirements
IS:13703 (part 2)
Low voltage fuses for voltage not exceeding 1000V AC or
1500V DC Part 2 Fuses for use of authorized persons
IS:6005
Code of practice of phosphating iron and steel
IS:5082
Wrought Aluminum and Aluminum alloys for electrical
purposes
IS:2633
Hot dip galvanizing.
IN JASIDIH GSS VOL-II
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Page 107
3.
LT SWITCHGEAR
IN JASIDIH GSS VOL-II
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SECTION: LTSWITCHGEAR
Table of contents
Clause No.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
Description
.
CONSTRUCTIONAL DETAILS OF SWITCHBOARDS AND
DISTRIBUTION BOARDS
DERATING OF EQUIPMENTS
POWER BUS BARS AND INSULATORS
EARTH BUS
AIR CIRCUIT BREAKERS
MOULDED CASE CIRCUIT BREAKER (MCCB) and
MCB
RELAYS
CONTACTORS
INSTRUMENT TRANSFORMERS
INDICATING INSTRUMENTS
CONTROL & SELECTOR SWITCHES
AIR BREAK SWITCHES
PUSH BUTTONS
INDICATING LAMPS
FUSES
TERMINAL BLOCKS
NAME PLATES AND LABELS
SPACE HEATER
CONTROL AND SECONDARY WIRING
POWER CABLES TERMINATION
TYPE TESTS
ERECTION, TESTING AND COMMISSIONING
COMMISSIONING CHECK TESTS
SPECIAL TOOLS AND TACKLES
EQUIPMENT TO BE FURNISHED
PARAMETERS
AUTOMATIC CONTROL OF OUTDOOR LIGHTING
AUTOMATIC SUPPLY CHANGEOVER
IN JASIDIH GSS VOL-II
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Page 109
SECTION: LT SWITCHGEAR
1.1.
CONSTRUCTIONAL
DETAILS OF SWITCHBOARDS
AND DISTRIBUTION BOARDS
1.1.1.
All
boards
shall
be
of
metal
enclosed,
compartmentalised construction and freestanding type.
1.1.2.
All board frames, shall be fabricated using suitable mild steel structural sections or
pressed and shaped cold-rolled sheet steel of thickness not less than 2.0 mm. Frames
shall be enclosed in cold-rolled sheet steel of thickness not less than 1.6 mm. Doors
and covers shall also be of cold rolled sheet steel of thickness not less than 1.6
mm. Stiffeners shall be provided wherever necessary.
1.1.3.
All panel edges and cover/door edges shall be reinforced against distortion by rolling,
bending or by the addition of welded reinforcement members.
1.1.4.
bends.
The complete structures shall be rigid, self-supporting, free from flaws, twists and
indoor
floor
mounted,
All cut-outs shall be true in shape and devoid of sharp edges.
1.1.5.
All boards shall be of dust and vermin proof construction and shall be provided with
a degree of protection of IP: 52 as per IS 13947 (Part-1). However, the busbar
chambers having a degree of protection of IP: 42, in accordance with IS 13947 (Part1), are also acceptable where continuous busbar rating exceeds 1000 Amp. Provision
shall be made in all compartments for providing IP: 52 degree of protection, when
Circuit breaker or module trolley, has been removed. All cut-outs shall be provided
with neoprene gaskets.
1.1.6.
Provision of louvers on boards would not be preferred. However, louvers backed
with metal screen are acceptable on the busbar chambers where continuous busbar
rating exceeds 1000 Amps.
1.1.7.
All boards shall be of uniform height not exceeding 2450 mm.
1.1.8.
Boards shall be easily extendible on both sides, by the addition of the vertical
sections after removing the end covers.
1.1.9.
Boards shall be supplied with base frames made of structural steel sections, alongwith
all necessary mounting hardware required for welding the base frames to the insert
plates.
1.1.10.
All boards shall be of double front construction and shall have
(i) A completely enclosed busbar compartment for running horizontal busbars and
vertical busbars. Busbar chambers shall be completely enclosed with
metallic
portions. Bolted covers shall be provided for access to horizontal and Vertical
IN JASIDIH GSS VOL-II
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busbars for repair and maintenance, which shall be feasible without disturbing
feeder compartment. Vertical bus bar chambers shall be accessible from front as
well as back side of the panel. One set of vertical busbars shall be used in
between two adjacent sections for switchgear connections. In case of Incomer(s),
Bus-coupler and ACB feeders, vertical busbars located in rear side shall be
additionally covered with metallic perforated bolted sheets to avoid direct access
after opening rear door of chamber.
(ii)
Completely enclosed switchgear compartment(s) one for each circuit for housing
circuit breaker or MCCB or motor starter.
(iii) A distinct compartment or alley for power and control cables on each side of panel.
Cable alley compartment shall have a through metallic partition for segregating
cables on both sides. Cable alley door shall preferably be hinged. Cable alley shall
have no exposed live parts. Any live terminals shall be fully shrouded/insulated
from safety aspects. However It shall be of at least 350mm width.
(iv) A compartment for relays and other control devices associated with a circuit
breaker.
1.1.11.
Sheet steel barriers shall be provided between two adjacent vertical panels running to the
full height of the switchboard, except for the horizontal busbar compartment. Each
shipping section shall have full metal sheets at both ends for transport and storage.
1.1.12.
All equipments associated with a single circuit except MCB circuits shall be housed in a
separate compartment of the vertical section. The Compartment shall be sheet steel
enclosed on all sides with the withdrawal units in position or removed. The front of the
compartment shall be provided with the hinged single leaf door, with locking facilities.
In case of circuits controlled by MCBs, group of MCB feeders can be offered in common
compartment. In such case number of MCB feeder to be used in a common compartment
shall not exceed 4 (four) and front of MCB compartment, shall have a viewing port of
toughen glass sheet for viewing and sheet steel door of module shall be lockable with
star knob/panel key.
1.1.13.
After isolation of power and control circuit connections it shall be possible to safely
carryout maintenance in a compartment with the busbar and adjacent circuit live. Necessary shrouding arrangement shall be provided for this purpose over the cable terminations
located in cable alley.
1.1.14.
The minimum clearance in air between phases and between phase and earth for the entire
run of horizontal and vertical busbars, shall be 25 mm. For all other components, the
clearance between "two live parts", " A live part and an earthed part" and isolating
distance shall be atleast ten (10) mm throughout. Wherever it is not possible to maintain
these clearances, insulation shall be provided by sleeving or barriers. However, for
horizontal run of busbar minimum clearance of 25 mm should be maintained even if they
are sleeved.
1.1.15.
The temperature rise of horizontal & vertical busbars when carrying rated current along
its full run shall in no case exceed 55°C, with silver plated joints and 40°C with all other
type of joints over an outside ambient temperature of 50°C.
1.1.16.
All busbar chambers shall be provided with removable bolted covers. The covers shall
be provided with danger labels.
IN JASIDIH GSS VOL-II
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Page 111
1.1.17.
All identical circuit breakers and module chassis of same test size shall be fully
interchangeable without having to carryout modifications.
1.1.18.
All Circuit breaker boards shall be of Single Front type, with fully drawout circuit
breakers, which can be drawn out without having to unscrew any connections. The circuit
breakers shall be mounted on rollers and guides for smooth movement between
SERVICE, TEST and ISOLATED positions and for withdrawal from the Switchboard.
Testing of the breaker shall be possible in the TEST position.
1.1.19.
Wherever two breaker compartments are provided in the same vertical section, insulating
barriers and shrouds shall be provided in the rear cable compartment to avoid accidental
touch with the live parts of one circuit when working on the other circuit.
1.1.20.
All disconnecting contacts for power circuits shall be of robust design and fully self
aligning. Fixed and moving contacts of the power drawout contact system shall be silver
plated. Both fixed and moving contacts shall be replaceable.
1.1.21.
1.1.22.
All AC & DC boards shall be of double Front type.
All module shall be fixed type except air circuit breaker module, which shall be drawout
type.
The connections from busbars to the main switch shall be fully insulated/shrouded, and
securely bolted. The partition between the feeder compartment and cable alley may be
non-metallic and shall be of such construction as to allow cable cores with lugs to be
easily inserted in the feeder compartment for termination.
All equipment and components shall be neatly arranged and shall be easily accessible for
operation and maintenance. The internal layout of all modules shall be subject to
PURCHASER approval. Bidder shall submit dimensional drawings showing complete
internal details of Busbars and module components, for each type and rating for approval.
The tentative power and control cable entries shall be from bottom. However, Purchaser
reserves the right to alter the cable entries, if required, during detailed engineering,
without any additional commercial implication.
Adopter panels and dummy panels required to meet the various busbar arrangements and
layouts required shall be included in Bidder's scope of work.
1.1.23.
1.1.24.
1.1.25.
1.1.26.
1.2.
1.2.1.
1.2.2.
1.3.
1.3.1.
1.3.2.
1.3.3.
1.3.4.
1.3.5.
DERATING OF EQUIPMENTS
The current ratings of all equipments as specified in the `Bill of Materials are the
minimum standards current ratings at a reference ambient temperature of 50°C as per
relevant Indian Standards.
The Bidder shall indicate clearly the derating factors employed for each component and
furnish the basis for arriving at these derating factors duly considering the specified
ambient temperature of 50°C.
POWER BUS BARS AND INSULATORS
All AC Distribution Boards shall be provided with three phase buses and a neutral bus
bars and the DC Distribution Boards shall be provided with two busbars.
All busbars and jumper connections shall be of high conductivity aluminium/copper of
adequate size the bus bar size calculation shall be submitted for approval.
The Cross-Section of the busbars shall be uniform through out the length of Switchgear
and shall be adequately supported and braced to withstand the stresses due to the
specified short circuit currents.
All busbars shall be adequately supported by Non-hygroscopic, non-combustible, trackresistant & high strength type Polyester fibre glass Moulded Insulators. Separate
supports shall be provided for each phase and neutral busbar. If a common support is
provided anti-tracking barriers shall be provided between the supports.
All busbars joints shall be provided with high tensile steel bolts. Belleville/spring
washers and nuts, so as to ensure good contacts at the joints. Non-silver plated Busbars
joints shall be thoroughly cleaned at the joint locations and a suitable contact grease shall
IN JASIDIH GSS VOL-II
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Page 112
1.3.6.
1.3.7.
1.4.
1.4.1.
1.4.2.
1.4.3.
1.4.4.
1.4.5.
1.4.6.
1.4.7.
1.4.8.
1.4.9.
1.4.10.
1.5.
1.5.1.
1.5.2.
1.5.3.
1.5.4.
be applied just before making a joint.
All busbars shall be colour coded as per IS: 11353
The Bidder shall furnish calculations alongwith the bid, establishing the adequacy of
busbar sizes for specified current ratings, On the basis of short circuit current and
temperature rise consideration at specified ambient temp.
EARTH BUS
A galvanised steel earthing shall be provided at the bottom of each panel and shall extend
throughout the length of each switchboard. It shall be welded/bolted to the frame work
of each panel and breaker earthing contact bar vertical bus shall be provided in each
vertical section which shall in turn be bolted/welded to main horizontal ground bus.
The earth bus shall have sufficient cross-section to carry the momentary short circuit and
short time fault currents to earth as indicated in `Bill of Materials' without exceeding the
allowable temperature rise.
Suitable arrangements shall be provided at each end of the horizontal earth bus for
bolting to Purchaser's earthing conductors. The horizontal earth bus shall project out the
switchboard ends and shall have predrilled holes for this connection. A joint spaced and
taps to earth bus shall be made through at least two bolts.
All non-current metal work of the Switchboard shall be effectively bonded to the earth
bus. Electrical conductivity of the whole switchgear enclosures frame work and the truck
shall be maintained even after painting.
The truck and breaker frame shall get earthed while the truck is being inserted in the
panel and positive earthing of the truck and breaker frame shall be maintained in all
positions. SERVICES & ISOLATED, as well as through out the intermediate travel.
Each module frame shall get engaged to the vertical earth bus. Before the disconnecting
contacts on these module are engaged to the vertical busbar.
All metallic cases of relays, instruments and other panel mounted equipments shall be
connected to earth by independent stranded copper wires of size not less than 2.5 mm2.
Insulation colour code of earthing wires shall be green. Earthing wires shall be
connected to terminals with suitable clamp connectors and soldering is not acceptable.
Looping of earth Connection which would result in loss of earth connection to the
devices when a device is removed is not acceptable. However, looping of earth
connections between equipment to provide alternative paths or earth bus is acceptable.
VT and CT secondary neutral point earthing shall be at one place only, on the terminal
block. Such earthing shall be made through links so that earthing of one secondary
circuit shall be removed without disturbing the earthing of other circuit.
All hinged doors shall be earthed through flexible earthing braid.
Caution nameplate `Caution-Live Terminals' shall be provided at all points where the
terminals are like to remain live and isolation is possible only at remote end.
AIR CIRCUIT BREAKERS
Circuit breakers shall be three-pole air break horizontal drawout type and shall have
inherent fault making and breaking capacities as specified in "Technical Parameters".
The circuit breakers which meet specified parameter only after provision of releases or
any other devices shall not be acceptable.
Circuit breakers shall be mounted along with it operating mechanism on a wheeled
carriage. Suitable guides shall be provided to minimise misalignment of the breaker.
There shall be `Service', `Test' and `Fully withdrawn positions for the breakers. In `Test'
position the circuit breaker shall be capable of being tested for operation without
energising the power circuits i.e. the power Contacts shall be disconnected while the
Control circuits shall remain undisturbed. Locking facilities shall be provided so as to
prevent movement of the circuit breaker from the `SERVICE', `TEST' OR FULLY
WITHDRAWN' position. It shall be possible to close the door in TEST position.
All circuit breakers shall be provided with 4 NO and 4 NC potentially free auxiliary
contacts. These contacts shall be in addition to those required for internal mechanism of
the breaker. Separate limit switches each having required number of contacts shall be
provided in both `SERVICE' & `TEST' position of the breaker. All contacts shall be
IN JASIDIH GSS VOL-II
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Page 113
1.5.5.
1.5.6.
1.5.7.
1.5.8.
1.5.9.
1.5.10.
1.5.11.
1.5.12.
1.5.13.
(i)
(ii)
1.5.15.
1.5.16.
1.5.17.
1.5.18.
1.5.19.
1.5.20.
1.5.21.
1.5.22.
1.5.23.
1.5.23.1.
rated for making continuously carrying and breaking 10 Amps at 240V AC and 1 Amp
(Inductive) at 220V DC.
Suitable mechanical indications shall be provided on all circuit breakers to show `OPEN'.
`CLOSE', `SERVICE', `TEST' and `SPRING CHARGED' positions.
Main poles of the circuit breakers shall operate simultaneously in such a way that the
maximum difference between the instants of contacts touching during closing shall not
exceed half cycle of rated frequency.
All circuit breakers shall be provided with the interlocks as explained in further clauses.
Movement of a circuit breaker between SERVICE AND TEST positions shall not be
possible unless it is in OPEN position. Attempted with drawl of a closed circuit breaker
shall trip the circuit breaker.
Closing of a circuit breaker shall not be possible unless it is in SERVICE, TEST
POSITION or in FULLY WITHDRAWN POSITION.
Circuit breaker cubicles shall be provided with safety shutters operated automatically by
the movement of the circuit breaker carriage to cover the stationary isolated contacts
when the breaker is withdrawn.
It shall however, be possible to open the shutters
intentionally, against spring pressure for testing purpose.
A breaker of particular rating shall be prevented from insertion in a cubicle of a different
rating.
Circuit breakers shall be provided with electrical anti-pumping and trip free feature, even if
mechanical antipumping feature is provided.
Mechanical tripping shall be possible by means of front mounted RED `Trip' pushbutton. In case of electrically operated breakers these push buttons shall be shrouded to
prevent accidental operation.
1.5.14. Breaker controlled motors shall operate satisfactorily under the following
conditions:
Direct on-line starting of Induction Motors rated 110 kW to 220 kW with a locked rotor
current of seven times the rated current, and starting time of up to 30 seconds.
Breaking on-load, full load and locked rotor currents of Induction Motors for rated 100
kW to 220 kW.
Means shall be provided to slowly close the circuit breaker in withdrawn position. If
required for inspection and setting of Contacts, in service position slow closing shall not
be possible.
Power operated mechanism shall be provided with a universal motor suitable for
operation 220V DC Control supply with voltage variation from 90% to 110% rated
voltage. Motor insulation shall be class `E' or better.
The motor shall be such that it requires not more than 30 seconds for fully charging the
closing spring.
Once the closing springs are discharged, after the one closing operation of circuit
breaker, it shall automatically initiate, recharging of the spring.
The mechanism shall be such that as long as power is available to the motor, a continuous
sequence of closing and opening operations shall be possible. After failure of power
supply at least one open-close-open operation shall be possible.
Provision shall be made for emergency manual charging and as soon as this manual
charging handle is coupled, the motor shall automatically get mechanically decoupled.
All circuit breakers shall be provided with closing and trip coils. The closing coils shall
operate correctly at all values of Voltage between 85% to 110% at rated control voltage.
The trip coil shall operate satisfactorily under all values of supply voltage between 70%
to 110% of rated control voltage.
Provision for mechanical closing of the breaker only in `TEST' and `WITHDRAWN'
positions shall be made.
PROTECTION CO-ORDINATION
It shall be the responsibility of the Contractor to fully co-ordinate the overload and short
circuit tripping of the circuit breakers with the upstream and down stream circuit
breakers/fuses/motor starters, to provide satisfactory discrimination.
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1.6.
1.6.1.
1.6.2.
1.6.3
1.6.4
1.6.5
1.7
1.7.1
1.7.2
1.7.3
1.7.4
1.7.5
1.7.6
1.7.7
1.8
1.8.1
1.8.2
1.8.3
1.8.4
1.8.5
1.9
1.9.1
1.9.2
MOULDED CASE CIRCUIT BREAKER (MCCB) and MCB
MCCB shall in general conform to IS: 13947 Part-2. All MCCB shall be of P2 duty.
MCCB shall be flush mounted on the AC/DC distribution boards.
MCCBs shall be provided with thermo-magnetic type release for over current and short
circuit protection. The setting of the thermal release shall be adjustable between 75% to
100% of the rated current. The MCCB shall have breaking capacity not less than 20kA.
MCCBs used for ACDB incomers and Bus coupler shall be equipped with stored energy
mechanism for electrical closing and tripping. All other MCCBs shall be manually
operated. The operating handle should give a clear trip indication.
Miniature circuit breaker (MCB) shall conform to IEC: 898-1987 and IS: 8828.
RELAYS
All relays and timers in protective circuits shall be flush mounted on panel front with
connections from the inside. They shall have transparent dust tight covers removable
from the front. All protective relays shall have a drawout construction for easy
replacement from the front. They shall either have built-in test facilities, or shall be
provided with necessary test blocks and test switches located immediately below each
relay. The auxiliary relays and timers may be furnished in non-drawout cases.
All AC relays shall be suitable for operation, at 50 Hz with 110 volts VT secondary and 1
amp or 5 amp CT secondary.
All protective relays and timers shall have at least two potentially free output contacts.
Relays shall have contacts as required for protection schemes. Contacts of relays and
timers shall be silver faced and shall have a spring action. Adequate number of terminals
shall be available on the relay cases for applicable relaying schemes.
All protective relays auxiliary relays and timers shall be provided with hand reset
operation indicators (Flags) for analysing the cause of operation.
All relays shall withstand a test voltage of 2 KV (rms) for one minute.
Motor starters shall be provided with three element, ambient temperature compensated,
time lagged, hand reset type overload relays with adjustable settings. The setting ranges
shall be properly selected to suit the motor ratings. These relays shall have a separate
black coloured hand reset push button mounted on compartment door and shall have at
least one changeover contact.
All fuse-protected contactor-controlled motors shall have single phasing protection,
either as a distinct feature in the overload relays (by differential movement of
bimetallicstrips), or as a separate device. The single phasing protection shall operate
even with80% of the set current flowing in two of the phases.
CONTACTORS
Motor starter contactors shall be of air break, electromagnetic type rated for
uninterrupted duty as per IS:13947 (Part 4).
Contactors shall be double break, non-gravity type and their main contacts shall be silver
faced.
Direct on line starter contactors shall be of utilisation category AC2. These contactors
shall be as per IS:13947 (Part 4).
Each contactor shall be provided with two (2) normally open (NO) and two (2) normally
close (NC) auxiliary contacts.
Operating coils of contactors shall be of 240V AC Unless otherwise specified elsewhere.
The Contactors shall operate satisfactorily between 85% to 110% of the rated voltage.
The Contactor shall drop out at 70% of the rated voltage.
INSTRUMENT TRANSFORMERS
All current and voltage transformers shall be completely encapsulated cast resin insulated
type suitable for continuous operation at the temperature prevailing inside the switchgear
enclosure, when the switchboard is operating at its rated condition and the outside
ambient temperature is 50°C.
All instrument transformers shall be able to withstand the thermal and mechanical
stresses resulting from the maximum short circuit and momentary current ratings of the
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1.9.3
1.9.4
1.9.5
1.10
1.10.1
1.10.2
1.10.3
1.10.4
1.10.5
1.11
associated switchgear.
All instrument transformer shall have clear indelible polarity markings. All secondary
terminals shall be wired to a separate terminal on an accessible terminal block where starpoint formation and earthing shall be done.
Current transformers may be multi or single core type. All voltage transformers shall be
single phase type. The Bus VTs shall be housed in a separate compartment.
All VTs shall have readily accessible HRC current limiting fuses on both primary and
secondary sides.
INDICATING INSTRUMENTS
All indicating and integrating meters shall be flush mounted on panel front. The
instruments shall be of at least 96 mm square size with 90 degree scales, and shall have
an accuracy class of 2.5 or better. The covers and cases of instruments and meters shall
provide a dust and vermin proof construction.
All instruments shall be compensated for temperature errors and factory calibrated to
directly read the primary quantities. Means shall be provided for zero adjustment without
removing or dismantling the instruments.
All instruments shall have white dials with black numerals and lettering. Black knife
edge pointer with parallax free dials will be preferred.
Ammeters provided on Motor feeders shall have a compressed scale at the upper current
region to cover the starting current.
Watt-hour meters shall be of 3 phase three element type, Maximum demand indicators
need not be provided.
CONTROL & SELECTOR SWITCHES
1.11.1
Control & Selector switches shall be of rotary type with escutcheon plates clearly marked
to show the function and positions. The switches shall be of sturdy construction suitable
for mounting on panel front. Switches with shrouding of live parts and sealing of
contacts against dust ingress shall be preferred.
1.11.2
Circuit breaker selector switches for breaker Controlled motor shall have three stay put
positions marked `Switchgear', `Normal' and `Trial' respectively. They shall have two
contacts of each of the three positions and shall have black shade handles.
1.11.3
Ammeter and voltmeter selector switches shall have four stayput position with adequate
number of contacts for three phase 4 wire system. These shall have oval handles
Ammeter selector switches shall have make before break type contacts to prevent open
circuiting of CT secondaries.
1.11.4
Contacts of the switches shall be spring assisted and shall be of suitable material to give a
long trouble free service.
1.11.5
The contact ratings shall be at least the following :
(i)
(ii)
Make and carry continuously
10 Amp.
Breaking current at 220V DC 1 Amp (Inductive)
(iii)
Breaking current at 240V AC
5 Amp (at 0.3 pf lagging)
1.12
AIR BREAK SWITCHES
1.12.1
Air breaker switch shall be of the heavy duty, single throw group operated, load break,
fault make type complying with IS:4064.
1.12.2
The Bidder shall ensure that all switches are adequately rated so as to be fully protected
by the associated fuses during all abnormal operating conditions such as overload, locked
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motor, short circuit etc.
1.12.3
Switch operating handles shall be provided with padlocking facilities to lock them in
`OFF' position.
1.12.4
Interlocks shall be provided such that it is possible to open the cubicle door only when
the switch is in `OFF' position and to close the switch only when the door is closed.
However suitable means shall be provided to intentionally defeat the interlocks explained
above.
1.12.5
Switches and fuses for AC/DC control supply and heater supply wherever required shall
be mounted inside and cubicles.
PUSH BUTTONS
1.13
1.13.1
Push-buttons shall be of spring return, push to actuate type. Their contacts shall be rated
to make, continuously carry and break 10A at 240V and 0.5A (inductive) at 220V DC.
1.13.2
All push-buttons shall have one normally open and one normally closed contact, unless
specified otherwise. The contact faces shall be of silver or silver alloy.
1.13.3
All push-buttons shall be provided with integral escutcheon plates marked with its
function.
1.13.4
The colour of the button shall be as follows :
(i)
(ii)
(iii)
GREEN
RED
BLACK
:
:
:
For motor START, Breaker CLOSE
For motor TRIP, Breaker OPEN
For overload reset.
1.13.5
All push-buttons on panels shall be located in such a way that Red-push-buttons shall
always be to the left of green push-buttons.
1.14
INDICATING LAMPS
1.14.1
Indicating lamps shall be of the panel mounting cluster LED type. The lamps shall have
escutcheon plates marked with its function, wherever necessary.
1.14.2
Lamps shall have translucent lamp-covers of the following colours, as warranted by the
application :
(i)
(ii)
(iii)
(iv)
RED
GREEN
WHITE
BLUE
:
:
:
:
(v)
AMBER
:
For motor ON, Breaker CLOSED
For motor OFF, Breaker OPEN
For motor Auto-Trip
For all healthy conditions (e.g. control supply, and also for
'SPRING CHARGED"
For all alarm conditions (e.g. overload) Also for
`SERVICE' and `TEST' positions indicators.
1.14.3
Lamps shall be easily replaceable from the front of the cubicle.
1.14.4
Indication lamps should be located just above the associated push buttons/control
switches. Red lamps shall invariable be located to the right of green lamps. In case a
white lamp is also provided, it shall be placed between the red and green lamps along
with the centre line of control switch/push button pair. Blue and Amber lamps should
IN JASIDIH GSS VOL-II
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normally be located above the Red and Green lamps.
1.14.5
1.15
1.15.1
When associated with push-buttons, red lamps shall be directly above the green push
button, and green lamps shall be directly above the red push-button. All indicating lamps
shall be suitable for continuous operation at 90 to 110% of their rated voltage.
FUSES
All fuses shall be of HRC cartridge fuse link type. Screw type fuses shall not be
accepted. Fuses for AC Circuits shall be of class 2 type, 20 kA (RMS) breaking current
at 415 AC, and for DC circuits Class 1 type 4 kA breaking current.
1.15.2
Fuses shall have visible operation indicators.
1.15.3
Fuses shall be mounted on fuses carriers, which are mounted on fuse bases, wherever it is
not possible to mount fuses on carriers fuses shall be directly mounted on plug in type of
bases. In such cases one set of insulated fuse pulling handles shall be supplied with each
switchgear.
Fuse rating shall be chosen by the Bidder depending upon the circuit requirements and
these shall be subject to approval of PURCHASER.
TERMINAL BLOCKS
Terminal blocks shall be of 750 volts grade and have continuous rating to carry the
maximum expected current on the terminals. It shall be complete with insulating barriers,
clip-on-type/stud type terminals for Control Cables and identification strips. Marking on
terminal strip shall correspond to the terminal numbering on wiring on diagrams. It shall
be similar to `ELEMEX' standard type terminals, cage clamp type of Phoenix or WAGO
or equivalent
Terminal blocks for CT and VT secondary leads shall be provided with test links and
isolating facilities. CT secondary leads shall be provided with short circuiting and
earthing facilities. It shall be similar to `Elem.' `CATD' - Type.
In all circuit breaker panels at least 10% spare terminals for external connections shall be
provided and these spare terminals shall be uniformly distributed on all terminal blocks.
Space for adding another 10% spare terminals shall also be available.
All terminal blocks shall be suitable for terminating on each side, two (2) Nos. of 2.5 mm
square size standard copper conductors.
All terminals shall be numbered for identification and grouped according to the function.
Engraved white-on-black labels shall be provided on the terminal blocks.
Wherever duplication of a terminal block is necessary it shall be achieved by solid
bonding links.
Terminal blocks shall be arranged with at least 100 mm clearance between two sets of
terminal block. The minimum clearance between the first row of terminal block and the
associated cable gland plate shall be 250 mm.
NAME PLATES AND LABELS
All switchgears, AC/DC distribution boards, shall be provided with prominent, engraved
identification plates. The module identification plate shall clearly give the feeder number
and feeder designation. For single front switchboards, similar panel and board
identification labels shall be provided at the rear also.
All name plates shall be of non-rusting metal or 3-ply lamicoid with white engraved
lettering on black back ground. Inscriptions and lettering sizes shall be subject to
PURCHASER approval.
Suitable plastic sticker labels shall be provided for easy identification of all equipments,
located inside the panel/module. These labels shall be positioned so as to be clearly
visible and shall give the device number as mentioned in the module wiring drawings.
1.15.4
1.16
1.16.1
1.16.2
1.16.3
1.16.4
1.16.5
1.16.6
1.16.7
1.17
1.17.1
1.17.2
1.17.3
1.18
SPACE HEATER
1.18.1
Space heater shall be provided in all the boards for preventing harmful moisture
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condensation.
1.18.2
The space heaters shall be suitable for continuous operation on 240V AC, 50 Hz, single
phase supply, and shall be automatically controlled by thermostats. Necessary isolating
switches and fuses shall also be provided.
1.19
CONTROL AND SECONDARY WIRING
1.19.1
All switchboards shall be supplied completely wired internally upto the terminal blocks
ready to receive Purchaser's control cables.
1.19.2
All inter cubicle and inter panel wiring and connections between panels of same
switchboard including all bus wiring for AC and DC supplies shall be provided by the
bidder.
1.19.3
All internal wiring shall be carried out with 1100 V grade, single core, 1.5 square mm or
larger stranded copper wires having colour coded, PVC insulation. CT circuits shall be
wired with 2.5 square mm copper wires. Voltage grade and insulation shall be same as
above. The cable shall be F.R.L.S. type.
1.19.4
Extra-flexible wires shall be used for wiring to device mounted on moving parts such as
hinged doors.
1.19.5
All wiring shall be properly supported, neatly arranged, readily accessible and securely
connected to equipment terminals and terminals blocks.
1.20
POWER CABLES TERMINATION
1.20.1
Cable termination compartment and arrangement for power cables shall be suitable for
stranded aluminium conductor, armoured XLPE/PVC insulated and sheathed, single
core/three core, 1100 V grade cables.
1.20.2
All necessary cable terminating accessories such as Gland plates, supporting clamps and
brackets, power cable lugs, hardware etc. shall be provided by the successful bidder, to
suit the final cable sizes which would be advised later.
1.20.3
The gland plate shall be of removable type and shall cover the entire cable alley. Bidder
shall also ensure that sufficient space is provided for all cable glands. Gland plates shall
be factory-drilled according to the cable gland sizes and number which shall be informed
to the Contractor later. For all single core cables, gland plates shall be of non-magnetic
Material.
TYPE TESTS
Type tests reports on Panels (Switchgear and Control gear assemblies) as per IS 8623 PartI shall be submitted for the following tests in line with clause 9.0 of Section GTR before
the fabrication of switchgear is started:
i)
Verification of temperature rise limits
ii)
Verification of the dielectric properties
iii)
Verification of short circuit strength
iv)
Verification of the continuity of the protective circuit
v)
Verification of clearances and creepage distances
vi)
Verification of mechanical operation
vii)
Verification of degree of protection
1.21
1.21.1
1.21.2
Contractor shall submit type test reports for the following Switchgear and Control gears
before the fabrication of switchgear is started:
1.
Circuit breakers/MCCB as per IS 13947 Part-II
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2.
Protective Relays as per IEC: 60255
For above equipments, test conducted once are acceptable (i.e. The requirement of test
conducted within last five years shall not be applicable)
1.22
ERECTION, TESTING AND COMMISSIONING
1.22.1
The Contractor shall unload, erect, install, test and put into commercial use all electrical
equipment included in this specification.
1.22.2
Equipment shall be installed in a neat, workman like manner so that it is level, plumb,
square and properly aligned and oriented. Tolerance shall be as established in
Contractor's drawings or as stipulated by purchaser. No equipment shall be permanently
bolted down to foundations until the alignment has been checked and found acceptable
by the purchaser.
1.22.3
Contractor shall furnish all supervision, labour tools equipment rigging materials, bolts,
wedges, anchors, concrete inserts etc. in proper time required to completely install, test
and commission the equipment.
1.22.4
Manufacturer's and purchaser's instructions and recommendations shall be correctly
followed in handling, setting, testing and commissioning of all equipment.
1.22.5
Contractor shall move all equipment into the respective room through the regular door or
openings specifically provided for this purpose. No part of the structure shall be utilised
to lift or erect any equipment without prior permission of Purchaser.
1.22.6
All boards shall be installed in accordance with Indian Standards IS:3072 and at
Purchaser's instructions. All boards shall be installed on finished surfaces, concrete or
steel stills. Contractor shall be required to install and align any channel sills which form
part of foundations. In joining shipping sections of switchboards together adjacent
housing of panel sections or flanged throat sections shall be bolted together after
alignment has been completed. Power bus, enclosures ground and control splices of
conventional nature shall be cleaned and bolted together being drawn up with torque
spanner of proper size or by other approved means.
1.22.7
All boards shall be made completely vermin proof.
1.22.8
Contractor shall take utmost care in holding instruments, relaying and other delicate
mechanism wherever the instruments and relays are supplied separately they shall be mentioned only
after the associated panels have been erected and aligned. The packing materials employed for
safe transit of instrument and relays shall be removed after ensuring that panel have been completely
installed and to further movement of the same should be necessary. Any damage shall be immediately
reported to Purchaser.
1.22.9
Equipment furnished with finished coats of paint shall be touched by up Contractor if
their surface is specified or marred while handling.
1.22.10
After installation of panels, power and control wiring and connections, Contractor shall
perform operational tests on all switchboards, to verify proper operation of switchboards/panels and correctness of all equipment in each and every respect. The cable
opening and cables entries for cables terminating to the panels shall be sealed with fire
sealing materials.
1.23
COMMISSIONING CHECK TESTS
The Contractor shall carry out the following commissioning checks, in addition to the
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other checks and tests recommended by the manufacturers.
1.23.1
General
1.23.1.1
Check name plate details according to the specification.
1.23.1.2
check for physical damage.
1.23.1.3
Check tightness of all bolts, clamps, joints connecting terminals.
1.23.1.4
Check earth connection.
1.23.1.5
Check cleanliness of insulators and bushings.
1.23.1.6
Check all moving parts for proper lubrication.
1.23.1.7
Check settings of all the relays.
1.23.2
Circuit Breakers
1.23.2.1
Check alignment of breaker truck for free movement.
1.23.2.2
Check correct operation of shutters.
1.23.2.3
Check control wiring for correctness of connections, continuity and IR values.
1.23.2.4
Manual operation of breaker completely assembled.
1.23.2.5
Power closing/opening operation, manually and electrically.
1.23.2.6
Breaker closing and tripping time.
1.23.2.7
Trip free and anti-pumping operation.
1.23.2.8
IR values, minimum pick up voltage and resistance of coils.
1.23.2.9
Contact resistance
1.23.2.10
Simultaneous closing of all the three phases.
1.23.2.11
Check electrical & mechanical interlocks provided.
1.23.2.12
Check on spring charging motor, correct operation of limit switches, and time of
charging.
1.23.2.13
All functional checks.
1.23.3
Current Transformers
1.23.3.1
Megger between winding and winding terminals to body.
1.23.3.2
Polarity test
1.23.3.3
Ratio identification checking of all ratios on all cores by primary injection of current.
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1.23.6.4
1.23.3.4
Spare CT cores, if available, to be shorted and earthed.
1.23.4
Voltage Transformer
1.23.4.1
Insulation resistance test
1.23.4.2
Ratio test on all cores.
1.23.4.3
Polarity test.
1.23.4.4
Line connections as per connection diagram.
1.23.5
Cubicle Wiring
1.23.5.1
Check all switch developments.
1.23.5.2
Each wire shall be traced by continuity tests and it should be made sure that the
is as per relevant drawing. All interconnections between panels/equipment
be similarly checked.
1.23.5.3
All the wires shall be meggered to earth.
1.23.5.4
Functional checking of all control circuit e.g. closing, tripping control, interlock,
supervision and alarm circuit.
1.23.6
Relays
1.23.6.1
Check connections and wiring.
1.23.6.2
Megger all terminals to body.
1.23.6.3
Megger AC to DC terminals.
wiring
shall
Check operating characteristics by secondary injection.
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1.23.6.5
Check minimum pick up voltage of DC coils.
1.23.6.6
Check operation of electrical/mechanical targets.
1.23.6.7
Relays settings.
1.23.6.8
Check CT and VT connections with particular reference to their polarities for directional
relays, wherever required.
1.23.7
Meters
1.23.7.1
Check calibration by comparing it with a sub-standard.
1.23.7.2
Megger all insulated portions.
1.23.7.3
Check CT and VT connections with particular reference to their polarities for power type
meters.
1.24
SPECIAL TOOLS AND TACKLES
1.24.1
The Bidder shall include in his proposal any special tools and tackles required for
erection, testing commissioning and maintenance of the equipments offered.
1.24.2
The list of these special tools and tackles shall be given in the bid proposal sheets
alongwith their respective prices.
1.24.3
The total price of the special tools and tackles shall be included in proposal sheets.
1.25
EQUIPMENT TO BE FURNISHED
1.25.1
The Bidder shall quote for various AC/DC distribution boards in accordance with this
specification
1.25.2
Standard scheme of interconnection of switchboards and distribution boards alongwith
tentative feeder disposition for each board shall be as per the requirement of the project.
The bidder shall quote board prices on the basis of their estimation of feeders for
entire present and future bays requirement. Any other feeder required as per system
requirement for efficient and reliable operation shall be deemed to be included in
bidder's scope.
1.25.3
The Bill of Materials for each type of module shall be as under. These are minimum
indicative requirement of the system. The necessary auxiliary relays, push buttons and
indicating lamps shall be provided as per scheme requirement. Any other
item/component required with in a module for efficient and reliable operation shall be
deemed to be included in bidder's scope. The scheme shall have provision for remote
annunciation for the followings:
a) Station LT (415V) AC incomer supply unhealthy
b) 220V DCDB U/V, O/V & Earth leakage relay operated
c) 50V DCDB U/V & O/V relay operated
d) DG set start
e) DG set protection operated.
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1.25.4
1.25.5
Module Type AE (Electrically controlled circuit breaker for incoming and Bus Coupler
Circuit).
(i)
One (1)
Triple pole air circuit breaker complete with all accessories and
power operated mechanism as specified.
(ii)
Two (2)
Neutral link.
(iii)
Three (3)
Current Transformer for metering.
(iv)
One (1)
Ammeter with selector switch.
(v)
Three (3)
Current Transformer for relaying.
(vi)
One (1)
Triple pole instantaneous over-current relay having the
setting range of 200-800% or 500-2000% of CT secondary
and adjustable definite minimum time.
(vii)
One (1)
Instantaneous earth fault relay having an adjustable setting range
of 10-40% or 20 - 80% of CT secondary current and adjustable
definite minimum time. The earth fault relay shall be provided
with a stabilising resistor.
Module Type - M1 (Circuit Breaker Controlled Motor Feeder)
(i)
One (1)
Triple pole Air Circuit Breaker complete with accessories,
and power operated mechanism as specified.
(ii)
One (1)
Three position 6 pole selector switch
'SWITCHGEAR/NORMAL /TRIAL'.
(iii)
Three (3)
Current Transformer for metering.
(iv)
One (1)
Ammeter with Ammeter Selector Switch
(v)
Three (3)
Current Transformer for relaying.
(vi)
One (1)
Triple pole instantaneous over-current relay for providing
positive sequence current protection in all the three phases.
The relay setting range shall be continuously adjustable
between 200-800% or 400-1600% of CT secondary rated
current as required.
(vii)
One (1)
Double pole inverse definite minimum time over current
relays connected in R & B phases for over current protection
of motor rated 110 kW - 200 kW. The relay shall have an
adjustable setting range of 50% - 200% of CT Secondary
current and time setting range of 0-30 Second. The relay
shall be CDGM-22 of EE or equivalent.
(viii) One (1)
Single pole adjustable definite time delay relay for motor
overload alarm connected in Y-phase only. The relay shall
have resetting ratio of not less than 90%. The relay shall have
continuously adjustable time delay range of 2.5 to 25 Sec.
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(ix)
1.25.6
1.25.8
1.25.9
1.25.10
Instantaneous earth fault relay having an adjustable setting
range of 10-40% or 20-80% of CT secondary current. The
earth fault relay shall be provided with a stabilising resistor.
Module Type E
(i)
1.25.7
One (1)
One (1)
Four pole MCCB
Module G-1 (VT Module with under Voltage Relay)
(i)
Three (3)
415 / 110 volts single phase voltage transformer star/star
√3
√3
connect with star point solidly earthed mounted on common
draw out chassis. Accuracy Class 0.5 for protection and
metering with 50VA Burden.
(ii)
Six (6)
HRC Fuses mounted on the above chassis.
(iii)
One (1)
Four position voltmeter selector switch.
(iv)
One (1)
Voltmeter (0-500V)
(v)
One (1)
Double pole instantaneous under voltage relays with
continuous variable setting range of 40-80% of 110 Volts.
(vi)
One (1)
Time delay pick up relay having a time setting range of 0.5
to 3 secs. with 3 `NO'. Self reset contacts, suitable for 220V
DC.
(vii)
One (1)
Auxiliary relay 220V DC with 2 NO. self reset contacts.
(viii)
Three (3)
Indicating lamps with series resistor and colour lenses (Red,
Blue & Yellow).
Module Type G-2
(i)
Three (3)
HRC Fuse
(ii)
One (1)
Voltmeter (0-500V)
(iii)
One (1)
Voltmeter selector switch four position (R-Y, Y-B, B-R
OFF).
(iv)
Three (3)
Indication lamps (Red, Blue & Yellow)
Module Type H & H (BC) (Isolating Switch Controlled Incoming Circuit)
(i)
One (1)
Four pole MCCB
(ii)
One (1)
Red Indicating lamp to indicate isolating switch closed
position.
Module Type S : (DC Metering and Protection Module)
IN JASIDIH GSS VOL-II
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1.25.11
(i)
One (1)
Voltmeter 300-0-300V DC for 220V DC DB/Voltmeter 075V DC for 50V DCDB
(ii)
One (1)
Three (3) position voltmeter selector switch
(iii)
One (1)
Instantaneous under voltage relay with 95% of 220V DC.
The resetting ratio of relay of relay should not be more than
1.25. The relay shall be provided with a series resistor and
a push button across if for resetting (pick up) the relay at
about 105% of the drop out voltage.
(iv)
One (1)
Instantaneous over voltage relay with setting range of 110%
of 220V DC. The resetting ratio of relay should not be less
than 0.8. The relay shall have a push button in series of
resetting the relay at about 95% of the operating voltage.
(v)
One (1)
Earth leakage relay only for 220V DC system having
adjustable pick up range between 3 to 7 milliamps the relay
shall be suitable for 220V DC/240V AC Auxiliary supply.
Module Type X
One (1)
1.25.12
1.25.13
Double pole 250 V MCB
Module Type-DC (Incomer from Battery & Chargers)
(i)
One (1)
Double pole 250V DC MCCB for incomer from Battery.
(ii)
One (1)
DC ammeter with shunt and range of 90-0-400 Amps. For
220V DC DB and 90-0-200 Amp for 50V DC DB.
(iii)
Two (2)
Double pole 250V DC MCCB/MCB
(iv)
One (1)
Double pole single throw 250V DC air break switch
connecting battery & charger sections to DC DB.
Module Type DG-1 (Electrically Controlled Circuit Breaker for Incomer from DG
Set)
a)
One (1)
Triple pole circuit breaker complete with all accessories
and power operated mechanism as specified.
b)
One (1)
Frequency meter.
c)
One (1)
Voltmeter with selector switch.
d)
One (1)
Remote/Local Selector switch.
e)
Three (3)
Current transformer for metering.
IN JASIDIH GSS VOL-II
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1.25.14
f)
Six (6)
Current Transformers for differential protection (out of this
3 Nos. will be supplied loose for mounting in DG set
panel).
g)
Three (3)
Current transformer for relaying.
h)
One (1)
Ammeter Selector Switch.
i)
One (1)
Ammeter
j)
One (1)
Wattmeter of range 0-300 KW.
k)
One (1)
Three pole voltage controlled definite time delay relay
having current setting range of 50-200% of CT secondary
current and adjustable time delay 0.3 to 3 secs.
l)
One (1)
Watt hour meter with six (6) digits and minimum count of
one (1) kwh.
m)
One (1)
Single pole definite time over current relay having a
continuous setting range of 50-200% of CT secondary current
and a time delay of 2.5-25 secs connected in CT of Y phase
for overload alarm. The relay shall have a setting ratio of
not less than 90%.
n)
One (1)
Three pole differential protection relay having an operating
current setting range of 10-40% of generator full load
current. The relay shall be of high impedance type, with
necessary stabilizing resistors.
o)
Two (2)
Push buttons for Remote starting & stopping of DG Set (Red,
Green).
Module Type H1
One (1)
1.25.15
Double pole DC Switch with pad locking facility in off position.
Module Type EL
(i)
One (1)
Four pole MCCB
(ii)
One (1)
Contactor
(iii)
Electronic Timer suitable for continuous operation, push button and selector
switch be as per scheme requirement
1.26
PARAMETERS
1.26.1
Power Supply
1.26.1.1
AC System
3 phase, 4 wire, solidly earthed
a)
415 Volts, ± 10%
Voltage
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b)
Frequency
50 Hz ± 5%
c)
Combined variation
± 10% Absolute Sum
in Voltage & frequency
d)
Fault Level
20 kA (rms)
DC System
2 Wire, unearthed
a)
System
voltage
220V ± 10%
b)
Fault Level
4 kA
c)
System
Voltage
50V ± 10%
1.26.1.2
1.26.2
Control Supply Voltage
a) Trip and closing
coils
220V DC Unearthed
b) Spring charging
220V DC Unearthed
1.26.3
Cubicle Data
1.26.3.1
Busbar Rating
a)
Continuous
for Vertical panels.
As specified in `Bill of Materials'
b)
Short time (1 sec.
kA (rms)
20 kA
c)
Momentary (kA)
PEAK
45 kA
d)
Ambient Temperature
50°C
e)
One Minute Power Frequency Withstand
I. Power Circuit
II. Control Circuit
1.26.3.2
Cubicle Colour Finish
a) Interior
b) Exterior
1.26.4
2500 Volts (rms)
2500 Volts (rms)
Smoke Grey shade No.692 of IS:5
Smoke Grey shade No.692 of IS:5
Circuit Breaker
a)
Type
Air Break
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1.26.5
b)
No. of poles
3
c)
Voltage & Frequency
415 ± 10%, 50 HZ + 5%
d)
Rated Operating Duty
As per IS
e)
Rated service short-circuit
Breaking capacity (Ics)
20 kA (RMS)
f)
Short Circuit
making current
45 kA (Peak)
g)
Short time
withstand current
for 1 sec. duration.
20 kA (RMS) for 1 sec.
h)
Operating Mechanism
current for 1 sec.
duration.
20 kA (RMS) for 1 sec.
i)
No. of auxiliary
contacts
4 NO & 4 NC contacts for Purchaser's
use on fixed portion of the cubicle
j)
Short Circuit
breaking
current
I. AC Component
20 kA (RMS)
II. DC Component
As per IS: 13947 (Part 2)
MOULDED CASE CIRCUIT BREAKER
AC System
DC System
a)
No. of poles
4
2
b)
Voltage & Frequency
415 ± 10%,
50 HZ + 5%
250V
c)
Rated Operating Duty
As per IS
d)
Rated service short-circuit
Breaking capacity (Ics)
20 kA (RMS)
4 kA
e)
Short Circuit
making current
45 kA (Peak)
-
f)
No. of auxiliary
contacts
2 NO & 2 NC
2 NO & 2 NC
g)
Short Circuit
breaking
current
I. AC Component
20 kA (RMS)
As per IS
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1.26.6
1.26.7
II. DC Component
As per
IS 13947
a)
Accuracy class
2.5
b)
One minute power
frequency withstand
test voltage in KV
2.0
Meters
Current Transformers
a)
Type
Cast resin, Bar primary
b)
Voltage class and
frequency
650V, 50 Hz
c)
Class of Insulation
E or better
d)
Accuracy
class metering CT
Class 1, VA adequate for application
but not less than 7.5 VA.
e)
Accuracy class
protection CT
5 P 15, VA adequate for application,
but not less than 7.5 VA.
f)
Accuracy class
differential
protection
PS, KPV = 300V
g)
Short Time Current Rating
(for CTs Associated with
circuit breakers)
I.
Current
20 kA (RMS)
II.
Duration
One Second
III.
Dynamic Rating
45 kA (Peak)
IV.
1.26.8
As per
IS 13947
One minute power
frequency
withstand test
voltage.
Voltage Transformer
a)
Type
b)
Rated Voltage
2.5 kV (rms)
Cast Resin
Primary
415/√3 V
Secondary
110/√3 V
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c)
1.26.9
Method of connection
Primary
Star
Secondary
Star
d)
Rated voltage factor
1.1 continuous, 1.5 for 3 seconds
e)
Class of insulation
E or better
f)
One minute power
frequency withstand
voltage
2.5 KV (RMS)
g)
Accuracy class
0.5, not less than 20VA
Relay
a) One minute power
frequency withstand test
2 kV (rms)
1.27
AUTOMATIC CONTROL OF OUTDOOR LIGHTING
1.27.1
EL-type module of 415V Main lighting distribution board and Emergency lighting
distribution board and shall be controlled by timer and contactor module to facilitate its
operation automatically.
1.28
AUTOMATIC SUPPLY CHANGEOVER
Automatic changeover between Incomer I, Incomer II, and DG set is to be carried out
during the failure of supply in one/or both the incomers. After the restoration of the
supply, system shall be restored to normal condition automatically. The requirement of
changeover under various conditions are as below:
(i)
(ii)
iii)
Under normal conditions i.e. when supply is available in both the incomers,
incomers I&II of 415 V Main switchboard, ACDB shall be in closed condition
and Bus couplers and DG set breaker shall be in open condition.
In case of failure of either of the sources, the incomer of that source shall trip and
Bus-coupler shall get closed. On restoration of supply, normal conditions
described above are to be established automatically.
In case of failure of supply in both the sources, both incomers, incomers of
ACDBs and ACDB Bus coupler shall trip and DG set breaker switched on.
On restoration of one or both sources, DG set breaker shall trip, DG set stopped
and conditions described in paragraph (i) /(ii) shall be restored.
To avoid unnecessary operation of switchgear for momentary disturbances all
changeovers from one state to another shall be initiated after a time delay, after the
conditions warranting such change has been detected.
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4. LT TRANSFORMER
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LT TRANSFORMER
1.0
INTENT
This specification is intended to cover outdoor type oil filled 33/0.433KV 315 KVA &
11/0.433kV, 630 & 250 kVA transformers.
2.0
Scope of Work
2.1
Scope of Supply
2.2
-
Transformers as listed above, with insulating oil, all materials and accessories,
and complete in all respects.
-
Gland plates, power cable, lugs, anchor bolts and hardwares.
-
Mandatory & optional spares and special maintenance equipments if any.
Scope of Service
The scope includes but is not limited to the following items of work to be performed for
all equipment and materials furnished under this section:
a)
Design, manufacturing, shop testing, packing & despatch
b)
Transportation inclusive of insurance and delivery, FOR site basis
c)
Unloading, handling, storing, transportation at site upto foundations, oil filling
and treatment, erection, testing and commissioning
d)
Civil Works
e)
Supply of external cables and termination as required.
f)
Fire protection system.
3.0
General Information
3.1
for
All temperature indicators, Buchholz relays and other auxiliary devices shall be suitable
4.0
4.1
220 V DC Control supply. All alarm and trip Contacts shall also be suitable for
connection in 220V DC Circuits.
TECHNICAL REQUIREMENTS
Core
The core shall be constructed from high grade, nonaging, cold rolled grain-oriented
silicon steel laminations. The maximum flux density in any part of the cores and yoke
at normal voltage and frequency shall be such that the flux density at any tap position
with 10% voltage variation from the voltage corresponding to the tap shall not exceed 1.9
Wb/sq-m.
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4.2
Windings
The conductor shall be of electrolytic copper, free from scales and
burrs.
4.3
Insulating Oil
The oil supplied with transformer shall be unused and have the parameters for unused
new oil conforming to IS:335 while tested at oil Contractor's premises, No inhibitors
shall be used in oil. Ten percent extra oil shall be supplied for topping up after
commissioning in nonreturnable containers suitable for outdoor storage.
4.4
Terminal Arrangement
a) Bushing terminals shall be provided with suitable terminal connectors of approved
type and size for cable/overhead conductors termination of HV side and cable
termination on LV side.
b) The neutral terminals of 433V winding shall be brought out on a bushing along with
the
433 volt phase terminals to form a 4 wire system for the 415 volt. Additional
neutral bushing shall also be provided for earthing.
4.5
Off Circuit Tap Changing Equipment
The tap change switch shall be three phase, hand operated for simultaneous switching
of similar taps on the three phases by operating an external hand wheel.
4.6
Marshalling Box
A metal enclosed, weather, vermin & dust proof marshalling box shall be provided with
each transformer to accommodate temperature indicators, terminal blocks etc. It shall
have a degree of protection of IP 55 as per IS: 2147
4.7
Cable boxes
Whenever cable connections are required, suitable cable boxes shall be provided and
shall be air insulated. They shall be of sufficient size to accommodate Purchaser's
cables and shall have suitable removable side/top cover to facilitate cable termination
and inspection. Cable boxes shall be dust & vermin proof.
5.0
Inspection and Testing
a) The Contractor shall draw up and carry out a comprehensive inspection and testing
program during manufacture and commissioning of the transformer. The programme
shall be duly approved by the Purchaser.
b) The Contractor shall submit cop y of all type tests and carryout routine tests on
the transformers as per relevant standards. Routine tests shall be carried out on all
IN JASIDIH GSS VOL-II
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transformers.
6.0
Inspection
6.1
Tank and Accessories
a)
Physical and dimensional check of transformer tank and
accessories. b)
Crack detection of major strength weld seams by dye
penetration test.
6.2
Core
a) Physical inspection and check of quality of varnish, if
used.
b) Sample testing of core material for checking
properties, magnestisation, characteristics and thickness.
specific
loss,
bend
c) Check on completed core for measurement of iron loss and check for any hot spot
by exciting the core so as to induce the designed value of flux density in the core.
d)
Test
6.3
HV
Insulating Material
a)
Sample checks for physical properties of the
material
b)
Check
strength
for
dielectric
c)
Check for the reaction of hot oil on insulating
material
6.4
Winding
a)
Sample check on winding conductor for mechanical properties and
electrical conductivity and on installation covering.
b)
Sample check on insulation paper for pH value, Bursting strength, Electric
strength.
6.5
Assembled Transformer
a) Check complete transformer against approved outline drawing provision for all
fittings, finish etc.
IN JASIDIH GSS VOL-II
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b) Jacking test on all the assembled transformers.
6.6
Oil
All standard tests in accordance with relevant Standards shall be carried out on oil
samples taken from the transformer before and after testing of the transformer.
The contractor shall also prepare a comprehensive inspection and testing programme for
all bought out sub-contracted items and shall submit the same to the Purchaser for
approval. Such programme shall include the following components:
a)
b)
c)
d)
e)
f)
Buchholz Relay
Winding temperature Indicator
Bushings
Marshaling Box
Tap changer switch
Oil temperature indicator
7.0
Factory Test
7.1
All standard routine tests in accordance with latest issue of IS : 2026 shall be carried out
on each transformer.
7.2
Report for all the type tests in accordance with latest issues of IS : 2026 shall be
furnished..
7.3
In addition to all type and routine tests, following additional type tests shall also be
carried out on one transformer of each rating as per IS : 2026.
a) Te mp R i se t e st .
b) Measurement of capacitance and tan delta of transformer winding.
c) Test on oil samples.
Sequence of testing shall be mutually agreed between Purchaser and Contractor after
award.
7.4
All auxiliary equipment shall be tested as per the relevant IS Test Certificates shall be
submitted for bought out items.
7.5
High voltage withstand test shall be performed on auxiliary equipment and wiring
after complete assembly.
7.6
Tank Tests:
a)
Routine Tests: As per CBIP Manual on Transformers
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7.7
b)
Type Tests:
i)
ii)
Vacuum Tests: As per CBIP Manual on Transformers
Pressure Test: As per CBIP Manual on Transformers
In addition to the above, the following checks should be carried out at manufacturer's
works before despatch for all transformers:
a) Check for interchangeability of components of similar transformers and for
mounting dimensions.
b) Check for proper packing and preservation of accessories like radiators,
bushings explosion vent, dehydrating breather, Buchholz relay, conservator etc.
c) Check for proper provision of bracings to arrest the movements of core and winding
assembly inside the tank.
d) Test for gas tightness and derivation of leakage rate. To ensure adequate reserve gas
capacity during transit and storage.
7.8
The Contractor shall submit a detailed inspection and testing programme for field
activities, covering areas right from the receipt of material stage upto commissioning
stage as per IS :
86 - Code of practice for installation and maintenance of transformers. The indicative
checks and tests are given below.
a)
b)
c)
d)
e)
f)
g)
h)
8.0
Physical checks on each transformer on receipt at site for any damage or
short supply.
Tests on oil samples
Oil leakage test
Physical checks for colour of silica in breather
Check for oil level in breather housing, conservator tank, etc.
Check for correct operation of all protections and alarms.
Insulation Resistance Measurement for Main Winding, control wiring etc.
Continuously observe the transformer operation at no load for 24 hours.
Fittings
The following fittings shall be provided with each transformer covered under
this specification.
i)
Conservator with drain plug and oil filling hole with blanking plate
ii)
Plain oil Gauge
iii)
Silica gel Breather
iv)
Pressure Relief vent
v)
Pocket on tank cover for Thermometer
vi)
Valves
vii)
Earthing Terminals
viii) Rating & Terminal Marking Plates
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ix)
x)
xi)
Lifting Lugs
Rollers
Air Release Plug
The fittings listed above are only indicative and any other fittings which generally
are required for satisfactory operation of transformer are deemed to be included.
9.0
Spare Parts
9.1
The list of spares for outdoor type transformers covered under this section shall be as
per .
9.2
In addition, the Bidder shall also recommend optional spare parts and
maintenance equipment necessary for three(3) years of successful operation of the
equipment. The prices of these shall be indicated in respective schedules and these shall
not be considered for the purpose of evaluation.
10.0
Technical Parameters
---------------------------------------------------------------------------------------------------------- S.No. Description
Parameters
-------------------------------------------------------------------------------------------------------a)
Type
Two Winding
b)
Service
Outdoor
c)
Number of phases
Three
d)
Frequency
50Hz
e)
Type of colling
ONAN
f)
Rating
250 kVA , 630 kVA
Ratio
33/0.433 kVA
g)
Impedance at 75oC with tolerance
0.05+10%
h)
Duty
Continuous
i)
Overload
As per IS:6600
j)
Maximum Temp. rise
over 50o C ambient
i)
Oil (Temp. rise
50o C
measurement by
thermometer)
ii)
Winding (Temp. rise
55o C
measured by
resistance method)
k)
Windings
33 KV
0.433 KV
630 Kva/250 kVA
i) System Apparent short
------------------------ As per IS:2026 (Part-I) ---circuit level (KA)
ii) Winding connection
Delta
Star
iii) Vector Group
------------------------- Dyn1 -----------------iv) Insulation
----------------------------Uniform --------------v) Insulation level (KV)
36
0.433
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a) Power frequency
test level (KV rms)
b) Basic impulse level
(KV peak)
vi) Highest voltage (KV)
for each winding
vii) Method of earthing
70
2
170
--
36
--
----------------------- Solidly earthed ----------
--------------------------------------------------------------------------------------------------------- S.No. Description
Parameters
--------------------------------------------------------------------------------------------------------- l) Tap Changer
i) Tap range
---- +5% / -10% in steps of 2.5% on HV side -------
ii) Tap control
m)
H.V. Bushings
i)
ii)
iii)
iv)
v)
vi)
n)
Off circuit tap
change switch
Rated Voltage, KV
Rated current, KV
Basic impulse
Level (KV)
Wet and dry power
frequency withstand
voltage (KV rms)
Minimum total Creepage
distance (mm)
Mounting
------------
630 KVA
33kV
36
100A -----------------170
70
900
------Tank/Transformer body -----
L.V. and Neutral bushing
i)
Rated Voltage (Volts)
1100
ii)
Rated current (amps)
1000
o)
Terminal details
i)
High Voltage
ii)
o)
i)
ii)
Low Voltage phase
and neutral
Suitable for 33 KV
cable or O/H
Conductor
Cable box
Minimum Clearance (mm)
in AIR
33 KV
630/250 KVA
Phase to Phase
350
ii)Phase to Earth
320
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0.433 KV
25
25
Page 139
5. SURGE ARRESTER
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SURGE ARRESTER
1.1.
General
The surge arresters shall conform in general to IEC-60099-1 or IEC-60099-4 except to
the extent explicitly modified in the specification.
1.1
The bidder shall offer surge arresters of gapless type without any series or shunt gap.
1.2
Arresters shall be hermetically sealed units, of self supporting construction, suitable
for mounting on structures.
The surge arrester shall be designed for use in this geographic and meteorological condition
as given in the chapter GTP.
1.3
2
2.1
2.2
2.3
Duty Requirements
The surge arresters shall be of heavy duty station class type.
The surge arresters shall be capable of discharging over voltage occurring during switching
of unloaded transformers and reactors.
Surge arresters shall be capable of spark over on severe switching surges and multiple
strokes.
2.4 The surge arresters shall be able to withstand wind load calculated at 195 kg/sq.m.
2.5 The gapless arrester, if provided, shall meet following additional requirements.
2.5.1 It shall be fully stabilized thermally to give a life expectancy of 100 years under site
conditions and shall take care of the effect of direct solar radiation.
2.5.2 The reference current of the arrester shall be high enough to eliminate the influence of
grading and stray capacitance on the measured reference voltage.The duty cycle of CB
installed in 245/145 KV sysyem shall be 0-0.3 sec-co-3min-co.The surge arrester should
be suitable for such current breaker duties in the system.
3
Constructional Features
The features and constructional details of surge arresters shall be in accordance with
requirement stipulated hereunder:
3.1 Gapless Type Surge Arrester
3.1.1 The non linear blocks shall be of sintered metal oxide material. These shall be provided
in such a way as to obtain robust construction, with excellent electrical and mechanical
properties even after repeated operations.
3.1.2 The surge arresters shall be fitted with pressure relief devices and arc diverting parts
suitable for preventing shattering of porcelain housing and providing path for flow of
rated fault currents in the event of arrester failure.
3.1.3 The arresters shall incorporate anti-contamination feature to prevent arrester failure
consequent to uneven voltage gradient across the stack in the event of contamination
of the arrester porcelain.
IN JASIDIH GSS VOL-II
Page 141
3.1.4 Seals shall be provided in such a way that these are always effectively maintained
even when discharging rated lightning current.
3.1.5
Outer insulator shall be porcelain used shall be homogenous, free from
laminations, cavities and other flaws or imperfection that might affect the
mechanical or dielectric quality and shall be thoroughly vitrified, tough and
impervious to moisture. Glazing of porcelain shall be of uniform brown colour, free
from blisters, burrs and other similar defects. Porcelain housing shall be so coordinated
that external flashover will not occur due to application of any impulse or
switching surge voltage upto the maximum design value for arrester.
3.1.6 The end fittings shall be made of non-magnetic and corrosion proof material.
3.1.7 The name plate shall conform to the requirement of IEC incorporating the year of
manufacture.
3.1.8 The arrester shall be supplied with suitable support structure either of tubular GI
pipe or lattice steel galvanised.
3.1.9 The heat treatment cycle details along with necessary quality checks used for individual
blocks along with insulation layer formed across each block to be furnished.
Metalised coating thickness for reduced resistance between adjacent
discs to be furnished along with procedure for checking the same. Details of thermal
stability test for uniform current distribution of current on individual disc to be furnished.
3.3
Fittings and Accessories
3.3.1 Each arrester shall be complete with insulating base, support structure and terminal
connector. The height of the support structure shall not be less than
2500 mm. The structure would be made of galvanized steel generally conforming to
IS:802. The surge arrester can also be mounted on the neutral grounding reactor in
lieu of separate support structure.
3.3.2 Self contained discharge counter, suitably enclosed for outdoor use and requiring
no auxiliary or battery supply for operation, shall be provided for each unit. The
counter shall be visible through an inspection window from ground level. The counter
terminals shall be robust and of adequate size and shall be so located that incoming and
outgoing connections are made with minimum possible bends.
3.3.3 Suitable milliammeter on each arrester with appropriate connections shall be supplied to
measure the resistor grading leakage current. The push buttons shall be mounted such that
it can be operated from ground level.
3.3.4 Discharge counter and milliammeter shall be suitable for mounting on support structure
of the arrester.
3.3.5 Grading/Corona rings shall be provided on each complete arrester unit as required for
proper stress distribution.
.4
Tests4.1 The surge arresters shall conform to type tests and shall be subjected to
IN JASIDIH GSS VOL-II
Page 142
acceptance test and routine tests as per IEC-60099.1/IEC-60099.4.
4.2 Surge arrester shall be subjected to additional acceptance tess.
(i)
Thermal stability test on three sections
(ii)
iii)
Ageing and Energy capability test on block
Wattloss test
5.1 Gapless Surge Arrester
245 KV
145 KV
5.1.2
Rated arrester voltage
216 kV
120 kV
5.1.2
Rated system voltage
245 kV
145 kV
5.1.3
Rated system frequency
50Hz
5.1.4
System neutral earthing
Effectively earthed
5.1.5
Installation
5.1.6
Nominal discharge current
10kA of 8/20 micro sec wave.
5.1.7
Class of arrester
10kA heavy duty type
5.1.8
Minimum discharge capacity
5.1.9
Continuous operating voltage at 50
5.1.10
Maximum switching surge
residual voltage (1kA)
5.1.11
Maximum residual voltage at
Outdoor
5.0 kJ/kV (referred to rated voltage)
ø
C
168 Kv
102kV
500 kVp
280kVp
(i)
5kA
560kVp
310kVp
(ii)
10kA nominal discharge
current
600kVp
330kVp
5.1.12
Long duration discharge class
5.1.13
High current short duration
test value (4/10microsec. wave)
5.1.14
Current for pressure relief
test
3
2
100kAp
40kArms
IN JASIDIH GSS VOL-II
Page 143
5.1.15
Low current long duration
test value (2000microsec.)
As per IEC
5.1.16
Min. total creepage distance.
5.1.17
One minute dry power
frequency withstand voltage of
arrester housing.
5.1.18
Impulse withstand voltage of
arrester housing with 1.2/50
microsec. Wave
±1050 kVp
5.1.19
Pressure relief class
A
5.1.20
RIV at 92 kVrms.
Less than 500microvolts
6125mm
3625 mm.
460kVrms
275kVrms
±650KVp
5.1.21
Partial discharge at 1.05
continuous over voltage
Not more than 50pC
5.1.22
Seismic acceleration
0.3 g horizontal.
5.1.23
Reference ambient
temperature
50 deg C
IN JASIDIH GSS VOL-II
Page 144
6.
SECTION: POWER & CONTROL CABLES
IN JASIDIH GSS VOL-II
Page 145
SECTION: POWER & CONTROL CABLES
SN
DESCRIPTION
1
POWER & CONTROL CABLES [ FOR WORKING
VOLTAGES UP TO AND INCLUDING 1100 V]
2
HV POWER CABLES[ FOR WORKING VOLTAGES
FROM 3.3 kV AND INCLUDING 33 kV]
3
EHV
4
CABLE DRUMS
5
TYPE TESTS
XLPE POWER CABLE [FOR
WORKING VOLTAGES FROM 66 kV UP TO
AND INCLUDING 500 kV]
STANDARD TECHNICAL DATA SHEETS ( UP TO
AND INCLUDING 1100 V)
XLPE INSULATED POWER CABLES
PVC INSULATED POWER CABLES
PVC INSULATED CONTROL CABLES
IN JASIDIH GSS VOL-II
Page 146
SECTION: POWER & CONTROL CABLES
1.
POWER & CONTROL CABLES[ FOR WORKING VOLTAGES
UP TO AND INCLUDING 1100 V]
CRITERIA FOR SELECTION OF POWER & CONTROL CABLES
1.1.1.
Aluminium conductor XLPE insulated armoured cables shall be used for main
power supply purpose from LT Aux. Transformers to control room, between
distribution boards and for supply for colony lighting from control room.
1.1.2
Aluminium conductor PVC insulated armoured power cables shall be used for
various other applications in switchyard area/control room except for
control/protection purposes.
1.1.3
For all control/protection/instrumentation
purposes
PVC insulated
armoured control cables of minimum 2.5 sq. mm. size with stranded
Copper conductors shall be used.
1.1.4
JUSNL has standardised the sizes of power cables for various feeders.
Bidders are to estimate the quantity of cables and quote accordingly. The
sizes of power cables to be used per feeder in different application shall be as
follows
S.No.
1.
From
Main
Board
2.
Main
Board
Main
Board
Main
Board
Main
Board
3.
4.
5.
6.
6.1
Switch
Switch
Switch
Switch
Switch
Main
Switch
Board
6.1
6
Lightling
transformer
To
LT Transformer
Cable size
2-1C X 630 mm2
per phase
1-1C X 630 mm2
for neutral
Cable type
XLPE
AC Distribution
Board
Oil Filtration Unit &
Air conditioning board
Colony Lighting
2-3½C X 300 mm2
XLPE
1-3½C X 300 mm2
XLPE
1-3½C X 300 mm2
XLPE
HVW pump LCP(Not
applicable for this
project)
1-3½C X 300 mm2
XLPE
Main
1-3½C X 300 mm2
XLPE
1-3½C X 300 mm2
XLPE
transformer
Main lighting
distribution board
IN JASIDIH GSS VOL-II
Page 147
7.
8.
9.
XLPE
PVC
PVC
1-3½CX70mm2
PVC
AC Kiosk
1- 3 ½ x 35m m2
PVC
Battery Charger
1-3½CX 70 mm2
PVC
13.
AC Distribution
Board
DCDB
Battery
2-1CX 150 mm2
PVC
14.
DCDB
Battery Charger
2-1CX 150 mm2
PVC
15.
DCDB
Protection/PLCC
panel
Main Lighting
Lighting
DB
panels(Indoor)
Main Lighting
Lighting panels
DB
(outdoor)
Main Lighting
Receptacles
DB
(Indoor)
Main Lighting
Receptacles
DB
(Outdoor)
Lighting Panel
Sub
lighting
panels
Lighting Panel
Street
Lighting
Poles
Lighting Panel/ Sub Lighting Fixtures
lighting panels (Outdoor)
1-4C X 16 mm2
PVC
1-3½CX 35 mm2
PVC
1-3½CX 70 mm2
PVC
1-3½CX 35 mm2
PVC
1-3½CX 70 mm2
PVC
1-4C X 16 mm2
PVC
1-4C X 16 mm2
PVC
1-2C X 6 mm2
PVC
Bay MB
1-4C X 16 mm2
/1-4C X 6 mm2
/1-2C X 6 mm2
PVC
11.
12.
16.
17.
18.
19.
20.
21.
22.
23.
1.1.6
AC Distribution
Board
AC Distribution
Board
Bay MB
D.G. Set AMF 2-3½C X 300 mm2
Panel
Emergency
1-3½CX 70 mm2
Lighting
distribution
board
ICT MB
1-3½CX 70 mm2
Bay MB
10.
1.1.5
AC Distribution
Board
AC Distribution
Board
Equipments
Bidder may offer sizes other than the sizes specified in clause 1.1.4. In such
case and for other application where sizes of cables have not been indicated in
the specification,
sizing of power cables shall be done
keeping in view continuous current, voltage drop & short-circuit
consideration of the system. Relevant calculations shall be submitted by bidder
during detailed engineering for purchaser’s approval.
Cables shall be laid conforming to IS : 1255.
IN JASIDIH GSS VOL-II
Page 148
1.1.7
While preparing cable schedules for control/protection purpose following shall
be ensured:
1.1.7.1
Separate cables shall be used for AC & DC.
1.1.7.2
Separate cables shall be used for DC1 & DC2.
1.1.8
For different cores of CT & CVT separate cable shall be used
1.1.9
Atleast one (1) cores shall be kept as spare in each copper control cable of 4C,
5C or 7C size whereas minimum no. of spare cores shall be two (2) for control
cables of 10 core or higher size.
1.1.10
For control cabling, including CT/VT circuits, 2.5 sq.mm. size copper
cables shall be used per connection.
However, if required from voltage
drop/VA burden consideration additional cores shall be used. Further for
potential circuits of energy meters separate connections by 2 cores of 2.5 sq.mm.
size shall be provided.
1.1.11
Standard technical data sheets for cable sizes up to and including
1100V are enclosed
at Annexure.
Cable
sizes
shall
be
offered/manufactured in accordance with parameters specified in standard
technical data sheets. Technical data sheet for any other cores/sizes required
during detailed engineering shall be separately offered for owner’s approval by
the contractor/supplier.
1.2.
TECHNICAL REQUIREMENTS
1.2.1.
General
1.2.1.1.
The cables shall be suitable for laying in racks, ducts, trenches, conduits and
underground buried installation with uncontrolled back fill and chances of
flooding by water.
1.2.1.2.
They shall be designed to withstand all mechanical, electrical and thermal
stresses under steady state and transient operating conditions. The XLPE
/PVC insulated L.T. power cables of sizes 240 sq. mm. and above shall
withstand without damage a 3 phase fault current of at least 45 kA for at least
0.12 second, with an initial peak of 105 kA in one of the phases at rated
conductor temperature ( 70 degC for PVC insulated cables and
90 degC for XLPE insulated cables).
The armour for these power
IN JASIDIH GSS VOL-II
Page 149
cables shall be capable of carrying 45 kA for at least 0.12 seconds without
exceeding the maximum allowable temperature of PVC outer sheath.
1.2.1.3.
The XLPE insulated cables shall be capable of withstanding a conductor
temperature of 250°C during a short circuit without any damage. The PVC
insulated cables shall be capable of withstanding a conductor temperature of
160°C during a short circuit.
1.2.1.4.
The Aluminium/Copper wires used for manufacturing the cables shall be true
circular in shape before stranding and shall be uniformly good quality, free from
defects. All Aluminium used in the cables for conductors shall be of H2 grade.
In case of single core cables armours shall be of H4 grade Aluminium.
1.2.1.5.
The fillers and inner sheath shall be of non-hygroscopic, fire retardant
material, shall be softer than insulation and outer sheath shall be suitable for the
operating temperature of the cable.
1.2.1.6.
Progressive sequential marking of the length of cable in metres at every one
metre shall be provided on the outer sheath of all cables.
1.2.1.7.
Strip wire armouring method (a) mentioned in Table 5, Page-6 of
IS :
1554 (Part 1 ) – 1988 shall not be accepted for any of the cables. For control
cables only round wire armouring shall be used.
1.2.1.8.
The cables shall have outer sheath of a material with an oxygen index of not
less than 29 and a temperature index of not less than 250°C.
1.2.1.9.
All the cables shall pass fire resistance test as per IS:1554 (Part-I)
1.2.1.10.
The normal current rating of all PVC insulated cables shall be as per
IS:3961.
1.2.1.11.
Repaired cables shall not be accepted.
1.2.1.12.
Allowable tolerance on the overall diameter of the cables shall be plus or minus
2 mm.
1.2.2.
XLPE Power Cables
1.2.2.1.
The XLPE (90°C) insulated cables shall be of FR type, C1 category
conforming to IS:7098 (Part-I) and its amendments read alongwith this
specification. The conductor shall be stranded aluminium circular/sector
shaped and compacted. In multicore cables, the core shall be identified by red,
yellow, blue and black coloured strips or colouring of insulation. A
IN JASIDIH GSS VOL-II
Page 150
distinct inner sheath shall be provided in all multicore cables. For XLPE cables, the
inner sheath shall be of extruded PVC of type ST-2 of IS:5831. When armouring is
specified for single core cables, the same shall consist of aluminium wires/strips. The
outer sheath shall be extruded PVC of Type ST-2 of IS:5831 for all XLPE cables.
1.2.3.
PVC Power Cables
1.2.3.1.
The PVC (70°C) insulated power cables shall be of FR type, C1 category, conforming
to IS: 1554 (Part-I) and its amendments read alongwith this specification and shall be
suitable for a steady conductor temperature of
70°C. The conductor shall be stranded aluminium. The Insulation shall be extruded
PVC to type-A of IS: 5831. A distinct inner sheath shall be provided in all multicore
cables. For multicore armoured cables, the inner sheath shall be of extruded PVC. The
outer sheath shall be extruded PVC to Type ST-1 of IS: 5831 for all cables.
1.2.4.
PVC Control Cables
1.2.4.1.
The PVC (70°C) insulated control cables shall be of FR type C1 category conforming to
IS: 1554 (Part-1) and its amendments, read alongwith this specification.
The
conductor shall be stranded copper.
The insulation shall be
extruded PVC to type A of IS: 5831. A distinct inner sheath shall be provided in all
cables whether armoured or not. The over sheath shall be extruded PVC to type ST-1 of
IS: 5831 and shall be grey in colour .
Cores shall be identified as per IS: 1554 (Part-1) for the cables up to five (5) cores and
for cables with more than five (5) cores the identification of cores shall be done by
printing legible Hindu Arabic Numerals on all cores as per clause 10.3 of IS 1554 (Part1).
1.2.4.2.
2.
2.1.
HV POWER CABLES[ FOR WORKING VOLTAGES FROM
3.3 kV AND INCLUDING 33 kV]
HV POWER CABLE FOR AUXILIARY POWER SUPPLY
(a)
The HV cable of 1Cx185 mm2 (Aluminium Conductor) or
1Cx120mm2 (Copper Conductor) of voltage class as specified for
630 kVA LT transformer for interconnecting 630kVA LT transformer to the
SEB feeder shall be, XLPE insulated, armoured cable conforming to IS
7098 (Part-II) or IEC 60502-2 1998. Terminating accessories shall conform
to IS 17573-1992 or IEC 614421997/IEC60502-4 1998.
(b)
The HV cable of 3Cx95 mm2 (Aluminium Conductor) or 3Cx70mm2
(Copper Conductor) of voltage class as specified for 250kVA LT transformer
for interconnecting 250kVA LT transformer to the SEB
feeder shall be, XLPE insulated, armoured cable conforming to IS
7098 (Part-II) or IEC 60502-2 1998. Terminating accessories shall conform to
IS 17573-1992 or IEC 61442-1997/IEC60502-4 1998.
IN JASIDIH GSS VOL-II
Page 151
2.2.
Bidder may offer sizes other than the sizes specified in clause 2.1 (a) and (b). In such
case sizing of power cables shall be done keeping in view continuous current,
voltage drop & short-circuit consideration of the system. Relevant calculations shall
be submitted by bidder during detailed engineering for purchaser’s approval.
2.3.
Constructional Requirements
Cable shall have compacted
circular Aluminium
conductor,
Conductor screened with extruded semi conducting compound , XLPE insulated,
insulation screened with extruded semi conducting compound, armoured with
non-magnetic
material,
followed by
extruded
PVC
outer
sheath(Type ST-2), with FR properties .
2.5
Progressive sequential marking of the length of cable in metres at every one metre
shall be provided on the outer sheath of the cable.
2.6
The cables shall have outer sheath of a material with an Oxygen
Index of not less than 29 and a Temperature index of not less than
250°C.
2.7
Allowable tolerance on the overall diameter of the cables shall be plus or minus 2
mm.
CABLE DRUMS
3.1
Cables shall be supplied in returnable wooden or steel drums of heavy construction.
Wooden drum shall be properly seasoned sound and free from defects. Wood
preservative shall be applied to the entire drum.
3.2
Standard lengths for each size of power and control cables shall be
500/1000 meters. The cable length per drum shall be subject to a tolerance of
plus or minus 5% of the standard drum length.
The owner shall
have the option of rejecting cable drums with shorter lengths. Maximum, One (1)
number non standard length of cable size(s) may be supplied in drums for completion
of project.
3.3
A layer of water proof paper shall be applied to the surface of the drums and over the
outer most cable layer.
3.4
A clear space of at least 40 mm shall be left between the cables and the lagging.
3.5
Each drums shall carry the manufacturer's name, the purchaser's name, address and
contract number and type, size and length of the cable, net and gross weight stencilled
on both sides of drum. A tag containing the same information shall be attached to the
leading end of the cable.
An arrow
and suitable accompanying wording shall be marked on one end of the reel indicating
the direction in which it should be rolled.
IN JASIDIH GSS VOL-II
Page 152
3.6
Packing shall be sturdy and adequate to protect the cables, from any injury due to
mishandling or other conditions encountered during transportation, handling and
storage. Both cable ends shall be sealed with PVC/Rubber caps so as to eliminate
ingress of water during transportation and erection.
4
TYPE TESTS
4.1
All cables shall conform to all type, routine and acceptance tests listed in the relevant
IS.
XLPE INSULATED POWER CABLES ( For working voltages up to and including
1100V ):-
4.2.1
4.2.1
Following type tests ( on one size in a contract) as per IS: 7098 (Part 1)
– 1988
including its amendments shall be carried out as a part of acceptance
tests on XLPE insulated
power cables for working voltages
up to and including 1100 V:
a) Physical tests for insulation
i)
Hot set test
ii)
Shrinkage test
b) Physical tests for outer sheath i)
Shrinkage test
ii)
Hot deformation iii)
Heat shock test iv) Thermal
stability
4.2.2
Contractor shall submit type test reports as per t echnical Specification, Section:
GTR for the following testsa)
b)
c)
d)
e)
f)
4.3
Water absorption (gravimetric) test.
Ageing in air oven
Loss of mass in air oven
Short time current test on power cables of sizes 240 sqmm and above on
i) Conductors. ii)
Armours.
Test for armouring wires/strips.
Oxygen and Temperature Index test. g)
Flammability test.
PVC INSULATED POWER & CONTROL
voltages up to and including 1100V)4.3.1
CABLES
(For working
Following type tests ( on one size in a contract) as per IS: 1554 (Part 1) 1988 including its amendments shall be carried out as a part of acceptance
tests on PVC insulated power & control cables for working voltages up to and
including 1100 V:
a)
Physical tests for insulation and outer sheath i)
IN JASIDIH GSS VOL-II
Page 153
b)
4.3.2
Shrinkage test
ii)
Hot deformation iii)
Heat shock test iv) Thermal
stability
High voltage test (water immersion test only a.c. test as per clause no. 16.3.1).
Contractor shall submit type test reports as per Technical Specification, Section:
GTR for the followinga)
High voltage test (water immersion d.c. test as per clause no. 16.3.2 of IS: 1554
(Part 1) - 1988).
b) Ageing in air oven.
c) Loss of mass in air oven.
d) Short time current test on power
cables of sizes 240 sqmm and above on
i) Conductors. ii)
Armours.
e) Test for armouring wires/strips.
f) Oxygen and Temperature Index test. g)
Flammability test.
4.4
XLPE INSULATED HV POWER CABLES( For working voltages from
3.3 kV and including 33 kV)-
4.4.1
Contractor shall submit type test reports as per clause no. 9.2 of Technical
Specification, Section: GTR for XLPE insulated HV power cables ( as per IS 7098
Part-II including its amendment or as per IEC).
4.5
4.5.1
TERMINATING & JOINTING ACCESSORIESContractor shall submit type test reports as per of Technical Specification for
Terminating/jointing accessories as per IS 17573:1992/ IEC 60840:1999/ IEC62067.
IN JASIDIH GSS VOL-II
Page 154
STANDARD TECHNICAL DATA SHEET
(1.1 kV GRADE XLPE POWER CABLES)
CUSTOMER :
BSEB
SN
Name of manufacturer :
Cable Sizes
1
2
3
4
5
6
As per approved list
1 C x 630
Manufacturer's type designation
Applicable standard
Rated Voltage(volts)
Type & Category
Suitable for earthed or unearthed system
:
:
:
:
:
3½ C x 300
A2XWaY
A2XWY
----------------------IS: 7098/PT-I/1988 & its referred specifications--------------------------------------------1100 V grade-----------------------------------------------------FR & C1
FR & C1
-----------------------for both-------------------------------------------------------------
o
Continuous current rating when laid in air in a ambient temp. of 50 C and
for maximum conductor temp. of 70 oC of PVC Cables[ For information
only]
7 Rating factors applicable to the current ratings for various conditions of
installation:
:
:
732
410
-------------------------------As per IS-3961-Pt-II-67--------------------------------------
8 Short circuit Capacity
a) Guranteed Short Circuit Amp. (rms)KA for 0.12 sec duration at rated
conductor temperature of 90 degree C, with an initial peak of 105 KA.
:
b) Maximum Conductor temp. allowed for the short circuit duty (deg
C.) as stated above.
:
--------------------------------------250 oC------------------------------------------------
:
:
:
Stranded Aluminium as per Class 2 of IS : 8130
------------------------------------- H 2 (Electrolytic grade) ------------------------630
53
9 Conductor
a) Material
b) Grade
c) Cross Section area (Sq.mm.)
d) Number of wires(No.)minimum
e) Form of Conductor
f) Direction of lay of stranded layers
10 Conductor resistance (DC) at 20 oC per km-maximum
11 Insulation
a) Composition of insulation
b) Nominal thickness of insulation(mm)
c) Minimum thickness of insulation
12 Inner Sheath
a) Material
b) Calculated diameter over the laid up cores,(mm)
c) Thickness of Sheath (minimum)mm
d) Method of extrusion
13 Armour
a) Type and material of armour
45 KA
45 KA
300/150
30/15
Stranded compacted
circular/sector shaped
Stranded and compacted circular
:
-------- Outermost layer shall be R.H lay & opposite in successive layers -------0.0469
0.1 / 0.206
:
:
:
-------------------------------------Extruded XLPE as per IS-7098 Part(1)----------------2.8
1.8/1.4
2.42
1.52/1.16
:
:
:
--------------------------------Extruded PVC type ST-2 as per IS-5831-84----------------NA
52
N.A
0.6
NA
Pressure/Vacuum extrusion
:
Al. Wire[ H4
grade]
Gal. Steel wire
b) Direction of armouring
c) Calculated diameter of cable over inner sheath (under armour), mm
:
:
33.9
d)Nominal diameter of round armour wire (minimum)
e)Guranteed Short circuit capacity of the armour for 0.12 sec at room
temperature.
:
2
2.5
45 KA
45 KA
f) DC resistance at 20 oC (Ω/Km)
14 Outer Sheath
a) Material ( PVC Type)
b) Calculated diameter under the sheath
c) Min.thickness of sheath(mm)
e) Guranteed value of minimum temperature index at 21 oxygen index
:
:
:
18 Identification of cores
a) colour of cores
b) Numbering
19 Whether Cables offered are ISI marked
20 Whether Cables offered are suitable for laying as per IS 1255
0.577
ST-2& FR
38.3
1.72
ST-2& FR
59.50
2.36
Min 29.0
Min 29.0
Min 250
Min 250
Black
$
---------------------------------+2/-2 mm--------------------------------------------------------------------- shall conform to IS 10418 and technical specification
1000/500
b) Non standard drum lengths
17 Whether progressive sequential marking on outer sheath provided at
1 meter interval
53.2
$
:
:
:
d) Guaranteed value of minimum oxygen index of outer sheath at 27 oC
f) colour of sheath
15 a) Nominal Overall diameter of cable
b) Tolerance on overall diameter (mm)
16 Cable Drums
a) Max./ Standard length per drum for each size of cable ( single
length) with ±5% Tolerance (mtrs)
----------------------------------left hand--------------------------------------------------
Black
$
1000/500
: Maximum one(1) non standard lengths of each cable size may be supplied in
drums only over & above the standard lengths as specified above.(if required
for completion of project).
:
----------------------------------------- YES -------------------------------------------------
:
:
----------------------------------------- N.A ------------------------------------------------------------------------------------------- YES ---------------------------------------------------
:
----------------------------------------- YES -----------------------------------------------------
As per IS 7098 Part(1)
$'- As per manufacturer design data
IN JASIDIH GSS VOL-II
Page 155
STANDARD TECHNICAL DATA SHEET
(1.1 kV GRADE PVC POWER CABLES)
CUSTOMER :
BSE.B
SN
Name of manufacturer :
As per approved list
Cable Sizes
1 Manufacturer's type designation
:
2 Applicable standard
:
3 Rated Voltage(volts)
:
4 Type & Category
:
5 Suitable for earthed or unearthed system
:
6 Continuous current rating when laid in air in a ambient temp. of
o
o
50 C and for maximum conductor temp. of 70 C of PVC Cables[ For
information only]
:
7 Rating factors applicable to the current ratings for various
conditions of installation:
:
1 c x 150
3.5 cx 70
AYWaY
AYFY
3.5 cx 35
AYFY
4 c x 16
AYFY
4c x 6
2cx6
AYWY
AYWY
------------ -------------------------IS: 1554/PT-I/1988 & its referred standards--------------------------------------------------1100 V grade---------------------------------------------FR & C1
FR & C1
FR & C1
FR & C1
FR & C1
FR & C1
24
28
-----------------------for both-----------------------------------------------------202
105
70
41
x-------------------------------As per IS-3961-Pt-II-67---------------------------------------------------------
8 Short circuit Capacity
a) Short Circuit Amp. (rms)KA for 1 sec duration
:
b) Conductor temp. allowed for the short circuit duty (deg C.)
:
11.2
5.22
2.61
1.19
0.448
0.448
--------------------------------------160 oC-----------------------------------------------------------------------
9 Conductor
a) Material
:
-------------------------------------STRANDED ALUMINIUM ---------------------------------------------------
b) Grade
:
------------------------------------- H 2 (Electrolytic grade) ----------------------------------------------------
c) Cross Section area (Sq.mm.)
d) Number of wires(No.)
e) Form of Conductor
f) Direction of lay of stranded layers
:
:
M-70
N-35
150
:
16
6
6
------------------------------------------- as per Table 2 of IS 8130 -----------------------------------------------Non-compacted
Standed circular
10 Conductor resistance (DC) at 20 oC per km-maximum
M-35
N-16
shaped
conductor
shaped
conductor
shaped
conductor
Non-compacted
Non-compacted
Standed circular
Standed circular
-------- Outermost layer shall be R.H lay & opposite in successive layers -------0.206
0.443/ 0.868
0.868/ 1.91
1.91
4.61
4.61
11 Insulation
a) Composition of insulation
:
b) Nominal thickness of insulation(mm)
:
2.1
1.4/1.2
1.2/1.0
1.0
1.0
1.0
c) Minimum thickness of insulation
:
1.79
1.16/0.98
0.98/0.8
0.8
0.8
0.8
-------------------------------------Extruded PVC type A as per IS-5831-84--------------------------
12 Inner Sheath
a) Material
:
b) Calculated diameter over the laid up cores,(mm)
:
N.A
27.6
20.4
15.7
11.6
9.6
c) Thickness of Sheath (minimum)mm
:
N.A
0.4
0.3
0.3
0.3
0.3
13 Armour
a) Type and material of armour
b) Direction of armouring
c) Calculated diameter of cable over inner sheath (under armour), mm
--------------------------------Extruded PVC type ST-I as per IS-5831-84----------------------------------
:
-------------------------- as per IS 3975/88 ---------------------------------------------------------------------
:
Al. Wire[H4 grade]
:
Gal.steel
strip
Gal.steel
strip
Gal.steel
strip
Gal. Steel wire
Gal. Steel wire
----------------------------------left hand-----------------------------------------------------------------------
:
18
28.4
21
16.3
12.2
10.2
d) Nominal diameter of round armour wire/strip
:
1.6
4 x 0.8
4 x 0.8
4 x 0.8
1.4
1.4
e) Number of armour wires/strips
:
f) Short circuit capacity of the armour along for 1 sec-for info only
o
g) DC resistance at 20 C (Ω/Km)
14 Outer Sheath
-------------------Armouring shall be as close as practicable-----------------------------------------: --K x A√ t (K Amp)(where A = total area of armour in mm 2& t = time in seconds), K=0.091 for Al & 0.05 for steel
:
0.44
2.57
3.38
a) Material ( PVC Type)
:
ST-1& FR
ST-1& FR
ST-1& FR
b) Calculated diameter under the sheath
:
21.2
30.1
22.6
17.9
15
13
c) Min.thickness of sheath(mm)
:
1.4
1.56
1.4
1.4
1.4
1.24
Min 29.0
Min 29.0
Min 29.0
Min 29.0
Min 29.0
Min 29.0
Min 250
Min 250
Min 250
Min 250
Min 250
Min 250
Black
Black
Black
Black
Black
Black
d) Guaranteed value of minimum oxygen index of outer sheath at
o
27 C
e) Guranteed value of minimum temperature index at 21 oxygen index
f) colour of sheath
:
15 a) Overall diameter of cable
b) Tolerance on overall diameter (mm)
16 Cable Drums
ST-1& FR
3.76
4.4
ST-1& FR
ST-1& FR
;--------------------------------------------------------------------$---------------------------------------:
:
a) Max./ Standard length per drum for each size of cable ( single
length) with ±5% Tolerance (mtrs)
---------------------------------+2/-2 mm------------------------------------------------------------------------------------------ shall conform to IS 10418 and technical specification
1000/500
b) Non standard drum lengths
:
17 Whether progressive sequential marking on outer sheath provided
3.99
1000/500
1000/500
1000/500
1000/500
1000/500
Maximum one(1) non standard lengths of each cable size may be supplied in drums only over & above the standard
lengths as specified above.(if required for completion of project).
:
----------------------------------------- YES -------------------------------------------------------------
:
----------------------------------------- N.A -------------------------------------------------------------
:
----------------------------------------- YES -------------------------------------------------------------
:
----------------------------------------- YES -------------------------------------------------------------
18 Identification of cores
a) colour of cores
b) Numbering
19 Whether Cables offered are ISI marked
20 Whether Cables offered are suitable for laying as per IS 1255
Red
R,Y,Bl &Bk
R,Y,Bl &Bk
R,Y,Bl &Bk
R,Y,Bl &Bk
Red & Bk
$'- As per manufacturer design data
IN JASIDIH GSS VOL-II
Page 156
TECHNICAL DATA SHEET
(1.1 kV GRADE PVC CONTROL CABLES)
CUSTOMER :
SN Name of manufacturer :
Cable Sizes
1 Manufacturer's type designation
2 Applicable standard
3 Rated Voltage(volts)
4 Type & Category
5 Suitable for earthed or unearthed system
Continuous current rating when laid in air in a ambient temp.
o
o
6 of 50 C and for maximum conductor temp. of 70 C of PVC
Cables[ For information only]
Rating factors applicable to the current ratings for various
conditions of installation:
8 Short circuit Capacity
a) Short Circuit Amp. (rms)KA for 1 sec-for information only
7
b) Conductor temp. allowed for the short circuit duty (deg C.)
9 Conductor
a) Material
b) Grade
c) Cross Section area (Sq.mm.)
d) Number of wires(No.)
e) Form of Conductor
f) Direction of lay of stranded layers
10 Conductor resistance (DC) at 20 oC per km(maxm)
11 Insulation
a) Composition of insulation
b) Nominal thickness of insulation(mm)
c) Minimum thickness of insulation
12 Inner Sheath
a) Material
b) Calculated diameter over the laid up cores,(mm)
c) Thickness of Sheath (minimum)mm
13 Armour
a) Type and material of armour
BSEB
As per approved list
2c x 2.5
3c x 2.5 5c x 2.5
7c x 2.5 10c x 2.5 14c x 2.5 19c x 2.5 27c x
: 2.5
YWY
YWY
YWY
YWY
YWY
YWY
YWY
YWY
:
-------------------------IS: 1554/PT-I/1988 & its referred standards-------------------------------:-- ---------------------------------------------------------1100----------------------------------------------------: ------------------------------------------------------FR & C1--------------------------------------------------:
--------------------------------for both-----------------------------------------------------:
:
:
:
e) Guranteed value of minimum temperature index at 21
oxygen index
f) colour of sheath
15 a) Overall diameter of cable
b) Tolerance on overall diameter (mm)
16 Cable Drums
a) Max./ Standard length per drum for each size of cable (
single length) with ±5% Tolerance (mtrs)
b) Non standard drum lengths
Whether progressive sequential marking on outer sheath
provided
18 Identification of cores
a) colour of cores
b) Numbering
19
14
12
10.5
9.7
8
-------------------------------As per IS-3961-Pt-II-67----------------------------------------
0.285
0.285
0.285
0.285
--------------------------------------160
0.285
0.285
0.285
0.285
o
C--------------------------------
----------- Plain annealed High Conductivity stranded Copper (as per IS 8130/84) -------------------------------------- Electrolytic-----------------------------------------------------2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
-------------------- as per Table 2 of IS 8130 -------------------------------------------------------------------------Non-Compacted stranded circular conductor-------------------------- Outermost layer shall be R.H lay -------------------------7.41
7.41
7.41
7.41
7.41
7.41
7.41
7.41
:
:
-------------------------------------Extruded PVC type A as per IS-5831-84----------------0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.71
0.71
0.71
0.71
0.71
0.71
0.71
0.71
:
:
:
:
--------------------------------Extruded PVC type ST-I as per IS-5831-84----------------7.2
7.8
9.7
10.8
14.4
15.9
18
22.1
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
-------------------------- as per IS 3975/99 -----------------------------------------------Gal.
Gal.
Gal.
Gal.
Gal.
Gal.
Gal.
Gal. Steel
Steel Steel
Steel
Steel
Steel
Steel
Steel
wire
wire
wire
wire
wire
wire
wire
wire
----------------------------------left land---------------------------------------------
:
:
7.8
8.4
10.3
11.4
15
16.5
18.6
22.7
:
1.4
1.4
1.4
1.4
1.6
1.6
1.6
1.6
:
-------------------Armouring shall be as close as practicable------------------
: --0.05 x A√t (K Amp)(where A = total area of armour in mm2& t = time in seconds)---:
------------ --As per IS 1554 Part(1), whereever applicable & IS 3975-1999-----------------
:
ST-1& FR ST-1& FR ST-1& FR ST-1& FR ST-1& FR ST-1& FR ST-1& FR ST-1&
:FR 10.6
11.2
13.1
14.2
18.2
19.7
21.8
25.9
:
1.24
1.24
1.24
1.24
1.4
1.4
1.4
1.56
:
Min 29.0 Min 29.0 Min 29.0 Min 29.0 Min 29.0 Min 29.0 Min 29.0 Min
29.0
Min 250 Min 250 Min 250 Min 250 Min 250 Min 250 Min 250
Min
250
:
Grey
Grey
Grey
Grey
Grey
Grey
Grey
Grey
:
$
:
---------------------------------+2/-2 mm--------------------------------------:
----------------- shall conform to IS 10418 and technical specification
:
1000/500 1000/500 1000/500 1000/500 1000/500 1000/500 1000/500
1000/500
: Maximum one(1) non standard lengths of each cable size may be supplied in
drums only over & above the standard lengths as specified above.(if required for
completion of project).
:
17
19 Whether Cables offered are ISI marked
20 Whether Cables offered are suitable for laying as per IS 1255
19
:
:--:
:
:
:
:
b) Direction of armouring
c) Calculated diameter of cable over inner sheath
(under armour), mm
d) Nominal diameter of round armour wire / dimensions of
armour strip
e) Number of armour wires
f) Short circuit capacity of the armour and duration-for info
only
g) DC resistance at 20 oC (Ω/Km) & Resistivity of armour
14 Outer Sheath
a) Material ( PVC Type)
b) Calculated diameter under the sheath
c) Min.thickness of sheath(mm)
d) Guaranteed value of minimum oxygen index of outer sheath
22
----------------------------------------- YES ------------------------------------------
:
R & Bk
:
:
R,Y &Bl R,Y,Bl,Bk&
Grey
Grey
Grey
Grey
Grey
Numeral
Numeral Numeral Numeral
Numerals
N.A.
N.A.
N.A.
s in
s in
s in
s in
in black
black ink black ink black ink black ink
ink
----------------------------------------- YES ---------------------------------------------------------------------------------- YES ------------------------------------------
$'- As per manufacturer design data
IN JASIDIH GSS VOL-II
Page 157
7. Control & Protection Panels
IN JASIDIH GSS VOL-II
Page 158
SECTION: CONTROL AND RELAY PANELS
1.
TYPE OF
PANELS Simplex
Panel
Simplex panel shall consist of a vertical front panel with equipment mounted
thereon and having wiring access from rear for control panels & either front or
rear for relay panels. In case of panel having width more than 800mm, double
leaf-doors shall be provided. Doors shall have handles with either built-in locking
facility or will be provided with pad-lock.
Duplex Panel
Duplex panel shall be walk-in tunnel type comprising two vertical front and rear
panel sections connected back-on-back by formed sheet steel roof tie members
and a central corridor in between. The corridor shall facilitate access to internal
wiring and external cable connections. In case of number of duplex panels
located in a row side by side, the central corridor shall be aligned to form a
continuous passage. Both ends of the corridor shall be provided with double
leaf doors with lift off hinges. Doors shall have handles either with built-in
locking facility or shall be provided with pad-locks. Separate cable entries shall
be provided for the front and rear panels. However, inter-connections between
front and back panels shall be by means of inter panel wiring at the top of the
panel.
2.
CONSTRUCTIONAL FEATURES
2.1.
Control and Relay Board shall be of panels of simplex or duplex type design as
indicated in bill of quantity. It is the responsibility of the Contractor to ensure that
the equipment specified and such unspecified complementary equipment
required for completeness of the protective/control schemes be properly
accommodated in the panels without congestion and if necessary, provide
panels with larger dimensions. No price increase at a later date on this account
shall be allowed . However, the width of panels that are being offered to be
placed in existing switchyard control rooms, should be in conformity with the
space availability in the control room.
2.2.
Panels shall be completely metal enclosed and shall be dust, moisture and
vermin proof. The enclosure shall provide a degree of protection not less than
IP-31 in accordance with IS: 2147.
2.3.
Panels shall be free standing, floor mounting type and shall comprise structural
frames completely enclosed with specially selected smooth finished, cold rolled
sheet steel of thickness not less than 3 mm for weight bearing members of the
panels such as base frame, front sheet and door frames, and 2.0mm for sides,
door, top and bottom portions. There shall be sufficient reinforcement to provide
level transportation and installation.
2.4.
All doors, removable covers and panels shall be gasketed all around with
synthetic rubber gaskets Neoprene/EPDM generally conforming with provision
of IS 11149. However, XLPE gaskets can also be used for fixing protective
IN JASIDIH GSS VOL-II
Page 159
glass doors. Ventilating louvers, if provided shall have screens and filters. The
screens shall be made of either brass or GI wire mesh
2.5.
Design, materials selection and workmanship shall be such as to result in neat
appearance, inside and outside with no welds, rivets or bolt head apparent from
outside, with all exterior surfaces tune and smooth.
2.6.
Panels shall have base frame with smooth bearing surface, which shall be fixed on
the embedded foundation channels/insert plates. Anti vibration strips made of
shock absorbing materials that shall be supplied by the contractor, shall be
placed between panel & base frame.
2.7.
Cable entries to the panels shall be from the bottom. Cable gland plate fitted on
the bottom of the panel shall be connected to earthing of the panel/station
through a flexible braided copper conductor rigidly.
2.8.
Relay panels of modern modular construction would also be acceptable.
3.
MOUNTING
3.1.
All equipment on and in panels shall be mounted and completely wired to the
terminal blocks ready for external connections. The equipment on front of panel
shall be mounted flush.
3.2.
Equipment shall be mounted such that removal and replacement can be
accomplished individually without interruption of service to adjacent devices and
are readily accessible without use of special tools.
Terminal marking on the
equipment shall be clearly visible.
3.3.
The Contractor shall carry out cut out, mounting and wiring of the free issue
items supplied by others which are to be mounted in his panel in accordance
with the corresponding equipment manufacturer's drawings.
Cut outs if any,
provided for future mounting of equipment shall be properly blanked off with
blanking plate.
3.4.
The centre lines of switches, push buttons and indicating lamps shall be not less
than 750mm from the bottom of the panel. The centre lines of relays, meters
and recorders shall be not less than 450mm from the bottom of the panel
3.5.
The centre lines of switches, push buttons and indicating lamps shall be
matched to give a neat and uniform appearance. Like wise the top lines of all
meters, relays and recorders etc. shall be matched.
3.6.
No equipment shall be mounted on the doors.
3.7.
At existing station, panels shall be matched with other panels in the control
room in respect of dimensions, colour, appearance and arrangement of
equipment (centre lines of switches, push buttons and other equipment) on the
front of the panel.
4.
PANEL INTERNAL WIRING
IN JASIDIH GSS VOL-II
Page 160
4.1.
Panels shall be supplied complete with interconnecting wiring provided between
all electrical devices mounted and wired in the panels and between the devices
and terminal blocks for the devices to be connected to equipment outside the
panels. When panels are arranged to be located adjacent to each other all inter
panel wiring and connections between the panels shall be furnished and the
wiring shall be carried out internally
4.2.
All wiring shall be carried out with 650V grade, single core, stranded copper
conductor wires with PVC insulation. The minimum size of the multi-stranded
copper conductor used for internal wiring shall be as follows:
•
All circuits except current transformer circuits and voltage
transfer circuits meant for energy metering - one 1.5mm sq. per
lead.
•
All current transformer circuits one 2.5 sq.mm lead.
•
Voltage transformer circuit (for energy meters): Two 2.5 mm
sq.per lead.
4.3.
All internal wiring shall be securely supported, neatly arranged, readily
accessible and connected to equipment terminals and terminal blocks. Wiring
gutters & troughs shall be used for this purpose.
4.4.
Auxiliary bus wiring for AC and DC supplies, voltage transformer circuits,
annunciation circuits and other common services shall be provided near the top of
the panels running throughout the entire length of the panels.
4.5.
Wire termination shall be made with solderless crimping type and tinned copper
lugs , which firmly grip the conductor. Insulated sleeves shall be provided at all
the wire terminations. Engraved core identification plastic ferrules marked to
correspond with panel wiring diagram shall be fitted at both ends of each wire.
Ferrules shall fit tightly on the wire and shall not fall off when the wire is
disconnected from terminal blocks. All wires directly connected to trip circuit
breaker or device shall be distinguished by the addition of red coloured
unlettered ferrule.
4.6.
Longitudinal troughs extending throughout the full length of the panel shall be
preferred for inter panel wiring. Inter-connections to adjacent panel shall be
brought out to a separate set of terminal blocks located near the slots of holes
meant for taking the inter-connecting wires.
4.7.
Contractor shall be solely responsible for the completeness and correctness of the
internal wiring and for the proper functioning of the connected equipments
5.
TERMINAL BLOCKS
5.1.
All internal wiring to be connected to external equipment shall terminate on
terminal blocks. Terminal blocks shall be 650 V grade and have 10 Amps.
continuous rating, moulded piece, complete with insulated barriers, stud type
terminals, washers, nuts and lock nuts. Markings on the terminal blocks shall
correspond to wire number and terminal numbers on the wiring diagrams. All
terminal blocks shall have shrouding with transparent unbreakable material.
IN JASIDIH GSS VOL-II
Page 161
5.2.
Disconnecting type terminal blocks for current transformer and voltage
transformer secondary leads shall be provided.
Also current transformer
secondary leads shall be provided with short circuiting and earthing facilities.
5.3.
At least 20% spare terminals shall be provided on each panel and these spare
terminals shall be uniformly distributed on all terminal blocks.
5.4.
Unless otherwise specified, terminal blocks shall be suitable for connecting the
following conductors of external cable on each side
•
All CT & PT circuits: minimum of two of 2.5mm Sq. copper.
•
AC/DC Power Supply Circuits : One of 6mm Sq. Aluminium.
•
All other circuits: minimum of one of 2.5mm Sq. Copper.
5.5.
There shall be a minimum clearance of 250mm between the first row of terminal
blocks and the associated cable gland plate or panel side wall.
Also the
clearance between two rows of terminal blocks edges shall be minimum of
150mm.
5.6.
Arrangement of the terminal block assemblies and the wiring channel within the
enclosure shall be such that a row of terminal blocks is run in parallel and close
proximity along each side of the wiring-duct to provide for convenient
attachment of internal panel wiring. The side of the terminal block opposite the
wiring duct shall be reserved for the Owner's external cable connections. All
adjacent terminal blocks shall also share this field wiring corridor. All
wiring shall be provided with adequate support inside the panels to hold them
firmly and to enable free and flexible termination without causing strain on
terminals.
5.7.
The number and sizes of the Owner's multi core incoming external cables will
be furnished to the Contractor after placement of the order. All necessary cable
terminating accessories such as gland plates, supporting clamps & brackets,
wiring troughs and gutters etc. (except glands & lugs) for external cables shall
be included the scope of supply.
6.
PAINTING
6.1.
All sheet steel work shall be phosphated in accordance with the IS:6005 "Code of
practice for phosphating iron and steel".
6.2.
Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning.
6.3.
Rust and scale shall be removed by pickling with dilute acid followed by washing
with running water rinsing with a slightly alkaline hot water and drying.
6.4.
After phosphating, thorough rinsing shall be carried out with clean water
followed by final rinsing with dilute dichromate solution and oven drying.
6.5.
The phosphate coating shall be sealed with application of two coats of ready
mixed, stoved type zinc chromate primer. The first coat may be "flash dried"
while the second coat shall be stoved.
6.6.
After application of the primer, two coats of finishing synthetic enamel paint shall
IN JASIDIH GSS VOL-II
Page 162
be applied, each coat followed by stoving. The second finishing coat shall be
applied after inspection of first coat of painting. The exterior colour of paint shall
be of a slightly different shade to enable inspection of the painting.
6.7.
A small quantity of finished paint shall be supplied for minor touching up
required at site after installation of the panels.
6.8.
In case the bidder proposes to follow any other established painting procedure
like electrostatic painting, the procedure shall be submitted for POWERGRID's
review and approval.
7.
MIMIC DIAGRAM
7.1.
Coloured mimic diagram and symbols showing the exact representation of the
system shall be provided in the front of control panels.
7.2.
Mimic diagram shall be made preferably of anodised aluminium or
plastic of approved fast colour material, which shall be screwed on to the panel
and can be easily cleaned. Painted overlaid mimic is also acceptable. The
mimic bus shall be 2mm thick.
The width of the mimic bus shall be 10mm
for bus bars and 7mm for other connections.
7.3.
Mimic bus colour will be decided by the JUSNL and shall be furnished to the
successful Bidder during Engineering.
7.4.
When semaphore indicators are used for equipment position they shall be so
mounted in the mimic that the equipment close position shall complete the
continuity of mimic.
7.5.
Indicating lamp, one for each phase, for each bus shall be provided on the
mimic to indicate bus charged condition
8.
NAME PLATES AND MARKINGS
8.1.
All equipment mounted on front and rear side as well as equipment mounted
inside the panels shall be provided with individual name plates with equipment
designation engraved. Also on the top of each panel on front as well as rear
side, large and bold nameplates shall be provided for circuit/feeder designation.
8.2.
All front mounted equipment shall also be provided at the rear with individual
name plates engraved with tag numbers corresponding to the one shown in the
panel internal wiring to facilitate easy tracing of the wiring.
8.3.
Each instrument and meter shall be prominently marked with the quantity
measured e.g. KV, A, MW, etc. All relays and other devices shall be clearly
marked with manufacturer's name, manufacturer's type, serial number and
electrical rating data.
8.4.
Name Plates shall be made of non-rusting metal or 3 ply lamicoid. Name plates
shall be black with white engraving lettering.
8.5.
Each switch shall bear clear inscription identifying its function e.g.
'BREAKER''52A', "SYNCHRONISING" etc.
Similar inscription shall also
be provided on each device whose function is not other-wise identified. If any
switch device does not bear this inscription separate name plate giving its
function shall be provided for it. Switch shall also have clear inscription
IN JASIDIH GSS VOL-II
Page 163
for each position indication e.g. "Trip- Neutral-Close", "ON-OFF", "R-Y-B-OFF"
etc
8.6.
All the panels shall be provided with name plate mounted
inside the panel
bearing LOA No & Date , Name of the Substation & feeder and reference
drawing number.
9.
MISCELLANEOUS ACCESSORIES
9.1.
Plug Point : 240V, Single phase 50Hz, AC socket with switch suitable to accept
5 Amps and 15 Amps pin round standard Indian plug, shall be provided in the
interior of each cubicle with ON-OFF switch.
9.2.
Interior Lighting : Each panel shall be provided with a fluorescent lighting
fixture rated for 240 Volts, single phase, 50 Hz supply for the interior illumination
of the panel controlled by the respective panel door switch. Adequate lighting
shall also be provided for the corridor in Duplex panels.
9.3.
Switches and Fuses: Each panel shall be provided with necessary arrangements for receiving, distributing and isolating of DC and AC supplies for various
control, signaling, lighting and space heater circuits.
The incoming and subcircuits shall be separately provided with Fuses. Selection of the main and subcircuit Fuses rating shall be such as to ensure selective clearance of sub-circuit
faults. Voltage transformer circuits for relaying and metering shall be protected
by fuses. All fuses shall be HRC cartridge type conforming to IS: 13703
mounted on plug-in type fuse bases. The short time fuse rating of Fuses
shall be not less than 9 KA. Fuse carrier base shall have imprints of the fuse
'rating' and 'voltage'.
9.4.
Space Heater :
Each panel shall be provided with a thermostatically
connected space heater rated for 240V , single phase , 50 Hz Ac supply for the
internal heating of the panel to prevent condensation of moisture. The fittings
shall be complete with switch unit
10.
EARTHING
10.1.
All panels shall be equipped with an earth bus securely fixed. Location of earth
bus shall ensure no radiation interference for earth systems under various
switching conditions of isolators and breakers. The material and the sizes of
the bus bar shall be at least 25 X 6 sq.mm perforated copper with threaded
holes at a gap of 50mm with a provision of bolts and nuts for connection with
cable armours and mounted equipment etc for effective earthing.
When
several panels are mounted adjoining each other, the earth bus shall be made
continuous and necessary connectors and clamps for this purpose shall be
included in the scope of supply of Contractor. Provision shall be made for
extending the earth bus bars to future adjoining panels on either side.
10.2.
Provision shall be made on each bus bar of the end panels for connecting
Substation earthing grid. Necessary terminal clamps and connectors for this
purpose shall be included in the scope of supply of Contractor.
10.3.
All metallic cases of relays, instruments and other panel mounted equipment
IN JASIDIH GSS VOL-II
Page 164
including gland plate, shall be connected to the earth bus by copper wires of
size not less than 2.5 sq. mm.
The colour code of earthing wires shall be
green.
10.4.
Looping of earth connections which would result in loss of earth connection to
other devices when the loop is broken, shall not be permitted. However,
looping of earth connections between equipment to provide alternative paths to
earth bus shall be provided.
10.5.
VT and CT secondary neutral or common lead shall be earthed at one place
only at the terminal blocks where they enter the panel. Such earthing shall be
made through links so that earthing may be removed from one group without
disturbing continuity of earthing system for other groups.
11.
INDICATING INSTRUMENTS, RECORDERS & TRANSDUCERS
All instruments, meters, recorders and transducers shall be enclosed in dust
proof, moisture resistant, black finished cases and shall be suitable for tropical
use. All megawatt , megavar, Bus voltage and frequency dicating
instruments shall be provided with individual transducers and these shall be
calibrated along with transducers to read directly the primary quantities. They
shall be accurately adjusted and calibrated at works and shall have means of
calibration check and adjustment at site. The supplier shall submit calibration
certificates at the time of delivery. However no separate transducers are
envisaged for digital bus voltmeters and digital frequency meters and the
indicating meters provided in the synchronising equipment.
11.1.
Indicating Instruments
11.1.1.
Unless otherwise specified, all electrical indicating instruments shall be of
digital type suitable for flush mounting.
11.1.2.
Instruments shall have 4-digit display; display height being not less than 25
mm
11.1.3.
Instrument shall confirm to relevant IS and shall have an accuracy class of 1.5
or better Watt and Var meters shall have an indication of (+) and (-) to
indicate EXPORT and IMPORT respectively.
11.1.4.
Digital voltage and frequency meters shall be of class: 0.5 and shall have
digital display of 5 and 4 digits respectively, with display size, not less
than25mm (height).
11.2.
Bus Voltage & Frequency Recording Instruments
11.2.1
Recording instruments shall be square or rectangular in shape and shall be
suitable for flush mounting on panels. They shall be of 'draw out' type and
suitable for back connection.
11.2.2
Recorders shall be furnished in dust tight metal cases with gasketed doors
and they shall be designed so as to require minimum maintenance.
11.2.3
The recorder shall
IN JASIDIH GSS VOL-II
Page 165
i.
be single pen type employing potentionmeteric servo drive principle.
ii.
be of continuous recording type with disposable fibre tip cartridge pens,
employing ink on paper.
iii.
have a Calibrated Chart width of at least 100 mm and a viewing area of
100x50mm, at least.
iv.
have an accuracy of + 1.0% span.
vi. have full span response time of less than 2
seconds.
vi.
have maximum chart speed facility of 60mm per hour.
vii.
be directly calibrated for CT and PT ratios in use.
viii.
be provided with chart rolls of adequate length requiring replacement, not
earlier than 27 days. The quantity of chart rolls and ink included with the
offer shall be 1000 metre length of paper and five pens with each recorder.
ix.
be suitable for operation with station DC source, in case of AC supply (230
volts, 1 phase, 50Hz) failure (inverter may be included ,if required) .
11.2.4
Alternatively, Static/Digital type frequency recorder and voltage recorder either
as individual units or composite unit for total substation with time tagged
information shall also be acceptable if it meets the accuracy of + 1.0% span
and full span response time of less than 2 seconds. The static/digital shall
also meet the high voltage susceptibility test , impulse voltage with stand test ,
high frequency disturbance test –class III and fast transient disturbance test –
level III as per IEC 60255.
11.3.
Transducers
11.3.1.1.
Transducers (for use with Indicating Instruments and Telemetry/Data
Communication application) shall in general conform to IEC:688-1
11.3.1.2.
The transducers shall be suitable for measurement of active power, reactive
power, voltage, current and frequency in three phase four wire unbalanced
system.
11.3.1.3.
The input to the transducers will be from sub-station current & potential
transformers. The output shall be in milli ampere D.C. proportional to the input
& it shall be possible to feed the output current directly to the telemetry
terminal or indicating instruments.
11.3.1.4.
The transducer characteristic shall be linear throughout the measuring range.
11.3.1.5.
The transducer output shall be load independent.
11.3.1.6.
The input & output of the transducer shall be galvanically isolated.
11.3.1.7.
Each transducer shall be housed in a separate compact case and have
suitable terminals for inputs & outputs.
11.3.1.8.
The transducers shall be suitably protected against transient high peaks of
voltage & current.
IN JASIDIH GSS VOL-II
Page 166
11.3.1.9.
The transducer shall withstand indefinitely without damage and work
satisfactorily at 120% of the rated voltage and 120% of the rated input current
as applicable.
11.3.1.10. All the transducers shall have an output of 4-20 mA.
11.3.1.11. The response time of the transducers shall be less than 1 second.
11.3.1.12.
The accuracy class of transducers shall be 1.0 or better for voltage/current
transducer, 0.5 or better for watt/VAR transducer and 0.2 or better for
frequency transducer.
11.3.1.13. The transducers shall have a low AC ripple on output less than 1%.
11.3.1.14. The transducers shall be suitable for load resistance of 1000-1500
11.3.1.15. The transducer shall have dual output.
12.
ANNUNCIATION SYSTEM
12.1.
Alarm annunciation system shall be provided in the control board by means of
visual and audible alarm in order to draw the attention of the operator to the
abnormal operating conditions or the operation of some protective devices.
The annunciation equipment shall be suitable for operation on the voltages
specified in this specification.
12.2.
The visual annunciation shall be provided by annunciation facia, mounted
flush on the top of the control panels.
12.3.
The annunciator facia shall be provided with translucent plastic window for
alarm point with approximate size of 35mm x 50mm. The facia plates shall be
engraved in black lettering with respective inscriptions.
Alarm inscriptions
shall be engraved on each window in not more than three lines and size of the
lettering shall not be less than 5 mm.
12.4.
Each annunciation window shall be provided with two white lamps in parallel
to provide safety against lamp failure. Long life lamps shall be used. The
transparency of cover plates and wattage of the lamps provided in the facia
windows shall be adequate to ensure clear visibility of the inscriptions in the
control room having high illumination intensity (350 Lux), from the location
of the operator's desk.
12.5.
All Trip facia shall have red colour and all Non-trip facia shall have white
colour.
12.6.
The audible alarm shall be provided by Buzzer/ Hooter /Bell having different
sounds and shall be used as follows.
12.7.
Sl. NO.
Hooter
Alarm Annunciation
Bell
Annunciation DC failure
Buzzer
AC supply failure
Sequence of operation of the annunciator shall be as follows :
Alarm Condition
Fault
Contact
Visual
Annunciation
IN JASIDIH GSS VOL-II
Audible
Annunciation
Page 167
1.
Normal
Open
OFF
OFF
2.
Abnormal
Close
Flashing
ON
3.
Accept Push Button Pressed
Close
Steady On
OFF
Open
Steady On
OFF
Close
On
OFF
Open
Of
f
OFF
4.
Reset Push Button Pressed
IN JASIDIH GSS VOL-II
Page 168
5.
Open
Lamp Test
Pressed
Steady On
Push
Button
OFF
12.8.
Audible annunciation for the failure of DC supply to the annunciation system shall
be provided and this annunciation shall operate on 240 Volts AC supply. On failure of
the DC to the annunciation system for more than 2 or 3 seconds. (adjustable setting), a
bell shall sound. A separate push button shall be provided for the cancellation of
this audible alarm alone but the facia window shall remain steadily lighted till the
supply to annunciation system is restored .
12.9.
A separate voltage check relay shall be provided to monitor the failure of supply
(240V AC) to the scheme mentioned in Clause above. If the failure of supply exists
for more than 2 to 3 seconds. this relay shall initiate visual and audible annunciation.
Visual and audible annunciation for the failure of AC supply to the annunciation
system shall be provided and this annunciation shall operate on Annunciation DC and
buzzer shall sound.
12.10.
The annunciation system described above shall meet the following additional
requirements :
a) The annunciation system shall be capable of catering to at least 20 simultaneous
signals at a time.
b) One set of the following push buttons shall be provided on each control panel:
•
Reset push button for annunciation system.
•
Accept push button for annunciation system.
•
Lamp test push button for testing the facia windows
c) One set of the following items shall be provided common for all the control panel
(not applicable for extension of substation) :
•
Flasher relay for annunciation system.
•
Push button for Flasher test .
•
Three Push buttons for test of all audible alarm systems
d) These testing circuits shall be so connected that while testing is being done it
shall not prevent the registering of any new annunciation that may land during the
test
e)
The annunciation shall be repetitive type and shall be capable of
registering the fleeting signal. Minimum duration of the fleeting signal
registered by the system shall be 15 milli seconds.
f) In case of static annunciator scheme, special precaution shall be taken to ensure
that spurious alarm condition does not appear due to influence of external
electromagnetic/ electrostatic interference on the annunciator wiring and
switching disturbances from the neighbouring circuits within the panels and the
static annunciator shall meet the high voltage susceptibility test , impulse voltage
with stand test , high frequency disturbance test– class III and fast transient
IN JASIDIH GSS VOL-II
Page 169
disturbance test –level III as per IEC 60255.
12.11.
13.
The annunciation system to be supplied for existing sub-stations shall be
engineered as an extension to the existing scheme.
SWITCHES
13.1.
Control and instrument switches shall be rotary operated type with escutcheon plates
clearly marked to show operating position and circuit designation plates and suitable
for flush mounting with only switch front plate and operating handle projecting
out.
13.2.
The selection of operating handles for the different types of switches shall be as
follows :
Breaker, Isolator control switches
: Pistol grip, black
Synchronising switches
: Oval,
Black,
Keyed
handle(one
common removable handle for a group of
switches or locking
facility
having
common key)
synchronising Selector switches
: Oval or knob, black Instrument
switches
: Round, knurled, black Protection
Transfer switch
: Pistol grip, lockable and black.
13.3.
The control switch of breaker and isolator shall be of spring return to neutral type.
The switch shall have spring return from close and trip positions to "after close" and
"after trip" positions respectively.
13.4.
Instrument selection switches shall be of maintained contact (stay put) type.
Ammeter selection switches shall have make-before-break type contacts so as to
prevent open circuiting of CT secondary when changing the position of the switch.
Voltmeter transfer switches for AC shall be suitable for reading all line- to-line and lineto-neutral voltages for non effectively earthed systems and for reading all line to line
voltages for effectively earthed systems.
13.5.
Synchronising switches shall be of maintained contact (stay put) type having a common
removable handle for a group of switches.
The
handle shall be
removable only in the OFF position and it shall be co-ordinated to fit in to all the
synchronising switches. These switches shall be arranged to connect the synchronising
equipment when turned to the 'ON' position.
One contact of each switch
shall be connected in the closing circuit of the respective breaker so that the breaker
cannot be closed until the switch is turned to the 'ON' position.
13.6.
Lockable type of switches which can be locked in particular positions shall be
provided when specified. The key locks shall be fitted on the operating handles.
IN JASIDIH GSS VOL-II
Page 170
13.7.
The contacts of all switches shall preferably open and close with snap action to
minimise arcing. Contacts of switches shall be spring assisted and contact faces shall
be with rivets of pure silver or silver alloy. Springs shall not be used as current
carrying parts
13.8.
The contact combination and their operation shall
completeness to the interlock and function of the scheme.
13.9.
The contact rating of the switches shall be as follows :
Description
Contact rating in Amps
220VDC 50V DC
Make and carry
Continuously
10
10
Make and carry
for 0.5 sec.
30
30
be
such
as
to
give
240V
AC
30
Break for:
Resistive load
3
20
7
Inductive load
0.2
-
-
with L/R = 40m sec.
4.
INDICATING LAMPS
14.1.
Indicating lamps shall be of cluster LED type suitable for panel mounting with rear
terminal connections. .Lamps shall be provided with series connected resistors
preferably built in the lamp assembly. Lamps shall have translucent lamp covers to
diffuse lights coloured red ,green, amber ,clear white or blue as specified .The lamp
cover shall be preferably of screwed type ,unbreakable and moulded from heat
resisting material.
14.2.
The lamps shall be provided with suitable resistors .
14.3.
Lamps and lenses shall be interchangeable and easily replaceable from the front of
the panel. Tools ,if required for replacing the bulbs and lenses shall also be included
in the scope of the supply.
14.4.
The indicating lamps with resistors shall withstand 120% of rated voltage on a
continuous basis.
15.
POSITION INDICATORS
IN JASIDIH GSS VOL-II
Page 171
15.1.
Position indicators of "SEMAPHORE" type shall be provided when specified as part
of the mimic diagrams on panels for indicating the position of circuit breakers,
isolating/earthing switches etc.
The indicator shall be suitable for semi-flush
mounting with only the front disc projecting out and with terminal connection from
the rear.
Their strips shall be of the same colour as the
associated mimic.
15.2.
Position indicator shall be suitable for DC Voltage as specified. When the
supervised object is in the closed position, the pointer of the indicator shall take up a
position in line with the mimic bus bars, and at right angles to them when the object
is in the open position.
When the supply failure to the
indicator occurs, the pointer shall take up an intermediate position to indicate the
supply failure.
15.3.
The rating of the indicator shall not exceed 2.5 W.
15.4.
The position indicators shall withstand 120% of rated voltage on a continuous basis.
16.
16.1.
SYNCHRONISING EQUIPMENT
The synchronising instruments shall be mounted either on a synchronising trolley or
on a synchronising panel. The panel/ trolley shall be equipped with double analog
voltmeters and double analog
frequency
meters,
synchroscope and lamps fully wired. The size of voltmeters and frequency meters
provided in the synchronising panel shall not be less than 144 X 144 sq.mm. Suitable
auxiliary voltage transformers wherever necessary shall also be provided for
synchronising condition.
In case the synchroscope
is not
continuously rated, a synchroscope cut-off switch shall be provided and an
indicating lamp to indicate that the synchroscope is energised, shall also be provided
16.2.
Synchronising check relay with necessary ancillary equipment’s shall be provided
which shall permit breakers to close after checking the requirements of synchronising
of incoming and running supply. The phase angle setting shall not exceed 35 degree
and have voltage difference setting not exceeding
10%. This relay shall have a response time of less than 200 milliseconds when the
two system conditions
are met within present limits and with the timer
disconnected.
The relay shall have a frequency difference setting not exceeding
0.45% at rated value and at the minimum time setting. The relay shall have a
continuously adjustable time setting range of 0.5-20 seconds. A guard relay shall be
provided to prevent the closing attempt by means of synchronising check relay
when control switch is kept in closed position long before the two systems are in
synchronism
16.3.
The synchronising panel shall be draw out and swing type which can be
swivelled in left and right direction. The synchronising panel shall be placed along
with control panels and the number of synchronising panel shall be as indicated in
PRICE SCHEDULE. The incoming and running bus wires of VT secondary shall be
connected and run as bus wires in the control panels and will be extended to
IN JASIDIH GSS VOL-II
Page 172
synchronising
panel for synchronisation of circuit breakers. The selector switch
provided for each circuit breaker in respective control panels shall be lockable type
with a common key so that only one selector switch is kept in synchronising mode
at a time.
16.4.
Alternatively, the trolley shall be of mobile type with four rubber-padding
wheels capable of rotating in 360 degree around the vertical axis. Suitable bumpers
with rubber padding shall be provided all around the trolley to prevent any
accidental damage to any panel in the control room while the trolley is in
movement. The trolley shall have two meter long flexible cord fully wired to the
instruments and terminated in a plug in order to facilitate connecting the trolley
to any of the panels. The receptacle to accept the plug shall be provided on the panel.
16.5.
At existing sub-stations, the synchronising scheme shall be engineered to be
compatible with the existing synchronising scheme and synchronising
socket/switch on the panel. In substations, where synchronising panels are available,
the bidder shall carry out the shifting of the above panels , if required , to
facilitate the extension of control panel placement .
17.
RELAYS
17.1.
All relays shall conform to the requirements of IS:3231/IEC-60255 or other
applicable standards. Relays shall be suitable for flush or semi-flush mounting on the
front with connections from the rear.
17.2. All protective relays shall be in draw out or plug-in type/modular cases with proper
testing facilities. Necessary test plugs/test handles shall be supplied loose and shall be
included in contractor's scope of supply.
17.3.
All AC operated relays shall be suitable for operation at 50 Hz. AC Voltage operated
relays shall be suitable for 110 Volts VT secondary and current operated relays for
1 amp CT secondary. All DC operated relays and timers shall be designed for the DC
voltage specified, and shall operate satisfactorily between 80% and 110% of rated
voltage. Voltage operated relays shall have adequate thermal capacity for continuous
operation.
17.4.
The protective relays shall be suitable for efficient and reliable operation of the
protection scheme described in the specification. Necessary auxiliary relays and
timers required for interlocking schemes for multiplying of contacts suiting contact
duties of protective relays and monitoring of control supplies and circuits, lockout
relay monitoring circuits etc. also required for the complete protection schemes
described in the specification shall be provided.
All
protective relays shall be provided with at least two pairs of potential free isolated
output contacts. Auxiliary relays and timers shall have pairs of contacts as
required to complete the scheme, contacts shall be silver faced with spring action.
Relay case shall have adequate number of terminals for making potential free
external connections to the relay coils and contacts, including spare contacts.
17.5.
All protective relays, auxiliary relays and timers except the lock out relays and
IN JASIDIH GSS VOL-II
Page 173
interlocking relays specified shall be provided with self-reset type contacts. All
protective relays and timers shall be provided with externally hand reset positive
action operation indicators with inscription. All protective relays which do not have
built-in hand-reset operation indicators shall have additional auxili- ary relays with
operating indicators (Flag relays) for this purpose.
Similarly, separate operating
indicator (auxiliary relays) shall also be provided in the trip circuits of protections
located outside the board such as Buchholtz relays, oil and winding temperature
protection, sudden pressure devices, fire protection etc.
17.6.
Timers shall be of the electromagnetic or solid state type. Pneumatic timers are not
acceptable.
Short time delays in terms of milliseconds may be
obtained by using copper slugs on auxiliary relays. In such case it shall be ensured
that the continuous rating of the relay is not affected. Time delay in terms of
milliseconds obtained by the external capacitor resistor combination is not preferred
and shall be avoided to the extent possible.
17.7.
No control relay which shall trip the power circuit breaker when the relay is deenergised shall be employed in the circuits.
17.8.
Provision shall be made for easy isolation of trip circuits of each relay for the purpose
of testing and maintenance.
17.9.
Auxiliary seal-in-units provided on the protective relays shall preferably be of shunt
reinforcement type.
If series relays are used the following shall be strictly
ensured:
(a)
The operating time of the series seal-in-unit shall be sufficiently shorter than
that of the trip coil or trip relay in series with which it operates to ensure
definite operation of the flag indicator of the relay.
(b)
Seal-in-unit shall obtain adequate current for operation when one or more
relays operate simultaneously.
(c)
Impedance of the seal-in-unit shall be small enough to permit
satisfactory operation of the trip coil on trip relays when the D.C. Supply Voltage
is minimum.
17.10.
All protective relays and alarm relays shall be provided with one extra isolated pair of
contacts wired to terminals exclusively for future use.
17.11.
The setting ranges of the relays offered, if different from the ones specified shall also
be acceptable if they meet the functional requirements.
17.12.
Any alternative/additional protections or relays considered necessary for providing
complete effective and reliable protection shall also be offered separately. The
acceptance of this alternative/ additional equipment shall lie with the CE (Trans.),
B.S.E.B.
17.13.
The bidder shall include in his bid a list of installations where the relays quoted have
IN JASIDIH GSS VOL-II
Page 174
been in satisfactory operation.
17.14.
All relays and their drawings shall have phase indications as R-Red, Y-yellow, B-blue
17.15.
Wherever numerical relays are used, the scope shall include the following:
a) Necessary software and hardware to up/down load the data to/from the relay
from/to the personal computer installed in the substation. However, the supply of
PC is not covered under this clause.
b) The relay shall have suitable communication facility for future connectivity to
SCADA. The relay shall be capable of supporting IEC 870-5-103 protocol.
Neither the interface hardware nor the software for connectivity to SCADA will
form part of the scope of this specification.
c)
In case of Numerical line protection and Numerical transformer/reactor
differential protection, the features like disturbance recorder and event logging
function as available in these relays shall be supplied and activated in
addition to requirement specified for disturbance recorder and event logging
elsewhere in the specification.
18.
TRANSMISSION LINE PROTECTION
18.1.
The line protection relays are required to protect the line and clear the faults on line
within shortest possible time with reliability, selectivity and full sensitivity to
all type of faults on lines. The general concept is to have two main protections
having equal performance requirement specially in respect of time as called Main-I
and Main-II for 400KV and 220KV lines. The general concept is to have Main and
back up protection for 132 KV lines.
18.2.
The Transmission system for which the line protection equipment are required
is detailed inspecification. The length of lines
and the line parameters (Electrical Constants) are also indicated there.
18.3.
The maximum fault current could be as high as 40 kA but the minimum fault current
could be as low as 20% of rated current of CT secondary. The starting &
measuring relays characteristics should be satisfactory under these extremely varying
conditions.
18.4.
The protective relays shall be suitable for use with capacitor voltage
transformers as well as Potential Transformers/ Voltage Transformers having nonelectronic damping and transient response as per IEC.
18.5.
Disturbance Recorder, Distance to fault Locator and Over voltage relay (stage 1) functions if offered as an integral part of line protection relay, shall be acceptable
provided these meet the technical requirements as specified in the respective clauses.
18.6.
Auto reclose relay function if offered as an integral part of line distance
protection relay, shall be acceptable for 132 KV lines provided the auto reclose
IN JASIDIH GSS VOL-II
Page 175
relay feature meets the technical requirements as specified in the respective clause.
18.7. The following protections shall be provided for each of the Transmission lines:
For 400 KV & 220KV
Main-I:
Numerical distance protection scheme
Main-II:
Numerical distance protection scheme of a make different from that of
Main –I
For 132KV
Main:
Numerical distance protection scheme
Back up :
Directional Over current and Earth fault Protection
18.8.
However, Phase segregated phase/direction comparison protection,
Protection based on directional wave detection principle, phase segregated line
differential protection as Main 2 protection in place of Numerical distance protection
scheme shall be provided if specified in the specification.
18.9.
Further, if specified, back up Over current and Earth fault
provided instead of Main -II protection scheme for
220KV lines to match with requirements at the remote ends.
18.10.
The detailed description of the above line protections is given here under.
protection shall be
18.10.1. Main-I & Main-II Numerical Distance Protection scheme :
(a)
shall be numerical type and shall have continuous self monitoring and
diagnostic feature.
(b)
shall be non-switched type with separate measurements for all phase to phase and
phase to ground faults
(c)
shall have stepped time-distance characteristics and three independent zones
(zone 1, zone-2 and zone-3)
(d)
shall have mho or quadrilateral or other suitably shaped characteristics for zone-1 ,
zone-2 and zone- 3.
(e)
shall have following maximum operating time (including trip relay time , if any)
under given set of conditions and with CVT being used on line (with all filters
included) .
(i)
for 400 KV & 220 KV lines:
IN JASIDIH GSS VOL-II
Page 176
Source to Impedance ratio
4
Relay setting (Ohms)
15
(10 or 20) and 2
2
Fault Locations
of relay setting)
50
50 (as %
Fault resistance (Ohms)
0
0
Maximum operating time
(Milliseconds )
40 for all
faults
45 for 3
ph. faults
&
60 for all other faults
(ii) for 132 KV lines :
A relaxation of 5 ms in above timings is allowed for 132 KV lines .
(f)
The relay shall have an adjustable characteristics angle setting range of 30 75 degree or shall have independent resistance(R ) and reactance (X)
setting.
(g)
shall have two independent continuously variable time setting range of 0-3 seconds
for zone-2 and 0-5 seconds for zone-3.
(h)
shall have resetting time of less than 55 milli-seconds (including the
resetting time of trip relays)
(i)
shall have facilities for offset features with adjustable 10-20% of Zone-3 setting.
(j)
shall have variable residual compensation.
(k)
shall have memory circuits with defined characteristics in all three phases to ensure
correct operation during close-up 3 phase faults and other adverse conditions and shall
operate instantaneously when circuit breaker is closed to zero-volt 3 phase fault
(l)
shall have weak end in-feed feature
(m)
shall be suitable for single & three phase tripping.
(n)
shall have a continuous current rating of two times of rated current.
The
voltage circuit shall be capable of operation at 1.2 times rated voltage. The relay
shall also be capable of carrying a high short time current of 70 times rated current
without damage for a period of 1 sec.
(o)
shall be provided with necessary self reset type trip duty contacts for
completion of the scheme (Minimum number of these trip duty contacts shall be
four per phase)
either through built in or through separate high speed
trip relays . Making capacity of these trip contacts shall be 30 amp for
IN JASIDIH GSS VOL-II
Page 177
0.2 seconds with an inductive load of L/R > 10 mill seconds . If separate high
speed trip relays are used , the operating time of the same shall not be more than 10
milliseconds
(p)
shall be suitable for use in permissive under reach / over reach /blocking
communication mode .
(q)
shall have suitable number of potential free contacts
for
Carrier
aided
Tripping, Auto reclosing, Event Logger, Disturbance recorder & Data acquisi- tion
system.
(r)
include power swing blocking protection which shall
•
have suitable setting range to encircle the distance protection
described above.
•
block tripping during power swing conditions. (s)
include fuse failure protection which shall
•
monitor all the three fuses of C.V.T. and associated cable against
open circuit.
•
inhibit trip circuits on operation and initiate annunciation.
•
have an operating time less than 7 milliseconds
•
remain inoperative for system earth faults
(t)
include a directional back up Inverse Definite Minimum Time (IDMT ) earth fault
relay with normal inverse characteristics as per IEC 60255-3 as a built in feature or
as a separate unit for 400 KV and 220KV transmission lines
(u)
In case the numerical distance relay is not having the built in feature as per above
clause (t), the same can be supplied as an independent relay
18.10.2.
Back-up Directional Over Current and Earth fault protection scheme
(a)
shall have three over current and one earth fault element(s) which shall be either
independent or composite unit(s
(b)
Numerical type
(c)
The scheme shall include necessary VT fuse failure relays for alarm purposes
.
IN JASIDIH GSS VOL-II
Page 178
(d)
Directional over current relay shall
• have IDMT characteristic with a definite minimum time of 3.0 seconds at
10 times setting
• have a variable setting range of 50-200% of rated current
• have a characteristic angle of 30/45 degree lead
• include hand reset flag indicators /LEDs . (e)
Directional earth fault relay shall
• have IDMT characteristic with a definite minimum time of 3.0 seconds at
10 times setting
• have a variable setting range of 20-80% of rated current
• have a characteristic angle of 45/60 degree lag
• include hand reset flag indicators or LEDs
• include necessary separate
interposing
voltage transformers or have
internal feature in the relay for open delta voltage to the relay.
18.10.3.
All trip relays usedin transmission line protection scheme shall be of
self/electrical reset type depending on application requirement.
19.
AUTO RECLOSING RELAY shall
(a)
have single phase and three phase reclosing facilities.
(b)
have a continuously variable single phase dead time range of 0.1-2
seconds.
(c)
have a continuously variable three phase dead time range of 0.1-2 seconds.
(d)
have a continuously variable reclaim time range of 5-25 seconds.
(e)
incorporate a four-position selector switch/ from which single
phase/three phase/single and three phase auto reclosure and non- auto
reclosure mode can be selected. Alternatively, the mode of auto reclosing can
be selected through programming.
IN JASIDIH GSS VOL-II
Page 179
(f)
have facilities for selecting check synchronising or dead line charging
features. It shall be possible at any time to change the required feature
by reconnection of links.
(g)
be of single shot type.
(h)
have priority circuit to closing of both circuit breakers in case one and half
breaker arrangements to allow sequential closing of breakers
(i)
be acceptable asbuilt in with line distance relay for132kv (j)
include check synchronising relay which shall
• have a time setting continuously variable between
facility of additional 10 seconds.
• have a response
disconnected.
time
within
200
milli
0.5-5 seconds. with a
seconds
with
the
timer
• have a phase angle setting not exceeding 35 degree
• have a voltage difference setting not exceeding10% (k)
include dead line charging relay which shall
• have two sets of relays and each set shall be able to monitor the three phase
voltage where one set shall be connected to the line CVTs with a fixed setting
of 20% of rated voltage and the other set
shall
be
connected to the bus CVTs with a fixed setting of 80% of rated voltage.
• incorporate necessary
comprehensive scheme.
20.
auxiliary
relays
and
timers
to
give
LINE OVER VOLTAGE PROTECTION RELAY shall
(a)
monitor all three phases
(b)
have two independent
acceptable as built in
respectively .
(c)
stages and stage- 1 & II
with line distance relays
relay
Main I
&
are
II
have an adjustable setting range of 100-170% of rated voltage with an
adjustable time delay range of 1 to 60 seconds for the first stage.
IN JASIDIH GSS VOL-II
Page 180
21.
21.1.
(d)
have an adjustable setting range of 100-170% of rated voltage with a time
delay of 100-200 mill seconds for the second stage.
(e)
be tuned to power frequency
(f)
provided with separate operation indicators (flag target) for each stage
relays.
(g)
have a drop-off to pick-up ratio greater than 95%.
(h)
provide separate out-put contacts for each 'Phase' and stage for breaker
trip relays, event logger and other scheme requirements.
REACTOR PROTECTION
Differential Protection shall
(a)
be triple pole type
(b)
have operation time less than 25 milli-seconds at 5 times setting. (c)
be
tuned to system frequency
21.2.
21.3.
(d)
have current setting range of 10 to 40% of 1 Amp. Or a suitable voltage
setting range.
(e)
be high impedance type
(f)
be stable for all external faults
(g)
be provided with suitable non-linear resistors across the relay to limit the peak
voltage to 1000 volts.
Restricted earth fault protection Relay shall
(a)
be single pole type
(b)
be of current/voltage operated high impedance type
(c)
have a current setting of 10-40% of 1 Amp./have a suitable voltage setting range.
(d)
be tuned to system frequency.
(e)
have a suitable non-linear resistor to limit the peak voltage to 1000 Volts.
Back up impedance protection Relay shall
(a)
be triple pole type, with faulty phase identification/ indication
(b)
be single step polarised 'mho' distance/ impedance relay suitable for measuring phase
IN JASIDIH GSS VOL-II
Page 181
to ground and phase to phase faults.
(c)
have adequate
ohmic setting range to cover at least 60
impedance of the reactor and shall be continuously variable.
%
of
the
(d)
have an adjustable characteristic angle of 30-80 degree.
(e)
have a definite time delay relay with a continuously adjustable setting range of 0.2-2.0
seconds.
(f)
22.
22.1.
include VT failure relay which shall block the tripping during VT fuse failure
condition.
TRANSFORMER PROTECTION
Transformer differential protection scheme shall
(a)
be triple pole type, with faulty phase identification/ indication
(b)
have an operating time not greater than 30 milli seconds at 5 times the rated current .
(c)
have three instantaneous high set over-current units
(d)
have an adjustable bias setting range of 20-50% (e)
be
suitable for rated current of 1 Amp.
(f)
have second harmonic or other inrush proof features and also should be stable under
normal over fluxing conditions. Magnetising inrush proof feature shall not be achieved
through any intentional time delay e.g use of timers to block relay operation or using disc
operated relays
(g)
have an operating current setting of 15% or less
(h)
include necessary separate interposing
current transformers for angle and ratio
correction or have internal feature in the relay to take care of the angle & ratio
correction
(i)
shall be numerical type and shall have continuous self monitoring and diagnostic
feature
(j)
have a fault recording feature to record graphic form of instantaneous values of
following analogue channels during faults and disturbances for the pre fault and post fault
period:
•
current in all three windings in nine analogue channels in case of 400kV class and
above transformers or
6 analogue channels for lower voltage transformers
and
•
Voltage in one channel
The disturbance recorder shall have the facility to record the following external digital channel signals
apart from the digital signals pertaining to differential relay.
1. REF protection operated
IN JASIDIH GSS VOL-II
Page 182
2. HV breaker status (Main and tie)
3. IV breaker status
4. Bucholz /OLTC Bucholz alarm / trip
5. WTI/OTI/PRD alarm/trip of transformer
Necessary hardware and software for automatic up-loading the data captured by disturbance
recorder to the personal computer (DR Work Station) available in the substation shall be included in
the scope.
(k)
22.2.
be acceptable with built in features of definite time over load protection (alarm) relay
provided the technical requirements of these relays specified under the relevant
clauses are met.
Over fluxing protection Relays shall
(a)
operate on the principle of Voltage to frequency ratio and shall be phase to phase
connected
(b)
have inverse time characteristics, matching with transformer over fluxing withstand
capability curve
(c)
provide an independent 'alarm' with the time delay
between 0.1 to 6.0 seconds at values of 'v/f' between 100% to
130% of rated values
(d)
tripping time shall be governed by 'v/f' Vs. time characteristics of the relay
(e)
have a set of characteristics for Various time multiplier settings.
The
maximum operating time of the relay shall not exceed 3 seconds and 1.5 seconds at 'v/f'
values of 1.4 and 1.5 times, the rated values, respectively.
(f)
Void
(g)
have an accuracy of operating time, better than ±10%.
(h)
have a resetting ratio of 95 % or better.
continuously adjustable
Restricted Earth Fault Protection shall
(a)
be single pole type
(b)
be of current/voltage operated high impedance type
(c)
have a current setting range of 10-40% of 1 Amp./ have a suitable voltage
setting range.
(d)
be tuned to the system frequency
(e)
have suitable non-linear resistor to limit the peak voltage to 1000
IN JASIDIH GSS VOL-II
Page 183
Volts.
22.4.
Back-up Over Current and Earth fault protection scheme with high set feature
(a)
Shall have three over current and one earth fault element(s) which shall be
either independent or composite unit(s).
(b)
Numerical type
(c)
The scheme shall include necessary VT fuse failure relays for alarm purposes
(d)
Over current relay shall
•
have directional IDMT characteristic with a definite minimum time
of 3.0 seconds at 10 times setting and have a variable setting range
of 50-200% of rated current
•
have low transient, over reach high set instantaneous unit of
continuously variable setting range 500-2000 % of rated current
•
have a characteristic angle of 30/45 degree lead
•
include hand reset flag indicators or LEDs. (e)
Earth fault relay shall
22.5.
•
have directional IDMT characteristic with a definite minimum time of
3.0 seconds at 10 times setting and have a variable setting range of
20-80% of rated current
•
have low transient, over reach high set instantaneous unit of
continuously variable setting range 200-800 % of rated current
•
have a characteristic angle of 45/60 degree lag
•
include hand reset flag indicators or LEDs
•
include necessary separate interposing voltage transformers or have internal
feature in the relay for open delta voltage to the relay
Transformer Overload Protection Relay shall
(a)
be of single pole type
(b)
be of definite time over-current type
differential relay shall also be acceptable .
and
built
in
IN JASIDIH GSS VOL-II
feature
with
Page 184
22.6.
(c)
have one set of over-current relay element,
adjustable setting range of 50-200% of rated current
with
continuously
(d)
have one adjustable time delay relay for alarm having setting range of 1 to
10.0 seconds, continuously.
(e)
have a drop-off/pick-up ratio greater than 95%.
LOCAL BREAKER BACK-UP PROTECTION SCHEME shall
(a)
be triple pole type
(b)
be of solid-state type
(c)
have an operating time of less than 15 milli seconds (d) have
a resetting time of less than 15 milli seconds (e) have three over
current elements
23.
(f)
be arranged to get individual initiation from the corresponding phase of main
protections of line for each over current element. However, common three
phase initiation is acceptable for other protections and transformer /reactor
equipment protections
(g)
have a setting range of 20-80% of rated current
(h)
have a continuous thermal
irrespective of the setting
(i)
have
(j)
have necessary auxiliary relays to make a comprehensive scheme.
a
withstand
two
times
rated
current
timer with continuously adjustable setting range of 0.1-1 seconds
TEE PROTECTION DIFFERENTIAL RELAYS
23.1. TEE-1 differential protection relays shall
(a)
be triple pole type
(b)
have an operating time less than 30 milliseconds at 5 times the rated current.
(c)
have three instantaneous high set over current units
(d)
have an adjustable bias setting range of 20-50%
IN JASIDIH GSS VOL-II
Page 185
(e)
23.2.
24.
have an operating current setting of 15% of 1 Amp or less
TEE-2 Differential relay shall
(a)
be triple pole type
(b)
have operating time less than 25 milliseconds at 5 times setting
(c)
be tuned to system frequency
(d)
have current setting range of 20 to 80% of 1 Amp
(e)
be voltage operated, high impedance type
(f)
be stable for all external faults
(g)
be provided with suitable non linear resistors across the relay to limit the peak
voltage to 1000 volts
TRIPPING RELAY
High Speed Tripping Relay shall
(a)
be instantaneous (operating time not to exceed 10 milli-seconds). (b)
reset within 20 milli seconds
25.
(c)
be D.C. operated
(d)
have adequate contacts to meet the requirement of scheme, other functions
like auto-reclose relay, LBB relay as well as cater to associated
equipment like event logger, Disturbance recorder, fault Locator, etc.
(e)
be provided with operation indicators for each element/coil.
FLAG RELAYS
These shall have
26.
(a)
hand reset flag indication
(b)
have minimum two contacts (NO or NC or combination as required)
for each relay
TRIP CIRCUIT SUPERVISION RELAY
IN JASIDIH GSS VOL-II
Page 186
27.
28.
28.1.
28.2.
28.3.
(a)
The relay shall be capable of monitoring the healthiness of each
'phase' trip-coil and associated circuit of circuit breaker during 'ON' and
'OFF' conditions.
(b)
The relay shall have adequate contacts for providing connection to alarm
and event logger.
(c)
The relay shall have time delay on drop-off of not less than 200 milli
seconds and be provided with operation indications for each phase.
DC SUPPLY SUPERIVISION RELAY
(a)
The relay shall be capable of monitoring the failure of D.C. supply to which,
it is connected.
(b)
It shall have adequate potential free contacts to meet the scheme
requirement.
(c)
The relay shall have a 'time delay on drop-off' of not less than 100 milli
seconds and be provided with operation indicator/flag.
BUS BAR PROTECTION
Two bus bar protection schemes shall be provided for each main bus for
400KV. The scheme shall be engineered so as to ensure that operation of any one
out of two scheme connected to main faulty bus shall result in tripping of the
same. However in case of transfer bus wherever provided, only one bus
bar protection scheme
on
transfer
bus shall be
Acceptable.
Single busbar protection scheme shall be provided for each main and
transfer bus for 220KV and 132 KV voltage levels
Each Bus Bar protection scheme shall
(a)
have maximum operating time up to trip impulse to trip relay for all types of
faults of 25 milli seconds at 5 times setting value.
(b)
(c)
operate selectively for each bus bar
give hundred percent security up to 40 KA fault level up to 40 KA for fault
level for 400KV and 220KV and 31.5 KA for 132 KV
(d)
incorporate continuous supervision for CT secondary against any possible
open circuit and if it occurs, shall render the relevant zone of protection
inoperative and initiate an alarm
(e)
not give false operation during normal load flow in bus bars. (f)
IN JASIDIH GSS VOL-II
Page 187
incorporate clear zone indication.
(g)
be of phase segregated and triple pole type
(h)
provide independent zones of protection (including transfer bus if any). If
the bus section is provided then each side of bus section shall have separate set
of bus bar protection schemes
(i)
include individual high speed hand reset tripping relays for each feeder
(j)
be transient free in operation
(k)
include continuous D.C. supplies supervision.
(l)
not cause tripping for the differential current below the load current
of heaviest loaded feeder. Bidder shall submit
application check for the same.
(m)
shall include necessary C.T. switching relays wherever C.T. switching is
involved and have 'CT' selection incomplete alarm
include protection 'IN/OUT' switch for each zone
(n)
(o)
shall include trip relays, CT switching relays(if applicable) , auxiliary CTs (if
applicable) as well as additional power supply modules, input
modules etc. as may be required to provide a Bus-bar protection scheme for
the complete bus arrangement i.e. for all the bay or breakers under this
specification
as well as for the future bays as per the Single line
diagram for new
substations. However
for
extension of bus bar
protection scheme ( if specified in PRICE
SCHEDULE) in existing
substations , scope shall be limited to
the bay or breakers covered under this specification . Suitable panels to
mount these are also included in the scope of the work.
28.4.
Built-in Local Breaker Backup protection feature as a part of bus bar
protection scheme shall also be acceptable.
28.5.
At existing substations, Bus-bar protection scheme with independent zones for each
bus, will be available. All necessary co-ordination for 'AC' and 'DC' interconnections
between existing schemes (Panels) and the bays proposed under the scope of this
contract shall be fully covered by the bidder. Any
auxiliary relay, trip relay, flag relay and multi tap auxiliary CTs (in case of biased
differential protection) required to facilitate the operation of the bays covered under
this contract shall be fully covered in the scope of the bidder.
29.
WEATHER PROOF RELAY PANELS
IN JASIDIH GSS VOL-II
Page 188
(a)
This panel shall include necessary number of electrically reset relays each
with at least eight contacts for isolator auxiliary contacts multiplication
and for changing the CT and DC circuits to relevant zones of bus bar
protection.
(b)
The panel shall be sheet steel enclosed and shall be dust, weather and vermin
proof. Sheet steel used shall be at least 2.0 mm thick and properly braced to
prevent wobbling.
(c)
The enclosures of the panel shall provide a degree of protection of not less than
IP-55 (as per IS:2147).
(d)
The panel shall be of free standing floor mounting type or pedestal
mounting type as per requirement.
(e)
The panel shall be provided with double hinged doors with padlocking
arrangement.
(f)
All doors, removable covers and panels shall be gasketed all around with
synthetic rubber gaskets Neoprene/EPDM generally conforming with
provision of IS 11149. However, XLPE gaskets can also be used for fixing
protective glass doors. Ventilating louvers, if provided shall have screens and
filters. The screens shall be made of either brass or GI wire mesh
(g)
Cable entries shall be from bottom. Suitable removable cable gland plate
shall be provided on the cabinet for this purpose.
(h)
All sheet steel work shall be degreased, pickled, phosphated and then applied
with two coats of zinc chromates primer and two coats of finishing
synthetic enamel paint, both inside and outside. The colour of the finishing
paint shall be light grey in accordance with shade no.697 of IS:5.
(i)
Suitable heaters shall be mounted in the panel to prevent
condensation. Heaters shall be controlled by thermostats so that the
cubicle temperature does not exceed 30oC. On-off switch and fuse shall be
provided.
Heater shall be suitable for 240V AC supply
Voltage.
The test terminal blocks (TTB) to be provided shall be fully enclosed with
removable covers and made of moulded, non-inflammable plastic material with
boxes and barriers moulded integrally. All terminals shall be clearly marked
with identification numbers or letters to facilitate connection to external
wiring.
Terminal block shall have shorting,
(j)
disconnecting and testing facilities for CT circuits.
30.
DISTURBANCE RECORDER(SEPARATE RECORDER
IN JASIDIH GSS VOL-II
Page 189
30.1.
Disturbance recorder shall be microprocessor based and shall be used to record the
graphic form of instantaneous values of voltage and current in all three phases, open
delta voltage & neutral current, open or closed position of relay contacts and
breakers during the system disturbances and built in feature of line distance relay
is acceptable provided the requirements of following clauses are met
30.2.
The disturbance recorder shall consist of individual acquisition units, one for each
feeder and an Evaluation unit which is common for the entire Substation.
Whenever, more than one acquisition units are connected to an Evaluation unit,
necessary hardware and software shall also be supplied for on line transfer of data
from all acquisition units to Evaluation unit . If there are any constraints for one
Evaluation unit to accept the data from number of acquisition units under the present
scope, adequate number of Evaluation units shall be supplied. In case of extension of
existing substation(s), one set of Evaluation unit shall be supplied for each
substation where ever disturbance recorders are specified.
30.3.
Disturbance recorder shall have 8 analogue and 16 digital channels for each feeder.
30.4.
Acquisition units shall acquire the fault data for the pre fault and post fault period
and transfer them to Evaluation unit automatically to store in the hard disk. The
acquisition units shall be located in the protection panels of the respective feeders.
30.5.
The acquisition unit shall be suitable for inputs from current transformers with 1A
rated secondary and capacitive voltage transformers with 63.5V (phase to neutral
voltage) rated secondary.
Any
device
required
for
processing of input signals in order to make the signals compatible to the
Disturbance recorder equipment shall form an integral part of it. However, such
processing of input signals shall in no way distort its waveform.
30.6.
The equipment shall be carefully screened, shielded, earthed and protected as may be
required for its safe functioning. Also, the disturbance recorder shall have stable
software, reliable hardware, simplicity of maintenance and immunity from the
effects of the hostile environment of EHV switchyard which are prone to various
interference signals typically from large switching transients.
The Evaluation unit shall consist of a desktop personal computer (including VGA
colour monitor, mouse and keyboard) and printer. The desktop PC shall have
Pentium - IV processor or better and having a clock speed 400
MHz or better. The hard disk capacity of PC shall not be less than 2 GB and
RAM capacity shall not be less than 256 MB.
30.7.
Necessary software for transferring the data automatically from local
evaluation unit to a remote station and receiving the same at the remote station
through owner’s PLCC/VSAT/LEASED LINE shall be provided.
30.8.
Evaluation software shall be provided for the analysis and evaluation of the recorded
data made available in the PC under DOS/WINDOWS
IN JASIDIH GSS VOL-II
Page 190
environment. The Software features shall include repositioning of analog and digital
signals, selection and amplification of time and
amplitude scales of each analog
and digital channel, calculation of MAX/MIN frequency, phase difference
values, recording of MAX/MIN values etc. of analog chan- nel, group of signal to
be drawn on the same axis etc, listing and numbering of all analog and digital
channels and current, voltage, frequency and phase difference values at the time of
fault/tripping.
Also, the software should be capable of carrying out Fourier
/Harmonic analysis of the current and voltage wave forms. The disturbance records
shall also be available in COMTRADE format ( IEEE standard- Common Format
for Transient data Exchange for Power System )
30.9.
The Evaluation unit shall be connected to the printer to obtain the graphic form of
disturbances whenever desired by the operator.
30.10.
Disturbance recorder acquisition units shall be suitable to operate from 220V DC or
110V DC as available at sub-station Evaluation unit along with the printer shall
normally be connected to 230V, single phase AC supply. In case of failure of AC
supply, Evaluation unit and printer shall be switched automatically to the
station DC through Inverter of adequate capacity which shall form a part of
Disturbance recorder system .
30.11.
The acquisition unit shall have the following features
(a)
(b)
(c)
(d)
Facility shall exist to alarm operator in case of any internal faults in the
acquisition units such as power supply fail, processor / memory fail etc and
same shall be wired to annunciation system.
The frequency response shall be 5 Hz on lower side and 250 Hz or better on
upper side.
Scan rate shall be 1000 Hz/channel or better.
Pre-fault time shall not be less than 100 milliseconds and the post fault
time shall not be less than 2 seconds (adjustable). If another system
disturbance occurs during one post-fault run time, the recorder shall
also be able to record the same. However, the total memory of acquisition
unit shall not be less than 5.0 seconds
(e)
The open delta voltage and neutral current shall be derived either through
software or externally by providing necessary auxiliary transformers.
(f)
The acquisition unit shall be typically used to record the following digital
channels :
Main CB R phase open
2
Main CB Y phase open
3
Main CB B phase open
4
Main-1 carrier received
5
Main-1 protection operated
6
Main/Tie /TBC Auto reclosed operated
7
Over Voltage -Stage-1 /2 operated
1
IN JASIDIH GSS VOL-II
Page 191
8
9
10
11
12
13
14
15
16
(g)
Reactor / Stub/TEE-1/2/UF protection operated
Direct Trip received
Main-2 carrier received
Main- 2/ Back Up protection operated
Bus bar protection operated
LBB operated of main /tie/TBC circuit breaker
Tie/TBC CB R phase open
Tie/TBC CB Y phase open
Tie/TBC CB B phase open
In case the disturbance recorder is in-built part of line distance
protection, above digital channels may be interfaced either externally or
internally.
(h)
30.12.
30.13.
Any digital signal can be programmed to act as trigger for the
acquisition unit. Analog channels should have programmable
threshold levels for triggers and selection for over or under levels should
be possible.
The printer shall be compatible with the desktop PC and shall use Plain paper.
The print out shall contain the Feeder identity, Date and time (in hour, minute and
second up to 100th of a second), identity of trigger source and Graphic form of
analog and digital signals of all the channels. Two packets of paper (500 sheets in each
packet) suitable for printer shall be supplied.
Each disturbance recorder shall have its own time generator and the clock of the time
generator shall be such that the drift is limited +0.5 sec/day, if allowed to run
without synchronisation. Further, Disturbance recorder shall have facility to
synchronise its time generator from Time Synchronisation Equipment having
output of following types
•
•
•
•
Voltage signal : (0-5V continuously settable, with 50m Sec.
minimum pulse duration)
Potential free contact (Minimum pulse duration of 50 m Sec.)
IRIG-B
RS232C
The recorder shall give annunciation in case of absence of synchronising pulse
within a specified time.
30.14.
31.
31.1.
Substations where Time Synchronisation Equipment is not available, time
generator of any one of the disturbance recorders can be taken as master and time
generators of other disturbance recorders and Event loggers in that station shall be
synchronised to follow the master.
EVENT LOGGER
The event logger shall be used to record Open and Close states of
switchyard equipment, relays and changes of alarms. The event logger shall include
Video Display unit (VDU), printer and keyboard.
Alternatively,
IN JASIDIH GSS VOL-II
Page 192
desktop PC with VDU, printer and keyboard can be supplied with Event Logger.
31.2.
The equipment is used to record changes in digital events. When such changes
occur, a display in VDU as well as print out on printer should result.
31.3.
The equipment should be constructed in clearly defined plug-in modules. A monitor
module should be provided for indicating internal faults such as Processor failure,
memory failure and other internal hardware failures. These failures should be
displayed on the LED's mounted on the monitor module and facility shall exist to
alarm the operator.
31.4.
The event logger
maintenance. The
protected against
which are prone
transients.
31.5.
The event Logger equipment shall meet the following requirements
31.6.
shall have stable software, reliable hardware, simplicity of
equipment shall be carefully screened, shielded, earthed and
severe hostile electrical environment of EHV switchyard
to various interference signals typically from large switching
(a)
At least 500 digital event
equipment.
inputs shall be accommodated
in single
(b)
The time resolution shall be 1 milli second.
(c)
Cope with up to 40 changes in any one 10 milli seconds interval.
(d)
The date and time should be printed to the nearest 1 milli second followed
by a message describing the point which has operated.
(e)
The operator shall be able to change the date and time from the key board
and allow normal inputs of Accept,
Alarm demand log , Plant state
demand log and date & time.
(f)
Events occurring whilst a previous event is in process of being printed are to
be stored to await printing.
Over 100 such events must be stored.
(g)
Necessary facility to change the text of the event by the operator shall exist.
Event Logger shall its own time generator and the clock of the time
generator shall be such that the drift is limited to ±0.5 seconds/day, if allowed
to run with out synchronisation. Further, Event Logger shall have facility to
synchronise its time generator from Time Synchronisation Equipment having
output of following types
• Voltage signal : (0-5V continuously settable, with 50 milli seconds
minimum pulse duration)
• Potential free contact (Minimum pulse duration of 50 milli seconds)
• IRIG-B
IN JASIDIH GSS VOL-II
Page 193
• RS232C
The Event Logger shall give annunciation in case of absence of
Synchronising pulse within a specified time.
31.7.
31.8.
The printer shall be compatible with event logger and VDU/ desktop personal
computer and shall use plain paper. Two packets of paper (500 sheets in each
packet) suitable for printer shall be supplied.
The printout of the events shall contain at least the station identification,
date& time (in hour, minutes, seconds & milliseconds), event number
and event description (at least 40 characters).
31.9.
Event Logger shall be suitable to operate from 220V DC or 110V DC as available
at sub-station. VDU along with the printer shall normally be connected to
230V, single phase AC supply .In case of failure of AC supply, VDU and printer
shall be switched automatically to the station DC through Inverter of adequate
capacity. The inverter supplied along with Disturbance Recorder can be shared for
the Event Logger also.
31.10.
At existing sub-stations where Event logger is provided, necessary potential free
contacts of various relays/equipment for plant and alarm states shall be provided and
co-ordinated with existing Event logger for proper logging of events. The
drawings containing schedule of events with necessary termination details shall
be submitted during Engineering of the project.
31.11.
Necessary software for transferring the data automatically from the local Event
logger to a remote station and receiving
the same at the remote station
through owner’s PLCC/VSAT/LEASED LINE shall be provided .
32.
DISTANCE TO FAULT LOCATOR
a) be electronic or microprocessor based type. b) be
'On-line' type
c) be suitable for breaker operating time of 2 cycles d) have
built-in display unit
e) the display shall be directly in percent of line length or kilometres without
requiring any further calculations
f) have an accuracy of 3% or better for the typical conditions defined for
operating timings measurement of distance relays .
g) The above accuracy should not be impaired under the following
conditions:
IN JASIDIH GSS VOL-II
Page 194
•
•
•
•
presence of remote end infeed
predominant D.C. component in fault current
high fault arc resistance
severe CVT transients
h) shall have mutual zero sequence compensation unit if fault locator is to be used
on double circuit transmission line.
i) built in feature of line distance relay is acceptable provided the
requirements of above clauses are met
33.
TIME SYNCHRONISATION EQUPMENT
33.1.
The Time synchronisation equipment shall receive the co-ordinated
Universal Time (UTC) transmitted through Geo Positioning Satellite System (GPS)
and synchronise equipments to the Indian Standard Time in a substation.
33.2.
Time synchronisation equipment shall include antenna, all special cables and
processing equipment etc.
33.3.
It shall be compatible for synchronisation of Event Loggers, Disturbance
recorders and SCADA at a substation.
33.4.
Equipment shall operate up
centigrade and 80% humidity.
33.5.
The synchronisation equipment shall have 2 micro second accuracy.
Equipment shall give real time corresponding to IST (taking into
consideration all factors like voltage, & temperature variations, propagation
& processing delays etc).
33.6.
Equipment shall meet the requirement of IEC 60255 for storage &
operation.
33.7.
The system shall be able to track the satellites to ensure no interruption of
synchronisation signal.
33.8.
The output signal from each port shall be programmable at site for either one hour,
half hour, minute or second pulse, as per requirement.
33.9.
The equipment offered shall have six (6) output ports.
Various
combinations of output ports shall be selected by the customer, during
detailed engineering, from the following :
to
the ambient
temperature of 50
degree
• Voltage signal : Normally 0-5V with 50 milli Seconds minimum pulse
duration. In case any other voltage signal required, it shall be decided during
detailed engineering.
IN JASIDIH GSS VOL-II
Page 195
• Potential free contact (Minimum pulse duration of 50 milli Seconds.)
• IRIG-B
• RS232C
33.10.
The equipment shall have a periodic time correction facility of one
periodicity.
33.11.
Time synchronisation equipment shall be suitable to operate from 220V DC
or 110V DC as available at Substation.
33.12.
Equipment shall have real time digital display in hour, minute, second (24 hour
mode) & have a separate time display unit to be mounted on the top of control panels
having display size of approx. 100 mm height.
34.
34.1.
RELAY TEST KIT
One relay test kit shall
under
3 sets
2 nos.
1 no.
35.
35.1.
second
comprise of the following equipment as detailed here
Relay tools kits.
Test plugs
Special type test plugs for using with modular type cases (if
applicable)
TYPE TESTS
The reports for following type tests shall be submitted by the bidder for the
Protective relays, Fault locator, Disturbance recorder and Event Logger a)
Insulation tests as per IEC 60255-5
b) High frequency disturbance test as per IEC 60255-4 (Appendix -E) -Class
IV (not applicable for electromechanical relays)
c) Fast transient test as per IEC 1000-4, Level IV(not applicable for
electromechanical relays)
d) Relay characteristics, performance and accuracy test as per IEC 60255
• Steady state Characteristics and operating time
• Dynamic Characteristics and operating time for distance protection relays
and current differential protection relays
For Distrubance recorder and Event logger only performance tests are
intended under this item.
IN JASIDIH GSS VOL-II
Page 196
e) Tests for thermal and mechanical requirements as per IEC 60255-6 f)
Tests for rated burden as per IEC 60255-6
g) Contact performance test as per IEC 60255-0-20 (not applicable for
Event logger, Distance to fault locator and Disturbance recorder)
35.2.
Steady state & Dynamic characteristics test reports on the distance protection
relays, as type test, shall be based on test programme specified in Appendix A on
simulator/network
analyser/PTL.
Alternatively,
the
files generated using
Electromagnetic transient Programme (EMTP) can also be used for carrying out
the above tests. Single source dynamic tests on transformer differential relay shall
be/ should have been conducted based on general guidelines specified in CIGRE
committee 34 report on Evaluation of characteristics and performance of Power
system protection relays and protective systems.
36.
CONFIGURATION OF C&R PANELS
The following is the general criteria for the selection of the equipments to be provided in each type of panel.
CONTROL PANEL
Various types of control panels shall consist of the following
a
b
Ammeter
Ammeter with Selector switch
3 set
for each Line, BC, and Transformer
1 set for each line reactor
c
Wattmeter with transducer
1 set
for each line, transformer
d
Varmeter with transducer
1 set
for each line, transformer,
e
Varmeter with transducer
f
1 set
for each Line Reactor(
CB Control switch
1 no.
for each Circuit breaker g
Isolator Control switch
1 no.
for each isolator
h
Semaphore
1 no.
for each earth switch
i
Red indicating lamp
1 no.
for each Circuit breaker j
indicating lamp
1 no.
for each isolator
k
Green indicating lamp
1 no.
for each Circuit breaker l
Green indicating lamp
1 no.
for each isolator
m
White indicating lamp
(DC healthy lamp)
2 nos
for each feeder
n
Annunciation windows with
annunciation
relays
18 nos
for each feeder associated
o
Push button for alarm
Accept/reset/lamp test
3 nos
for each control panel
p.
Synchronising Socket
q. Synchronising selector
1 No.
1 No.
Red
for each Circuit Breaker if required (NA for Tehta & Jandaha)
for each Circuit Breaker switch if required
IN JASIDIH GSS VOL-II
Page 197
Protection Transfer
1 No.
r
Mimic to represent SLD
s
Voltmeter with selector Switch
t
Cut out, mounting and wiring
Lot
for each breaker in case of SMT schemes
(Except BC breaker) - isolator
in all control panels
1 no.
for each line, transformer , bus coupler
lot
for transformers
for RWTI and selector switch
u.
HT Electronic Energy meter 1 No.
1 No. for line panels & Bus coupler Panel, 2 No. for Transformer panels i.e.
of 0.2 class
1 No. each HV & LV as per the specification of Board
1
For transformer feeders, all equipments of control panel shall be provided separately for HV and MV sides.
2.
In case of incomplete diameter (D and I type layouts), control panel shall be equipped fully as if the diameter is complete, unless
otherwise specified. Annunciation relays shall also be provided for the same and if required, necessary panel shall be supplied to
accommodate the same.
3.
The above list of equipments mentioned for control panel is generally applicable unless it is defined elsewhere .
4.
Each line /HV side of transformer/MV/LV side of transformer /Bus reactor /TBC /BC/ Bus Section shall be considered as one
feeder for above purpose.
LINE PROTECTION PANEL
The Line Protection panel for transmission lines shall consist of following relays and protection schemes
Sl
No.
1
Description
Main 1 Numerical Distance
Protection scheme
2
Distance to fault Locator
3
3 phase trip relays
(Hand reset)
4
132
KV
1 set
(Part of feature
distance relays)
1no.
Flag relays , carrier receive relays ,aux. Relays
timers etc as per scheme requirements
Lot
5
6
Under voltage relay for isolator /earth
switch
2nos
Cutout & wiring with TTB for energy
meter
1 set
7
Directional back up over current and E/F Protection
Scheme
1 set
8
D.C. Supply supervision Relay
2 Nos.
9
Trip Ckt Supervision Relay
2 Nos.
TRANSFORMER PROTECTION PANEL
The protection panel for Auto transformer/Transformer shall consists of the following equipments
1
2
Transformer Differential
Protection scheme
Restricted Earth fault
Protection scheme
HV side
MV/LV side
1 no.
NIL
1 no.
1 no@
(@ not applicable for Tehta, Imamgang & Jandaha)
IN JASIDIH GSS VOL-II
Page 198
3
Directional back up Over
current and E/F Relay with
non directional high set
feature
1 set
1 set
Over fluxing protection
scheme
1 no.
NIL
Over load protection
Scheme
1 no.
NIL
6
Three phase trip relays
2 no.
2 no.
7
CVT selection relay as per
scheme requirement
Lot
Lot
8
Flag relays ,aux .relays ,
timers etc as
per scheme
requirements including transformer
alarms and
trip functions
Lot
Lot
4
5
9
Cut out & wiring with
TTB for energy meter
1 set
10
D.C. Supply supervision
Relay
11
Trip Circuit Supervision
Relays
1.
1 set
2 Nos.
2 Nos.
2 Nos
1 No.
Breaker failure
COMMON EQUIPMENTS
The following common equipments shall be provided for each new substation. These equipments shall be mounted and wired in the C& R
panel offered.
37.
38.
1
Common Annunciation Scheme
1 set
2
Bus voltage recorder
1 no. for each main bus
3
Bus frequency recorder
1 no. for each main bus
4
Bus voltmeter(Digital)
1 no. for each main bus
5
Bus frequency meter (Digital)
1 no. for each main bus
6
Bus healthy indication lamps
3 nos for each bus
ERECTION AND MAINTENANCE TOOL EQUIPMENTS
All special testing equipment required for the installation and maintenance of the
apparatus, instruments devices shall be furnished in relevant schedule
TROPICALISATION
All equipments shall be suitable for installation in a tropical monsoon area having
hot, humid climate and dry and dusty seasons with ambient conditions specified
in the specification. All control wiring, equipment and accessories shall be
protected against fungus growth, condensation, vermin and other harmful effects
due to tropical environment.
IN JASIDIH GSS VOL-II
Page 199
8.PLCC
PLCC
IN JASIDIH GSS VOL-II
Page 200
1.
1.1
2.
2.1
3.
3.1
4.
4.1
GENERAL
All the PLCC equipment covered under the package shall conform to the
requirements of the latest edition of the relevant IEC/IS Specifications or
equivalent National Standards,
Standard And Drawing
The IEC/IS Specifications and international publication relevant to the
equipment covered under this specification shall include but not be limited to the list
given at Section - GTR:
Location of Equipment
The PLCC Equipment and Line traps as specified shall be installed at the respec- tive
ends of the transmission lines. The Contractor shall be responsible for coordinating
the equipment supplied by him with the already existing carrier equipment at the
respective sub-stations. Contractor shall also be responsible for collecting all the
necessary information/data from
the
respective
substations for the installation of the equipment.
Frequency Planning
For planning frequency and output power of carrier terminals Bidders may plan for a
minimum receive signal to noise ratio of 25 dB for the speech channels without
companders. The noise power in 2.1 kHz band (300-2400 Hz) may be taken as -13
dBm referred to the coupling point of the H.T. line. An additional minus two and a
half dB may be assumed for psophometric factor. As far as coupling loss (phase to
phase) is concerned the Bidders may assume the same as
6dB at one coupling end for evaluating SNR. For protection channels the
minimum SNR shall not be less than 15 dB under adverse weather. A safety margin
of 9 dB shall be taken over and above these SNR values in order to cater for variations
in line attenuation from the computed value as inhand reserve. Frequency and output
power of PLC terminals for protection shall be planned such that the protection signal
is received with full reliability even when one of the phase is earthed or is on open
circuit on the line side causing an additional minimum loss of 6 dB.The Bidder shall
indicate the noise power in the bandwidth used for protection signaling and shall
submit the SNR calculations for speech as well as protection channels on all the line
section given in at the proposed frequencies. Sample calculations for SNR requirement
and power allocation over different channels must be furnished alongwith the bid.
Maximum permissible line attenuation shall be clearly brought out in these calculations.
Further, Bidder shall submit details of frequency planning done (including computer
studies carried out and facilities available) for PLCC links on EHV lines in the past in
the relevant schedule of DRS. Bidder must enclose one copy of computer study result
done in the past along with the Bid.
4.2
Successful Bidder shall be fully responsible for the coordination required finalising
the frequency plan.
4.3
The frequency plan will be referred to wireless Adviser/DOP Department for
clearance and in case any change in the Contractor’s recommended carrier
frequency and power output is proposed by these authorities, the Contractor shall have
to modify his proposal accordingly. Change of power output shall, however, not involve
repeater stations.
Proposed Arrangement
The power line carrier communication equipment required by the OWNER is to
5.
5.1
IN JASIDIH GSS VOL-II
Page 201
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
provide primarily efficient, secure and reliable information link for carrier aided
distance protection and direct tripping of remote-end breaker and also for speech
communication between 765/400/220 kV sub-stations. It shall include separate carrier
terminals of multipurpose type for speech and protection purposes.
All carrier
terminals including those for protection shall be suitable for point to point speech
communication also.
132kV transmission lines shall have Main I protection same as above alongwith backup
over current and earth fault protections.
The requirement of carrier information on each link covered under this
specification is as below :
a)
One protection channel for Main-I and another for Main-II distance
protection schemes. Further these channels will also be used as main and backup channel for direct circuit breaker inter-tripping for 765kV/ 400kV lines.
In case of 400KV/220 KV/132 KV lines ,speech and data channel can also be used for
protection wherever possible.
b)
One speech channel with a facility to superimpose data signals upto
1200Baud.
However, the number of channels for protection signaling , speech and data
communication for SAS and Load dispatch centre shall be as per the BOQ given
in .
The equipment for protection signals shall have high degree of reliability and speed.
It shall be guaranteed to function reliably in the presence of noise impulse caused by
isolator or breaker operation. The equipment shall be suitable for direct tripping of
remote end breaker for fault in unswitched Shunt Reactor & Operation of Buchholz
relays of reactor etc. It shall also be possible to effect direct tripping of breaker at one
end when the other end breaker opens out either manually or by relays such as Bus fault
relay etc.
The time intervals between receipt of a trip command on the transmit side, its
transmission over the carrier link, reception at the far end and giving command to the
trip relays at the distant end shall not exceed 20 mS. for permissive inter- tripping
and 30 m sec. for direct inter-tripping even for the longest line section. The above
timings are inclusive of operating time for auxiliary relays and interposing relays,
if any, included in the PLCC equipment.
The requirement of protection signaling channel is such that security against
incorrect signals being received shall be at least two to three orders higher than
reliability against a signal not being received.
For reasons of security and reliability, phase to phase coupling shall be employed.
Double differential coupling shall also be considered for double circuit lines.
Bidders must furnish detailed write-up on methods of coupling and recommend
suitable coupling mode for double-circuit lines along- with the bids.
The Contractor shall have to check and prove through the results of his computer
studies that attenuation due to transpositions in the EHV lines is within limits and
the offered equipment will perform satisfactorily.
The Bidder shall submit curves illustrating ‘incorrect tripping’ and “Failure to trip”
probability plotted against corona noise level, in the presence of impulse noise due to
switching of isolator and circuit breaker etc. Details of field tests and laboratory tests for
successful operation of his equipment, under such adverse conditions shall be
furnished by the Bidder. These are to be related to end-to-end signaling and shall take
IN JASIDIH GSS VOL-II
Page 202
6.
6.1
into account the type of communication link e.g. account shall be taken of transpositions
in the phase to phase coupled H.T. line. Details of field tests and laboratory tests for
successful operation of the equipment under the above circumstances shall be
submitted by the Bidder illustrating the above parameters.
LINE TRAP
Line trap shall be broad band tuned for its entire carrier frequency range.
Resistive component of impedance of the line trap within its carrier frequency
blocking range shall not be less than 570 ohms for 220kV and 132 kV systems..
6.2
Line trap shall be provided with a protective device in the form of surge arrestors which
shall be designed and arranged such that neither significant alteration in its protective
function nor physical damage shall result from either temperature rise or the magnetic
field of the main coil at continuous rated current or rated short time current. The
protective device shall neither enter into operation nor remain in operation, following
transient actuation by the power frequency voltage developed across the line trap
by the rated short time current.
The lightning arrestor shall be station class current limiting active gap type. Its rated
discharge current shall be 10 kA. Coordination, however, shall be done by taking 20
kA at 8/20 micro-sec. discharge current into account. Bidder has to furnish full
justification in case the use of gap-less metal oxide arrestor is recommended by
them.
6.3
The lightning arrestor provided with the line trap of each rating shall fully comply with
the requirements of IS:3070 Part-I/IEC-60099-I Part-I. It shall conform to type tests as
applicable and type test certificate for the same shall be submitted by the Bidder.
6.4
The lightning arrestor provided with the line trap shall be subject to routine and
acceptance tests as per IEC-60099-1 (Part-I).
6.5
Radio interference voltage for 245/132 kV shall not exceed 500 micro volts at 163/97
kV (rms) respectively.
6.6
Line trap shall be equipped with the bird barriers.
6.7
Line trap shall conform to IEC 60353 (latest) fulfilling all the technical
requirements. The rated short time current for 1 Second shall be 31.5 kA as per
requirement.
6.8
The Bidder shall indicate continuous current rating of the line trap at 65 deg. C
ambient.
6.9
Reports for the following type tests on each type of line trap shall be submitted as per
GTR .
1.
2.
3.
4.
Measurement of Inductance of the main coil.
Measurement of temperature rise.
Insulation test.
Short time current test.
IN JASIDIH GSS VOL-II
Page 203
5.
6.
Corona Extinction Voltage test (procedure for this shall be mutually agreed
).
Radio Interference Voltage measurement test (procedure for this shall be
mutually agreed ).
6.10
The Bidder must enclose with his bid the reports of type and routine tests
conducted on similar equipment earlier as per IEC-60353.
6.11
Welding
All the welding included in the manufacture of line traps shall be performed by
personnel and procedure qualified in accordance with ASME-IX and all the critical
welds shall be subject to NDT as applicable.
6.12
Line Trap Mounting
6.12.1
The Line Trap shall be suitable for outdoor pedestal or suspension mounting and shall
be mechanically strong enough to withstand the stresses due to maximum wind
pressure of 260 kg/square meter.
6.12.2
For pedestal mounting, each line trap shall be mounted on a tripod structure formed
by three insulator stacks arranged in a triangular form. All the accessories and hardware,
mounting stool including bolts for fixing the line trap on insulators shall be of nonmagnetic material and shall be supplied by the Contractor.
6.12.3
For suspension mounting, Contractor shall be required to coordinate the mounting
arrangement with the existing arrangement. Non-magnetic suspension hook/link of
adequate length and tensile strength to provide necessary magnetic clearance between
the line trap and suspension hardware shall be supplied by the Contractor.
6.13
Terminal Connectors
6.13.1
The line traps shall be suitable for connecting to or ACSR single/twin M o o s e
conductor with horizontal or vertical take off. Necessary connector shall be supplied by
the Contractor.
6.13.2
Terminal Connectors shall conform to IS:5561.
6.13.3
No part of clamp or connector (including hardware) shall be of magnetic material.
6.13.4
Radio interference Voltage for 132 kV shall not exceed 500 microvolts at 97 kV
(rms) respectively.
Clamps/connectors shall be designed for the same current ratings as line trap and
temperature rise shall not exceed 35 deg. C over 50 deg. C ambient. No current
carrying part shall be less than 10 mm thick.
Clamps/connectors shall conform to type test as per IS:5561.
Bidders are required to submit alongwith their bid typical drawings clearly
indicating the above mentioned features of the line traps, line trap mounting
6.13.5
6.13.6
6.13.7
IN JASIDIH GSS VOL-II
Page 204
arrangement and terminal connectors. For suspension mounted line traps, Bidder shall
submit drawings showing single point as well as multipoint (normally 3 point)
suspension arrangements.
COUPLING DEVICE
The coupling devices shall be interposed between the capacitor voltage
transformer and coaxial line to the PLC transmitter/receiver, and in conjunction with
the capacitor voltage transformer shall ensure :
a)
Efficient transmission of carrier frequency signals between the carrier
frequency connection and the power line.
7.
7.1
b)
7.2
7.3
7.4
Safety of personnel and protection of the low voltage parts and
installation, against the effects of power frequency voltage and transient over
voltages.
The coupling device, in conjunction with the CVT shall from an electric filter of band
pass type :
a)
It shall match characteristic impedance of H.T. line to impedance of the carrier
frequency connection.
b)
Galvanic isolation between primary and secondary terminals of the
coupling device shall be performed by the above mentioned transformer.
c)
Power frequency currents derived by the CVT may be drained to the earth by a
separate inductance termed drain coil of suitable rating.
d)
Voltage surges coming from the power line at the terminals of the
coupling device shall be limited by a non-linear surge arrestor of suitable rating
in the primary side. Requirement of a gas type voltage arrestor in secondary
side of the coupling device shall have to be fully justified, but
in any case the input circuit of PLC. equipment shall have protective devices
in the form of zener diodes and surge suppressers.
The surge arrester shall have power frequency spark over voltage
coordinated with the equipment ahead of it.
e)
For direct and efficient earthing of its primary terminals, the coupling device
shall be equipped with an earthing switch. The Earth Switch shall be available
for earthing of CVT-HT terminals, when the coupling filter units are removed
from circuit for maintenance/ replacement. The design shall take due regard of
requirements for safety in accordance with the Indian Electricity Rules.
Two numbers ‘phase to earth’ type coupling filters shall be used to achieve
‘phase to phase’/ ‘inter-circuit coupling’. Connection between secondaries of the two
phase to earth type coupling device shall be through a balancing
transformer/hybrid such that reliable communication shall be ensured even when one of
the coupled phase is earthed or open circuited on the line side.
Coupling device shall conform to IEC-60481 and shall have the following carrier
frequency characteristics as applicable to a phase to earth type coupling device:
a)
Nominal line side
i) 240 ohms for 765kV and 400 kV Quad/triple
impedance
bundle conductor line.
ii) 320 ohms for 400kV twin bundle conductor line. iii)
400 ohms for 220/132 kV line
b)
Nominal equipment 75 ohms (unbalanced)
side impedance
c)
Composite loss
Not more than 2 dB
IN JASIDIH GSS VOL-II
Page 205
d)
e)
Return Loss
Bandwidth
f)
7.5
7.6
7.7
7.8
Not less than 12 dB
Shall suit the frequency plan between 36 and
500 kHz
Not less than 650 Watt.
Nominal peak
envelope power
(for Inter-modulation product 80 dB down)
The coupling device shall be suitable for outdoor mounting. Temperature of
metallic equipment mounted outdoor is expected to rise upto 65 deg. C during the
maximum ambient temperature of 50 deg. C specified. The equipment offered by the
Bidder shall operate satisfactorily under these conditions.
The H.T. Terminal of coupling device shall be connected to H.F. Terminal of the CVT
by means of 6 mm sq. copper wire with suitable lugs & taped with 11 kV insulation
by the contractor.
Coupling device shall have at least two terminals for carrier equipment
connection. Bidder shall confirm that such a parallel connection to coupling device
directly will not result in any additional attenuation.
The coupling device including the drainage coil, surge arrester and earthing switch
shall conform to type tests and shall be subject to routine tests as per IEC60481/IS:8998.
Routine tests shall include but not be limited to the following :
7.9
i)
Composite loss and return loss tests on coupling device.
ii)
Turns ratio test and insulation tests on the balancing transformer.
iii)
Milli volt drop test, power frequency voltage test and mechanical
operation test on earthing switch.
iv)
Power frequency spark over test for lightning arrester as per relevant
IS/IEC.
Reports for the following type tests on coupling device shall be submitted as per GTR .
1.)Return loss test.
2.)Composite loss test.
3. )Distortion and inter modulation test .
4.)Impulse voltage test.
5)Tests on Arrestors
Bidder shall furnish, alongwith his bid copies of all type and routine test
conducted earlier on similar coupling device in accordance with relevant
standards.
IN JASIDIH GSS VOL-II
Page 206
8.
High Frequency Cable
8.1
High frequency cable shall connect the coupling device installed in the switchyard to the
PLC terminal installed indoor.
8.2
The cable shall be steel armoured and its outer covering shall be protected against attack
by termites. Bidder shall offer his comments on method employed by him for earthing
of screen and submit full justification for the same with due regard to safety
requirements.
Bidder must enclose in his bid a detailed construction drawing of the cable being
offered, with mechanical and electrical parameters.
8.3
Impedance of the cable shall be such as to match the impedance of the PLC terminal
on one side and to that of the coupling device on the other side over the entire carrier
frequency range of 40-500 kHz.
8.4
Conductor resistance of cable shall not exceed 16 ohms per Km at 20°C.
8.5
The cable shall be designed to withstand test voltage of 4 kV between conductor and
outer sheath for one minute.
8.6
Bidder shall specify attenuation per Km of the cable at various carrier frequencies in the
range of 40 to 500 kHz. The typical attenuation figures for H.F. cable shall be in the
range of 1 to 5 dB/km in the frequency range of 40-500 kHz.
8.7
The H.F. cable shall conform to type tests and be subjected to routine tests as per
IS 11967(Part 2/Sec 1): 1989/IS 5026:1987.
8.8
All HF cables within the scope of this specification shall be laid and termination shall
be carried out by the Contractor.
8.9
The cables shall be supplied wound on drums containing nominal length of 500 meters
each.
However, exact requirement of drum lengths shall be finalised during
detailed engineering to avoid joint in HF cable and its wastage.
9.
Power Line Carrier Terminal
9.1
As already indicated the information link shall be provided for speech, protection, telex
and data services.
9.2
PLC terminal shall use Amplitude Modulation and shall have single side band
transmission mode. These shall be equipped for fixed frequency duplex working.
Characteristic input and output parameters of the SSB PLC terminals shall be as per
IEC-60495, unless otherwise specified.
IN JASIDIH GSS VOL-II
Page 207
9.3
9.4
The salient features are detailed out below :
a)
Mode of transmission
Amplitude Modulation single side band with
suppressed carrier or reduced carrier.
b)
Carrier frequency
40 to 500 kHz range c)
Nominal carrier frequency
band in either direction of
transmission
4.0 kHz
d)
Power output (PEP)
terminal
20/40/80 Watt at HF
e)
Frequency difference
between a pair of
PLC terminals
Frequency difference between VF
signal at the transmitting and receiving ends will not exceed 2 Hz with
suppressed
carrier.
With
reduced
carrier
frequency difference shall be zero. This shall
include
permissible
ambient
temperature variation and supply frequency and
voltage variation of (+) 15% and (-)
10%.
f)
Automatic gain
control
For 40 dB change in carrier frequency signal level within the regulation range,
change in VF receive levels of both speech and
other signals shall be less than
1dB.
g)
Supply voltage
48 V DC + 15%, - 10%. (Positive pole
earthed)
All the PLC terminals shall be of multipurpose type. The Bidder shall confirm that the
total transmission time for teleprotection shall not exceed 20 ms for permissive and
30 ms for direct tripping signals. Speech and teleprotection channels shall
independently fulfill the SNR requirements out of the power allocated to its channel
from the total power of the PLC terminals.
Detailed calculation for SNR requirement and power
channels should be furnished alongwith the bid.
9.5
9.6
allocation over different
In the input circuit of the PLC terminal protective devices shall be provided in the form
of zener diodes or surge suppressers in order to eliminate any surge transfer through the
coupling device or the surge induced in the connecting path of H.F. cable.
To improve voice transmission characteristics for the system, compressors and
expanders shall be provided. The companders shall have at least 2:1 compression ratio
with a corresponding expansion ratio of 1:2. The operating range of compander
shall be compatible with the audio power levels specified for 4 wire operation. The
IN JASIDIH GSS VOL-II
Page 208
improvement gained by companders shall however not be taken into account for power
allocation and shall be in-hand reserve.
9.7
Sudden changes in input level to the receiver shall not cause false tripping. The Bidder
shall clearly indicate in his offer the methods adopted to ensure above phenomenon.
The receiver design shall also provide protection against false tripping from random
noise.
9.8
Fail-safe devices shall be provided, so that a malfunction in one unit or
subassembly cannot cause damage elsewhere in the system. All plug-in
equipment shall be fitted with features to prevent improper insertion. The
electrical cables shall not be routed across sharp edges or near sources of high
temperature. The adjustments, which are susceptible to misadjustment from
accidental contact/vibration, shall be equipped with suitable locking devices.
9.9
The PLC set shall be designed to give guaranteed performance from 0 deg. C to
50 deg. C ambient temperature. The thermal capability of the equipment shall be so
designed that the equipment remains operational successfully upto 60 deg. C ambient
temperature. Any ventilation fans provided for circulation of air inside the cabinets
shall conform to relevant Indian Standards.
9.10
The terminals shall be provided with built-in indicating instrument to facilitate
checking of important voltages and current values and signal levels in different parts
of the PLC Terminals. Protection fuses shall be provided in all important circuits and
fuses shall be so mounted as allow their easy inspection and replacement. All test
points shall be easily accessible.
The carrier set shall be provided with suitable supervision and alarm facilities.
Individual parts of the carrier set should be accessible from front, making it
possible to place the carrier cabinets side-by-side. All components and parts of the carrier
set shall be suitably tropicalised.
9.11
PLC terminals shall be housed in floor mounting sheet metal cabinets, suitable for
mounting on concrete plinth as well as channel frame by means of nuts and bolts or
welding. All the panels shall be properly earthed to the OWNER’s earthing grid by
the Contractor. Contractor shall submit detailed drawings for earthing connections.
9.12
All the panels shall be protected against moisture ingress and corrosion during storage.
Panels shall be properly dried before they are installed and energized.
Bidder shall indicate measures adopted to prevent ingress of moisture during
operation.
9.13
All cabinets having PLC terminals shall be provided with lamps of sufficient wattage
for interior illumination with switch. Each panel shall be provided with
240 V AC single phase socket with switch to accept 5 & 15A standard Indian plugs.
9.14
A name plate shall be provided on the front door of each cabinet indicating channel
function, transmitter frequency and direction etc.
IN JASIDIH GSS VOL-II
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9.15
Reports for the following type tests for PLC Terminals shall be submitted as per GTR .
Tests to determine various characteristics of PLC terminals as per IEC –60495.
a)Voltage variation
b)Carrier frequency range band.
c)Frequency accuracy
d)Transmit/Receive frequency difference.
e)Automatic gain control
f)Harmonic distortion g)
Selectivity
h)Output impedence, Return loss&Tapping loss
i)Return loss, Afinputs/Outputs
j)Balance to ground
k)Limiter action l)Spurious
emission
m)Carrier frequency levels and levels
n)Attenuation distortion
o)Noise generated within terminal
p)Near and far end cross talk
q)Group delay distortion
r)Conducted noise
s)Telephone signaling channel
t)Speech levels
u)Voltage withstand test
v)Insulation test
9.16
10.
10.1
Heat Soaking of panels
All the solid state equipment/system panels shall be subjected to the Heat Soaking as per
the following procedure :
All solid state equipment shall be burn-in
for minimum of 120 hours
continuously under operation condition. During the last 48 hours of testing, the
ambient temperature of the test chamber shall be 50°C. Each PLC panel shall be
complete with all associated sub-systems and the same shall be in operation during
the above test. During the last 48 hours of the above test, the temperature inside the
panel shall be monitored with all the doors closed. The temperature of the panel interior
shall not exceed 65°C.
SPEECH COMMUNICATION
PLC equipment offered shall provide telephone communication between the
stations where the transmission lines are terminating. The equipment shall be suitable
for providing the following facilities :
a)
It shall be possible for subscriber at any of the stations to contact the
subscriber at all other stations connected in the system as shown in the
specification drawing by dialing his call number. To achieve this a 24 lines
EPAX with 4 wire interface & remote subscriber units shall be
IN JASIDIH GSS VOL-II
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provided/available at different stations.
b)
The equipment shall contain all normal facilities like ring back tone, dial tone,
engage tone & priority tone, and suitable pulses to establish and disconnect
communication between subscribers.
c)
The equipment shall be provided with necessary alarm circuits and fuses etc.
d)
The equipment shall be of 4 kHz bandwidth on either direction and be
for providing superimposed data and teleprinter facilities at a later date
major modifications and high cost. The Bidder shall clearly indicate
bid the provision made in his proposal for future development
extent to which such additional facilities can be added at a later date.
e)
The system shall be completely automatic with definite number allocated for
each telephone. The numbering scheme for telephones, exchange and tie lines
shall be developed by the Bidder and indicated in the bid. Final numbering
scheme shall be fully coordinated with the existing/ proposed future systems by
the Contractor.
Arrangement for over-riding facilities shall be provided by means of
priority keys wherever specified. The over-riding facility shall enable
cutting-in ongoing calls with the priority key and ask the concerned parties to
finish their conversation. The
wanted number should then get
automatically connected without having to redial the number.
All the carrier telephone conversations shall be secret and it should not be
possible for anybody to over hear the conversation going on between any two
parties excepting those provided with over-riding facilities.
The necessary cables for connecting all the telephone instruments ordered for at
each sub-station (including wiring and termination) shall be provided by
the Contractor. These telephone instruments shall be located within control room
building at respective sub-station.
f)
g)
h)
suitable
without
in his
and the
i)
The cabinets housing the equipment for EPAX, four wire E/M interface & remote
subscriber units (four wire) shall have mounting arrangement similar to that
for PLC terminals.
j)
All the terminals for speech shall be with Transit Band Pass Filter suitable for
tuning at site and shall be wired for addition of VFTs in future.
k)
Equipment for speech communication must be fully compatible with
OWNER’s existing equipment. Any interfaces required for proper
matching and connection with the OWNER’s existing equipment shall be
provided by the Contractor.
l)
Terminals for protection shall be suitable for speech between two ends of each
transmission line or on tandem operation basis with back to back connection at
the intermediate stations.
IN JASIDIH GSS VOL-II
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n)
Each PLC terminal for speech as well as protection purposes shall be
provided with a plug-in type service telephone and buzzer. Further, 4 wire
remote telephone instruments (parallel to service telephone) shall also be
provided on one PLC terminal for protection for each link. These
instruments shall be located in respective Switchyard control room to enable
the operator to make emergency calls on point-to-point basis. Each such
instrument shall be equipped with a buzzer and ‘press-to-call’ key and shall not
require any additional power supply units.
10.4
Network Protection Equipment (Protection Coupler)
10.4.1
The Bidder shall offer voice frequency transmission equipment which shall work on
frequency shift or coded signal principle for transmission/reception of protection
signals as single purpose channel. The equipment shall be suitable for connection to the
power line carrier terminal.
10.4.2
The voice frequency transmission equipment shall not only be insensitive to corona
noise but shall also remain unaffected by impulse type noise which are generated by
electrical discharge and by the opening and closing of circuit breakers, isolators,
earthing switches etc. The equipment shall also be made immune to a field strength
of 10V/m expected to be caused by portable radio transmitters in the range of 20-1000
MHz. In his offer, bidder shall clearly explain as to what measures have been taken to
make the equipment insensitive to corona noise, white noise and to impulse noise of an
amplitude larger than the wanted signal and submit full field test and laboratory test
reports. The guarantee on design data shall not be acceptable.
10.4.3
The equipment shall be unaffected by spurious tripping signals. The Bidder shall submit
proof as to how this is achieved satisfactorily.
10.4.4
The equipment shall be suitable for transmission of direct and permissive trip signal
as well as blocking signals for protective gear of power system. The equipment
shall be operated in the audio frequency
range in speech band or above
speech band as superimposed channel in 4 kHz band of SSB carrier. The equipment
shall operate with full duplex frequency shift mode of operation or by switching
between two frequencies in case of coded signals . The protection signaling
equipment shall be of solid state design, modular in construction and have a proven
operating record in similar application over EHV systems. Details regarding application
of the equipment over 765kV/400kV/220kV systems shall be submitted along with
the bid. Each protection signaling equipment shall provide:
i)
Transmission facilities for minimum three protection signals. ii)
Reception facilities for minimum three protection signals.
10.4.5
The equipment shall be designed for remote tripping/ blocking on permissive basis
and direct tripping for reactor fault and others. The overall time of PLC,VFT and
transmission path for permissive trip/blocking shall be 20 m. Sec. or less and for direct
tripping 30 m. Sec. or less even for the longest line section.
IN JASIDIH GSS VOL-II
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Operating time lower than specified above may be preferred provided they fulfill the
requirements of security and reliability as mentioned below :
-5
False - trip probability
10 (Noise
burst of any amplitude)
10-2 for
Fail to trip probability
S/N 6 dB in 3.1 kHz Band
(white Noise Measurement)
10.4.6
It may be emphasized that specified time, as mentioned above is composed of the
following :
a)
Back-to-back signal delay in frequency shift or coded signals protection
equipment.
b)
Back-to-back delay in PLC terminal. c)
Delay in transmission line.
d)
Operation time of interposing relay, if any, in frequency shift or coding
equipment.
Reference is invited in this regard to the guide lines expressed in CIGRE
Publication “Teleprotection” report by Committee 34 and 35.
10.4.7
The following transfer criteria shall be provided by the equipment:
a)
Transmit side
One number potential free NO (normally open) contact of protective relays
(To be supplied by the OWNER) of under noted rating for each of the following
functions:
i)
Permissive trip command ii)
Direct trip command
Contact Rating:
b)
Maximum voltage
Maximum current rating
power rating
Receive Side
: 660 Volts
: 5 amps Maximum
: 1250 W/VA
Voice frequency transmission equipment for network protection shall be
provided with one potential free NO (normally open) contact of the under noted
rating for each of the following functions:
IN JASIDIH GSS VOL-II
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i)
Permissive trip command ii)
Direct trip command
Contact Rating:
Rated voltage
current
Other Parameters
:
:
:
250 Volts DC Rated
0.1 A DC
As per IEC-60255-25 c)
Alarm
In addition, the voice frequency protection terminal shall provide at least one
number potential free change over contact of the following rating for alarm
purposes.
Rated voltage
current
Other Parameters
:
:
:
250 volts DC Rated
0.1 A DC
As per IEC-60255-25
10.4.8
The Contractor shall submit drawings showing inter-connection between PLCC
and protection panels for approval by the OWNER.
10.4.9
It has to be ensured that under no circumstances protection channel should share the
power. Each protection channel shall be able to transmit power for which system is
designed. For example, a 40 W PLC terminal shall transmit 40 Watt (max.) for
protection channel alone in the event of fault. Speech and super- imposed data
channels, in the same protection terminal must get disconnected momentarily during
the operation of protection channels.
10.4.10
The equipment shall be constructed such that in permissive line protection system,
operational reliability of the protection channel may be checked over the carrier link
by means of a loop test. It shall be possible to carry out the above test from either end
of the carrier link. During healthy condition of the transmission line, the loop test shall
not initiate a tripping command. In the event of a system fault, while loop test is in
progress, protection signal shall over-ride the test signal.
10.4.11
The equipment shall be complete with built in counters for counting the number of trip
commands sent and number of trip commands received.
10.4.12
Reports for the following tests as per GTR shall be submitted for approval for
protection coupler and the relays associated with PLCC equipment for network
protection signaling equipment and interface unit with protective relay units if any :
1)Protection coupler ( As per IEC 60834 -1)
a)Power supply variation b)Power
IN JASIDIH GSS VOL-II
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supply interruption c)Reflected
noise
d)Reverse polarity
e)Interference by discrete frequency
f)Transmission time
g) Interference by frequency deviation. ( Wherever applicable)
h)Alarm function g)Security
h)Dependability i)Voltage
withstand test j)Insulation test.
j) Electrical fast transient test (along with carrier terminal)
k)HF disturbance test (along with carrier terminal)
l )Electro static discharge test (along with carrier terminal)
m)Radiated electromagnetic field susceptibility test (along with carrier terminal)
n)Environment test (as per IS 9000 )
:
2.
12.
Relays.
a)
Impulse voltage withstand test as per Clause 5.1 of IS:8686 (for a test
voltage appropriate to Class III as per Clause 3.2 of IS:8686).
b)
High Frequency Disturbance test as per Clause 5.2 of IS:8686 (for a test
voltage appropriate to Class III as per Clause 3.2 of IS:8686).
LIST OF COMMISSIONING TESTS
The following tests shall be carried out on complete system/subsystem during
commissioning:
1.
Composite loss and return loss on coupling device using dummy load.
2.
Composite loss (Attenuation) for HF Cable coupling device.
3.
End to end attenuation measurement for verification of optimum coupling mode.
IN JASIDIH GSS VOL-II
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Test shall be done for all combinations.
4.
End to end return loss for optimum coupling mode. a.
open behind line trap.
b.
grounded behind line trap.
5.
If end to end return loss for optimum coupling mode is not satisfactory, same
shall be measured for other coupling modes also.
6.
Adjustment of Tx/Rx levels on PLCC equipment as per test schedule.
7.
AF frequency response (end to end) for the entire 4 kHz Bandwidth for speech
and teleoperation channels.
8.
Measurement of noise in 2 kHZ bandwidth with and
energised.
9.
SNR (test-one) with line energised noting down weather conditions.
10.
Transmission time for teleprotection and other data channels.
11.
Observation of Tx/Rx levels (test-tone) for each channel at both ends by
sequential switching on/off parallel channels using dummy load and also with
the transmission line.
12.
Observation of end to end and trunk dialing performance.
13.
Observation of end-to-end protection signaling (command sent &
received) in conjunction with protective relays, noting down
transmission/receipt of unwanted commands under switching operations in the
switchyard during protective relay testing.
without line
Notes
1.
All measurements for link attenuation, composite loss and return loss shall be
carried out for the entire range of carrier frequencies with specific attention to
the frequencies.
i.
within coupling device bandwidth. ii.
within line trap bandwidth, and
iii.
2
operating frequencies.
Following tests shall be carried out independently at each and i.
IN JASIDIH GSS VOL-II
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Composite loss & return loss for coupling device.
ii.
Attenuation test for HF cable + coupling device.
iii.
Levels and other local adjustments (on dummy load).
Final adjustment shall be on end to end basis.
iv.
Test for loading by parallel channels with dummy load.
This test can be done alongwith tests for coupling device. v.
Protection signaling under local loop test (dummy load).
3.
Necessary test instruments required for all the above tests shall be brought by
commissioning engineers of the contractor.
IN JASIDIH GSS VOL-II
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10. TECHNICAL SPECIFICATION FOR CIRCUIT BREAKERS
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SPECIFICATION FOR CIRCUIT BREAKERS
1.0
GENERAL
1.0
The circuit breakers and accessories shall conform to IEC: 62271-100,
IEC: 60694 and other relevant IEC standards except to the extent explicitly
modified in the specification and shall also be in accordance with
requirements specified in specification.
1.1
145 kV circuit breakers offered would be of Sulphur Hexafluoride
(SF6) type only and of class C1-M1 as per IEC. The bidder may also offer
circuit breakers of either live tank type or dead tank type of proven design.
1.2
The circuit breaker shall be complete with terminal connectors,
operating mechanism, control cabinets, piping, inter pole cable, cable
accessories like glands, terminal blocks, marking ferrules, lugs, pressure
gauges, density monitors (with graduated scale), galvanised support structure
for CB and control cabinets, their foundation bolts and all other circuit
breaker accessories required for carrying out all the functions the CB is
required to perform.
All necessary parts to provide a complete and operable circuit breaker
installation such as main equipment, terminals, control parts, connectors and
other devices whether specifically called for herein or not shall be provided.
1.4
The support structure of circuit breaker as well as that of control cabinet shall
be hot dip galvanised. All other parts shall be painted as per shade 697 of IS -5.
1.5
The circuit breakers shall be designed for use in the geographic and
meteorological conditions as given in specification.
2.0
2.3
2.4
DUTY REQUIREMENTS:
2.1
The circuit breakers shall be capable of performing their duties without
opening resistors.
2.2
The circuit breaker shall meet the duty requirements for any type of fault
or fault location also for line switching when used on a 145 KV effectively
grounded system, and perform make and break operations as per the stipulated
duty cycles satisfactorily.
The breaker shall be capable of interrupting the steady state and transient
magnetising current corresponding of power transformers.
The circuit breaker shall also be capable of:
i) Interrupting line/cable charging current as per IEC without use of opening
resistors.
ii) Clearing short line fault (Kilometric faults) with source impedance behind
the bus equivalent to symmetrical fault current specified.
IN JASIDIH GSS VOL-II
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iii) Breaking 25% of the rated fault current at twice rated voltage under phase
opposition condition.
2.5
The Breaker shall satisfactorily withstand the high stresses imposed on them
during fault clearing, load rejection and re-energisation of lines with trapped
charges. The breaker shall also withstand the voltages specified under clause
– 17. of this specification
3.0
TOTAL BREAK TIME:
3.1
The total break time as specified under this Chapter shall not be exceeded
under any of the following duties:
i)
Test duties 1,2,3,4,5
ii)
Short line fault L75, L90
(TRV as per IEC: 62271-100)
( - do - )
3.2
The Bidder may please note that total break time of the breaker shall not
be exceeded under any duty conditions specified such as with the combined
variation of the trip coil voltage and arc extinguishing medium pressure etc. While
furnishing the proof of the total break time of complete circuit breaker, the
Bidders may specifically bring out the effect of non-simultaneity between
contacts within a pole or between poles and show how it is covered in the
guaranteed total break time.
3.3
The values guaranteed shall be supported with the type test reports.
4.0
CONSTRUCTIONAL FEATURES:
The features and constructional details of circuit breakers shall be in
accordance with requirements stated hereunder:
4.1
Contacts
4.1.1
The gap between the open contacts shall be such that it can withstand atleast
the rated phase to ground voltage for 8 hours at zero gauge pressure of SF6
gas due to the leakage. The breaker should be able to withstand all dielectric
stresses imposed on it in open condition at lock out pressure continuously (i.e.
2 p.u. across the breaker continuously).
4.2
If multibreak interrupters are used, these shall be so designed and
augmented that a uniform voltage distribution is developed across them.
Calculations/ test reports in support of the same shall be furnished. The thermal
and voltage withstand of the grading elements shall be adequate for the service
conditions and duty specified.
4.3
The SF6 Circuit Breaker shall meet the following additional
requirements:
a) The circuit breaker shall be single pressure type. The design and
construction of the circuit breaker shall be such that there is a minimum
possibility of gas leakage and entry of moisture. There should not be any
condensation of SF6 gas on the internal insulating surfaces of the circuit
IN JASIDIH GSS VOL-II
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breaker.All gasketted surfaces shall be smooth, straight and reinforced, if
necessary, to minimise distortion and to make a tight seal, the operating
rod connecting the operating mechanism to the arc chamber (SF6 media)
shall have adequate seals. The SF6 gas leakage should not exceed 1% per
year. In case the leakage under the specified conditions is found to be
greater than 1% after one year of commissioning of circuit breaker, the
manufacturer will have to supply free of cost, the total gas requirement for
subsequent ten (10) years, based on actual leakage observed during first
year of operation after commissioning.
b)
In the interrupter assembly there shall be an absorbing product box to minimise
the effect of SF6 decomposition products and moisture. The material used in the
construction of the circuit breakers shall be such as fully compatible with SF6 gas
decomposition products.
c)
For CBs of voltage class of 145 kV or less, a common SF6 scheme/density
monitor shall be acceptable.
d)
The dial type SF6 density monitor shall be adequately temperature compensated
to model the pressure changes due to variations in ambient temperature within the
body of circuit breaker as a whole. The density monitor shall have graduated scale
and shall meet the following requirements:
i) It shall be possible to dismantle the density monitor for
checking/replacement without draining the SF6 gas by providing
suitable interlocked non return valve coupling.
4.4
f)
Each Circuit Breaker shall be capable of withstanding a vacuum of minimum 8
millibars without distortion or failure of any part.
g)
Sufficient SF6 gas including that will be required for gas analysis during filling
shall be provided to fill all the circuit breakers installed. In addition spare gas
shall be supplied in separate unused cylinders as per requirement specified.
Provisions shall be made for attaching an operational analyser after
installation of circuit breakers at site to record contact travel, speed and
making measurement of operating timings, preinsertion timings of closing
resisters if used, synchronisation of contacts in one pole. In case operation
analyser is already available at a particular site, the contractor shall have to
supply a suitable adapter/transducer so that the offered circuit breaker can be
used with the operational analyser.
IN JASIDIH GSS VOL-II
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5.0
6.0
SULPHUR HEXAFLUORIDE GAS (SF6 GAS):
a)
The SF6 gas shall comply with IEC 376, 376A and 376B and shall
be suitable in all respects for use in the switchgear under the operating
conditions.
b)
The high pressure cylinders in which the SF6 gas is shipped and
stored at site shall comply with requirements of the relevant standards
and regulations.
c)
Test: SF6 gas shall be tested for purity, dew point, air, hydrolysable
fluorides and water content as per IEC 376, 376A and 376B and test
certificates shall be furnished to Employer indicating all the tests as
per IEC 376 for each lot of SF6 gas in stipulated copies as indicated in
specification. Gas bottles should be tested for leakage during receipt
at site.
INSULATORS:
a)
The porcelain of the insulators shall conform to the requirements
stipulated under specification.
b)
The mechanical characteristics of insulators shall match with the
requirements specified under this Chapter.
c)
All insulators shall conform to IEC-61264 (for pressurised hollow
column insulators) and IEC-233 (for others). All routine and sample
tests shall be conducted on the hollow column insulators as per these
standards with requirements and procedures modified as under:
i)
Pressure test as a routine test.
ii)
Bending load test as a routine test.
iii) Bending load test as a sample test on each lot.
iv) Burst pressure test as a sample test on each lot.
v)
d)
7.0
In addition to above, ultrasonic test shall be carried out as
additional routine test.
Hollow Porcelain for pressurised columns/chambers should be in one
integral piece in green and fired stage.
SPARE PARTS AND MANDATORY MAINTENANCE EQUIPMENT:
The bidder shall include in his proposal spare parts and maintenance
equipment in accordance with specification. Calibration certificates of each
maintenance equipment shall be supplied along with the equipment.
IN JASIDIH GSS VOL-II
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8.0
OPERATING MECHANISM AND CONTROL
8.1
General Requirements
8.1.1
8.1.2
8.2
Circuit breaker shall be operated by spring charged mechanism.
The mechanism shall be housed in a weather proof and dust proof control
cabinet as stipulated in specification.
The operating mechanism shall be strong, rigid, not subject to rebound
and shall be readily accessible for maintenance for a man standing on
ground.
8.1.3
The mechanism shall be antipumping and trip free (as per IEC
definition) under every method of closing.
8.1.4
The mechanism shall be such that the failure of any auxiliary spring
will not prevent tripping and will not cause trip or closing operation of the
power operating devices.
8.1.5
A mechanical indicator shall be provided to show open and close
position of the breaker. It shall be located in a position where it will be
visible to a man standing on the ground level with the mechanism housing
closed. An operation counter shall also be provided in the central control
cabinet.
8.1.6
Working parts of the mechanism shall be corrosion resisting material,
bearings which require grease shall be equipped with pressure type grease
fittings. Bearing pin, bolts, nuts and other parts shall be adequately pinned
or locked to prevent loosening or changing adjustment with repeated
operation of the breaker.
8.1.7
The bidder shall furnish detailed operation and maintenance manual
of the mechanism along with the operation manual for the circuit breaker.
The instruction manuals shall contain exploded diagrams with complete
storage, handling, erection, commissioning, troubleshooting, servicing and
overhauling instructions.
Control:
8.2.1
The close and trip circuits shall be designed to permit use of
momentary contact switches and push buttons.
8.2.2
Each breaker pole shall be provided with two (2) independent tripping
circuits, pressures switches and coils each connected to a different set of
protective relays.
8.2.3
The breaker shall normally be operated by remote electrical control.
Electrical tripping shall be performed by shunt trip coils. However,
IN JASIDIH GSS VOL-II
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provisions shall be made for local electrical control. For this purpose a
local/remote selector switch and close and trip control switch/push buttons
shall be provided in the Breaker central control cabinet.
8.2.4
The trip coils shall be suitable for trip circuit supervision during both
open and close position of breaker. The trip circuit supervision relay would be
provided on relay panels.
8.2.5
Closing coil and associated circuits shall operate correctly at all values of
voltage between 85% and 110% of the rated voltage. Shunt trip coil and
associated circuits shall operate correctly under all operating conditions of the
circuit breaker upto the rated breaking capacity of the circuit breaker and at all
values of supply voltage between 70% and 110% of rated voltage. However, even
at 50% of rated voltage the breaker shall be able to open. If additional elements
are introduced in the trip coil circuit their successful operation and reliability for
similar applications on outdoor circuit breakers shall be clearly brought out in the
additional information schedules.
8.2.6
Density Meter contacts and pressure switch contact shall be suitable for
direct use as permissive in closing and tripping circuits. Separate contacts have to
be used for each of tripping and closing circuits. If contacts are not suitably rated
and multiplying relays are used then fail safe logic/schemes are to be employed.
DC supplies for all auxiliary circuits shall be monitored and provision shall be
made for remote annunciations and operation lockout in case of D.C. failures.
Density monitors are to be so mounted that the contacts do not change on
vibration during operation of circuit Breaker.
8.2.7
The auxiliary switch of the breaker shall be positively driven by the
breaker operating rod.
8.2.8
The preferred basic control schematic of the Circuit breaker is enclosed
with the bid documents and it is expected to be followed by the bidder. This,
however, does not absolve the bidder from the responsibility for safe and reliable
operation of the breaker in its lifetime.
8.3
Blank.
8.4
Spring operated mechanism:
a)
Spring operated mechanism shall be complete with motor in accordance
with specification. Opening spring and closing spring with limit switch for
automatic charging and other necessary accessories to make the
mechanism a complete operating unit shall also be provided.
b)
As long as power is available to the motor, a continuous sequence of the
closing and opening operations shall be possible. The motor shall have
adequate thermal rating for this duty.
c)
After failure of power supply to the motor one close open operation shall
be possible with the energy contained in the operating mechanism.
d)
Breaker operation shall be independent of the motor which shall be used
IN JASIDIH GSS VOL-II
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solely for compressing the closing spring. Facility for manual charging of
the closing spring shall also be provided. The motor rating shall be such
that it requires not more than 30 seconds for full charging of the closing
spring.
e)
Closing action of circuit breaker shall compress the opening spring ready
for tripping.
f)
When closing springs are discharged after closing a breaker, closing
springs shall be automatically charged for the next operation and an
indication of this shall be provided in the local and remote control
cabinet.
g)
Provisions shall be made to prevent a closing operation of the breaker
when the spring is in the partial charged condition. Mechanical interlocks
shall be provided in the operating mechanism to prevent discharging of
closing springs when the breaker is already in the closed position.
h) The spring operating mechanism shall have adequate energy stored in the
operating spring to close and latch the circuit breaker against the rated
making current and also to provide the required energy for the tripping
mechanism in case the tripping energy is derived from the operating
mechanism.
9.0
SUPPORT STRUCTURE:
a)
The structure design shall be such that during operation of circuit breaker
vibrations are reduced to minimum.
b)
If required, the Contractor shall provide suitable platform with steps on both
sides of the circuit breaker for easy accessibility for monitoring the
density/pressure of gas.
10.0
TERMINAL CONNECTOR PAD:
The circuit breaker terminal pads shall be made up of high quality electrolytic
copper or aluminium. The terminal pad shall have protective covers which
shall be removed before interconnections.
11.0
INTERPOLE CABLING:
11.1
All cables to be used by contractor shall be armoured and shall be as per
IS -1554 (1100 Volts Grade). All cables within & between circuit breaker poles
shall be supplied by the CB manufacturer.
11.2
Only stranded conductor shall be used. Minimum size of the conductor
shall be 2.5 sq.mm. (Copper).
11.3
The cables shall be with oxygen index Min-29 and temp. index as 250° C as
per relevant standards.
IN JASIDIH GSS VOL-II
Page 225
12.0
FITTINGS AND ACCESSORIES
12.1
Following is a partial list of some of the major fittings and accessories to be
furnished by Contractor in the Central Control cabinet. Number and exact location of
these parts shall be indicated in the bid.
i)
Cable glands (Double compression type), Lugs, Ferrules etc.
ii)
Local/remote changeover switch.
iii) Operation counter
iv)
v)
vi)
vii)
Blank
Control switches to cut off control power supply.
Fuses as required.
The number of terminals provided shall be adequate enough to wire out
all contacts and control circuits plus 24 terminals spare for future use.
viii) Antipumping relay.
ix) Pole discrepancy relay.
x) D.C. Supervision relays.
xi) Rating and diagram plate in accordance with IEC incorporating year of
manufacture.
13.0
ADDITIONAL DATA TO BE FURNISHED ALONGWITH THE
OFFER:
a)
Drawing, showing contacts in close, arc initiation, full arcing, arc extinction and
open position.
b)
The temperature v/s pressure curves for each setting of density monitor alongwith
details of density monitor.
c)
Method of checking the healthiness of voltage distribution devices (condensers)
provided across the breaks at site.
d)
Data on capabilities of circuit breakers in terms of time and number of operations at
duties ranging from 100% fault currents to load currents of the lowest possible value
without requiring any maintenance or checks.
e)
The effect of non-simultaneity between contacts between poles and also show how
it is covered in the guaranteed total break time.
f)
g)
Sectional view of non-return couplings if used for SF6 pipes.
Details & type of filters used in interrupter assembly and also the operating
experience with such filters.
h)
Details of SF6 gas:
i) The test methods used in controlling the quality of gas used in the
circuit breakers particularly purity and moisture content.
ii) Proposed tests to assess the conditions of the SF6 within a circuit
breaker after a period of service particularly with regard to
IN JASIDIH GSS VOL-II
Page 226
moisture contents of the gas.
i)
A complete catalogue on operation analyser satisfying all the
requirements of this Chapter.
j)
The bidders shall furnish along with the bid, curves supported by test
data indicating the opening time under close open operation with
combined variation of trip coil voltage and pneumatic/hydraulic
pressure.
k)
Field test report or laboratory test report in case of CB meant for reactor
switching duty.
l)
All duty requirement as applicable to 245 KV ckt. Breakers specified
under Clause 2.0 of this chapter shall be provided with the support of
adequate test reports to be furnished along with the bid failing which
the bid is likely to be rejected.
14.0
TESTS:
14.1
In accordance with the requirements stipulated under specification the circuit
breaker along with its operating mechanism shall conform to IEC:62271-100.
14.2
The test reports of the type tests and the following additional type tests shall
also be submitted for Purchaser’s review:
i) Corona extinction voltage test .
ii) Out of phase closing test as per IEC:62271-100.
iii) Line charging breaking current for proving parameters as per clause no.
17.9 of this Chapter.
iv) Test to demonstrate the Power Frequency withstand capability of breaker
in open condition at Zero Gauge pressure and at lockout pressure.
v) Seismic withstand test in unpressurised condition.
vi)
Verification of the degree of protection.
vii) Low & high temperature test.(if applicable)
viii) Humidity test.(if applicable)
ix)
Static Terminal Load test.
x)
Critical Currents test (if applicable).
xi)
Switching of Shunt Reactors.
14.3
Routine Tests
Routine tests as per IEC:62271-100 shall be performed on all circuit breakers.
In addition to the mechanical and electrical tests specified by IEC, the
following tests shall also be performed.
1)
Speed curves for each breaker shall be obtained with the help of a suitable
operation analyser to determine the breaker contact movement during opening,
closing, auto-reclosing and trip free operation under normal as well as limiting
operating conditions (control voltage, pneumatic/hydraulic pressure etc.). The
tests shall show the speed of contacts directly at various stages of operation, travel
of contacts, opening time, closing time, shortest time between separation and
meeting of contacts at break make operation etc. This test shall also be performed
at site for which the necessary operation analyser alongwith necessary
transducers, cables, console, etc. where included in scope of supply shall be
furnished and utilised. In case of substations where operation analyser is existing
IN JASIDIH GSS VOL-II
Page 227
the bidder shall utilise the same. However necessary adopter and transducers etc.
if required shall have to be supplied by the bidder.
2)
Measurement of Dynamic Contact resistance measurement for arcing & main
contacts. Signature of Dynamic contact resistance measurements shall be taken as
reference for comparing the same during operation and maintenance in order to
ascertain the healthiness of contacts.
14.4
Site Tests:All routine tests except power frequency voltage dry withstand test
on main circuit breaker shall be repeated on the completely assembled breaker at site.
15.0
DEAD TANK TYPE CIRCUIT BREAKER
15.1
In case dead tank type circuit breaker is offered, the Bidder shall offer
bushing type CTs on either side of dead tank circuit breaker instead of
conventional outdoor CTs.
15.2
The enclosure shall be made of either Al/Al Alloy or mild steel (suitably
hot dip galvanised).
The enclosure shall be designed for the mechanical and thermal loads to
which it is subjected in service. The enclosure shall be manufactured and
tested according to the pressure vessel codes {i.e., latest edition of the ASME
code for pressure vessel - Section VIII of BS-5179, IS4379, IS-7311 (as
applicable) and also shall meet Indian Boiler Regulations}.
The maximum temperature of enclosure with CB breaker carrying full load
current shall not exceed the ambient by more than 20 deg C.
15.3
The enclosure has to be tested as a routine test at 1.5 times the design
pressure for one minute. A bursting pressure test shall be carried out at 5
times the design pressure as type test on the enclosure.
16.0
Blank
17.0 TECHNICAL PARTICULARS
C.
245 KV & 145 KV CIRCUIT BREAKER:
C17.1
Rated continuous current
(A) at design ambient
temperature.
C17.2
Rated short circuit current
breaking capacity at rated
voltage
C17.3
Symmetrical interrupting
capability (kA rms)
C17.4
Rated short circuit
making current (kAp)
1600/2500/1250
40 Ka
31.5 kA for/Sec with
percentage DC component as per IEC:
62271-100 corresponding to minimum
opening time under operating conditions
specified
40
31.5
100
80
IN JASIDIH GSS VOL-II
Page 228
C17.5
Short time current
carrying capability
for one second (kA rms)
40
31.5
C17.6
Out of phase braking
current capacity (kA rms)
As per IEC
C17.6
Rated operating duty
O-0.3sec-CO-3min-CO cycle
IN JASIDIH GSS VOL-II
Page 229
C17.7
Reclosing
C17.8
First pole to clear factor
1.3/NA
C17.9
Rated line/cable charging
Single phase/ Three phase autoreclosing
As per IEC
interrupting current at 90 deg.
leading power factor angle (A. rms)
(The breaker shall be able to interrupt the rated line/cable charging current with test
voltage immediately before opening equal to the product of U/√3 & 1.4 as per IEC:
62271-100).
C17.10
Temperature rise
AS per IEC
Over the design
65
ambient temp.
C17.11
i)
ii)
Total break time as per Cl.3.0
of this Chapter (ms)
65
Rated break time as per IEC (ms)
60
C17.12
Total closing time (ms) ----not
more than 200
C17.13
Operating mechanism---pneumatic/spring/hydraulic or a
combination of these
C17.14
C17.15
Max. difference in the instants of
closing/ opening of contacts (ms) ----between poles(opening) 3.3 ;
between poles (closing) – 5.0 at
rated control voltage and rated
operating and quenching media
pressures.
Trip coil and closing coil
voltage -----250 V DC
As per IEC 62271-100
IN JASIDIH GSS VOL-II
Page 230
C17.16 Noise level at base and upto 50 m
distancefrom base of breaker
140dB (max.)
C17.17 Rated terminal load
or as per the value calculated
u
n
d
e
r
as per IEC
By
Chapter-GTR , whichever is higher.
C17.18
Auxiliary contacts
requirement of specification, the
a
n
y
Besides
bidder shall
wire up 5
NO + 5 NC
contacts for
future use of
Purchaser.
s
w
i
t
c
h
i
n
g
C17.19
No. of Terminals in
All contacts
& control circuits to be wired
common control cabinet
out upto
common control cabinet plus 24
terminals
exclusively
for
Purchaser’s
use.
C17.20
Maximum allowable
s
w
i
t
c
h
i
n
g
c
o
n
d
i
t
i
o
n
As per IEC
C17.21
Rated
small
inductive
c
u
r
r
e
n
t
o
v
e
r
v
o
l
t
a
g
e
s
w
i
t
c
h
i
IN JASIDIH GSS VOL-II
Page 231
n
g
A
)
c
a
p
a
b
i
l
i
t
y
(
A
u
x
i
l
i
a
r
y
w
i
t
h
s
w
i
t
c
h
o
v
e
r
v
o
l
t
a
g
e
s
h
a
l
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a
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s
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c
o
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.
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r
e
q
u
i
p
.
u
.
(
IN JASIDIH GSS VOL-II
Page 232
rements stipulated under specification).
18.0
TESTING AND
COMMISSIONING
18.1
An indicative list of tests is given
below. Contractor shall perform any
additional test based on specialties of the
items as per the field Q.P./instructions of
the equipment Supplier or Employer
without any extra cost to the Employer.
The Contractor shall arrange all
instruments required for conducting these
tests alongwith calibration certificates and
shall furnish the list of instruments to the
Employer for approval.
n
(a)
Insulation resistance of each pole.
(b)
Check adjustments, if any suggested by
manufacturer.
Breaker closing and opening time.
(d)
Slow and Power closing operation and
opening.
Trip free and anti pumping operation.
(f)
Minimum pick-up voltage of coils.
(g)
Dynamic Contact resistance measurement.
l
i
b
r
a
i
o
o
f
p
Functional checking of control circuits
interlocks, tripping through protective
relays and auto reclose operation.
Insulation resistance of control circuits,
motor etc.
r
e
s
s
(k) Resistance of closing and tripping coils.
(l)
a
Functional checking of compressed air
plant and all accessories.
(j)
C
n
(e)
(i)
)
t
(c)
(h)
(
SF6 gas leakage check.
u
r
(m) Dew Point Measurement
e
IN JASIDIH GSS VOL-II
Page 233
switches and gas density monitor.
(q) Checking of mechanical ‘CLOSE’
interlock, wherever applicable
IN JASIDIH GSS VOL-II
Page 234
TECHNICAL SPECIFICATION FOR ISOLATOR
IN JASIDIH GSS VOL-II
Page 235
9. TECHNICAL SPECIFICATION FOR 132KV ISOLATOR
1.0
1.1
GENERAL:
The Isolators and accessories shall conform in general to IEC: 62271-102
(or IS: 9921) except to the extent explicitly modified in specification and shall be
in accordance with requirement of specification.
1.2
Isolators shall be outdoor, off-load type. Earth switches shall be provided
on Isolators wherever called for.
1.3
Complete isolator with all the necessary items for successful operation
shall be supplied including but not limited to the following.
1.3.1
Isolator assembled with complete base frame, linkages, operating
mechanism, control cabinet, interlocks etc.
1.3.2
All necessary parts to provide a complete and operable isolator
installation, control parts and other devices whether specifically called for herein
or not.
1.3.3
The isolator shall be designed for use in the geographic and
meteorological conditions as given in specification.
2.0
DUTY REQUIREMENTS:
a)
Isolators and earth switches shall be capable of withstanding the dynamic and
thermal effects of the maximum possible short circuit current of the systems in
their closed position. They shall be constructed such that they do not open
under influence of short circuit current.
b)
The earth switches, wherever provided, shall be constructionally interlocked so
that the earth switches can be operated only when the isolator is open and vice
versa. The constructional interlocks shall be built in construction of isolator
and shall be in addition to the electrical and mechanical interlocks provided in
the operating mechanism.
c)
In addition to the constructional interlock, isolator and earth switches shall
have provision to prevent their electrical and manual operation unless the
associated and other interlocking conditions are met. All these interlocks shall
be of fail safe type. Suitable individual interlocking coil arrangements shall be
provided. The interlocking coil shall be suitable for continuous operation from
DC supply and within a variation range as stipulated in specification.
The earth switches shall be capable of discharging trapped charges of the associated
lines.
3.0
d)
The isolator shall be capable of making/breaking normal currents when no
significant change in voltage occurs across the terminals of each pole of isolator
on account of make/break operation.
e)
The isolator shall be capable of making/breaking magnetising current of 0.7A at
0.15 power factor and capacitive current of 0.7A at 0.15 power factor at rated
voltage.
CONSTRUCTIONAL FEATURES:
The features and constructional details of Double Break Isolators, turn twist
IN JASIDIH GSS VOL-II
Page 236
type earth switches and accessories shall be in accordance with requirements
stated hereunder:
3.1
Contacts:
a) The contacts shall be self aligning and self cleaning and so designed that binding
cannot occur after remaining closed for prolonged periods of time in a heavily polluted
atmosphere.
b) No undue wear or scuffing shall be evident during the mechanical endurance tests.
Contacts and spring shall be designed so that readjustments in contact pressure shall
not be necessary throughout the life of the isolator or earth switch. Each contact or
pair of contacts shall be independently sprung so that full pressure is maintained on all
contacts at all time.
c) Contact springs shall not carry any current and shall not loose their characteristics due
to heating effects.
3.2
Base :
Each single pole of the isolator shall be provided with a complete galvanised
steel base provided with holes and designed for mounting on a supporting
structure.
3.3
Blades :
a) All metal parts shall be of non-rusting and non-corroding material. All
current carrying parts shall be made from high conductivity
electrolytic copper/aluminium. Bolts, screws and pins shall be
provided with lock washers. Keys or equivalent locking facilities if
provided on current
carrying parts, shall be made of copper silicon alloy or stainless steel or equivalent. The
bolts or pins used in current carrying parts shall be made of non-corroding material. All
ferrous castings except current carrying parts shall be made of malleable cast iron or caststeel. No grey iron shall be used in the manufacture of any part of the isolator.
b)
The live parts shall be designed to eliminate sharp joints, edges and other corona
producing surfaces, where this is impracticable adequate corona shield shall be
provided. Corona shields/rings etc., shall be made up of aluminum/aluminum alloy.
c)
Isolators and earth switches including their operating parts shall be such that they
cannot be dislodged from their open or closed positions by short circuit forces,
gravity, wind pressure, vibrations, shocks, or accidental touching of the connecting
rods of the operating mechanism.
d)
The switch shall be designed such that no lubrication of any part is required except
at very infrequent intervals. i.e. after every 1000 operations or after 5 years whichever
is earlier.
3.4
a)
Insulator :
The insulator shall conform to IS: 2544 and/or IEC-168. The porcelain of the
insulator shall conform to the requirements stipulated in specification and shall have a
minimum cantilever strength of 600 Kg. for 145 kV insulators and 800 kg for 245 Kv
isolator.
Pressure due to the contact shall not be transferred to the insulators after the main
blades are fully closed.
IN JASIDIH GSS VOL-II
Page 237
b)
The parameters of the insulators shall meet the requirements specified in
specification.
c)
Insulator shall be type and routine tested as per IEC-168. Besides following
additional tests shall also be conducted:
(i) Bending load test in four directions at 50% of minimum bending
load guaranteed on all insulators, as a routine test.
(ii) Bending load test in four directions at 100% of minimum bending
load as a sample test on each lot.
(iii) Torsional test on sample insulators of a lot.
(iv) Ultrasonic test as a routine test.
e)
For 245 Kv and 145 kV Insulator : (For Isolator)
Top PCD
No. of holes
Bottom PCD
No. of holes
3.5
=
=
=
=
127 mm
4 x M16
254 mm
8 x 18 dia
Name Plate :
The name plate shall conform to the requirements of IEC incorporating year
of manufacture.
4.0
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
EARTH SWITCHES :
Where earth switches are specified these shall include the complete operating
mechanism and auxiliary contacts.
The earth switches shall form an integral part of the isolator and shall be mounted
on the base frame of the isolator.
Earth switches shall be only locally operated.
The earth switches shall be constructionally interlocked with the
isolator so that the earth switches can be operated only when the
isolator is open and vice versa. The constructional interlocks shall be built in
construction of isolator and shall be in addition to the electrical
interlocks.Suitable mechanical arrangement shall be provided for de-linking
electrical drive for mechanical operation.
Each earth switch shall be provided with flexible copper/aluminum braids for
connection to earth terminal. These braids shall have the same short time current
carrying capacity as the earth blade. The transfer of fault current through swivel
connection will not be accepted.
The plane of movement and final position of the earth blades shall be such that
adequate electrical clearances are obtained from adjacent live parts in the course
of its movement between ON and OFF position.
The frame of each isolator and earth switches shall be provided with two reliable
earth terminals for connection to the earth mat.
Isolator design shall be such as to permit addition of earth switches at a future
date. It should be possible to interchange position of earth switch to either side.
The earth switch should be able to carry the same fault current as the main blades
of the Isolators and shall withstand dynamic stresses.
The earth switches shall also comply with the requirements of IEC-1129, 1992 in
IN JASIDIH GSS VOL-II
Page 238
respect of induced current switching duty as defined for Class-B earth switches.
5.0
OPERATING MECHANISM :
a)
The bidder shall offer motor operated Isolators and earth switches.
b)
Control cabinet/operating mechanism box shall conform to the requirement
stipulated in specification and shall be made of aluminum sheet of adequate
thickness (minimum 3 mm).
c)
A “Local/Remote” selector switch and a set of open/ close push buttons shall be
provided on the control cabinet of the isolator to permit its operation through local
or remote push buttons.
d)
Provision shall be made in the control cabinet to disconnect power supply to prevent
local/remote power operation.
d)
Motor shall be an AC motor and conform to the requirements of
specification.
f)
Suitable reduction gearing shall be provided between the motor and the
drive shaft of the isolator. The mechanism shall stop immediately when
motor supply is switched off. If necessary a quick electromechanical
brake shall be fitted on the higher speed shaft to effect rapid braking.
g) Manual operation facility (with handle) should be provided with
necessary interlock to disconnect motor.
h) Gear should be of forged material suitably chosen to avoid
bending/jamming on operation after a prolonged period of non operation.
Also all gear and connected material should be so chosen/surface treated
to avoid rusting.
i) The test report for blocked rotor test of motor shall be submitted as per the
requirement of Technical Specification.
6.0
OPERATION :
a)
The main Isolator and earth switches shall be individual pole operated gang
operated in case of 145 kV. The operating mechanism of the three poles shall
be well synchronized and interlocked.
b)
c)
d)
The design shall be such as to provide maximum reliability under all service
conditions. All operating linkages carrying mechanical loads shall be designed
for negligible deflection. The length of inter insulator and inter pole operating
rods shall be capable of adjustments, by means of screw thread which can be
locked with a lock nut after an adjustment has been made. The isolator and
earth switches shall be provided with “over center” device in the operating
mechanism to prevent accidental opening by wind, vibration, short circuit
forces or movement of the support structures.
Each isolator/pole of isolator and earths shall be provided with a manual
operating handle enabling one man to open or close the isolator with ease in
one movement while standing at ground level. The manual operating handle
shall have provision for pad locking. The operating handle shall be located at a
height of 1000 mm(approximately) from the base of isolator support structure.
The isolator shall be provided with positive continuous control throughout the
entire cycle of operation. The operating pipes and rods shall be sufficiently
rigid to maintain positive control under the most adverse conditions and when
operated in tension or compression for isolator closing. They shall also be
capable of withstanding all torsional and bending stresses due to operation
of the isolator.Wherever supported the operating rods shall be provided with
IN JASIDIH GSS VOL-II
Page 239
e)
f)
g)
7.0
8.0
9.0
9.1
9.2
10.0
11.0
bearings on either ends. The operating rods/ pipes shall be provided with
suitable universal couplings to account for any angular misalignment.
All rotating parts shall be provided with grease packed roller or ball bearings
in sealed housings designed to prevent the ingress of moisture, dirt or other
foreign matter. Bearings pressure shall be kept low to ensure long life and ease
of operation. Locking pins wherever used shall be rustproof.
Signaling of closed position shall not take place unless it is certain that the
movable contacts, have reached a position in which rated normal current, peak
withstand current and short time withstand current can be carried safely.
Signaling of open position shall not take place unless movable contacts have
reached a position such that clearance between contacts is at least 80% of the
isolating distance.
The position of movable contact system (main blades) of each of the Isolators
and earth switches shall be indicated by a mechanical indicator at the lower
end of the vertical rod of shaft for the Isolators and earth switch. The indicator
shall be of metal and shall be visible from operating level.
h) The contractor shall furnish the following details along with quality norms,
during detailed engineering stage.
(i) Current transfer arrangement from main blades of isolator along with
milli volt drop immediately across transfer point.
(ii) Details to demonstrate smooth transfer of rotary motion from motor
shaft to the insulator along with stoppers to prevent over travel.
TERMINAL CONNECTORS:
The terminal connector shall meet the requirements as given in specification.
SUPPORT STRUCTURE:
245 kV / 145 kV Isolators shall be suitable for mounting on support structures
to be supplied in accordance with specification.
TESTS:
In continuation to the requirements stipulated under specification, the
isolator along with its earth switch and operating mechanism should have
been type tested as per IEC/IS and shall be subjected to routine tests in
accordance with IEC-129/IEC-1129. Power frequency voltage withstand
tests shall be performed on at least one completely assembled isolator pole
of each type. Alternatively, power frequency test may be performed on two
nos. of Post Insulators (complete) for each voltage rating and type of
Isolator. Minimum 50 Nos. mechanical operations will be carried out on 1
(one) isolator out of every ten Isolators assembled completely with all
accessories as acceptance test for the lot.
Site Tests:
All routine tests including 50 operation test, except power frequency dry
voltage withstand test on isolator shall be repeated on completely assembled
isolator of each type at site.
SPARE PARTS AND MAINTENANCE EQUIPMENT:
Bidder shall include in his proposal mandatory spare parts in accordance with
the requirements stipulated in Section - Project.
TECHNICAL PARAMETERS:
245kV & 145 kV ISOLATORS:
IN JASIDIH GSS VOL-II
Page 240
11.1
11.2
Type
Rated Current at 50deg. Ambient
temperature
11.3
Rated short time withstand current
of isolator and earth switch
Rated dynamic short circuit
withstand current of isolator and
earth switch
Temperature rise over design
ambient temperature
Rated mechanical
terminal load.
11.4
11.5
11.6
11.7
11.8
Operating mechanism of
isolator/earth switch
No. of auxiliary contacts on
each isolator
11.9
No. of auxiliary contacts on
each earthing switch
11.10
11.11
Operating time
Number of terminal in control
cabinet (Interpole cabling
shall be supplied by
Contractor)
Outdoor
1600/2500A
1250/1600 A
as applicable
And detailed under .
40 kA
31.5 kA for 1 Sec.
100kAp
80 kAp
As per table V of IEC-694.
As per table III of IEC-129(1984)
or as per value calculated in
Chapter-GTR whichever is higher.
A.C. Motor operated
Besides requirement of this spec.,
5 NO + 5 NC to contacts, wired
to terminal block exclusively for
Purchaser’s use in future.
Besides requirement of this spec.,
the bidder shall wire up 3 NO + 3
NC to TBs (Reversible) for
Purchaser’s future use.
12 sec. or less
All contacts & control circuits are
to be wired upto control cabinet
plus 24 spare terminals evenly
distributed.
IN JASIDIH GSS VOL-II
Page 241
12.0 TESTING AND COMMISSIONING
(a)
(b)
(c)
(d)
(e)
(f)
12.1 An indicative list of tests on isolator and earthswitch is given below.
Contractor shall perform any additional test based on specialties of the items
as per the field Q.P./instructions of the equipment Supplier or Purchaser
without any extra cost to the Purchaser. The Contractor shall arrange all
instruments required for conducting these tests along with calibration
certificates and shall furnish the list of instruments to the Purchaser for
approval.
Insulation resistance of each pole.
Manual and electrical operation and interlocks.
Insulation resistance of control circuits and motors.
Ground connections.
Contact resistance.
Proper alignment so as to minimise to the extreme possible the vibration
during operation.
Measurement of operating Torque for isolator and Earth switch.
(h) Resistance of operating and interlocks coils.
(i) Functional check of the control schematic and electrical & mechanical
interlocks.
IN JASIDIH GSS VOL-II
Page 242
10. 33 KV EQUIPMENT SPECIFICATION/ SYSTEM
PARAMATER
IN JASIDIH GSS VOL-II
Page 243
33KV EQUIPMENT SPECIFICATION / SYSTEM PARAMETER
2.
The technical requirements for various equipments and systems are furnished in
this section. The equipments and works to be executed against this tender shall
necessarily meet the requirement and parameters furnished below.
1. 33kV System Fault current & duration – 25kA for 3 seconds
Min. clearances
(i)
Phase to phase
320mm
(ii) Phase to earth
320mm
(iii) Safety working clearance
3000mm
3. Major Technical Parameters
The major technical parameters of the equipments are given below:
1)
(A) For 33 kV Vacuum Circuit Breaker and Isolator:
Rated voltage kV (rms)
36
Rated frequency (Hz)
50
No. of Poles
3
Design ambient temperature (°C)
50
Rated insulation levels :
Full wave impulse withstand voltage (1.2/50 micro sec.)
-
between line
terminals and ground
±170 kVp
-
between terminals with circuit
breaker open
±170 kVp
-
between terminals with
isolator open
±170 kVp
2)
One minute power frequency dry and wet withstand voltage
-
between line terminals and
ground
70kV(rms)
-
between terminals with circuit
breaker open
70kV(rms)
between terminals with
Isolator open
70kV(rms)
IN JASIDIH GSS VOL-II
Page 244
Minimum creepage distance:
Phase to ground (mm)
900
Between CB Terminals (mm)
900
System neutral earthing
Seismic acceleration
Rating of Auxiliary Contacts
Effectively earthed
0.3 g
10 A at 250 V DC
Breaking capacity of
2 A DC with circuit time
Auxiliary Contacts
constant of not less than 20ms
Auxiliary Switch shall also Comply with other clauses of specification.
(B) FOR 33kV CT/VT/SA
Rated voltage kV (rms)
36
Rated frequency (Hz)
50
No. of poles
1
Design ambient temperature (°C)
50
Rated insulation levels :
1)
Full wave impulse withstand voltage (1.2/50 micro sec.)
-
between line
±170 kVp
terminals and ground
for arrester housing
±170 kVp
2)
One minute power frequency dry and wet withstand voltage
-between line
70kV rms
terminals and ground
-for arrester housing
70kV rms
Minimum creepage distance
:
Phase to ground (mm)
900
Between Terminals (mm)
System neutral earthing
Seismic acceleration
900
- Effectively earthed 0.3 g
Cantilever strength of bushing
350 kg (minimum)
IN JASIDIH GSS VOL-II
Page 245
(C) Technical Parameters of Bushings/Hollow Column Insulators/support
insulators for 33kV:
(a)
Rated Voltage (kV)
36
(b)
Impulse withstand
±170
voltage (Dry & Wet) (kVp)
(c)
Power frequency
70
withstand voltage
(dry and wet) (kV rms)
(d)
Total creepage
900
distance (mm)
(e)
Pollution Class-III Heavy (as per IEC 71) and as specified in
specification for all class of equipments.
The requirement of alternate long & short sheds stated in technical
specification shall not be applicable in case of 33 kV.
4. TECHNICAL PARAMETERS FOR SWITCHGEAR
A.)33KVVacuum Circuit Breaker
a)Rated operating duty cycle
0-3min-CO-3 min-CO
b)First pole to clear factor
1.3
c)Rated line/cable charging interrupting As per IEC
current at 90 deg. Leading power factor angle
(A rms)
(The breaker shall be able to interrupt the rated line/cable charging current with test
voltage immediately before opening equal to the product of U/(root)3 & 1.4 as per IEC –
62271-100)
e)Rated break-time as per IEC (ms)
60
f)Total closing time (ms)
Not more than 80
g)Operating mechanism
SPRING
h) Max. difference in the instants of
closing/opening of contacts between poles at
rated control voltage and rated operating and
quenching media pressures (ms).
i) Trip coil & closing coil voltage
3.3
j)Noise level at base of CB and up to 50 mtr
distance from base of CB.
k) Rated terminal load
l) Auxiliary contracts
(Auxiliary switch
shall also comply with requirements
140 db (max)
250V DC with variation as specified
As per IEC
Besides requirement of specification,
the bidder shall wire up to 5 NO + 5
IN JASIDIH GSS VOL-II
Page 246
Stipulated under specification
m) No. of Terminals in Common Control
cabinet
n)Rated continuous current at design ambient
temperature (amp).
o)Rated short circuit current breaking
capacity at total voltage.
corresponding to minimum opening time
& operating conditions specified.
p) Symmetrical interrupting capability
(KA,rms)
q) Rated short circuit making current (KAP)
r)Short time current carrying capability for 3
second (KA,rms)
s)Reclosing
NC contacts for future use of owner.
All Contacts & control circuits to be
wired out up to common control
cabinet plus 24 terminals exclusively
for BSEB use.
1250
25 KA with pcercentage DC
component as per IEC-62271-100
25
As per IEC
25
Three phase auto reclosing
B. 33kV Isolator
(a) Type
(a) Temperature rise over design
ambient temperature
(b) Rated mechanical terminal load
Outdoor (Double Break)
As per table V of IEC 694
As per table-III of IEC 62271-102 IEC
129(1984) or as per value calculated in
Specification whichever is higher
(c) Number of terminals in control
cabinet
(Interpole cabling shall be
Supplied by contractor)
All contacts and control circuits
are to be wired upto control
cabinet plus 24 terminals
exclusively for Board’s use.
(d) Rated current at design
ambient temperature
1250/1600 Amps(as applicable).
(e) Rated short time withstand
Current of isolator and earthswitch
25 kA for 3 Sec
IN JASIDIH GSS VOL-II
Page 247
(f) Rated dynamic short circuit
withstand current of isolator
and earth switch
As per IEC
(g) Operating mechanism for Isolator
and Earth switch
Manual
(h) No. of auxiliary contacts on each
isolator
5 NO + 5 NC contacts, wired
to terminal block exclusively
for Board's use in future.
(i) No. of auxiliary contacts on each
earthing switch
3 NO + 3 NC contacts wired
to terminal block exclusively
for Board’s use in future.
4 NO + 4 NC contacts wired
to terminal block
(j) No. of spare auxiliary contacts
B.1 The porcelain of the 36 kV insulators shall have minimum cantilever strength
of 450 kgs
B.2 33 kV Isolator shall be gang operated for main blades and earth switches.
C. Surge Arresters
___________________________________________________________
Equipment to
BIL of the equipment to be protected
be protected
33 kV system (kVp)
___________________________________________________________
Power Transformer
+ 170
Instrument Transformer
+ 170
CB/Isolator
Phase to ground
+ 195
Across open contacts
+ 195
__________________________________________________________
(a)
Rated arrester voltage
30 kV
(b)
Nominal discharge capability 10 kA of 8/20 microsecond wave
IN JASIDIH GSS VOL-II
Page 248
(c)
Minimum discharge
capability
5kJ/kV (referred to rated arrester
voltage corresponding to minimum
discharge characteristics).
(d)
Continuous operating
voltage at 50 deg.C
24 kV rms
(e)
Max. switching surge
residual voltage (0.5kA)
63 kVp
(f)
Max. residual voltage
(i) 5 kA
(ii) 10 kA nominal
discharge current
80 kVp
85 kVp
Long duration discharge class
2
(g)
(h)
High current short duration
100 kAp
test value (4/10 micro second wave)
(i)
Current for Pressure Relief test
40kA rms
(j)
Low current long duration
test value (2000 micro sec)
As per IEC.
(k)
Pressure relief class as per IEC-99-1
D. 33 KV Current Transformers
1.(a).Rated Primary current
600/1200A(as applicable)
(b)Rated Extended Primary current
2. Rated short time thermal Current
3.
Rated dynamic current
4.
Maximum temperature
rise over design ambient
Temperature
5.
One minute power
frequency withstand
voltage sec. terminal &
earth
120% (on all cores)
25 kA for 3 sec.
As per IEC
As per IEC:44-1,5KV
IN JASIDIH GSS VOL-II
Page 249
6.
Number of terminals
All terminals of control
circuits are to be wired
upto marshaling box plus
20% spare terminals
evenly distributed on all
TBs.
7.
Type of insulation
Class A
Current transformers shall also comply with requirements of Table – I given
below:
TABLE – I
A.
Current Transformer (600A)
No. Cor
of
e
Core No.
s
3
1
Applicati
on
Curre
nt
Ratio
O/C &
E/F
600300
2
Metering
3
4
Trafo.
Diff.
Protection
Spare
5
Spare
/1
600300150/1
600300/1
Outp Accura
ut
cy
Burde Class as
n
per
(VA) IEC 441
PS
Min.
Knee
Point
Volta
ge Vk
Max.
CT Sec.
Winding
Resistan
ce
(Ohms)
Max.
Exc.
Curre
nt at
Vk
(mA)
.
-
-
Max.
CT Sec.
Winding
Resistan
ce
(Ohms)
-
Max.
Exc.
Curre
nt at
Vk
(mA)
25 on
1200/1
Tap,
50 on
600/1
Tap.
600/3
00
20
0.5
-
-
PS
600/3
00
All Relaying CT shall be accuracy class PS as per IS: 2705
B. Current Transformer (1200A)
No.
of
Cor
es
Cor
e
No.
Applicati
on
Curre
nt
Ratio
3
1
O/C &
E/F
1200600/1
Outp Accura
ut
cy
Burde Class
n
as per
(VA) IEC 441
PS
Min.
Knee
Point
Voltag
e Vk
1200/6
00
IN JASIDIH GSS VOL-II
Page 250
2
Metering
1200600/1
30
0.5
-
-
-
3
Trafo.
Diff.
Protection
1200600/1
-
PS
1200/6
00
-
25 on
1200/1
Tap,
50 on
600/1
Tap.
4
Spare
5
Spare
All Relaying CT shall be accuracy class PS as per IS: 2705
F. 33 kV POTENTIAL TRANSFORMERS
1.
2.
3.
4.
5.
6.
7.
Rated primary
voltage (kV
rms)
Type
No. of
secondaries
Rated voltage
factor
Phase angle
error
Standard
reference
range of
frequenci
es for
which the
Accuracie
s are valid
One minute
power
frequency
Withstand
voltage:
i) Between LV
terminal and earth terminal
ii) For secondary winding
8.
Maximum
temperature rise over
design ambient
IN JASIDIH GSS VOL-II
Page 251
temperature
9. Number of terminals in
control Cabinet
10.Rated total thermal
burden
36
Single phase PT
3
1.2 continuous
1.5 - 30 seconds
+/- 20 minutes (for metering core)
96% to 102% for protection and
99% to 102% for measurement
10kVrms for exposed terminals and
4kVrms for terminals enclosed in a
weather proof box.
2 kVrms
As per IEC 186
All terminals of control circuits are
wired upto marshalling box Plus
spare 20% terminals evenly
distributed on all TBs
75 VA
11.
12.
13.
14.
.Vol
tage
Rati
o
Appl
icati
on
Acc
urac
y
Outp
ut
burd
en
(VA
)
(min
imu
m)
Secondary I
Secondary II
SecondaryIII
33/0.11
33/0.11
33/0.11
Protection
Protection
3P
3P
50
50
IN JASIDIH GSS VOL-II
Metering
0.5
25
Page 252
5. INSULATOR STRING (33 KV)
a)
Power frequency withstand
: 75
voltage of the complete
string with Corona Control ring (wet) - kV rms
b)
Lightning impulse withstand
: ±170
Voltage of string with corona
control rings (dry) – kVp
Power frequency puncture with- :
1.3 times actual wet flashover
stand voltage for a string insulator
voltage of the unit
c)
d)
900
f)
Total creepage distance of the :
complete insulator string (mm)
Total no. of discs per strings
:
6.
33kV Bus Post Insulators.
a)
b)
Type
Voltage class (kV)
c)
Dry and wet one minute power
70
frequency withstand voltage(kV rms)
d)
f)
Dry lightning impulse
withstand Voltage (kVp)
Total minimum cantilever
strength (Kg)
Minimum torsional moment
As per IEC-273
g)
Total height of insulator (mm)
As per requirement
h)
Pollution level as per
IEC-815
Minimum creepage distance for
Heavy Pollution (mm)
Heavy(III)
e)
i)
5 ( S/T & S/S )
Solid Core
36
±170
450
900
IN JASIDIH GSS VOL-II
Page 253
11. AIR CONDITIONING SYSTEM
IN JASIDIH GSS VOL-II
Page 254
TECHNICAL SPECIFICATION
FOR
AIR CONDITIONING
SYSTEM
TABLE OF CONTENTS
Clause No.
Description
1.00.00 General
2.00.00 Air Conditioning System For Control Room Building
3.00.00 Air Conditioning System For Switchyard Panel Rooms
IN JASIDIH GSS VOL-II
Page 255
IN JASIDIH GSS VOL-II
Page 256
TECHNICAL SPECIFICATION FOR
AIR CONDITIONING SYSTEM
1.00.00
GENERAL
1.01.00
This specification
covers
supply,
installation,
testing and
commissioning and handing over to BSEB of Air conditioning system for
the control room building and switchyard panel rooms.
1.01.01
Air conditioning units for control room building shall be set to
maintain the inside DBT at 24.4 o C ± 2oC and the air conditioning
system for switchyard panel rooms shall be designed to maintain DBT
inside switchyard panel rooms below 24oC.
2.00.00
AIR CONDITIONING SYSTEM FOR CONTROL ROOM BUILDING.
2.01.00
The following rooms shall be air conditioned. i)
Control room
ii) Conference Room
iii) AEE room
i v ) Battery room
2.02.00
Air conditioning requirement of rooms indicated at clause no.2.01.00 shall
be met using split AC units. High wall type split AC units of 2TR capacity
each with high wall type indoor evaporator unit shall be used for all
rooms.
2.03.00
Scope
The scope of the equipment to be furnished and services to be
provided under the contract are outlined hereinafter and the same is to be
read in conjunction with the provision contained in other sections/
clauses. The scope of the work under the contract shall be deemed to
include all such items, which although are not specifically mentioned in the
bid documents and/or in Bidder's proposal, but are required to make the
equipment/system complete for its safe, efficient, reliable and trouble
free operation.
2.03.01.
Twelve (12) nos. of high wall type split AC units of 2TR capacity each
complete with air cooled outdoor condensing unit having
hermetically sealed compressor and high wall type indoor evaporator unit
with cordless remote controller.
2.03.02
Copper refrigerant piping complete with insulation between the indoor
and remote outdoor condensers as required.
2.03.03
PVC drain piping from the indoor units upto the nearest drain point.
2.03.04
Power and control cabling between the indoor unit and outdoor unit
IN JASIDIH GSS VOL-II
Page 257
and earthing.
2.03.05
MS Brackets for outdoor condensing units, condensers as required.
2.04.00
Specification for Split AC units.
2.04.01
The split AC units will be complete with indoor evaporator unit,
outdoor condensing units and cordless remote control units.
2.04.02
Outdoor unit shall comprise of hermetically sealed reciprocating/ rotary
compressors mounted on vibration isolators, propeller type axial flow
fans and copper tube aluminium finned coils all assembled in a sheet metal
casing. The casing and the total unit shall be properly treated and shall be
weatherproof type. They shall be compact in size and shall have horizontal
discharge of air.
2.04.03
The indoor units shall be high wall type. The indoor unit shall be
compact and shall have elegant appearance. They shall have low noise
centrifugal blowers driven by special motors and copper tube aluminium
finned cooling coils. Removable
and washable
polypropylene filters shall be provided. They shall be complete with multi
function cordless remote control unit with special features like
programmable timer, sleep mode and soft dry mode etc.
2.04.04
The Split AC units shall be of Carrier, Voltas, Blue Star, Hitachi,
Daikin, LG, National, O’ General or Samsung make.
IN JASIDIH GSS VOL-II
Page 258
12. DIESEL GENERATOR SET
IN JASIDIH GSS VOL-II
Page 259
SECTION: DIESEL GENERATOR SET
Table of contents
Clause
No.
1.1
Description
SCOPE OF SUPPLY
1.2
SCOPE OF SERVICE
1.3
TECHNICAL REQUIREMENTS
1.4
PLANT DESIGN
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
1.4.7
1.4.8
1.4.9
DIESEL ENGINE
Air Suction & Filtration
FUEL AND LUBRICATING SYSTEM
ENGINE STARTING SYSTEM
FUEL INJECTION AND REGULATOR
ALTERNATOR
COUPLING
MOUNTING ARRANGEMENT
PERIPHERALS
1.5
CONTROL AND INSTRUMENTATION
1.6
D.G.SET Enclosure
1.7
INSTALLATION ARRANGMEN
1.8
DOCUMENTS
1.9
TESTS
1.10
Commissioning checks
IN JASIDIH GSS VOL-II
Page 260
SECTION: DIESEL GENERATOR SET
1.1.
SCOPE OF SUPPLY
1.1.1.
The scope covers supply of. Diesel Generator set of stationary type having a net electrical
output of 100kVA capacity at specified site conditions of 50o C ambient temperature and
100% relative humidity on FOR site basis. DG set shall be equipped with : (i)
Diesel
engine complete with all accessories. (ii) An alternator directly coupled to the engine
through coupling, complete with allaccessories. (iii) Automatic voltage regulator.
(iv) Complete starting arrangement, including two nos. batteries & chargers. (v)
Base
frame, foundation bolts etc. (vi) Day tank of 990 capacity. (vii) Engine Cooling and
lubrication system. (viii) Engine air filtering system. (ix) Exhaust silencer package. (x)
Set of GI pipes, valves, strainers, unloading hose pipes as required for fuel transfer system
from storage area to fuel tank including electrically driven fuel pump. (xi) All
lubricants, consumable, touch up paints etc. for first filing, testing &commissioning at
site. The fuel oil for first commissioning will also be providedby the contractor. (xii)
AMF panel for control, metering and alarm. (xiii) Enclosure for silent type D.G. Set
1.2.
SCOPE OF SERVICE
1.2.1.
a)
b)
c)
d)
The Contractor shall provide following services:
Design, manufacture, shop testing including assembly test.
Despatch, transportation to site.
Erection, testing & commissioning with all equipments/materials required for the purpose.
Drawings, data, design calculations and printed erection, operation & maintenance
manual.
e)
Certification and compliance for meeting noise level & emission parameters and other
requirements in accordance with latest Notification of MOEF.
1.3.
TECHNICAL REQUIREMENTS
1.3.1.
The rating of DG sets are as follows :
1.3.1.1. DG set net out put after considering deration for engine and alternator separately due to
temperature rise in side the enclosure and on account of power reduction due to auxiliaries
shall be 100 kVA, 1500RPM, 0.8Pf, 415V, 3 phase, 50Hz. The above ratings are the
IN JASIDIH GSS VOL-II
Page 261
minimum requirements.
1.3.1.2.
DG sets shall also be rated for 110% of full load for 1 hour in every twelve hrs of
continuous running.
1.3.2.
The output voltage, frequency and limits of variation from open circuit to full load shall
be as follows :
a)
Voltage variation
+5% of the set value provision shall exist to adjust the
set value between 90% to 110% of nominal Generator
voltage of 415V.
b)
Frequency
50Hz +2%
1.3.3.
The Diesel Generator and other auxiliary motor shall be of H class with temperature
rise limited to Class-F for temperature rise consideration.
1.3.4.
NOISE LEVEL & EMISSION PARAMETERS : These shall be as per latest
Notification of MOEF
1.4.
PLANT DESIGN
1.4.1.
DIESEL ENGINE
1.4.1.1.
The engine shall comply with the IS 10002/BS 5514/ISO 3046; latest edition
1.4.1.2.
Diesel engine shall be turbo charged multicylinder V-type in line type with
mechanical fuel injection system.
1.4.1.3.
The engine with all accessories shall be enclosed in a enclosure to make it work
Silently (within permissible noise level) without any degradation in its performance.
1.4.1.4.
The Diesel Engines shall be directly water cooled. Cooling of water through radiator
and fan as envisaged.
1.4.1.5.
The fuel used shall be High Speed Diesel oil (HSD) or Light Diesel Oil (LDO) as per
IS:1460.
1.4.2.
Air Suction & Filtration
1.4.2.1.
Suction of air shall be from indoor for ventilation and exhaust flue gasses will be let out
to outside atmosphere, Condensate traps shall be provided on the exhaust pipe.
1.4.2.2.
Filter shall be dry type air filter with replaceable elements.
IN JASIDIH GSS VOL-II
Page 262
1.4.3.
FUEL AND LUBRICATING OIL SYSTEM
1.4.3.1. The engine shall have closed loop lubricating system. No moving parts shall require
lubrication by hand prior to the start of engine or while it is in operation.
1.4.4.
ENGINE STARTING SYSTEM
1.4.4.1.
Automatic electric starting by DC starter motor shall be provided.
1.4.5.
FUEL INJECTION AND REGULATOR
1.4.5.1.
The engine shall be fitted with electronic governor suitable for class A-1 as per IS
10000.
1.4.5.2.
1.4.6.
The engine shall be fitted with a heavy, dynamically balanced fly wheel suitable
for constant speed governor duty.
ALTERNATOR
1.4.6.1.
1.4.6.2.
1.4.6.3.
The alternator shall comply with BS 2613/IS 4722/IEC 34; latest edition.
The alternator shall be of continuously rated duty, suitable for 415 V, 3 phase, 50
Hz. Power development having brush-less, synchronous, self-excited, self-regulating
system.
The alternator shall be drip-proof, screen protected as per IP-23 degree of
Protection.
1.4.6.4.
The rotor shall be dynamically balanced to minimize vibration.
1.4.6.5.
The alternator shall be fitted with shaft mounted centrifugal fan.
1.4.6.6.
It shall have the winding of class H but limited to Class-F for temperature rise
consideration.
1.4.6.7.
The Alternator regulator shall be directly coupled to the engine and shall be
complete with the excitation system, automatic voltage regulation of +/- 1%, voltage
adjusting potentiometer and under/over speed protection.
1.4.6.8.
Terminal Box
1.4.6.8.1. Six (6) output terminals shall be provided in alternator terminal box. Terminals shall be
Suitable for 1 No. of single core, 3½Core 300 mm2 XLPE cable for 100 kVA DG set. The
neutral shall be formed in AMF panel. The generator terminal box shall be suitable to
house necessary cables and should be made of non-magnetic material.
1.4.6.9.
The alternator with all accessories shall be enclosed in a enclosure to make it work
Silently (within permissible noise level)
IN JASIDIH GSS VOL-II
Page 263
1.4.7.
1.4.8.
COUPLING
1.4.7.1.
The engine and alternator shall be directly coupled by means of selfaligning flexible flange coupling to avoid misalignment.
1.4.7.2.
The coupling shall be provided with a protecting guard to avoid accidental
contract.
MOUNTING ARRANGEMENT
1.4.8.1.
The engine and alternator shall be mounted on a common heavy duty, rigid
fabricated steel base frame constructed from ISMC of suitable sections.
1.4.8.2.
Adequate number of anti-vibration mounting pads shall be fixed on the common
base frame on which the engine and the alternator shall be mounted to isolate the
vibration from passing on to the common base frame or the foundation of the D.G.
Set.
1.4.9.
PERIPHERALS
1.4.9.1.
FUEL TANK
1.4.9.1.1. The Fuel tank of suitable capacity shall be provided on a suitably fabricated steel
platform. The tank shall be complete with level indicator marked in litres, filling inlet
with removable screen, an outlet, a drain plug, an air vent, an air breather and
necessary piping. The tank shall be painted with oil resistant paint and shall be erected
in accordance with Indian explosive act of 1932. Fuel tank shall be kept outside of
enclosure. The fuel piping shall be carried out to connect the D.G set kept inside.
1.4.9.1.2. For transferring fuel to Fuel tank transfer pump is envisaged. The capacity of
transfer pump shall be adequate to fill the day tank in about 30 minutes. Fuel pump
shall be electrically driven.
1.4.9.2.
BATTERY and BATTERY CHARGER
1.4.9.2.1. Two nos. 24V batteries complete with all leads, terminals and stand shall be provided.
Each battery shall have sufficient capacity to give 10 nos. successive starting impulse to the
diesel engine.
1.4.9.2.2. The battery charger shall be complete with transformer, suitable rating (415 V, 3 Ph., 50
Hz./230V, 1Ph., 50 Hz) rectifier circuit, charge rate selector switch for “trickle”/’boost’ charge,
D.C. ammeter & voltmeter, annunciation panel for battery charge indication / loading / failures.
1.4.9.2.3. The charger shall float and Boost Charge the battery as per recommendation of
manufacturer of battery. The charger shall be able to charge a fully discharged battery to a state
of full charge in 8 Hrs. with 25% spare capacity.
IN JASIDIH GSS VOL-II
Page 264
1.4.9.2.4. Manual control for coarse and fine voltage variation shall be provided. Float charger shall
have built-in load limiting features.
1.4.9.2.5. Ripple shall not be more than 1%(r.m.s) to get smooth DC voltage shall be provided.
1.4.9.2.6. Charger shall be provided with Out-put Voltmeter & Ammeter.
1.4.9.2.7. Changeover scheme for selecting battery and battery charger by changeover switch
should be provided.
1.5.
CONTROL AND INSTRUMENTATION
1.5.1.
Each D.G. Set shall be provided with suitable instruments, interlock and protection
arrangement, suitable annunciation and indications etc. for proper start up, control,
monitoring and safe operation of the unit. One local AMF control panel alongwith each
D.G. set shall be provided by the Supplier to accommodate these instruments, protective
relays, indication lamps etc. The AMF Panel shall have IP-52 degree of Protection as per
IS:12063.
1.5.2.
The D.G. sets shall be provided with automatic start facility to make it possible to take full
load within 30 seconds of Power Supply failure.
1.5.3.
Testing facility for automatic operation of D.G.Set shall be provided in AMF panel.
1.5.4.
A three attempt starting facility using two impulse timers and summation timer for engine
shall be proved and if the voltage fails to develop within 40 sec. from receiving the first
impulse, the set shall block and alarm to this effect shall be provided in the AMF panel.
1.5.5.
Following instruments shall be provided with Diesel Engine
a)
Lub oil pressure gauge
b)
Water temperature thermometers
c)
Engine tachometer/HR
d)
Any other instruments necessary for DG Set operation shall be
provided.
1.5.6.
DG set shall be capable of being started/ stopped manually from remote as well as local.
(Remote START/STOP push button shall be provided in 415V ACDB). However,
interlock shall be provided to prevent shutting down operation as long as D.G. Circuit
breaker is closed.
1.5.7.
The diesel generator shall commence a shutdown sequence whenever any of the following
conditions appear in the system :
a)
Overspeed
b)
Overload
c)
High temperature of engine and cooling water.
d)
High temperature inside enclosure
IN JASIDIH GSS VOL-II
Page 265
e)
f)
g)
h)
i)
j)
Low lube oil pressure
Generator differential protection
Short circuit protection
Under voltage
Over voltage
Further interlocking of breaker shall be provided to prevent parallel operation of
DG set with normal station supply.
1.5.8.
Following indication lamps for purposes mentioned as under shall be provided in AMF
panel :
1.5.8.1.
Pilot indicating lamp for the following :
a)
Mains ON
b)
Alternator ON
c)
Charger ON/OFF
d)
Breaker ON/OFF
e)
Main LT Supply ON/OFF
1.5.8.2.
Visual annunciation shall be provided for set shut down due to :
a)
engine overheating
b)
low oil pressure
c)
lack of fuel
d)
Set failed to start in 30 secs after receiving the first start impulse
e)
high cooling water temperature
f)
Low level in daily service fuel tank
g)
Overspeed trip
Audio & visual Annunciation for alternator fault.
h)
1.5.9.
Thermostatically controlled space heaters and cubicle illumination operated by Door
Switch shall be provided in AMF panel. Necessary isolating switches and fuses shall also
be provided.
1.5.10.
AMF panel shall have facility for adjustment of speed and voltage including fine
adjustments in remote as well as in local mode.
a)
Following shall also be provided in
AMF panel: Frequency meter
b)
3 Nos. single phase CT's for metering
c)
d)
e)
f)
g)
h)
3 Nos. (Provided by LT swgr manufacturer) single phase CT's with KPV 300V &
RCT 0.25 ohm for differential protection of DG Set on neutral side only for
250kVA.
One (1) DC Ammeter (0-40A)
One (1) DC Voltmeter (0-30V)
One (1)
Voltmeter Selector switch
One (1)
One (1)
AC Ammeter
AC Voltmeter
IN JASIDIH GSS VOL-II
Page 266
i)
Three (3) Timers (24V DC)
j)
Two (2)
Auto/Manual Selector Switch
k)
Two (2)
Auto/test/Manual Selector Switch
l)
Eleven (11) Aux. Contactors suitable for 24V DC
m)
One (1)
Motorised potentiometer for voltage adjustment
n)
Two (2)
Set Battery charger as specified in Technical Specification
o)
One (1)
Set Phase & Neutral busbars.
p)
Any other item required for completion of Control scheme shall be deemed to be
included.
1.6.
D.G. SET Enclosure
1.6.1.
General requirements
1.6.1.1.
Diesel engine, alternator, AMF panel, Batteries and Chargers shall be installed outdoor in
a suitable weather-proof enclosure which shall be provided for protection from rain, sun,
dust etc. Further, in addition to the weather proofing, acoustic enclosures shall also be
provided such that the noise level of acoustic enclosure DG set shall meet the requirement
of MOEF The diesel generator sets should also conform to Environment (Protection)
Rules, 1986 as amended. An exhaust fan with louvers shall be installed in the enclosure
for temperature control inside the enclosure. The enclosure shall allow sufficient
ventilation to the enclosed D.G. Set so that the body temperature is limit to 50°C. The air
flow of the exhaust fan shall be from inside to the outside the shelter. The exhaust fan
shall be powered from the DG set supply output so that it starts with the starting of the DG
set and stops with the stopping of the DG set. The enclosure shall have suitable viewing
glass to view the local parameters on the engine.
1.6.1.2.
Fresh air intake for the Engine shall be available abundantly; without making the Engine
to gasp for air intake. A chicken mess shall be provided for air inlet at suitable location in
enclosure which shall be finalised during detailed engineering.
1.6.1.3.
The Enclosure shall be designed and the layout of the equipment inside it shall be such
that there is easy access to all the serviceable parts.
1.6.1.4.
Engine and Alternator used inside the Enclosure shall carry their manufacturer’s Warranty
for their respective Models and this shall not degrade their performance.
1.6.1.5.
Exhaust from the Engine shall be let off through Silencer arrangement to keep the noise
level within desired limits. Interconnection between silencer and engine should be through
stainless steel flexible hose/ pipe.
1.6.2.
All the Controls for Operation of the D.G. Set shall be easily assessable. There should be
provision for emergency shut down from outside the enclosure.
1.6.3.
Arrangement shall be made for housing the Battery set in a tray inside the Enclosure.
1.6.4.
Construction Features:
IN JASIDIH GSS VOL-II
Page 267
1.6.4.1.
The enclosure shall be fabricated from at least 14 Gauge CRCA sheet steel and of
Modular construction for easy assembling and dismantling. The sheet metal components
shall be pre-treated by Seven Tank Process and Powder coated (PURO Polyester based)
both-in side and out side – for long life. The hard-ware and accessories shall be high
tensile grade. Enclosure shall be given a lasting anti-rust treatment and finished with
pleasant environment friendly paint. All the hardware and fixtures shall be rust proof and
able to withstand the weather conditions.
1.6.4.2.
Doors shall be large sized for easy access and provided with long lasting gasket to make
the enclosure sound proof. All the door handles shall be lockable type.
1.6.4.3.
The Enclosure shall be provided with anti-vibration pads (suitable for the loads and
vibration they are required to carry) with minimum vibration transmitted to the surface the
set is resting on.
1.6.4.4.
High quality rock wool of required density and thickness shall be used with fire retardant
thermo – setting resin to make the Enclosure sound proof.
1.6.5.
1.6.5.1.
Provision for Neutral/Body Earthing
Points shall be available at two side of the enclosure with the help of flexible copper wires
from alternator neutral, and electrical panel body respectively. The earthing point shall be
isolated through insulator mounted on enclosure.
1.7.
INSTALLATION ARRANGEMENT
1.7.1.
DG set enclosed in enclosure shall be installed on Concrete Pedestal 300mm above FGL
1.8.
DOCUMENTS
1.8.1.
Following drawings and data sheet shall be submitted for approval:
(i) Data sheet for Engine, Alternator, Battery, AMF panel and Enclosure
(ii) GA drawing of DG set
(iii) Layout of DGset in the enclosure along with sections
(iv) GA and schematic of AMF panel
(v) Arrangement of inclined roof and pedestal.
1.8.2.
The D G Set shall be supplied with
(i) D G Set test certificate
(ii) Engine Operation & maintenance Manual.
(iii) Engine Parts Catalogue.
(iv) Alternator Operation, maintenance & Spare parts Manual.
(v) Alternator test certificate.
1.9.
TESTS
a) The Diesel generator sets shall be tested for routine and acceptance tests as per the
relevant IS/IEC standards.
b) The type test report for diesel engine and alternator are not required to be submitted
for the makes indicated at approved list of subvendors. For the new makes (Other than
those indicated at approved list of subvendors) type test reports as per relevant
standard shall be submitted for purchaser’s approval.
IN JASIDIH GSS VOL-II
Page 268
1.10.
Commissioning Checks
In addition to the checks and test recommended by the manufacturer, the Contractor shall
carryout the following commissioning tests to be carried out at site.
1. Load Test
The engine shall be given test run for a period of atleast 6 hours. The set shall be
subjected to the maximum achievable load as decided by Purchaser without exceeding the
specified DG Set rating :
During the load test, half hourly records of the following shall be taken :
a)
b)
c)
Ambient temperature.
Exhaust temperature if exhaust thermometer is fitted.
Cooling water temperature at a convenient point adjacent to the water output from
the engine jacket.
d)
Lubricating oil temperature where oil cooler fitted.
e)
Lubricating oil pressure.
f)
Colour of exhaust gas
g)
Speed
h)
Voltage, wattage and current output. i)
Oil tank level
The necessary load to carryout the test shall be provided by the purchaser.
2. Insulation Resistance Test for Alternator
Insulation resistance in mega-ohms between the coils and the frame of the alternator when
tested with a 500V megger shall not be less than IR=2x(rated voltage in KV)+1
3. Check of Fuel Consumption
A check of the fuel consumption shall be made during the load run test. This test shall be
conducted for the purpose of proper tuning of the engine.
4. Insulation Resistance of Wiring
Insulation resistance of control panel wiring shall be checked by 500V Megger. The IR
shall not be less than one mega ohm.
5. Functional Tests
a) Functional tests on control panel.
b) Functional test on starting provision on the engine.
c) Functional tests on all Field devices.
IN JASIDIH GSS VOL-II
Page 269
d) Functional tests on AVR and speed governor.
6. Measurement of Vibration
The vibration shall be measured at load as close to maximum achievable load
and shall not exceed 250microns.
7. Noise Level check as per relevant standard
8. The tests shall be carried out with the DG set operating at rated speed and at
maximum achievable load. Necessary correction for Test environment condition
& background noise will be applied as per IS:12065.
IN JASIDIH GSS VOL-II
Page 270
13. LIGHTING SYSTEM
IN JASIDIH GSS VOL-II
Page 271
1 LIGHTING SYSTEM
1.1 The scope of work comprises of design, engineering, testing, supply, installation,
testing and commissioning of various lighting fixtures complete with lamps, supports and
accessories, ceiling fans complete with electronic regulators, exhaust fans for toilets and
pantry & accessories, lighting panels, lighting poles complete with distribution boxes,
galvanised rigid steel conduits, lighting wires, G.I. Earthwire, receptacles, tag block &
telephone socket, switchboards, switches, junction boxes, pull out boxes complete with
accessories, lighting transformer.
1.2 SYSTEM DESCRIPTION
A typical arrangement of lighting system is shown in enclosed sketch no. C-ENG-GENLS .The lighting system shall comprise of the following :
1.2.1 AC Normal Lighting
AC lights will be connected to AC lighting panels. All the lights connected to the AC
lighting system in different areas will be connected to the main lighting distribution boards.
1.2.2 AC Emergency Lighting
This system will be available in control room building, Fire fighting pump house ,DG Set
building & switchyard. AC lighting load will be connected to this system which will be
normally ‘ON’. The lighting panels of this system will be connected to the Emergency
lighting board which is fed from diesel generator during the emergency. 50% of lighting
fixtures shall be connected on AC emergency lighting.
1.2.3 D.C. Emergency lighting
A few DC emergency lighting fixtures operated on the DC system will be provided in the
strategic locations including staircase, corridors, electrical rooms, Battery charger room,
LT switchgear room in control room building, Fire fighting pump house and DG Set
building so that the operating personnel can safely find their way even during emergency
of a total AC failure. These lights will be normally 'OFF' and will be switched 'ON'
automatically when under voltage occurs in the AC main lighting distribution board. GLS
lamp down lighters in false ceiling area and Bulkhead fixtures in non false ceiling area to
be used.
1.2.4 Portable Fixtures
Three numbers of battery operated, portable fixtures will be provided in the Control room
building and one number shall be provided in DG Set Building Cum Fire fighting pump
house.
These fixtures will be provided at important locations in the above mentioned areas.
1.3 The lighting layout for and around Control Room Cum Administrative Office Building
IN JASIDIH GSS VOL-II
Page 272
& DG House indicating the type & BOQ for various items shall be furnished by tenderers
The lux levels to be maintained in the switchyard shall be as per following:
Sl.No Area
Average Lux Level
i) Switchyard -50 lux on main Equipments(i.e, Transformer, Reactor
ISO,CB,CT,CVT,SA) at first level
(Equipment connections level.)
-20 lux on balance area of switchyard and street / Road
at ground level
The minimum lux level to average lux level ratio should not be less than 0.3
(i.e Emin/Eav>0.3 ). The maintenance factor for outdoor illumination design shall be
considered as 0.65.
For achieving the specified lux levels in the switchyard, the contractor can provide
luminaries of 1x400 W/1x250 W and 2x400 W/ 2x250 W flood light as per requirement.
The contractor shall submit detailed calculation for reaching the above Lux level.
Contractor shall conform the Lux levels at different locations of the switch yard and street
lighting by measurement.
In addition to the normal lighting provided in the switchyard area to maintain the desired
lux levels, few high beam fixtures on swivel support shall be provided in
strategic
locations near equipments which shall be kept normally OFF and these shall be switched
ON in case of maintenance work.
1.4 Ceiling fans (1400 mm sweep, AC 230 volts ) shall be provided in DG Set building,
fire fighting pump house and non AC rooms in the control room building as shown in the
enclosed drawings. Wall mounted fans shall be provided in the conference room, shift
manager and substation incharge rooms in control room building. Exhaust fans shall be
provided in toilets and pantry.
1.5 One no. of aluminium ladder of each size shall be supplied by the contractor for
maintenance purpose.
1.6 The following specific areas are included in the scope of lighting: (i) Switchyard Area.
(ii) Switchyard Control Room cum Administrative Office Building (iii) DG Building
cum Fire fighting pump house (iv) Street lighting (peripherial) inside switchyard fencing
(Street lighting shall Technical Specification, Section : LS Page 2 of 21 C / ENGG /
be done using street lighting poles)
v) Landscape Lighting around control room as shown in the tender drawing
1.7 For Outdoor Illumination
The switchyard and street lighting design, detailed drawings showing the lighting layout
and Electrical distribution diagram shall be prepared by the Contractor and submitted for
approval. The above layout drawings will include disposition and location of lighting
fixtures, receptacles, etc.
For Indoor Illumination
The conduit layout for substation buildings based on the tender drawings, Electrical
IN JASIDIH GSS VOL-II
Page 273
distribution diagram for substation buildings & for landscape lighting cable schedule for
substation yard etc. shall be prepared by the Contractor. All wiring including telephone
wiring (tinned two pair copper) shall be in concealed conduit. Concealed MS junction
boxes for sockets and light points shall be provided in all the rooms of Control Room cum
Administrative Office Building and DG Building cum Fire Fighting pump house.
1.8 Each cable and conduit run shall be tagged with number that appear in the cable and
conduit schedules. Cables and conduits shall be tagged at their entrance and/or exit from
any piece of equipment, junction or pull box, floor opening etc.
1.9 The tag shall be made up of aluminium with the number punched on it and securely
attached to the cable by not less than two turns of G.I. wire. Cable tags shall be rectangular
in shape for power cables and circular shape for control cables.
supply
1.10 Location of cables laid directly under ground shall be indicated clearly by cable
marker made of galvanised iron plate embedded in concrete block.
1.11 The location of under ground cable joints if any, shall be clearly indicated with cable
marker with an additional inscription "cable joint".
1.12 The marker, which is a concrete block, shall project 150 mm above ground and shall
be spaced at an interval of 30 meters and at every change of direction. It shall also be
located on both sides of the road or drain crossing.
2. DESCRIPTION OF ITEMS
The Contractor shall and install the following equipment and accessories in accordance
with the specification.
2.1 LIGHTING PANELS
2.1.1 OUTDOOR
415 AC lighting panel with 415V, 63A, 3 phase 4 wire bus and one no. 63A, TPN, MCB
with neutral unit as incomer and 20A, MCB as outgoing feeders, the details are as follows:
Type Description Details of outgoing feeders) ACP-2 Outdoor 6 nos.-20 A single pole
MCB and3 No. 32 A Tripple pole MCB with Neutral and suitable timer and contactor for
automatic switching.
ACP-3 Outdoor street lighting 3 nos. 32A Tripple pole MCB panel
suitable timer and contactor for automatic switching
with Neutral with
Note: The number of outgoing feeders indicated above are the minimum.
2.1.2
INDOOR
415 V indoor AC lighting panel ,63 A 3 phase 4 wire bus and one number 63 amp TPN
MCB with 300ma 63 A RCCB. Flush mounted with per phase isolation and indication
lamps din mounted . The DB will be flush mounted.
ACP-1 Indoor 18 nos outgoing 16-32 Amps SPMCP
IN JASIDIH GSS VOL-II
Page 274
2.2 220V DC indoor type change over board and 220V DC 32A two wire bus and one 32A
contractor backed up by 32A double pole MCB as incomer. The panel shall have local
push button controls. Following are the various types of panels required with control timer.
Type Description Details of outgoing feeders) DCP Indoor 6 nos.-16A DP MCB unit
2.3 Sub-Lighting Panels
--------------------------------------------------------------------------------------------------- Type
Description -------------------------------------------------------------------------------------------------- SLP 4 pole 32A Isolator suitable for 415V, 50 cycles AC supply, with LILO facility
using 8 nos terminal
blocks suitable for cable upto 16 mm sq cable
Enclosure shall be suitable for outdoor use with IP-55 degree of protection as per IS:13947
(Part-1).
-------------------------------------------------------------------------------------------------2.4 Lighting Fixtures and Receptacles
Lighting Fixtures
--------------------------------------------------------------------------------------------------Type
Description
--------------------------------------------------------------------------------------------------SC 150W SON-T Tubular Sodium Vapour lamp in street lighting luminare. A special
optical reflector clear acrylic cover, a single piece die cast aluminium housing made out of
LM6 and corrosion resistance proof. Similar to Philips Cat No. SRX- 51 and Bajaj Cat No.
BJMSDT/150 / Crompton Greaves Cat No. SSG 23151H .(Street Light Luminaire should
be suitable for Bottom Entry/Side entry both for pipe mounting)
FI 2x36W flourescent lamps in industrial reflector type fixture, complete with
accessories and suitable for pendent Mounting, similar to Philips Cat. No. TKC
24/236/Bajaj Cat. No. : BJIV-236 /Crompton Greaves Cat No. 1VE 1224 HSB
IF Incandescent GLS lamp in recessed down light having high purity aluminium reflector
electrochemically brightened and anodized.
Stainless steel leaf springs and pressure die cast 1ceiling similar to Philips Cat.No. DN622 Crompton greaves cat DDLV 10-BC
SFI Wheather proof integral Floor Lighting with housing made of corrosion resistant die
cast aluminium painted black. Grey powder coated outside suitable for 150W SON-T lamp
complete with all accessories and suitable for termination with conduits/flexible
Cat. No. F69045 (C).Similar to Philips Cat. No. SWF230/150/BajajCat.No.BGEMF150WSV Crompton Greaves Cat No. FAD 11151H
SF2 2 x 400 / 2x250W HP Sodium vapour lamps in high Flood lighting fixture suitable
for outdoor mounting with aluminium enclosure : similar to PhilipsCat.No. SNT001/Bajaj
Cat.No. BJEF-22CA /Crompton Greaves Cat No. FHD1324
SF3 1 x 250 / 1 x 400 HP sodium vapour lamps in high Technical Specification,
IN JASIDIH GSS VOL-II
Page 275
flood lighting fixture suitable for outdoor mounting with aluminium enclosure and integral
control gear: similar to Phillips cat. No. SWF 330/ CGL Cat. No. FAD 1114/ Bajaj Cat.
No. BJEF T14CA.
PF 1x11 W CFL Lamp emergency light with Battery operated portable fixture with built
in chargable Batteries and battery charger suitable for a lighting period of six hours similar
to ALPHA DELUX of M/s DELTA FLASH LITE/MICRO LITE OF M/s MICRO /BPL
MAKE
FB 9W CFL lamp in Bulkhead fixtures with Cast Aluminium alloy body, suitable for
column, wall,and ceiling mounting finished stove enameled silver grey outside white
inside, to be supplied complete ( with front cover, wire guard, tropicalised, gasket and
lamp holder taped 3/4" E.T. for conduit entry) similar to Philips Cat.No.FXC 101/Bajaj
Cat.No. BJBE-19/Crompton Greaves.
FF 2x36W flourescent lamp with mirror optics in recessed mounting type decorative
flourescent fitting consisting of white stove enamelled sheet steel housing with accessories
and reflector of aluminium sheet steel duty electro-chemically brightened and anodised
fitted with aluminium lamellae painted white.Similar to Philips Cat.No. TBS-285/236 and
Bajaj Cat.No. BJLM-236/ Crompton Greaves Cat. No. CRFA 24 HSB
FL 2x36W flourescent lamps in decorative lighting fixture with widespread mirror
optics suitable for pendent mounting with twin tube complete with all accessories : similar
to philips cat-No. TCS-306/236 and Bajaj Cat.No. BJSM-236/Crompton Greaves Cat
No.CSB W 1124 HSB
MP 125 HP MV Lamp in weather proof post top latern with case aluminium canopy,
mounting piece, opal acrylic cover tropicated gasket and all other accessories for mounting
on pole top similar to philips Cat.No. HPC-101/Bajaj / Crompton Greaves
Cat No. MPT12IH/BC
IB 60/100w GLS lamp in Bulkhead fixtures with Cast
Aluminium alloy body, suitable for column, wall,and ceiling mounting finished stove
enameled silver grey outside white inside, to be supplied complete ( with front glass, wire
guard, tropicalised, gasket and E.S. Porcelain, lamp holder taped 3/4" E.T. for conduit
entry) similar to Philips Cat.No.NXC 101/ /Crompton Greaves IBH1110/BC
BL 2X9 Or 1x18 watt CFL bollard light for landscape lighting having FRP/LLDPE
housing similar to Philips FGC202 /Crompton Greaves Cat No CFBL1129
DLR
2x18 watt CFL Down light for recess mounting lighting having similar to
Philips FBH225/2X18 /Crompton Greaves Cat No DDLH218TG
DSM 1X13 WATT surface mounted CFL similar to Art Light Make Cat NO RL 3146
HL 2X 18 CFL Decorative hanging down Light Simiilar to cat no Art light RL 3166/HL
CL 1X 18 WATT Decorative celling mounted luminaire similar to Philips Dixie Cat FL
343/118
--------------------------------------------------------------------------------------------------IN JASIDIH GSS VOL-II
Page 276
2.5 RECEPTACLES
RO 15A, 240V, Outdoor Receptacle 2 pole, 3- pin type R1
5/15A, 240V,
Indoor Receptacle 3-pin type.
RP 63A, 415V, Interlocked switch
socket, outdoor receptacle ------------------------------------------------------------------------------------------------2.6 SWITCH BOARDS
Modular type switches, 5/15 Amp. Receptacles.
2.7 CONDUITS AND ACCESSORIES
Galvanised Rigid Steel Conduits of 19mm/25mm/32mm/40mm dia.
2.8 JUNCTION BOXES with 5 Nos.of terminal blocks
2.9 LIGHTING POLES - (Type A1 poles & Type E1 poles)
2.10 CEILING FANS-1400 mm Sweep with Electronic regulator
2.11 MAINTENANCE EQUIPMENT
i) A type Aluminium ladder of 3 mtr vertical height. ii) Cartwheel mounted
aluminium ladder Vertical Height 7.5 Mtrs. When
Extended
2.12 LIGHTING TRANSFORMER
Supply, erection, testing and commissioning of 100 kVA or above (in case the capacity of
transformer required is higher than 100 KVA as per approved calculations) / 25KVA (in
case of substations where highest voltage level is 132kV), 415/415 V, 3 phase, 50 Hz Dry
type natural air cooled lighting
transformers. The technical parameters of these
lighting transformers are as follows:
Technical Parameters of Lighting Transformer
Type of transformer : Dry type natural air cooled Rating : 100 KVA or above
25
KVA (as applicable) Voltage ratio : 415/415 volts No. of phases : Three Frequency
: 50 Hz Winding connection : Dyn-1 Class of insulation : 'B' class Impedance : 4% ±
10% No. of taps & steps : 5, ± 5% in steps of 2.5% Ref. standard : IS:2026
The enclosure for the above transformer shall have degree of protection not less than IP42. The rating of lighting transformer should be suitable for lighting load. The contractor
shall submit the supporting calculation for the rating of lighting transformer.
3. LIGHTING FIXTURES AND ACCESSORIES
3.1 General
All lighting fixtures and accessories shall be designed for continuous operation under
atmospheric conditions existing at site, without reduction in the life or without any
deterioration of materials, internal wiring.
3.2 Temperature Rise
All lighting fixtures and accessories shall be designed to have a low temperature rise
according to the relevant Indian Standards. The design ambient temperature shall be taken
as 50 deg.C.
IN JASIDIH GSS VOL-II
Page 277
3 .3 Supply Voltage
3.3.1 Lighting fixtures and accessories meant for 240V A.C. operation shall be suitable for
operation on 240V A.C. 50Hz, supply voltage variation of ± 10%, frequency variation of ±
5% and combined voltage and frequency variation of ± 10%. Technical
3.3.2 Lighting fixture and accessories meant for 220V DC operation shall be suitable for
operation on 220V DC with variation between 190 to 240 Volts.
3.4 Lighting Fixtures
The lighting fixtures shall be philips or Bajaj or Crompton Greaves make only except for
fixtures type ‘DSM’ & ‘HL’ for which make has been specified elsewhere in this section.
The different types of lighting fixtures are also indicated elsewhere in this Section.
3.4.1 All fixtures shall be designed for minimum glare. The finish of the fixtures shall be
such that no bright spots are produced either by direct light source or by reflection.
3.4.2 All lighting fixtures shall be complete with fluorescent tubes / incandesent
lamps/mercury vapour/sodium vapour lamps as specified and shall be suitably wired up.
3.4.3 All flourescent lamp fixture shall be complete with all accessories like ballasts, power
factor improvement capacitors, lamps, starters, holders etc.
3 4.4. High beam fixtures shall be suitable for pendant mounting and flood lights shall
have suitable base plate / frame for mounting on steel structural member. Hook mounted
high beam fixtures are not acceptable.
3.4.5 Each lighting fixture shall be provided with an earthing terminal suitable for
connection to 16 SWG GI earthing conductors.
3 .4 6. All light reflecting surfaces shall have optimum light reflecting co-efficient such as
to ensure the overall light output as specified by the manufacturer.
3.4.7 Height of fixtures should be such that it is easy to replace the lamps with normal
ladder/stool. In case the ceiling height is very high, the fixtures may be placed on the walls
for ground lighting.
3.5 ACCESSORIES
3.5.1 Reflectors
The reflectors shall be manufactured from sheet steel or aluminium as applicable. They
shall be securely fixed to the captive type.
3.5.2 Lamp holders and Starter Holders
(a) Lamp holders/starter holders for fluorescent tubes shall be of the spring loaded, low
contact resistance, bi-pin rotor type, resistant to wear and suitable for operation at the
specified temperature, without deterioration in insulation value, contact resistance or
IN JASIDIH GSS VOL-II
Page 278
retention of the lamp/starter. They shall hold the lamp/starter in position under normal
condition of shock and vibration.
(b) Lamp holders/starter for incandescent lamps and HPMV/HPSV lamps shall be of
screwed type, manufactured in accordance with relevant standard and designed to give
long and satisfactory service.
3.5.3 Ballasts
a) The Ballasts shall be designed, manufactured and supplied in accordance with relevant
standard and function satisfactorily under site condition specified. The ballasts shall be
designed to have a long service life and low power loss.
b) Ballasts shall be mounted using self locking anti-vibration fixing and shall be easy to
remove without dismantling the fixtures. They shall be totally enclosed units.
c) The ballasts shall be of the inductive, heavy duty type, filled with thermosetting
insulating moisture repellent polyester compound filled under pressure or vacuum. The
ballast wiring shall be of copper wire. They shall be free from hum. Ballasts which
produce humming sound shall be replaced free of cost by the Contractor. Ballasts for high
pressure mercury vapour/ HPSV lamps shall be provided with suitable tappings to set the
voltage within the range specified. End connections and taps shall be brought out in a
suitable terminal block, rigidly fixed to the ballast enclosure.
d) Separate ballast for each lamp shall be provided in case of multi-lamp fixtures.
3.5.4 Starters
Starters shall have bimetal electrodes and high mechanical strength. Starters shall be
replaceable without disturbing the reflector or lamps and without the use of any tool.
Starters shall have brass contacts and radio interference suppressing capacitor.
3.5.5 Capacitors
a) The capacitors shall have a constant value of capacitance and shall be connected across
the supply of individual lamp circuits.
b) The capacitors shall be suitable for operation at supply voltage as specified and shall
have a value of capacitance so as to correct the power factors of its corresponding lamp
circuit to the extent of 0.98 lag.
c) The capacitors shall be hermetically sealed in a metal enclosure.
3.6 Lamps
3.6.1 General Lighting Services (GLS) lamps shall be provided with screwed caps and
shall be of 'clear' type unless otherwise specified.
3.6.2 The flourescent lamps shall be 'Day-light-colour' type unless otherwise specified and
shall also be provided with features to avoid blackening of lamps ends. The Bidder should
clearly state these features in the bid.
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3.6.3 Mercury vapour lamps, sodium vapour lamps shall be colour corrected type, with
screwed caps.
3.7 The Bidder shall furnish typical wiring diagram for Fluorescent, HPMV & HPSV
fitting including all accessories. The diagram shall include technical details of accessories
i.e. starters, chokes, capacitors etc.
3.8 Flexible conduits if required, for any fixture shall be deemed to be included in
Contractor’s scope.
4. RECEPTACLES
a) All receptacles shall be of cast steel/aluminium, heavy duty type, suitable for fixing on
wall/column and complete with individual switch.
b) In general the receptacles to be installed are of the following types :
i) Type RO-15A, 240V, 2 pole, 3 pin type with third pin grounded, metal clad with gasket
having cable gland entry suitable for 2Cx6 sq.mm. PVC/aluminium armoured cable and a
metallic cover tied to it with a metallic chain and suitable for installation in moist location
and or outdoor. The switch shall be of rotary type. Receptacles shall be housed in an
enclosure made out of 2 mm thick Gl sheet with hinged doors with padlocking
arrangements. Door shall be lined with good quality gasketing. This shall conform to IP55.
ii) Type RI The 5/15 amp 6 pin receptacles with switches will be of Modular type with
flush type switches and electroplated metal enclosures of approved make
iii) Type RP - 63A, 415V, 3 phase, 4 pin interlocked plug and switch with earthing
contacts. Other requirements shall be same as type RO. The receptacle shall be suitable
for 3.5C x 35/3.5Cx70
sq.mm. aluminium conductor cable entry and shall also be suitable for loop-in and loop out
connection of cables of identical size. Receptacle shall be suitable for outdoor application.
Receptacles shall be housed in a box made out of 2mm thick G.I. sheet, with hinged door
with padlocking arrangement. Door shall be lined with good quality gasketing. This shall
conform to IP-55.
5. SWITCH AND SWITCHBOARD
(a) All Switch board/boxes, 5/15 Amp Receptacles and electronic fan regulators located in
office/building areas shall be modular flush mounted type or brick wall with only the
switch knob projecting outside.
(b) Switch boards/boxes shall have conduit knock outs on all the sides. Adequate
provision shall be made for ventilation of these boxes.
(c) The exact number of switches including regulator for fans and layout of the same in
the switchboard shall be to suit the requirement during installation.
(d) The maximum number of luminaires ,controlled by one no 6 amp switch would 4
nos. For DC fixtures there will be no switch and the same shall be directly controlled
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from DC LP
(e)
The luminaires shall be wired in such a fashion that luminaires on each
phase are evenly distributed all over the room.
6. CONDUITS & CONDUIT ACCESSORIES
6.1 The conduits shall conform to IS:9537. All conduits shall be seemed by welding, shall
be of heavy gauge and shall be hot dip galvanised.
6.2 Flexible conduits wherever required shall be made with bright, cold rolled annealed
and electro-galvanised mild steel strips.
6.3 All conduits accessories shall conform to relevant IS and shall be hot dip galvanised.
7. JUNCTION BOXES
7.1 The junction boxes shall be concealed type for indoor lighting and suitable for
mounting on columns, lighting poles, structures etc., for outdoor lighting.
7.2 Junction boxes shall be of square/rectangular type of 1.6 mm sheet steel with minimum
6 mm thick pressure diecast aluminium material LM-6 and shall have bolted cover with
good quality gasket lining.
7.3 The junction box and cover shall be hot dip galvanised.
7.4. The junction boxes shall be complete with conduit knockouts/threaded nuts and
provided with terminal strips .The junction boxes shall be suitable for termination of
conduit/glands of dia 20 mm, 25 mm, 32 mm, 40 mm on all sides. The junction boxes
shall be provided with 4 way terminals suitable for two numbers 10 sq. mm. wire & for
street lighting/switchyard lighting suitable for 2 numbers 4C x 16 Sq.mm Al. cable.
7.5 The junction boxes shall have the following indelible markings
(i) Circuit Nos. on the top.
(ii) Circuit Nos. with ferrules (inside) as per drawings. (iii) DANGER sign in case of 415
volt junction box.
7.6 The junction boxes shall be weather proof type with gaskets conforming to IP 55 as per
IS:13947 (Part I) . The conduit connections shall also be properly sealed to prevent entry of
water.
8. TERMINAL BLOCKS
8.1 Each terminal shall be suitable for terminating upto 2 Nos. 10 sq.mm. stranded
Aluminium Conductors without any damage to the conductors or any looseness of
connections. Terminal strips provided in street - lighting poles shall be suitable for
terminating upto 2 nos. 4C x 16 sq. mm aluminium cables.
9. PULL OUT BOXES
9.1. The pull out boxes shall be concealed type for indoor lighting and suitable for
mounting on column, structures etc., for outdoor lighting. The supply of bolts, nuts and
screws required for the erection shall be included in the installation rates.
9.2 The pull out boxes shall be circular of cast iron or 16 SWG sheet steel and shall have
IN JASIDIH GSS VOL-II
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cover with good quality gasket lining.
9.3 The pull out boxes and cover shall be hot dip galvanised.
9.4 The pull out boxes shall be completed with conduit knock outs/threaded hubs and
provided at approximately 3 meters intervals in a conduit run.
10. LIGHTING PANELS (L.P.)
10.1 Each panel shall be provided with one incoming triple pole MCB with neutral link and
outgoing miniature circuit breakers as per clause 2.0. The panels shall conform to IS-8623.
10.2 Constructional Features
10.2.1 Panels shall be sheet steel enclosed and shall be dust, weather and vermin proof.
Sheet steel used shall be of thickness not less than 2.00 mm (cold rolled) or 2.5 mm (hot
rolled) smoothly finished, levelled and free from flaws. Stiffners shall be provided
wherever necessary.The indoor lighting panels will be ready made DB of minimum 20 swg
sheet thickness .
10.2.2 The panels shall be of single front construction, front hinged and front connected,
suitable for either floor mounting on channels, sills or on walls/columns by suitable M.S.
brackets.
10.2.3 Panels shall have a dead front assembly provided with hinged door(s) and out door
panels will be with padlocking arrangement with single key supplied in duplicate.
10.2.4 All out door panels , removable covers, doors and plates shall be gasket all around
with neoprene gaskets.
10.2 5 The panels shall be suitable for cable/conduit entry from the top and bottom.
Suitable removable cable gland-plate shall be provided on the top and bottom of panels.
Necessary number of double compression cable gland shall be supplied, fitted on to this
gland plate. The glands shall be screwed on top and made of tinned brass.
10.2.6 The panels shall be so constructed as to permit free access to connection of
terminals and easy replacement of parts.
10.2.7 Each panel shall have a caution notice fixed on it.
10.2.8 Each panel will be provided with directory holder in which printed and laminated as
built circuit directory would be kept
10.2.9 Each Outdoor lighting panel shall be provided with one no. ‘ON’ indicating lamp
for each phase alongwith fuses.For indoor lighting panels din mounted phase indication
lamps will be provided , mounted along side of the MCB
10.3 Main Bus Bars
10.3.1 Bus bars shall be of aluminium alloy conforming to IS:5082 and shall have adequate
cross-section to carry the rated continuous and withstand short circuit currents. Maximum
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operating temperature of the bus bars shall not exceed 85 deg. C. The bus bars shall be
able to withstand a fault level of 9 kA for 1 sec. for AC panels and 4 KA for 1 sec. for DC
panels.The Indoor lighting panels shall have copper bus bar
10.4 Residual Current Circuit Breakerss (RCCB)
10.4.1 For indoor panels 63A 4pole 300 ma conforming IS 12640 will be provided
along with incomer
10.5 Miniature Circuit Breaker (MCB)
a) The miniature circuit breakers shall be suitable for manual closing, opening, automatic
tripping under overload and short circuit. The MCBs shall also be trip free.
b) Single pole as well as three pole versions shall be furnished as required in the Schedule
of Lighting Panels.
c) The MCBs and panel MCCB together shall be rated for full fault level. In case the
MCB rating is less than the specified fault level the bidder shall co-ordinate these breaker
characteristics with the back up MCCB in such a way that if fault current is higher than
breaker rating, the MCCB should blow earlier than the breaker. If the fault current is less
than MCB breaking capacity, MCB shall operate first and not the incomer MCCB.
d) The MCBs shall be suitable for housing in the lighting panels and shall be suitable for
connection with stranded copper wire connection at both the incoming and outgoing side
by copper lugs or for bus bar connection on the incoming side.
e) The terminals of the MCBs and the ‘open’ ‘close’ and ‘trip’ conditions shall be clearly
and indelibly marked.
f) The tenderer shall check and co-ordinate the ratings of MCBs with respect to starting
characteristics of discharge lamps. The vendor has to furnish overload and short circuit
curve of MCB as well as starting characteristics curves of lamps for Employer’s approval.
g) The MCB shall generally conform to IS:8828.
10.6 Contactors
Contactors shall be of the full voltage, direct-on line air break, single throw, electromagnetic type. They shall be provided with atleast 2-’NC’ and 2’NO’ auxiliary contacts.
Contactor shall be provided with the three element, positive acting, ambient temperature
compensated time lagged, hand reset type thermal overload relay with adjustable settings
to suit the rated current. Hand reset button shall be flush with the front of the cabinet and
suitable for resetting with starter compartment door closed. The Contactor shall be suitable
for switching on Tungsten filament lamp also. The bidder shall check the adequacy of the
Contactors rating wire with respect to lighting load.
10.7 Push Buttons
All push buttons shall be of push to actuate type having 2 ‘NO’ and 2 ‘NC’ self
reset contacts. They shall be provided with integral escutcheon plates engraved with their
functions. Push buttons shall be of reputed make.
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10.8 Labels
a) The lighting panels shall be provided on the front with panel designation labels on a 3
mm thick plastic plate of approved type. The letter shall be black engraved on white back
ground.
b) All incoming and outgoing circuits shall be provided with labels. Labels shall be made
of non-rusting metal or 3 ply lamicold. Labels shall have white letters on black or dark
blue background.
10.9 Earthing Terminals
Panels shall be provided with two separate and distinct earthing terminals suitable to
receive the earthing conductors of size 50x6 G.S. Flat.
10.10 Type test reports for following tests on all lighting panels shall be submitted for
approval as per clause 9.2 of section : GTR.
(i) Wiring continuity test
(ii) High voltage (2.5 KV for 1 minute) and insulation test (iii) Operational test
(iv) Degree of protection (not less than IP-55 test on outdoor Lighting Panels and IP-52
test on indoor Lighting Panels as per IS 13947 (part I)) (v) Heat run test
10.11 Lighting Transformer
Lighting transformer shall be located in MCC room, in seperate enclosure. Enclosure shall
have degree of protection not less than IP-42 as per IS-13947 (Part-I).
11. Emergency Portable Lighting Fixtures
11.1 The portable fixtures shall have a built in battery rated for six hours, battery chargers
and solid state inverters. These shall be of approved make.
11.2 The portable fixtures shall be of a single unit, completely tropicalised and suitable for
prolonged use with no maintenance.
11.3 The portable fixtures shall be supplied and necessary supporting brackets of
galvanised steel suitable for wall/column mounting shall also be supplied.
11.4 The portable fixture shall come up automatically in the event of failure of normal
supply.
12. LIGHTING POLES
12.1 The Contractor shall supply, store and install the following types of steel tubular
lighting poles required for street lighting.
a) Type A1 Street Lighting Pole - for one fixture
b) Type E1 Post top lantern pole - for one fixture
12.2 Street/flood light poles shall conform to the enclosed drawings. In front of control
room building , DG Set and Fire Fighting Buildings, decorative post top lantern (Type E1)
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poles and Bollards shall be installed as per the quantities given in the tender drawing.
12.3 Lighting poles shall be complete with fixing brackets and junction boxes. Junction
boxes should be mounted one meter above ground level.
12.4 The lighting poles shall be coated with bituminous preservating paint on the inside as
well as on the embedded outside surface. Exposed outside surface shall be coated with two
coats of metal primer (comprising of red oxide and zinc chromate in a synthetic medium).
12.5 The galvanised sheet steel junction box for the street lighting poles shall be
completely weather proof conforming to IP-55 and provided with a lockable door and HRC
fuse mounted on a fuse carrier and fuse base assembly. The fuses & junction box shall be
as specified in the specification. However, terminals shall be stud type and suitable for 2
nos. 16 sq.mm. cable.
12.6 Wiring from junction box at the bottom of the pole to the fixture at the top of the pole
shall be done through 2.5 sq. mm wire.
12.7 Distance of centre of pole from street edge should be approximately 1000 to 1200
mm.
12.8 Earthing of the poles should be connected to the switchyard main earth mat wherever
it is available and the same should be earthed through 3M long, 20 mm dia, earth electrode.
13. CEILING & WALL MOUNTED FANS AND REGULATORS
13.1 The contractor shall supply and install 1400 mm sweep ceiling fans complete with
electronic regulator and switch, suspension rod, canopy and accessories.The wall mounted
fans shall be of 400 mm sweep
13.2 The contractor shall supply and install the switch, electronic regulator and board for
mounting switch and electronic regulator for celling fans.
13.3 Winding of the fans and regulators shall be insulated with Class-E insulating
material. Winding shall be of copper wire.
13.4 Electronic regulator with smooth control shall be provided.
13.5 Fans and electronic regulators shall be of Alstom / Crompton Greaves / Bajaj
Electricals / Usha Electricals make.
14. LIGHTING WIRES
14.1 The wiring used for lighting shall be standard products of reputed manufacturers.
14.2 The wires shall be of 1100 V grade, PVC insulated product of reputed manufacturers.
14.3 The conductor sizes for wires used for point wiring beyond lighting panels shall be
single core 4 sq. mm., 6 sq.mm and 10 sq.mm stranded aluminium wires and 2.5 sq.mm, 4
sq.mm, 6 sq.mm and 1.5 sq.mm stranded copper wire.
14.4 The wires used for connection of a lighting fixture from a nearest junction box or for
loop-in loop-out connection between two fluorescent fixtures shall be single core copper
stranded conductor, 1100V grade flexible PVC insulated cords, unsheathed, conforming to
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IS:694 with nominal conductor cross sectional areas of 2.5 sq. mm.
14.5 The wires shall be colour coded as follows:
Red for R - Phase
Yellow for Y - Phase
Blue for B - Phase
Black for Neutral
White for DC (Positive)
Grey for DC (Negative)
15. PAINTING OF SHOP MADE ITEMS
15.1 All sheet steel work shall be phosphated in accordance with the following procedure
and in accordance with IS:6005 'Code of Practice for Phosphating Iron and Steel'.
15.2 Oil grease and dirt shall be thoroughly removed by emulsion cleaning.
15.3 Rust and scale shall be removed by pickling with dilute acid followed by washing
with running water, rinsing with slightly alkaline hot water and drying.
15.4 After phosphating through rinsing shall be carried out with clean water, followed by
final rinsing with diluted dichromate solution and oven drying.
15.5 The phosphate coating shall be sealed by the application of two coats of ready mixed
stoving type metal primer (comprising of red oxide and Zinc chromate in a
synthetic medium). The first coat may be 'flash dried' while the second coat shall be stoved.
15.6 After application of the primer, two coats of finishing synthetic enamel paint shall be
applied with each coat followed by stoving. The second finishing coat for the external of
panels shall be applied after completion of tests.The panels can also be powder coated
instead of painting after surface treatment as given above.
15.7 Both outside and inside of lighting panel, sheet metal fabricated junction boxes etc.
and outside of lighting fixtures shall be finished in light grey (IS-5 shade 631). Inside of
lighting fixtures shall be finished in white. The colour of indoor lighting panels should
match with colour of wall.
15.8 Each coat of primer and finishing paint shall be of slightly different shade so as to
enable inspection of the painting.
15.9 The final finished thickness of paint film on steel shall not be less than 100 microns
and shall not be more than 150 microns.The final thickness of powder coating will not be
less than 50 microns. For indoor lighting panels the painting will be as per approved
manufacturers specification.
15.10 Finished painted appearance on equipment shall present on aesthetically pleasing
appearance, free from dents and uneven surfaces.
16. LIGHTING SYSTEM INSTALLATION WORKS
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16.1 General
16.1.1 In accordance with the specified installation instructions as shown on
manufacturer’s drawings or as directed by Employer, Contractor shall unload, erect, install,
test and put into commercial use all the electrical equipment included in the contract.
Equipment shall be installed in a neat, workmanship manner so that it is level, plumb
square and properly aligned and oriented. Tolerances shall be as established in
manufacturers drawing or as stipulated by Purchaser.
16.1.2 All apparatus, connections and cabling shall be designed so as to minimise risk of
fire or any damage which will be caused in the event of fire.
16.2 Conduit System
16.2.1 Contractor shall supply, store and install conduits required for the lighting
installation as specified. All accessories/fittings required for making the installation
complete, including but not limited to pull out boxes (as specified in specification ordinary
and inspection tees and elbow, checknuts, male and female bushings (brass or galvanised
steel), caps, square headed make plugs, nipples, gland sealing fittings, pull boxes, conduits
terminal boxes, glands,
gaskets and box covers, saddle terminal boxes, and all steel supporting work shall be
supplied by the Contractor. The conduit fittings shall be of the same material as
conduits.The contractor shall also supply 19 mm PVC conduit and accessories for
telephone wiring.
16.2.2 All unarmoured cables shall run within the conduits from lighting panels to lighting
fixtures, receptacles. etc.
16.2.3 Size of conduit shall be suitably selected by the Contractor.
16.2.4 Conduit support shall be provided at an interval of 750 mm for horizontal runs and
1000 mm for vertical runs.
16.2.5 Conduit supports shall be clamped on the approved type spacer plates or brackets by
saddles or U-bolts. The spacer plates or brackets in turn, shall be securely fixed to the
building steel by welding and to concrete or brick work by grouting or by nylon rawl plugs.
Wooden plug inserted in the masonary or concrete for conduit support is not acceptable.
16.2.6 Where conduits are alongwith cable trays they shall be clamped to supporting steel
at an interval of 600 mm.
16.2.7 For directly embedding in soil, the conduits shall be coated with an asphalt-base
compound. Concrete pier or anchor shall be provided wherever necessary to support the
conduit rigidly and to hold it in place.
16.2.8 For long conduit run, pull boxes shall be provided at suitable intervals to facilitate
wiring.
16.2.9 Conduit shall be securely fastened to junction boxes or cabinets, each with a lock
nut inside and outside the box.
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16.2.10 Conduits joints and connections shall be made through water-tight and rust proof
by application of a thread compound which insulates the joints. White lead is suitable for
application on embedded conduit and red lead for exposed conduit.
16.2.11 The entire metallic conduit system, shall be embedded, electrically continuous and
thoroughly grounded. Where slip joints are used, suitable bounding shall be provided
around the joint to ensure a continuous ground circuit.
16.2.12 Conduits and fittings shall be properly protected during construction period against
mechanical injury. Conduit ends shall be plugged or capped to prevent entry of foreign
material.
16.3 Wiring
16.3.1 Wiring shall be generally carried out by PVC insulated wires in conduits. All wires
in a conduit shall be drawn simultaneously. No subsequent drawings of wires is
permissible.
16.3.2 Wires shall not be pulled through more than two equivalent 90 deg. bends in a
single conduit run. Where required, suitable junction boxes shall be used.
16.3.3 Wiring shall be spliced only at junction boxes with approved type terminal strip.
16.3.4 For lighting fixtures, connection shall be teed off through suitable round conduit or
junction box, so that the connection can be attended without taking down the fixture.
16.3.5 For vertical run of wires in conduit, wires shall be suitably supported by means of
wooden/hard rubber plugs at each pull/junction box.
16.3.6 Maximum two wires can be terminated to each way of terminal connections.
16.3.7 Separate neutral wires are to be provided for each circuit.
16.3.8 AC and DC wiring should not run through the same conduit.
16.4 Lighting Panels
16.4.1 The lighting panels shall be erected at the locations to be finalised during detailed
engineering.
16.4.2 Suitable foundations/supporting structures for all outdoor type lighting panels shall
be provided by the Contractor.
16.5 Foundation & civil works
16.5.1 Foundation for street lighting poles, panel foundation and transformer foundation
shall be done by the Contractor..
16.5.2 All final adjustment of foundation levels, chipping and dressing of foundation
surfaces, setting and grouting of anchor bolts, sills, inserts and flastening devices shall be
carried out by the Contractor including minor modification of civil works as may be
required for erection.
16.5.3
Any cutting of masonary / concrete work, which is necessary shall be done by
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the Contractor at his own cost and shall be made good to match the original work.
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14. BATTEY AND BATTEY CHARGER
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BATTEY AND BATTEY CHARGER
Table of contents
Clause No.
Description
1.1
GENERAL TECHNICAL REQUIREMNTS
1.2
Battery
1.3
Battery Charger
Annexure-I
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1.
1.1
2.
2.0
2.1
2.2
2.3
2.3.1
2.4
3.
3.1
3.1.1
3.1.2
3.1.3
4.
4.1
4.2
General Technical Specification for Battery
SCOPE
This standard specifies rated Ah capacities, overall dimensions, performance requirements
and tests for tubular type lead-acid stationary batteries in transparent SAN container and
associated accessories for indoor installation.
TERMINOLOGY
For the purpose of this standard, the definitions given in IS:1651-1979, DIN40736 in addition
to the following shall apply.
Fully-Charged Condition – The Cell shall be considered as fully charged when the specific
gravity readings and the voltage of the cell at a specific temperature remains constant over
three consecutive hourly readings; the charging rate during the period being maintained
constant.
Type Tests – Tests carried out to prove conformity with the requirements of this standard.
These are intended to prove the general quality and design of a given type of battery.
Acceptance Tests – Tests carried out on samples selected from a lot for the purpose of
verifying the acceptability of the lot.
Lot – All batteries of the same type, design and rating, manufactured by the same factory
during the same period, using the same process and materials, offered for inspection at a time
shall constitute a lot.
Routine Tests – Tests carried out on every battery.
RATING AND DESIGNATION
Ampere-Hour Rating – The rating assigned to the cell shall be the capacity expressed in
ampere-hours (after correction to 270C) stated by the manufacturer to be obtainable when the
cell is discharged at the 10-hour rate (C10) to a final voltage of 1.85 volts.
The positive plates being of tubular type shall be designated by the letter ‘T’.
The capacity rating shall be indicated by a number equal to the capacity in Ah.
The material of container shall be designated by any one of the following letters, as the case
may be:
G – For Glass;
H – For Hard-Rubber;
P – For Plastics;
W – For wood, lead-lined; or
F – For fiber reinforced plastics (FRP).
DESIGN AND CONSTRUCTIONAL FEATURES OF BATTERY
Type: The battery shall be lead acid tubular type in Transparent SAN container. Sealed
Maintenance Free VRLA type/ Nickel Cadmium type batteries are not acceptable.
Positive Plates:
The plates shall be of first class material and workmanship and shall be
free from blow-holes, cracks and other imperfections. The tubular positive plates shall consist
of a suitable bar with spines cast of suitably alloyed lead to give adequate mechanical strength
and minimum electrical resistance.
The tubular spines shall be cast of an alloy of Pb and Antimony with Antimony content not
greater than 3% by weight. The casting shall be done using proper controlled procedure
preferably using high pressure casting machine with an operating pressure not less than 90100 Bars. Low antimony alloy (not greater than 3%) will ensure low water loss and a
guaranteed topping up frequency of not more than once in 12 months. High pressure cast
spines will ensure a long life and trouble-free operation.
Porous, acid resistant and oxidation resistant tubes shall be inserted one over each spine. After
insertion, the tube shall be adequately filled and packed with active material (preferable
through a rotary shaking machine) before their lower ends are closed by common plastic bar.
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4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
The construction and material of tube shall be such as to reduce the loss of active material and
shall be able to withstand normal internal stresses developed during service.
Negative Plates:
The negative plates shall be of flat pasted type and should be made of
lead-calcium alloy. The pasting shall be done on an automated machine for better control of
process parameters. It should have adequate mechanical strength and would be so designed
that active material isd maintained in intimate contact with the grid under normal working
conditions throughout the life of the battery.
Separators: The separators shall be micro-porous type to avoid direct as well as side shorts.
It should be acid resistant, chemically inert and should have excellent oxidation resistance and
high degree of porosity to ensure minimum internal resistance. Average volume porosity
should be more than 45%. It should not exhibit any tendency to swell or shrink at temperature
encountered during operation. Micro-porous synthetic separators shll conform to latest
IS:6071.
Containers: Containers shall preferably be made of transparent SAN copolymer giving
excellent clarity, outstanding chemical resistance, rigidity and toughness with very high
insulating qualities which eliminate the need for separate cell insulators. It shall have
adequate mechanical strength to prevent bulging, cracking etc. during the life span of battery
when operating under expected temperature range and due to action of static and dynamic
loads and the action of electrolyte. These containers should enable the electrolyte level and
the cell condition to be monitored at a glance. The containers shall conform to latest edition of
IS-1146.
Cell Lids:
It should be moulded from opaque SAN or ABS and sealed to the container. It
should be easily removable if the need arises.
Micro-porous Ceramic Vent Plugs:
The vent plugs should be specially designed
incorporating a micro-porous ceramic filter which effectively returns all acid spray to the cell,
but allow free exit of oxygen and hydrogen which is generated at the end of boost charging.
On removal, the plugs shall permit drawing of the electrolyte sample for servicing and of
checking of the electrolyte level. The vent plug should preferably be flame retardant type to
prevent any fire hazard in the battery room.
Connectors and Fasteners: Connectors shall be made of copper and completely insulated
with rubber/ plastics. Connectors should be adequately designed to carry maximum duty cycle
as specified and shall offer minimum resistance. The current density for Copper connectors
shall not be more than 15 Amps/ sq. mm. While considering the terminal voltage of the cell at
the time of testing for discharge, the voltage drop due to inter-row and inter-cell connectors
shall be considered. Connectors shall be adequately designed to withstand various stresses due
to temperature changes, attack of acid and dynamic forces that could occur during the
operation of the battery. Fasteners should be made of suitable material and should also be
completely insulated.
Electrolyte: The electrolyte shall be battery grade sulphuric acid conforming to latest
edition of relevant IS 266. The strength of the electrolyte in the cell during operation shall
conform to the governing IS specification for the cell. Required quantity of electrolyte for the
initial filling with 10% extra quantity shall be supplied in no-returnable no-degradable acid
resistant strong plastic containers.
Water:
Water used in preparation of electrolyte and also to bring the level of
electrolyte to the correct position during the course of operation or testing shall conform to the
latest edition of IS-1069.
Terminal Post:
Positive and negative terminal posts of the cells shall be clearly and
unmistakably identifiable. Terminal posts shall be designed to accommodate external bolted
connections conveniently and positively. All metal parts of the terminals shall be of lead
coated type. Bolts, heads and nuts, except seal nuts, shall be hexagonal and shall be lead
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5
5.1
5.2
6
6.1
6.2
7
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.3
7.4
coated. Terminal posts shall be adequately fixed to prevent its turning or twisting when the
connectors are being fixed or removed. The junction between terminal posts and cover and
between the cover and container shall be adequately sealed to prevent any seepage of the
electrolyte. All terminals shall be provided with insulated covers.
The pole terminal should be of lead with a brass core insert, which shall increase the
conductivity. The pole should have a double layered protection against crevice corrosion. The
lead lining of the terminal should be protected against any contact with the electrolyte at the
place where it emerges out of the cell interior through an injection moulded plastic
encapsulation.
MARKING AND PACKING
Marking – The following information shall be indelibly and durably marked on the outside of
the cell.
a)
Manufacturer’s type and trade name,
b)
Ah capacity at 10-hour rate,
c)
Upper and lower electrolyte level in case of transparent containers,
d)
Year of manufacture, and
e)
Country of origin.
Packing – The cells shall be suitably packed so as to avoid any loss or damage during transit.
MANUAL OF INSTRUCTIONS
The manufacturer shall supply one copy of instruction manual for initial treatment and routine
maintenance during service, with every batch of batteries.
The following information shall be provided on the instruction cards:
a)
Designation of cell or battery;
b)
Ah capacity;
c)
Nominal voltage;
d)
Manufacturer’s instructions for filling, initial charging;
e)
Normal and finishing charging rates; and
f)
Maintenance instructions.
GENERAL REQUIREMENTS FOR TESTS
Temperature for Testing – Unless it becomes unavoidable, test discharge should not be
taken when the temperature of the electrolyte exceeds 350C.
Test Equipment
Voltmeter – The voltmeter used for tests shall be of an accuracy class not inferior to 0.5 in
accordance with IS:1248-1968. The resistance of the voltmeter used shall be at least 1000
ohms per volt (see IS:1248-1968). The range of the voltmeter used shall be such that the
magnitude of the voltage to be measured falls in the last third part of the scale.
Ammeter – The ammeter used for tests shall have an accuracy class not inferior to 1.0 (see
IS:1248-1968). The range of ammeter used shall be such that the magnitude of the current to
be measured falls in the last third part of the scale.
Thermometer – A thermometer with an appropriate scale shall be used for measuring
temperature and one division of the graduated scale shall represent at the most 10C. The
accuracy of the calibration shall be not less than 0.50C.
Hydrometer – The specific gravity of the electrolyte shall be measured by a hydrometer
provided with a graduated scale, one division of which shall represent at the lost 0.005 unit of
specific gravity. The accuracy of calibration shall be not less than 0.005 unit of specific
gravity.
First Charge – The cell if received in dry uncharged condition shall be filled with the
electrolyte and shall be first charged in accordance with the manufacturer’s instructions.
Specific Gravity of Electrolyte – The standard specific gravity of a fuly charged cell shall be
adjusted to 1.200 + 0.005 corrected at 270C in accordance with 3.2.2 of IS:8320-1976.
IN JASIDIH GSS VOL-II
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7.5
7.5.1
7.5.2
7.5.3
7.5.4
7.6
Observation
While charging the cell, the voltmeter hydrometer and thermometer readings shall be recorded
at suitable intervals.
During the discharge at 10-hour rate the voltmeter readings shall be recorded every hour for
the first eight hours and every fifteen minutes thereafter upto the end voltage.
The hydrometer and thermometer readings at hourly intervals and at the end of the discharge
shall be recorded only on the pilot cell (s).
The first and the last readings of hydrometer and thermometer shall be made on all the cells.
Water shall be added, if required to correct the electrolyte level during a test, just before the
charge so that thorough mixing with electrolyte is facilitated.
Note : For 48V, 500AH and 250v, 500 AH suitable battery and charger sets comprising above
components and meeting technical requirements with suitable increased rating as and where
applicable, must be furnished.
IN JASIDIH GSS VOL-II
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48V, 500 AH BATTERY SET
One set of 48 V indoor storage battery bank, each set comprising of 24 Nos. closed type lead acid
cells with positive plates and capacity of 500 AH at 10 hours discharge rate at 27 degree C complete
with all accessories and devices including but not limited to the following:
i)
Battery stand made of first class CP teak wood.
ii)
Rubber cell pads, if required, for each cell.
iii)
Supporting porcelain insulators.
ii)
Set of vinilyte (or equivalent) cell number plates.
iii)
Set of inter cell and inter row connectors and inter bank connectors for the battery.
iv)
Three connector bolt wrenches/ spanners.
v)
One center zero 5-0-5 volt DC voltmeter (portable) complete with leads for measuring cell
voltage.
vi)
Three hydrometer syringes suitable for vent holes provided in the cells.
vii)
Three vent plug thermometers to be permanently should mounted in any three cells, each cell
should have suitable clamps for holding the thermometers in position.
viii) Three pocket thermometers with 0 – 1500C scale.
ix)
Two rubber aprons.
x)
Four sets of rubber gloves.
xi)
Two nos. acid mixing jars.
xii)
Electrolyte required for first filling plus 10% extra.
xiii) Sufficient quantity of petroleum jelly for covering exposed metal parts of the battery plus
10% extra.
xiv) One no. nylon brush with stout bristles for clearing connections.
xv)
Suitable tapping and terminals arrangement in the battery for incoming supply to DC board.
xvi) Cable lugs suitable for accommodating single core vent plugs.
xvii) Acid level indicator for each cell.
xviii) Other special tools and tackles, if required.
BATTERY CHARGER FOR 48V, 500 AH BATTERY SET
The battery charger shall be comprising of 1 no. thyristor controlled float-cum-boost charger
equipped with quality filter for ripple suppression along with all associated hardware and
housed in a single floor mounted steel cabinet. The equipment should be well ventilated and
suitable for floor mounting with hinged door at from and rear sides. Cable entry holes shall be
provided at both front and rear sides. The charger shall work in conjunction with 24 Nos.
Plane type cells, each of 2 volts viz. 48V/ 500 AH capacity battery sets. The charger unit shall
be capable for delivering requisite current under float, quick and boost condition as may be
necessary for the battery to keep them healthy in the useful life and in the manner as specified
by the battery manufacturer at varying voltages to meet the requirement of battery charging
characteristics. Constant current charging of the battery sets shall be the essence of initial
charging while setting to service in order to ensure feeding of specified ampere – hour to the
battery sets being commissioned. Modular construction to incorporate the desired features to
define the individual function as specified here under is desired.
High galvanic insulation level should be maintained. Insulation resistance measured between
earth and input/ output terminals and between input and output terminals shall not be less than
5 Meg-ohms when measured with 500 V DC insulation tester.
The charger shall be able to charge the battery maintaining across the equipment a voltage of
48V +0.5 or maintain a voltage to reach a maximum of 2.3V per cell under float conditions
and offer to the load the specified voltage. The quick and boost-charging mode should ensure
that the load is fed with its rated voltage only by means of dropper diodes.
IN JASIDIH GSS VOL-II
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TECHNICAL SPECIFICATION FOR BATTERY CHARGER
1.00.00
SCOPE
This specification covers the design, manufacture, testing at manufacturer’s works,
supply and delivery of
Battery Charger for 220V, 500 AH Battery
2.00.00
INSTRUCTION FOR TENDERERS
Complete Bill of Materials along with make, rating and type of each items shall be
furnished for each of the equipment.
3.00.00
EQUIPMENTS REQUIRED
The equipment to be supplied under this specification shall be as detailed below:
3.01.00
BATTERY CHARGER FOR 220 VOLT BATTERY
The Battery Charger Board shall be comprising of two numbers Float-cum-Boost
Chargers – one Main and another stand by. The two chargers shall be housed in a
single continuous board but in two separate detachable section so that any one board
can be disconnected and removed for maintenance purpose.
The charger board will be operated from 3 phase, 4 wire, 440 plus or minus 10%
Volt, 50 plus or minus 5% HZ A.C. input supply. There shall be two A.C. source –
one main and the other stand by, only one of which will be in service at any time.
The float charger output shall be automatic SCR controlled with change over facility
to manual control. The boost charger shall be manual SCR controlled.
The float charger shall be capable of floating the battery cells to 2.15 Volt/Cell (or as
recommended by the battery manufacture) and the boost charger shall be capable of
charging the battery cells upto 2.75 Volt/cell (or as recommend by battery
manufacturer).
There shall be provision for two output feeders controlled by two Nos. isolators (each
having 400 A capacity) for connecting to D.C. board.
3.03.01
CAPACITY OF CHARGERS
Each charger when in float mode shall be capable of supplying 100 Amp D.C. load
over the above the normal trickle charge current and when in boost mode, shall be
capable to quick charge the 110 Nos. 500 AH lead acid battery set but not less than
100 Amp D.C.
The arrangement and capacity shall be such that one or trickle both the charger can be
used either in float mode for charging cater the load and when any one charger will be
the battery put to service to boost charge the battery then and to the other charger may
IN JASIDIH GSS VOL-II
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be simultaneously put to service to cater the D.C. load.
3.03.02
The battery charger board shall be equipped with the accessories and devices
including but not limited to the following: A.
Charger Board:
i)
TPN ON/OFF switches for A.C. Mains.
ii)
A.C. Voltmeter (Flush mounted) with selector switch.
iii)
Cubicle heater with switch and fuse.
iv)
v)
Cubicle lamps with door switch and fuse.
Main failure relay unit.
vi)
Silicon diodes for connection to 80% tapping of battery set with diode
fail indication.
vii)
ON LOAD isolator (3 pole) for connecting the battery to the charge bus
with indication lamp.
viii)
Indicating lamps with resistance for ground indication.
ix)
2 Nos. 400 Amp isolators for connecting the load bus to D.C. Board.
x)
D.C. voltmeter (flush mounted) for charge bus.
xi)
Under voltage/ over voltage relay for load.
xii)
24 way solid state annunciation system with ‘Accept’, ‘Reset’ and
‘Test’ push buttons.
The annunciation windows shall have LCDs.
D.C. over voltage relay for charge bus.
xiii)
IN JASIDIH GSS VOL-II
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B.
FLOAT CHARGER-CUM-BOOST CHARGER
i)
TPN OF/ OFF switch for A.C. Mains.
ii)
HRC fuse for A.C. input protection.
iii)
A.C. contractor with overload tripping facility.
iv)
White pilot lamps to indicate A.C. power ‘ON’.
v)
A.C. under voltage relay.
vi)
Rectifier transformer of on capsulated dry type/ plan dry type and shall
be as per IS-2026, IS-4540 and IS-11170.
vii)
Silicon rectifiers mounted on suitable heat sinks for 3 ph rectification
with electronic control system and rectifier protection fuses with fuse
fail indication.
viii)
Smoothening filter circuit to suppress the ripple content in D.C. output
within 1%.
ix)
D.C. voltmeter (flush mounted) to measure output voltage.
x)
HRC fuses for rectifier output protection with fuse fail indication.
xi)
D.C. Ammeter (flush mounted) with external shunt to measure load
current.
xii)
Red lamp for A.C. contractor ‘ON’ indication.
xiii)
D.C. under voltage relay.
xiv)
All necessary control cards.
xv)
All necessary mode selection switches.
xvi)
Surge suppression circuits.
xvii)
D.C. contractor to isolate the charger and the battery (+ve terminal)
from the load bus when boost charging.
xviii) Silicon blocking diodes at the charger output with neon lamp for
indication of diode failure.
xix)
100 A MCCB (2 pole) for connecting charger output to charge bus.
IN JASIDIH GSS VOL-II
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NOTE: All the cards shall be glass epoxy boards and provided with detachable harp
connectors with redundant contacts for easy maintenance and reliability. Control cards
mentioned above should be mounted flat wise (and not edgewise) so that access to
component and test points can be had without removing the card for maintenance
purpose.
The name of the manufacturer or make of the components being utilized in the charger
shall be clearly indicated.
6.00.00
DESIGN RATING
6.02.00
Battery Charger (for 250V battery)
6.02.01
Input – 415 Volt + 10%, 50 Hz + 3%
Fault current – 25 KA for 3 seconds.
6.02.02
Output : a) Float charger :
Sufficient to float charge
110 Nos. 500 AH battery cells
plus a D.C. load of 100 Amps.
b) Boost charger :
Sufficient to quick charge
110 Nos. 500 AH battery cells
but not less than 100 Amps.
c) D.C. Bus :
The capacity of the D.C. Bus shall be 400 Amps
(minimum)
Material – copper
Fault MVA – 15 KA
Degree of Protection – IP – 52.
7.00.00
DETAIL DESIGN REQUIREMENT
7.01.00
Battery Charger (for 220 Volt Battery)
i)
The Float charger unit of charging equipment shall be able to supply the
continuous load mostly comprising of indicating lamps on the control panels,
switch gears and the charging current of the battery on normal floating
condition.
ii)
The Boost charger unit of the charging equipment shall be able to supply the
current required by the battery during boost charging state in the manner
specified by the manufacturer at varying voltages to meet the requirements of
the battery charging characteristics.
The basic operational requirement of the charging equipment would be as
under: -
iii)
IN JASIDIH GSS VOL-II
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7.05.01
a)
Normally either or both the charger unit would operate in float mode
and in parallel with the battery supplying the load current and sending a
small float charging current into the battery such that the battery is
maintained in a fully charged conditions.
b)
When the battery would be required to be quick charged, any one of the
charger unit will be placed in boost mode and the battery with the quick
charger unit would be automatically isolated from the load which
would continue to be supplied by the float charger.
c)
During quick charging condition, 80 (eighty) per cent of the battery
voltage would be made available at the positive terminal of the load
through a series parallel combination bank of blocking diodes (each of
100% capacity) to ensure uninterrupted D.C. supply to the load in the
event of failure of the Float Charger/ A.C. supply fail.
d)
The control circuit shall be such that any one charger unit can be placed
in Float mode and the other can be placed in Boost mode without
affecting each other.
iv)
The panel shall be switchboard type fabricated from 3 mm thick leveled steel
plate and light section structural steel. The front plates should be of formed
construction with minimum 25 mm turned back edges. The front plates shall
also be hinged making breakers accessible and removable from the front. The
panel shall be free standing, fitting with louvers for proper ventilation and must
be suitable for use in tropical climate.
v)
All instruments shall be switchboard type, back connected, semi-flush mounted
type. Marking on scales shall be black on white background. The instruments
shall be provided with front board Zero adjuster capable of being handled
while the instrument is in service. Provision for adjustment above and below
zero point shall be not less than 3 per cent of the full scale length. Suitable
means of adjusting the accuracy in a laboratory shall be provided.
vi)
Wiring shall be single core, multi conductor, tinned; PVC insulated annealed
copper wire suitable for 660 Volts service and shall be flame proof. Terminals
ends of all wires shall be provided with numbered plastic ferrules. Ends shall
be fitted with Ross Courtney terminals/ cable and sockets wherever applicable.
vii)
All current free metallic parts shall be earthed with soft drawn PVC insulated
standard copper conductor. Colour of the insulation shall be invariably green.
The main earth connection shall be brought out to the terminals for
connections to station earthing system.
System Particulars
The low tension A.C. power would be obtained through 33,000/433 Volts, 500
KVA/250/KVA, 3 – phase station service transformers. The star point will be solidly
grounded. The frequency of supply is 50 cycles per second.
IN JASIDIH GSS VOL-II
Page 301
7.05.02
The following arrangements for the station. Service supply would be adopted. Two (2)
Nos. 250 KVA, zig-zag/star transformer, or 1 (one) No. 500 KVA Delta/ star
transformer with the star point solidly grounded would to provide and the L.T. side
will be connected to the A.C. bus of the switchboard.
7.05.03
Fault level of the 415 Volt A.C. system.
The fault level of 415 Volt system in this station shall be 25KA R.M.S. symmetrical.
All fault interrupting devices shall have adequate breaking capacity to suit the fault
level of the system as specified above. The making capacity of the breakers at the
above condition shall not be less than 25 KA.
All incoming breakers, however, shall be suitable for 25KV R.M.S. symmetrical
breaking capacity and shall be absolutely interchangeable.
7.05.04
Rating of Bus Bars
The bus bars shall be rated for 1000 AMP continuous current carrying capacity and
shall satisfactorily with stand the fault currents as specified above.
8.00.00
9.01.00
TEST & TEST REPORTS
i)
The equipment shall be inspected and tested by purchaser’s Engineers in
accordance with the relevant Indian/British/ American or other standards.
ii)
Six (06) copies of certified test reports of test carried out on each equipments
shall be furnished..
iii)
Test certificates literature and manuals of all bought out items shall be
submitted.
The successful bidder shall supply ten (10) copies each of the approved drawings
consisting of but not limited to the following: a)
Details drawings of the battery charger showing front, rear and side views with
dimensions.
b)
Internal wiring diagram of all devices and elementary wiring relays.
c)
Erection and maintenance instructions.
d)
Hard bound literatures describing design construction, operation, maintenance
and adjustment and rating specifications of all the equipment.
e)
List of space parts identification number, renewable parts of all equipment
mounted on the switchboard and contained in a battery to procure spare parts
correctly at a later date.
IN JASIDIH GSS VOL-II
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f)
Complete bill of materials indicating type, make, rating, and specification of
all the components.
9.02.00
A set of velographs of all the drawings shall be supplied before dispatch of equipment.
10.00.00
CO-OPERATION WITH OTHER MANUFACTURERS AND CONSULTING
ENGINEERS.
a)
The contractor shall fully co-operate with purchaser’s other contractors and
freely exchange technical information with them to avoid duplication of work.
b)
No remuneration shall be payable by the purchaser for such technical cooperation.
c)
The contractor shall forward the purchaser copies of all correspondence and drawings so
exchanged.
IN JASIDIH GSS VOL-II
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15. SWITCHYARD ERECTION
IN JASIDIH GSS VOL-II
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15. SWITCHYARD ERECTION
1.0
GENERAL
The detailed scope of work includes design, engineering, manufacture, testing at
works, supply on FOR destination site basis, insurance, handling, storage,
erection testing and commissioning of various items and works as detailed herein.
This section covers the description of the following items.
A- Supply of
-
String insulators and hardware
-
Galvanised Steel Earthwire
-
Aluminium Tubular Bus Bars(Not applicable for Tehta)
-
Spacers
-
Bus post insulators
-
Earthing & Earthing materials
-
Lightning protection materials
-
Cabling material
-
Other items
B.
1.1
Erection Of all items
String Insulators & Hardware
The insulators for suspension and tension strings shall conform to IEC60383 and
long rod insulators shall conform to IEC-60433. Insulator hardware shall conform
to IS:2486.
1.1.1
Construction Features
1.1.1.1
Suspension and tension insulators shall be wet process porcelain with ball
and socket connection.Insulators shall be interchangeable and shall be
suitable for forming either suspension or tension strings. Each insulator shall have
rated strength markings on porcelain printed and applied before firing.
1.1.1.2
Porcelain used in insulator manufacture shall be homogeneous, free from
laminations, cavities and other flaws or imperfections that might affect the
IN JASIDIH GSS VOL-II
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mechanical or dielectric quality and shall be thoroughly vitrified, tough and
impervious to moisture.
1.1.1.3
Glazing of the porcelain shall be uniform brown colour, free from blisters, burrs
and other similar defects.
1.1.1.4
When operating at normal rated voltage there shall be no electric discharge
between conductor and insulator which would cause corrosion or injury to
conductors or insulators by the formation of substances due to chemical action.
No radio interference shall be caused when operating at normal rated voltage.
1.1.1.5
The design of the insulator shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration. All ferrous
parts shall be hot dip galvanized in accordance with the latest edition of IS: 2629.
The zinc used for galvanizing shall be of grade Zn-99.95 as per IS-209. The zinc
coating shall be uniform, adherent, smooth, reasonably bright, continuous and
free from imperfections such as flux, ash, rust stains bulky white deposits and
blisters.
1.1.1.6
Bidder shall make available data on all the essential features of design including
the method of assembly of discs and metal parts, number of discs per insulator
string insulators, the manner in which mechanical stresses are transmitted through
discs to adjacent parts, provision for meeting expansion stresses, results of corona
and thermal shock tests, recommended working strength and any special design or
arrangement employed to increase life under service conditions.
1.1.1.7
Clamps for insulator strings and Corona Control rings shall be of aluminium alloy
as stipulated for clamps and connectors.
1.1.1.8
Insulator hardware shall be of forged steel. Malleable cast iron shall not be
accepted except for insulator disc cap. The surface of hardware must be clean,
smooth, without cuts, abrasion or projections. No part shall be subjected to
excessive localized pressure. The metal parts shall not produce any noise
generating corona under operating conditions.
1.1.1.9
The tension Insulator hardware assembly shall be designed for 11500 kg
IN JASIDIH GSS VOL-II
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tensile load. Earth wire tension clamp shall be designed for 1000 kg tensile load
with a factor of safety of two (2).
1.1.1.10
The tension string assemblies shall be supplied along with suitable turn buckle.
Sag compensation springs if required may also be provided.
1.1.1.11
All hardware shall be bolted type.
1.2
Long Rod Insulators
1.2.1
As an alternative to disc insulator , Bidder can offer long rod insulators
strings, with suitable hardware. The combination should be suitable for
application specified and should offer the identical / equivalent parameters as
would be available from insulator string comprising disc insulators and hardware
combination.
1.2.2
1.3
All constructional features specified at Clause 1.1.1 of this Section shall
also apply to the long rod insulator string.
Tests
In accordance with the stipulations of the specification, the suspension and
tension strings, insulator and hardware shall be subjected to the following type
tests, acceptance tests and routine tests:
1.3.1
Type Tests on Insulator Strings : The test reports for following type
tests shall be submitted for approval :
a)
Power frequency voltage withstand test with corona control rings under wet
condition as per IEC 60383.
b)
Switching surge voltage withstand test [400 kV class only] under wet condition
as per IEC-60383.
c)
Lightning Impulse voltage withstand test with corona control rings under dry
condition as per IEC-60383
d)
Voltage distribution test (Dry)
The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted into percentage. The
voltage across any disc shall not exceed 9% and 10% for 400KV
suspension string and tension insulator string respectively, 13% for
220KV suspension and tension insulator
IN JASIDIH GSS VOL-II
Page 307
strings, 20% and 22% for 132KV suspension and tension insulator strings
respectively.
e)
Corona Extinction Voltage test (Dry)
The sample assembly when subjected to power frequency voltage shall
have a corona extinction voltage of not less than 320kV(rms) for 400kV
and 156kV(rms) for 220kV line to ground under dry condition. There shall
be no evidence of Corona on any part of the sample. The atmospheric
condition during testing shall be recorded and the test results shall be
accordingly corrected with suitable correction factor as stipulated in IEC
60383.
f)
RIV Test (Dry)
Under the conditions as specified under (e) above the insulator string
alongwith complete hardware fittings shall have a radio interference
voltage level below 1000 microvolts at 1 MHz when subjected to 50 Hz
AC line to ground voltage of 320kV for 400kV and 156kV for 220kV
string under dry conditions. The test procedure shall be in accordance with
IS 8263/IEC 60437.
g)
Mechanical strength test
The complete insulator string alongwith its hardware fitting excluding
arcing horn, corona control ring, grading ring, tension/suspension clamps
shall be subjected to a load equal to 50% of the specified minimum
ultimate tensile strength (UTS) which shall be increased at a steady rate to
67% of the minimum UTS specified. The load shall be held for five
minutes and then removed. After removal of the load, the string
components shall not show any visual deformation and it shall be possible
to dismantle them by hand. Hand tools may be used to remove cotter pins
and loosen the nuts initially. The string shall then be reassembled and
loaded to 50% of UTS and the load shall be further increased at a steady
rate till the specified minimum UTS and held for one minute. No fracture
should occur during this period. The applied load shall then be increased
until the failing load is reached and the value recorded.
1.3.2
Type Tests on Insulators
Type test report for Thermal Mechanical Performance tests as per
IEC:60575, Clause 3 shall be submitted for approval as per clause
IN JASIDIH GSS VOL-II
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specification.
1.3.3
Acceptance Tests for Insulators:
a)
Visual examination as per IEC 60383
b)
Verification of Dimensions as per IEC 60383.
c)
Temperature cycle test as per IEC 60383.
d)
Puncture Test as per IEC 60383.
e)
Galvanizing Test as per IEC 60383.
f)
Mechanical performance test as per IEC-60575 Cl. 4.
g)
Test on locking device for ball and socket coupling as per IEC-60372(2)
h)
1.3.4
Porosity test as per IEC 60383.
Acceptance Test on Hardware Fitting
a)
Visual Examination as per Cl. 5.10 of IS:2486 (Part-I).
b)
Verification of Dimensions as per Cl. 5.8 of IS : 2486 (Part-I)
c)
Galvanising/Electroplating tests as per Cl. 5.9 of IS : 2486 (Part-I).
d)
Slip strength test as per Cl 5.4 of IS-2486 (part-I)
e)
Shore hardness test for the Elastometer (if applicable as per the value guaranteed
by the Bidder).
f)
Mechanical strength test for each component (including corona control rings and
arcing horns).
The load shall be so applied that the component is stressed in the same
way as it would be in actual service and the procedure as given in 1.2.13.1
(g) above should be followed.
g)
Test on locking devices for ball and socket coupling as per
IEC:60372(2).
IN JASIDIH GSS VOL-II
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1.3.5
Routine Test on Insulator
1.3.6
1.3.7
a)
Visual Inspection as per IEC60383
b)
Mechanical Routine Test as per IEC60383
c)
Electrical Routine Test as per IEC60383
Routine Test on hardware Fittings
a)
Visual examination as per Cl 5.10 of IS : 2486 (Part-I).
b)
Mechanical strength Test as per Cl. 5.11 of IS : 2486 (Part-I).
Test during manufacture on all Components as applicable on
insulator
a)
Chemical analysis of zinc used for galvanising:
Samples taken from the zinc ingot shall be chemically analyzed as per IS :
209. The purity of zinc shall not be less than 99.95%.
b)
Chemical Analysis, mechanical hardness tests and magnetic particle
inspection for malleable casting:
The chemical analysis, hardness tests and magnetic particle inspection for
malleable casting will be as per the internationally recognized procedures
for these tests. The sampling will be based on heat number and heat
treatment batch. The details regarding tests will be as discussed and
mutually agreed to by the Contractor and Owner in Quality Assurance
Program.
1.3.8
Test during manufacture on all components as applicable on
hardware fittings:
a)
Chemical analysis of zinc used for galvanising:
Samples taken from the zinc ingot shall be chemically analyzed as per IS :
209. The purity of zinc shall not be less than 99.95%
b)
Chemical analysis, hardness tests and magnetic particle for
forgings:
IN JASIDIH GSS VOL-II
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s, hardness tests and magnetic particle inspection for forgings will be as
per the internationally recognized procedures for these tests. The sampling
will be based on heat number and heat treatment batch. The details
regarding tests will be as discussed and mutually agreed to by the
Contractor and Owner in Quality Assurance Programme.
Chemical analysis and mechanical hardness tests and magnetic particle
inspection for fabricated hardware:
The chemical analysis, hardness tests and magnetic particle inspection for
fabricated hardware will be as per the internationally recognized
procedures for these tests. The sampling will be based on heat number and
The heat treatment batch. The details regarding tests will be as discussed and
chemic mutually agreed to by the Contractor and Owner in Quality Assurance
programme.
al
analysi
c)
1.4
Parameters
1.4.1
Disc Insulators
400/220/132 kV
a)
Type of insulators
:
ANTI Fog type
b)
Size of insulator units (mm)
:
255x145
c)
Electro mechanical strength
:
120 kN
d)
Creepage distance of
individual
insulator units (minimum
and as required to meet
total creepage distance)
:
430 mm
e)
Markings
:
Markings on porcelain
shall be printed and
applied before firing
f)
Power frequency puncture
withstand voltage
:
1.3 times the actual wet
flashover voltage.
*Long rod insulators should conform to equivalent electrical and
mechanical parameters.
IN JASIDIH GSS VOL-II
Page 311
1.14.2
INSULATOR STRING
400kV
a)
b)
c)
d)
Power frequency withstand :
voltage of the complete string
with Corona Control ring (wet) –
kV rms
680
Lightning impulse withstand :
Voltage of string with corona
control rings (dry) – kVp
±1550
Switching surge withstand :
voltage of string with corona
control rings (wet) – kVp
±1050
320
Minimum corona extinction :
voltage level of string with Corona
Control rings (dry) - kV rms
220kV
132kV
460
275
+1050
NA
156
+650
NA
NA
e)
RIV level in micro volts of string: 1000 (Max.)
1000 with
Corona Control
(Max.) rings at
320 kV (rms) for 400 kV string and 156 kV for 220 kV string
across 300 Ohms resistor at 1 MHz
NA
f)
Total creepage distance of the :
insulator string (mm)
10500
6125
3625
Total no. of discs per strings : 25
g)
15
10
For tension application, double insulator strings and for
suspension purpose single suspension insulator string shall be used for 400 KV,
220 KV and 132KV system.
IN JASIDIH GSS VOL-II
Page 312
ACSR ‘MOOSE’ CONDUCTOR(TO BE SUPPLIED BY JUSNL)
2.0
Details of Conductor
2.1
2.1.1
The Conductor shall conform to IS:398 (Part V) - 1982 except where otherwise
specified herein.
The details of the conductor are tabulated below:
2.1.2
a)
Stranding and wire diameter
:54/3.53 mm Al+7/3.53mm Steel
:
b)
Number of Strands Steel
centre 1st Steel Layer 1st
Aluminium Layer 2nd
Aluminium Layer 3rd
Aluminium Layer
1
6
12
18
24
:
:
528.5 mm2
c)
Sectional area of aluminium
d)
Total sectional area
:
e)
Overall diameter
:
f)
Approximate weight
:
597.00 mm2
31.77 mm
2004 kg/km
0.05552 ohm/km
g)
Calculated d.c. resistance at 20oC :
161.2 KN
2.1.3
2.1.4
h)
Minimum UTS
:
The details of aluminium strand are as follows:
i)
Minimum breaking load
of strand before stranding
:
1.57 kN
ii)
Minimum breaking load
of strand after stranding
:
1.49 kN
iii)
Maximum D.C. resitance
of strand at 20oC.
:
2.921 Ohms/Km
:
12.86 kN
The details of steel strand are as follows:
i)
Minimum breaking load
IN JASIDIH GSS VOL-II
Page 313
of strand before stranding
2.2
ii)
Minimum breaking load
of strand after stranding
:
12.22 kN
iii)
Minimum number of
twist to be withstood in torsion test when
tested on a gauge length
of 100 times diameter of
wire
:
18 - before stranding
16 - after stranding
Workmanship
2.2.1
The finished conductor shall be smooth, compact, uniform and free from all
imperfections including spills and splits, die marks, scratches, abrasions, scuff marks,
kinks (protrusion of wires), dents, press marks, cut marks, wire cross over, over riding,
looseness (wire being dislocated by finger/hand pressure and/or unusual bangle noise on
tapping), material inclusions, white rust, powder formation or black spots (on account of
reaction with trapped rain water etc.), dirt, grit etc.
2.2.2
All the aluminium and steel strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, die marks, scratches, abrasions and kinks after
drawing.
2.2.3
The steel strands shall be hot dip galvanised and shall have a minimum zinc
coating of 260 gm/sq.m. after stranding of the uncoated wire surface. The zinc coating
shall be smooth, continuous and of uniform thickness, free from imperfections and shall
withstand minimum three dips after stranding in standard Preece test. The finished strands
and the individual wires shall be of uniform quality and have the same properties and
characteristics as prescribed in ASTM designation : B 498-74.
2.2.4
The Steel strands shall be preformed and postformed in order to prevent
spreading of strands in the event of cutting of composite core wire. Care shall be taken to
avoid damage to galvanisation during preforming and post-forming operation.
IN JASIDIH GSS VOL-II
Page 314
Joints in Wires
2.3
2.3.1
Aluminium Wires
No joints shall, be permitted in the individual wires in the outermost layer of the
finished conductor. However, joints in the 12 wire and 18 wire inner layers of the
conductor shall be allowed but these joints shall be made by cold pressure butt
welding and shall be such that no such joints are within 15 metres of each other in
the complete stranded conductor.
Steel Wires
2.3.2
There shall be no joint of any kind in the finished wire entering into the
manufacture of the strand. There shall also be no strand splices in any length of
the completed stranded steel core of the conductor.
Tolerances
2.4
The manufacturing tolerances to the extent of the following limits only shall be
permitted in the diameter of individual aluminium and steel strands and lay-ratio
of the conductor.
a)
Diameter of Aluminium and steel strands:
Standard
Maximum
Aluminium
Steel
b)
Lay ratio of Conductor:
Steel
Aluminium
2.5
Materials
2.5.1
Aluminium
3.53 mm
3.53 mm
3.55 mm
3.60 mm
Maximum
6 wire layer 18 12
wire layer 14 18
wire layer 13 24
wire layer 12
Minimum
3.51 mm
3.46 mm
Minimum
16
12
11
10
The aluminium strands shall be hard drawn from electrolytic aluminium rods
having purity not less than 99.5% and a copper content not exceeding 0.04%.
IN JASIDIH GSS VOL-II
Page 315
2.5.2
Steel
The steel wire strands shall be drawn from high carbon steel wire rods and shall
conform to the following chemical composition:
Element
-
Carbon
-
0.50 to 0.85
Manganese -
0.50 to 1.10
Phosphorous -
not more than 0.035
Sullphur
not more than 0.045
Silicon
2.5.3
% Composition
-
0.10 to 0.35
Zinc
The Zinc used for galvanising shall be electrolytic High Grade Zinc of 99.95%
purity. It shall conform to and satisfy all the requirements of IS:209-1979.
2.6
Standard Length
2.6.1
The Conductor shall be supplied in standard length of 1500 / 1800 metres
as required. No joint shall be allowed within a single span of stringing.
2.7
Tests :
2.7.1
The following type, acceptance & routine tests
and tests during manufacturing shall be carried out on the
conductor.
2.7.2
Type Tests
In accordance with the stipulation of specification, the following type tests reports
of the conductor shall be submitted for approval :
a)
UTS test on stranded
conductor.
b)
Corona extinction
voltage test (dry)
.
) As per Annexure-A
)
IN JASIDIH GSS VOL-II
Page 316
(c)
Radio Interference
voltage test (dry)
(d)
DC resistance test
on stranded conductor
)
)
)
)
)
)
Acceptance Tests
2.7.3
a)
Visual check for joints,
) )
scratches etc. and lengths of )
As per Annexure - A
conductor
b)
Dimensional check on steel
and aluminium strands
c)
Check for lay ratios of
various layers
d)
Galvanising test on steel
strands
e)
Torsion and Elongation test
on steel strands
f)
Breaking load test on steel
and aluminium strands
g)
Wrap test on steel and
aluminium strands
h)
DC resistance test on
aluminium strands
i)
UTS test on welded joint of
aluminium strands
NOTE:
All the above tests except test
shall be carried out on aluminium
after stranding only.
)
)
)
)
) -do)
)
)
)
)
)
)
)
)
IS:398 (Part V) 1982
Clauses 12.5.2, 12.7 &
12.8
) As per Annexure - A
)
)
mentioned at (a)
and steel strands
IN JASIDIH GSS VOL-II
Page 317
2.7.4
2.7.5
Routine Tests
a)
Check to ensure that the joints are as per specification.
b)
Check that there are no cuts, fins etc. on the strands.
c)
All acceptance test as mentioned in Clause 2.7.3 above to be carried out
on each coil.
Tests During Manufacture
a)
b)
c)
2.7.6
Chemical analysis of
)
zinc used for galvanising )
)
Chemical analysis of
)
aluminium used for
) As per Annexure - A
making aluminium strands )
)
Chemical analysis of
)
steel used for making )
steel strands
)
Sample Batch for Type Testing
The Contractor shall offer material for selection of samples for type testing, only
after getting quality assurance plans approved from Owner’s Quality Assurance
Department. The sample shall be manufactured strictly in accordance with the
Quality Assurance Plan approved by Owner.
3.0
GALVANISED STEEL EARTHWIRE
3.1
Details of Earthwire
3.1.1
The galvanised steel earth wire shall generally conform to the specification of
ACSR core wire as mentioned in IS : 398 (Part-II)-1976 except where otherwise
specified herein.
3.1.2
The details of the earth wire are tabulated below:
a)
Stranding and wire
diameter
b)
Number of strands
:
7/3.66 mm steel
IN JASIDIH GSS VOL-II
Page 318
Steel core Outer
:
1
Steel Layer
:
6
c)
Total sectional area
:
73.65 mm2
d)
Overall diameter
:
10.98 mm
e)
Approximate weight
:
583 kg/km
f)
Calculated d.c. resistance at 20 Co
:
2.5 ohms/km
g)
Minimum ultimate tensile
strength
:
68.4 kN
:
Right hand
h)
Direction of lay of
outer layer
3.2
WORKMANSHIP
3.2.1
All steel strands shall be smooth, uniform and free from all imperfections, such as
spills and splits, die marks, scratches, abrasions and kinks after drawing and also
after stranding.
3.2.2
The finished material shall have minimum brittleness as it will be subjected to
appreciable vibration while in use.
3.2.3
The steel strands shall be hot dip galvanised (and shall have a minimum zinc
coating of 275 gms/sq.m.) after stranding of the uncoated wire surface. The zinc
coating shall be smooth, continuous, of uniform thickness, free from
imperfections and shall withstand three and a half dips after stranding in standard
Preece test. The steel wire rod shall be of such quality and purity that, when
drawn to the size of the strands specified and coated with zinc, the finished
strands shall be of uniform quality and have the same properties and
characteristics in ASTM designation B498-74.
3.2.4
The steel strands shall be preformed and postformed in order to prevent spreading
of strands while cutting of composite earthwire. Care shall be taken to avoid
damage to galvanisation during preforming and postforming operation.
IN JASIDIH GSS VOL-II
Page 319
3.2.5
To avoid susceptibility towards wet storage stains (white rust), the
finished material shall be provided with a protective coating of boiled linseed oil.
3.3
JOINTS IN WIRES
There shall be no joint of any kind in the finished steel wire strand entering into
the manufacture of the earth wire. There shall be no strand joints or strand splices
in any length of the completed stranded earth wire.
3.4
TOLERANCES
The manufacturing tolerances to the extent of the following limits only shall be
permitted in the Diameter of the individual steel strands and lay length of the
earth wire:
Standard
Maximum Minimum ———
———
3.66 mm
3.75 mm
3.57
Diameter
mm
Lay length
3.5
MATERIALS
3.5.1
Steel
Element
—————
Carbon
181 mm
165
mm
The steel wire strands shall be drawn from high carbon steel
rods and shall conform to the following requirements as to the
chemical composition :
% Composition
———————————Not more than 0.55
Manganese
0.4 to 0.9
Phosphorous
Not more than 0.04
Sulphur
Silicon
Not more than 0.04
0.15 to 0.35
3.5.2
198 mm
Zinc
The zinc used for galvanising shall be electrolytic High Grade Zinc of 99.95%
purity. It shall conform to and satisfy all the requirements of IS:209-1979.
IN JASIDIH GSS VOL-II
Page 320
STANDARD LENGTH
3.6
The earthwire shall be supplied in standard drum length of manufacturer.
3.6.1
TESTS
3.7
3.7.1
The following type, routine & acceptance tests and tests during manufacturing
shall be carried out on the earthwire.
TYPE TESTS
3.7.2
In accordance with the stipulation of specification, the following type tests reports
of the earthwire shall be submitted for approval as per clause 9.2 of Section GTR.
a)
UTS test
)
As per Annexure - B
b)
3.7.3
DC resistance test
)
ACCEPTANCE TESTS
a)
Visual check for joints,
scratches etc. and length
of Earthwire
b)
Dimensional check
c)
Galvanising test
d)
Lay length check
e)
Torsion test
f)
Elongation test
g)
Wrap test
h)
DC resistance test
i)
Breaking load test
j)
Chemical Analysis of
steel
)
)
)
)
) As per Annexure - B
)
)
)
)
)
)
)
)
)
)
) IS:398 (Part-III) 1976
)
)
)
IN JASIDIH GSS VOL-II
Page 321
3.7.4
3.7.5
3.7.6
ROUTINE TESTS
a)
Check that there are no cuts, fins etc. on the strands.
b)
Check for correctness of stranding.
TESTS DURING MANUFACTURE
a)
Chemical analysis of
zinc used for
galvanising
b)
Chemical analysis of
steel
) As per Annexure - B
)
)
)
)
)
SAMPLE BATCH FOR TYPE TESTING
The Contractor shall offer material for sample selection for type testing, only after
getting quality assurance programme approved by the Owner. The samples for
type testing shall be manufactured strictly in accordance with the Quality
Assurance Programme approved by the Owner.
4.0
TUBULAR BUS CONDUCTORS
4.1
General
Aluminium used shall be grade 63401 WP(range 2) conforming toIS:5082.
4.2
Constructional Features
4.2.1
For outside diameter (OD) & thickness of the tube there shall be no minus
tolerance, other requirements being as per IS : 2678 and IS: 2673.
4.2.2
The aluminium tube shall be supplied in suitable cut length to minimize wastage.
4.2.3
The welding of aluminium tube shall be done by the qualified welders duly
approved by the owner.
4.3
Test
IN JASIDIH GSS VOL-II
Page 322
In accordance with stipulations of the specification, Routine tests shall be
conducted on tubular bus conductors as per IS: 5082. Also the wall thickness and
ovality of the tube shall be measured by the ultrasonic method. In addition to the
above tests, 0.2% proof tests on both parent metal and Aluminium tube after
welding shall be conducted.
4.4
Parameters
a)
Size
4"IPS (EH Type)
b)
Outer diameter(mm)
114.2
c)
Thickness (mm)
8.51
d)
Cross-sectional area
(sq.mm)
2825.61
e)
Weight (kg/m)
7.7
5.0
EARTHING CONDUCTORS
5.1
General
All conductors buried in earth and concrete shall be of mild steel. All conductors
above ground level and earthing leads shall be of galvanised steel, except for
cable trench earthing. The minimum sizes of earthing coductor to be used shall be
as per specification.
5.2
Constructional Features
5.2.1
Galvanised Steel
a)
Steel conductors above ground level shall be galvanised according to
IS:2629.
b)
The minimum weight of the zinc coating shall be 618 gm/sq. m. and
minimum thickness shall be 85 microns.
c)
The galvanised surfaces shall consist of a continuous and uniformly thick
coating of zinc, firmly adhering to the surfaces of steel. The finished
surface shall be clean and smooth and shall be free from defects like
discoloured patches, bare spots, unevenness of coating, spelter which is
loosely attached to the steel globules, spiky deposits, blistered surfaces,
flaking or peeling off etc. The
IN JASIDIH GSS VOL-II
Page 323
presence of any of these defects noticed on visual or microscopic
inspection shall render the material liable to rejection.
5.3
Tests
In accordance with stipulations of the specifications galvanised steel shall be
subjected to four one minute dips in copper sulphate solution as per IS : 2633.
6.0
SPACERS
6.1
General
Spacers shall conform to IS: 10162. The spacers are to be located at a suitable
spacing to limit the short circuit forces as per IEC 865. Wherever Owner’s 400
kV & 220 kV standard gantry structures are being used, the spacer span(s) for
different conductor / span configurations and corresponding short circuit forces
shall be as per specification.
Wherever Owner’s 400 kV & 220 kV standard gantry structures are not being
used, necessary spacer span calculation shall be provided by the contractor during
detailed engineering for the approval of Owner.
6.2
Constructional Features
6.2.1
No magnetic material shall be used in the fabrication of spacers except for GI
bolts and nuts.
6.2.2
Spacer design shall be made to take care of fixing and removing during
installation and maintenance.
6.2.3
The design of the spacers shall be such that the conductor does not come in
contact with any sharp edge.
6.3
Tests
Each type of spacers shall be subjected to the following type tests, acceptance
tests and routine tests:
6.3.1
Type Tests: Following type test reports shall be submitted for approval
as per Section - GTR.
a)
Clamp slip tests
IN JASIDIH GSS VOL-II
Page 324
The sample shall be installed on test span of twin conductor bundle string
or quadruple conductor bundle string (as applicable) at a tension of 44.2
kN. One of the clamps of the sample when subjected to a longitudinal pull
of 2.5 kN parallel to the axis of the conductor shall not slip on the
conductor. The permanent displacement between the conductor and the
clamp of sample measured after removal of the load shall not exceed 1.0
mm. Similar tests shall be performed on the other clamps of the same
sample.
b)
Fault current test as per Cl 5.14.2 of IS : 10162
c)
Corona Extinction Voltage Test (Dry).
This test shall be performed on 400 kV and 220 kV equipment as per
procedure mentioned at Annexure - C, Minimum Corona Extinction
voltage shall be 320 kV (rms) line to ground and 156 kV (rms) line to
ground for 400 kV and 220 kV spacers respectively.
d)
RIV Test (Dry)
This test shall be performed as per procedure mentioned at Annexure - C,
Maximum RIV level at 305 kV (rms) line to ground and 156 kV (rms) line
to ground for 400 kV and 220 kV spacers respectively shall be 1000 micro
volts, across 300 ohm resistor at 1 MHz
6.3.2
e)
Resilience test (if applicable)
f)
Tension Test
g)
Log decremant test (if applicable)
h)
Compression test
i)
Galvanising test
Acceptance Test (As per IS : 10162 )
a)
Visual examination
b)
Dimensional verification
c)
Movement test
IN JASIDIH GSS VOL-II
Page 325
d)
Clamp slip test
e)
Clamp bolt torque test (if applicable)
f)
Assembly torque test
g)
Compression test
h)
Tension test
i)
Galvanising test
j)
Hardness test for neoprene (if applicable)
The shore hardness of different points on the elastometer surface of
cushion grip clamp shall be measured by shore hardness meter. It shall be
between 65 to 80.
k)
Ultimate Tensile Strength Test
The UTS of the retaining rods shall be measured. It shall not be less than
35 kg/Sq. mm.
6.3.3
7.0
Routine test
a)
Visual examination
b)
Dimensional verification
BUS POST INSULATORS
The post insulators shall conform in general to latest IS: 2544, IEC-168 and IEC815.
7.1
Constructional Features
7.1.1
Post type insulators shall consist of a porcelain part permanently secured in a
metal base to be mounted on the supporting structures. They shall be capable of
being mounted upright. They shall be designed to withstand any shocks to which
they may be subjected to by the operation of the associated equipment. Only solid
core insulators will be acceptable.
7.1.2
Porcelain used shall be homogeneous, free from lamination, cavities and
IN JASIDIH GSS VOL-II
Page 326
other flaws or imperfections that might affect the mechanical or dielectric quality
and shall be thoroughly vitrified, tough and impervious to moisture.
7.1.3
Glazing of the porcelain shall be of uniform brown in colour, free from blisters,
burrs and other similar defects.
7.1.4
The insulator shall have alternate long and short sheds with aerodynamic profile,
The shed profile shall also meet the requirements of IEC-815 for the specified
pollution level.
7.1.5
When operating at normal rated voltage there shall be no electric discharge
between conductor and insulators which would cause corrosion or injury to
conductors or insulators by the formation of substance produced by chemical
action.
7.1.6
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.
7.1.7
All ferrous parts shall be hot dip galvanised in accordance with the latest edition
of IS: 2633, & IS: 2629. The zinc used for galvanising shall be grade Zn 99.95 as
per IS: 209. The zinc coating shall be uniform, adherent, smooth, reasonably
bright, continuous and free from imperfections such as flux ash, rust stains, bulky
white deposits and blisters. The metal parts shall not produce any noise generating
corona under the operating conditions.
7.1.8
a)
7.1.9
Every bolt shall be provided with a steel washer under the nut so
that part of the threaded portion of the bolts is within the thickness of the
parts bolted together.
b)
Flat washer shall be circular of a diameter 2.5 times that of bolt and of
suitable thickness. Where bolt heads/nuts bear upon the beveled surfaces
they shall be provided with square tapered washers of suitable thickness to
afford a seating square with the axis of the bolt.
c)
All bolts and nuts shall be of steel with well formed hexagonal heads
forged from the solid and shall be hot dip galvanised. The nuts shall be
good fit on the bolts and two clear threads shall show through the nut
when it has been finally tightened up.
Bidder shall make available data on all the essential features of design
IN JASIDIH GSS VOL-II
Page 327
including the method of assembly of shells and metals parts, number of shells per
insulator, the manner in which mechanical stresses are transmitted through shells
to adjacent parts, provision for meeting expansion stresses, results of corona and
thermal shock tests, recommended working strength and any special design or
arrangement employed to increase life under service conditions.
7.2
Tests
In accordance with the stipulations of the specification, the post insulators shall be
subject to type, acceptance, sample and routine tests as per IS : 2544 and IEC168.
7.2.1
7.2.2
In addition to acceptance/sample/routine tests as per IS : 2544 and IEC168, the following tests shall also be carried out.
a)
Ultrasonic test as an acceptance test
b)
Soundness test, metallurgical tests and magnetic test on MCI caps and
pedestal tests as acceptance test.
c)
All hot dip galvanised components shall be subject to check for uniformity
of thickness and weight of zinc coating on sample basis.
d)
The bending test shall be carried out at 50% minimum failing load in four
directions as a routine test and at 100% minimum failing load in four
directions as an acceptance test.
e)
Acceptance norms for visual defects allowed at site and also at works shall
be agreed in the Quality plan.
In accordance with the stipulation of specification, the following type tests
reports of the post insulators shall be submitted for approval :
a)
Power frequency withstand test (dry & wet)
b)
Lightning impulse test (dry)
c)
Switching impulse test (wet) (For 420 kV Insulator only)
d)
Measurement of R.I.V (Dry)
e)
Corona extinction voltage test (Dry) (As per Annexure – C)
(As per Annexure – C)
IN JASIDIH GSS VOL-II
Page 328
.
f)
Test for deflection under load
g)
Test for mechanical strength.
Technical Parameters of Bus Post Insulators.
7.3
a)
Type
b)
Voltage class (kV)
c)
Solid Core
Dry and wet one minute
power frequency withstand
voltage (kV rms)
Solid Core
420
245
145
680
460
275
d)
Dry lightning impulse
withstand Voltage (kVp)
±1425
+ 1050
e)
Wet switching surge
withstand voltage (kVp)
±1050
—-
f)
g)
h)
i)
Max. radio interference voltage
(in microvolts) at voltage of 305
kV (rms) and 156 (rms) for 400
kV & 220 kV respectively
between phase to ground.
Corona extinction voltage
(kV rms)
Solid Core
500
+650 —-
500
500
320 (Min.) 156 (Min.) 105 (Min)
Total minimum cantilever
strength (Kg)
800
Minimum torsional moment
j)Total height of insulator (mm)
800
600
---- As per IEC-273 ---------2300
3350
(Minimum) Necessary subStructure/stool required to
match bus height using
standard structure shall be
provided by the Contractor.
IN JASIDIH GSS VOL-II
Page 329
k)
l)
m)
P.C.D Top
(mm)
127
127
---
Bottom (mm)
300
254
---
No. of bolts
Top
4
4
---
Bottom
8
8
---
Top
M16
M16
---
Bottom dia
18
18
---
Diameter of bolt/holes (mm)
n)
Pollution level as per
IEC-815
o)
Minimum total creepage
distance for Heavy
Pollution (mm)
Heavy(III)
Heavy(III)
10500
6125
Heavy(III)
3165
7.3.1
If corona extinction voltage is to be achieved with the help of corona ring or any
other similar device, the same shall be deemed to be included in the scope of the
Contractor.
8.0
EARTHING
8.1 The earthing shall be done in accordance with requirements given hereunder
and drawing titled ‘Earthing Details’ enclosed with the specification. The
earthmat design shall be done by the Contractor as per IEEE-80. The soil
resistivity measurement shall also be done by the Contractor. The resistivity
measurement of stone (to be used for stone spreading) shall also be done by the
Contractor to confirm the resistivity value of stone considered in earth mat design.
For measurement purpose, one sample of stones from each source (in case stones
are supplied from more than one source) shall be used. The main earthmat shall
be laid in the switchyard area in accordance with the approved design
requirements.
8.2
Neutral points of systems of different voltages, metallic enclosures and
frame works associated with all current carrying equipments and
extraneous metalworks associated with electric system shall be connected.
IN JASIDIH GSS VOL-II
Page 330
to a single earthing system unless stipulated otherwise.
8.3
Earthing and lightning protection system installation shall be in strict accordance
with the latest editions of Indian Electricity Rules, relevant Indian Standards and
Codes of practice and Regulations existing in the locality where the system is
installed.
a)
Code of practice for Earthing IS:3043
b)
Code of practice for the protection of Building and allied structures
against lightning IS:2309.
c)
Indian Electricity Rules 1956 with latest amendments.
d)
National Electricity Safety code IEEE-80.
Details of Earthing System
8.4
-------------------------------------------------------------------------------------------------Item
Size
Material
a)Main Earthing
Conductor to be
buried in ground
40mm dia
Mild Steel
rod
b)Conductor above
ground & earthing leads
(for equipment)
75x12mm
G.S. flat
Galvanised Steel
c)Conductor above
ground & earthing leads
(for columns & aux.
structures)
75x12mm
G.S. flat
Galvanised Steel
d)Earthing of indoor LT
panels, Control panels and
out door marshalling boxes,
MOM boxes, Junction
boxes & Lighting Panels
etc.
50x6 mm
G.S. flat
Galvanised Steel
e)Rod Earth Electrode
40mm dia,
3000mm long
Mild Steel
--------------------------------------------------------------------------------------------------
IN JASIDIH GSS VOL-II
Page 331
Pipe Earth Electrode (in
treated earth pit) as per
IS.
40 mm diaGalvanised
3000 mm long steel
25x3mm GS flat Galvanised steel
f)Earthing for motors
g)
50x6mm MS
Earthing conductor
along outdoor cable
trenches
Mild steel flat
h)
i) Earthing of Lighting PolesThe sizes of
20 mm dia mild steel rod
Steel rod 3000 mm long
the earthing conductor indicated above
are the minimum sizes.
8.5
Earthing Conductor Layout
8.5.1
Earthing conductors in outdoor areas shall be buried at least 600 mm below
finished ground level unless stated otherwise.
8.5.2
Wherever earthing conductor crosses cable trenches, underground service ducts,
pipes, tunnels, railway tracks etc., it shall be laid minimum 300 mm below them
and shall be circumvented in case it fouls with equipment/structure foundations.
8.5.3
Tap-connections from the earthing grid to the equipment/structure to be earthed,
shall be terminated on the earthing terminals of the equipment/structure as per
“Earthing Details”.
8.5.4
Earthing conductors or leads along their run on cable trench, ladder, walls etc.
shall be supported by suitable welding/cleating at intervals of 750 mm. Wherever
it passes through walls, floors etc., galvanised iron sleeves shall be provided for
the passage of the conductor and both ends of the sleeve shall be sealed to prevent
the passage of water through the sleeves.
8.5.5
8.5.6
Earthing conductor around the building shall be buried in earth at a minimum
distance of 1500 mm from the outer boundary of the building. In case high
temperature is encountered at some location, the earthing conductor shall be laid
minimum 1500 mm away from such location.
Earthing conductors crossing the road shall be laid 300 mm below road or at
greater
depth
to
suit
the
site
conditions.
IN JASIDIH GSS VOL-II
Page 332
8.5.7
Earthing conductors embeded in the concrete shall have approximately 50
mm concrete cover.
8.6
Equipment and Structure Earthing
8.6.1
Earthing pads shall be provided for the apparatus/equipment at accessible position.
The connection between earthing pads and the earthing grid shall be made by two
short earthing leads (one direct and another through the support structure) free
from kinks and splices. In case earthing pads are not provided on the item to be
earthed, same shall be provided in consultation with Owner.
8.6.2
Whether specifically shown in drawings or not, steel/RCC columns, metallic
stairs etc. shall be connected to the nearby earthing grid conductor by two
earthing leads. Electrical continuity shall be ensured by bonding different sections
of hand-rails and metallic stairs.
8.6.3
Metallic pipes, conduits and cable tray sections for cable installation shall be
bonded to ensure electrical continuity and connected to earthing conductors at
regular interval. Apart from intermediate connections, beginning points shall also
be connected to earthing system.
8.6.4
Metallic conduits shall not be used as earth continuity conductor.
8.6.5
Wherever earthing conductor crosses or runs along metallic structures such as gas,
water, steam conduits, etc. and steel reinforcement in concrete it shall be bonded
to the same.
8.6.6
Light poles, junction boxes on the poles, cable and cable boxes/glands, lockout
switches etc. shall be connected to the earthing conductor running alongwith the
supply cable which inturn shall be connected to earthing grid conductor at a
minimum two points whether specifically shown or not.
8.6.7
Railway tracks within switchyard area shall be earthed at a spacing of 30m and
also at both ends.
8.6.8
Earthing conductor shall be buried 2000 mm outside the switchyard fence. All the
gates and every alternate post of the fence shall be connected to earthing grid.
The stone spreading shall also be done 2000 mm outside switchyard fence. The
criterian for stone spreading shall be followed in line with requirement specified
elsewhere in the specification
IN JASIDIH GSS VOL-II
Page 333
8.6.9
Flexible earthing connectors shall be provided for the moving parts.
8.6.10
All lighting panels, junction boxes, receptacles fixtures, conduits etc. shall be
grounded in compliance with the provision of I.E. rules
8.6.11
A continuous ground conductor of 16 SWG GI wire shall be run all along each
conduit run. The conductor shall be connected to each panel ground bus. All
junction boxes, receptacles, switches, lighting fixtures etc. shall be connected to
this 16 SWG ground conductor.
8.6.12
50mm x 6mm MS flat shall run on the top tier and all along the cable trenches and
the same shall be welded to each of the racks. Further this flat shall be earthed at
both ends and at an interval of 30 mtrs. The M.S. flat shall be finally painted with
two coats of Red oxide primer and two coats of Post Office red enamel paint.
8.6.13
A 40 mm dia , 3000 mm long MS earth electrode with test link , CI frame and
cover shall be provided to connect down conductor of lightning mast and towers
with peak.
8.7
Jointing
8.7.1
Earthing connections with equipment earthing pads shall be bolted type. Contact
surfaces shall be free from scale, paint, enamel, grease, rust or dirt. Two bolts
shall be provided for making each connection. Equipment bolted connections,
after being checked and tested, shall be painted with anti corrosive
paint/compound.
8.7.2
Connection between equipment earthing lead and main earthing conductors and
between main earthing conductors shall be welded type. For rust protections, the
welds should be treated with red lead and afterwards coated with two layers
bitumen compound to prevent corrosion.
8.7.3
Steel to copper connections shall be brazed type and shall be treated to prevent
moisture ingression.
8.7.4
Resistance of the joint shall not be more than the resistance of the equivalent
length of the conductor.
8.7.5
All ground connections shall be made by electric arc welding. All welded joints
shall be allowed to cool down gradually to atmospheric temperature before putting any load on it. Artificial cooling shall not be allowed.
IN JASIDIH GSS VOL-II
Page 334
8.7.6
Bending of earthing rod shall be done preferably by gas heating.
8.7.7
All arc welding with large dia. conductors shall be done with low hydrogen
content electrodes.
8.7.8
The 75x12mm GS flat shall be clamped with the equipment support structures at
1000mm interval.
8.8
Power Cable Earthing
Metallic sheaths and armour of all multi core power cables shall be earthed at
both equipment and swithgear end. Sheath and armour of single core power
cables shall be earthed at switchgear end only.
8.9
Specific Requirement for Earthing Systems
8.9.1
Each earthing lead from the neutral of the power transformer/Reactor shall be
directly connected to two pipe electrodes in treated earth pit (as per IS) which in
turn, shall be buried in Cement Concrete pit with a cast iron cover hinged to a cast
iron frame to have an access to the joints. All accessories associated with
transformer/reactor like cooling banks, radiators etc. shall be connected to the
earthing grid at minimum two points.
8.9.2
Earthing terminal of each lightning arrester & capacitor voltage trasformer shall
be directly connected to rod earth electrode which in turn, shall be connected to
station earthing grid.
8.9.3
Auxiliary earthing mat comprising of 40mm dia M.S. rods closely spaced (300
mm x 300 mm) conductors shall be provided at depth of 300mm from ground
level below the operating handles of the M.O.M. Box of the isolators. M.O.M.
boxes shall be directly connected to the auxiliary earthing mat.
9.0
Main Bus Bars
The brief description of the bus switching scheme, bus bar layout and equipment
connection to be adopted are indicated elsewhere in the specification. The bus bar
arrangements are shown in drgs enclosed with the bid documents.
9.1
The Contractor shall furnish supporting calculations
bars/conductors to show adequacy of design parameters for:
for
IN JASIDIH GSS VOL-II
the
bus
Page 335
a)
Fibre-stress
b)
Cantilever strength of post insulators
c)
Aeolain vibrations
d)
Vertical deflection of bus bars
e)
Short circuit forces in bundle conductor and spacer location for each span
of ACSR conductor stringing as per layout drawings.
9.1.1
The welds in the aluminium tubes shall be kept to the minimum and there shall
not be more than one weld per span. The procedure and details of welding shall
be subject to Owner’s approval. Material for welding sleeve shall be same as that
of Aluminium tube. Welding sleeve shall be of 600mm length
9.1.2
Corona bells shall be provided wherever the bus extends beyond the clamps and
on free ends, for sealing the ends of the tubular conductor against rain and
moisture and to reduce the electrostatic discharge loss at the end points. There
shall be a small drain hole in the corona bell. The material of Corona bell shall be
Aluminium alloy similar to that of clamps & connectors.
9.1.3
To minimise the vibrations in the aluminium tubes, damping conductor shall be
provided inside the aluminium tubes. For this purpose, the cut pieces of ACSR
conductor which otherwise are considered wastages, shall be used as damping
conductor.
9.1.4
Details of past experience of the persons proposed to be employed for Aluminium
tube welding and the test reports of the welded pieces to prove the electrical and
mechanical characteristics shall also be furnished along with the bid. Welding at
site shall be done by adopting a qualified procedure and employing qualified
welders as per ASME-Section IX.
10.0
BAY EQUIPMENT
10.1
The disposition of various bay equipments shall be as per single line diagrams and
layout drawings.
10.2
Bay Marshalling Kiosk:-One no. of bay marshalling kiosk shall be provided for
each bay. In
IN JASIDIH GSS VOL-II
Page 336
addition to the requirements specified elsewhere in the specification, the bay
marshalling kiosk shall have three distinct compartments for the following purpose:(i)
To receive two incoming 415V, 3 phase, 63Amps, AC supply with auto
changeover and MCB unit and distrubute minimum six (four in case of S/S having
highest voltage 132kV) outgoing 415V, 3 phase, 16 Amps AC supplies controlled by
MCB.
(ii) To distribute minimum ten (six in case of S/S having highest voltage 132kV)
outgoing 240V, 10 Amps single phase supplies to be controlled by MCB
to be drawn from above 3 phase incomers
(iii) 200 (100 in case of S/S having highest voltage 132kV) nos. terminal blocks
in vertical formation for intertocking facilities.
Additional marshalling Kiosk shall be provided incase the existing
marshalling kiosks in a Diametre do not have adequate spare feeders.
11.0
LIGHTNING PROTECTION
11.1
Direct stroke lightning protection (DSLP) shall be provided in the EHV
switchyard by lightning masts and shield wires. The layout drawings enclosed
indicate the tentative arrangement. The final arrangement shall be decided after
approval of the DSLP calculations.
11.2
The lightning protection system shall not be in direct contact with underground
metallic service ducts and cab.
11.3
Conductors of the lightning protection system shall not be connected with
the conductors of the safety earthing system above ground level.
11.4
Down conductors shall be cleated on the structures at 2000 mm interval.
11.5
Connection between each down conductor and rod electrodes shall be made via
test joint (pad type compression clamp) located approximately 1500 mm above
ground level. The rod electrode shall be further joined with the main earthmat.
11.6
Lightning conductors shall not pass through or run inside G.I. conduits.
12.0
EQUIPMENT ERECTION DETAILS
12.1
For equipment interconnection, the surfaces of equipment terminal pads,
IN JASIDIH GSS VOL-II
Page 337
Aluminium tube, conductor & terminal clamps and connectors shall be properly
cleaned. After cleaning, contact grease shall be applied on the contact surfaces of
equipment terminal pad, Aluminium tube/conductor and terminal clamps to avoid
any air gap in between. Subsequently bolts of the terminal pad/terminal
connectors shall be tightened and the surfaces shall be cleaned properly after
equipment interconnection.
12.2
Muslin or leather cloth shall be used for cleaning the inside and outside of hollow
insulators .
12.3
All support insulators, circuit breaker interrupters and other fragile equipment
shall preferably be handled with cranes having suitable booms and handling
capacity.
12.4
Bending of Aluminium tube and compressed air piping if any should be done by a
bending machine and through cold bending only. Bending shall be such that inner
diameter of pipe is not reduced.
12.5
Cutting of the pipes wherever required shall be such as to avoid flaring of the
ends. Hence only a proper pipe cutting tool shall be used. Hack saw shall not be
used.
12.6
Handling of equipment shall be done strictly as per manufacturer’s/supplier’s
instructions/instruction manual.
12.7
Handling equipment, sling ropes etc. should be tested periodically before erection
for strength.
12.8
The slings shall be of sufficient length to avoid any damage to insulator due to
excessive swing, scratching by sling ropes etc.
13.0
STORAGE
13.1
The Contractor shall provide and construct adequate storage shed for proper
storage of equipments, where sensitive equipments shall be stored indoors. All
equipments during storage shall be protected against damage due to acts of nature
or accidents. The storage instructions of the equipment manufacturer/Owner shall
be strictly adhered to.
14.0
CABLING MATERIAL
14.1
CABLE TAGS AND MARKERS
14.1.1
Each cable and conduit run shall be tagged with numbers that appear in
IN JASIDIH GSS VOL-II
Page 338
the cable and conduit schedule.
14.1.2
The tag shall be of aluminium with the number punched on it and securely
attached to the cable conduit by not less than two turns of 20 SWG GI wire
conforming to IS:280. Cable tags shall be of rectangular shape for power cables
and of circular shape for control cables.
14.1.3
Location of cables laid directly underground shall be clearly indicated with cable
marker made of galvanised iron plate.
14.1.4
Location of underground cable joints shall be indicated with cable marker with an
additional inscription “Cable joints”.
14.1.5
The marker shall project 150 mm above ground and shall be spaced at an interval
of 30 meters and at every change in direction. They shall be located on both sides
of road and drain crossings.
14.1.6
Cable tags shall be provided on all cables at each end (just before entering the
equipment enclosure), on both sides of a wall or floor crossing, on each
duct/conduit entry and at each end & turning point in cable tray/trench runs.
Cable tags shall be provided inside the switchgear, motor control centres, control
and relay panels etc., wherever required for cable identification, where a number
of cables enter together through a gland plate.
14.2
Cable Supports and Cable Tray Mounting Arrangements
14.2.1
The Contractor shall provide embedded steel inserts on concrete floors/walls to
secure supports by welding to these inserts or available building steel structures.
14.2.2
The supports shall be fabricated from standard structural steel members.
14.2.3
Insert plates will be provided at an interval of 750 mm wherever cables are to be
supported without the use of cable trays, such as in trenches, while at all other
places these will be at an interval of 2000 mm.
14.3
Cable Termination and Connections
14.3.1
The termination and connection of cables shall be done strictly in accordance with
cable and termination kit manufacturer’s instructions, drawing and/or as directed
by the Owner.
14.3.2
The work shall include all clamping, fittings, fixing, plumbing, soldering,
IN JASIDIH GSS VOL-II
Page 339
drilling, cutting, taping, heat shrinking (where applicable), connecting to cable
terminal, shorting and grounding as required to complete the job.
14.3.3
Supply of all consumable material shall be in the scope of Contractor.
14.3.4
The equipment will be generally provided with undrilled gland plates for
cables/conduit entry. The Contractor shall be responsible for drilling of gland
plates, painting and touching up. Holes shall not be made by gas cutting.
14.3.5
Control cable cores entering control panel/switch-gear/MCCB/MCC/
miscellaneous panels shall be neatly bunched, clamped and tied with nylon strap or
PVC perforated strap to keep them in position.
14.3.6
The Contractor shall tag/ferrule control cable cores at all terminations, as
instructed by the Owner. In panels where a large number of cables are to be
terminated and cable identification may be difficult, each core ferrule may include
the complete cable number as well.
14.3.7
Spare cores shall be similarly tagged with cable numbers and coiled up.
14.3.8
All cable entry points shall be sealed and made vermin and dust proof.Unused
openings shall be effectively closed.
14.3.9
Double compression type nickel plated (coating thickness not less than 10
microns) brass cable glands shall be provided by the Contractor for all power and
control cables to provide dust and weather proof terminations.
14.3.10
The cable glands shall conform to BIS:6121. They shall comprise of heavy duty
brass casting, machine finished and nickel plated, to avoid corrosion and
oxidation. Rubber components used in cable glands shall be neoprene and of
tested quality. Cable glands shall be of approved make.
14.3.11
The cable glands shall also be suitable for dust proof and weather proof
termination. The test procedure, if required, has to be discussed and agreed to
between Owner and cable gland manufacturer.
14.3.12
If the cable-end box or terminal enclosure provided on the equipment is found
unsuitable and requires modification, the same shall be carried out by the
Contractor, as directed by the Owner.
14.3.13
Crimping tool used shall be of approved design and make.
IN JASIDIH GSS VOL-II
Page 340
14.3.14
Cable lugs shall be tinned copper solder less crimping type conforming to IS8309 & 8394. Bimetallic lugs shall be used depending upon type of cables used.
14.3.15
Solder less crimping of terminals shall be done by using corrosion inhibitory
compound. The cable lugs shall suit the type of terminals provided.
14.4
Storage and handling of Cable Drums
14.4.1
Cable drums shall be unloaded, handled and stored in an approved
manner and rolling of drums shall be avoided as far as possible. For short
distances, the drums may be rolled provided they are rolled slowly and in proper
direction as marked on the drum.
15.0
DIRECTLY BURIED CABLES
15.1
The Contractor shall construct the cable trenches requried for directly buried
cables. The scope of work shall include excavation, preparation of sand bedding,
soil cover, supply and installation of brick or concrete protective covers, back
filling and ramming, supply and installation of route markers and joint markers.
The Bidder shall ascertain the soil conditions prevailing at site, before submitting
the bid.The cable (power and control) between LT station, control room, DG set
building and fire lighting pump house shall be laid in the buried cable trenches. In
addition to the above, for lighting purpose also, buried cable trench can be used in
outdoor area.
15.2
Cable route and joint markers and RCC warning covers shall be provided
wherever required. The voltage grade of cables shall be engraved on the marker.
16.0
INSTALLATION OF CABLES
16.1
Cabling in the control room shall be done on ladder type cable trays while cabling
in switchyard area shall be done on angles in the trench.
16.2
All cables from bay cable trench to equipments including and all interpole cables
(both power and control) for all equipment, shall be laid in PVC pipes of
minimum 50 mm nominal outside diameter of class 4 as per IS 4985 which shall
be buried in the ground at a depth of 250mm below finish formation level.
Separate PVC pipes shall be laid for control and power cables.
IN JASIDIH GSS VOL-II
Page 341
16.3
Cables shall be generally located adjoining the electrical equipment through the
pipe insert embedded in the floor. In the case of equipments located away from
cable trench either pipe inserts shall be embedded in the floor connecting the
cable trench and the equipment or in case the distance is small, notch/opening on
the wall shall be provided. In all these cases necessary bending radius as
recommended by the cable manufacturer shall be maintained.
16.4
Cable racks and supports shall be painted after installation with two coats of metal
primer (comprising of red oxide and zinc chromate in a synthetic medium)
followed by two finishing coats of aluminium paint. The red oxide and zinc
chromate shall conform to IS:2074.
16.5
Suitable arrangement should be used between fixed pipe / cable trays and
equipment terminal boxes, where vibration is anticipated.
16.6
Power and control cables in the cable trench shall be laid in separate tiers. The
order of laying of various cables shall be as follows, for cables other than directly
buried.
a)
Power cables on top tiers.
b)
Control instrumentation and other service cables in bottom tiers.
16.7
Single core cables in trefoil formation shall be laid with a distance of three times
the diameter of cable between trefoil centre lines. All power cables shall be laid
with a minimum centre to centre distance equal to twice the diameter of the cable
of higher size of cables.
16.8
Trefoil clamps for single core cables shall be of pressure die cast aluminium (LM6), Nylon -6 or fibre glass and shall include necessary fixing GI nuts, bolts,
washer etc. These are required at every 2 metre of cable runs.
16.9
Power and control cables shall be securely fixed to the trays/supports with self
locking type nylon ties with deinterlocking facility at every 5 metre interval for
horizontal run. Vertical and inclined cable runs shall be secured with 25 mm wide
and 2 mm thick aluminium strip clamps at every 2m.
16.10
Cables shall not be bent below the minimum permissible limit. The permissible
limits are as follows :
IN JASIDIH GSS VOL-II
Page 342
Table of Cable and
Minimum bending radius
Power cable
12 D
Control cable
10 D
D is overall diameter of cable
16.11
Where cables cross roads, drains and rail tracks, these shall be laid in reinforced
spun concrete or steel pipes buried at not less than one metre depth.
16.12
In each cable run some extra length shall be kept at a suitable point to enable one
(for LT cables)/two (for H.T. cables) straight through joints to be made in case the
cable develop fault at a later date.
16.13
Selection of cable drums for each run shall be so planned as to avoid using
straight through joints. Cable splices will not be permitted except where called for
by the drawings, unavoidable or where permitted by the Owner. If straight
through joints are unavoidable, the Contractor shall use the straight through joints
kit of reputed make.
16.14
Control cable terminations inside equipment enclosures shall have sufficient
lengths so that changing of termination in terminal blocks can be done without
requiring any splicing.
16.15
Metal screen and armour of the cable shall be bonded to the earthing system of
the station, wherever required by the Owner.
16.16
Rollers shall be used at intervals of about two metres while pulling cables.
16.17
All due care shall be taken during unreeling, laying and termination of cable to
avoid damage due to twist, kinks, sharp bends, etc.
16.18
Cable ends shall be kept sealed to prevent damage. In cable vault, fire resistant
seal shall be provided underneath the panels.
16.19
Inspection on receipt, unloading and handling of cables shall generally be in
accordance with IS:1255 and other Indian Standard Codes of practices.
16.20
Wherever cable pass through floor or through wall openings or other partitions,
GI/PVC wall sleeves with bushes having a smooth curved internal surface so as
not to damage the cable, shall be supplied, installed and properly sealed by the
Contractor at no extra charges.
16.21
Contractor shall remove the RCC/Steel trench covers before taking up the work
and shall replace all the trench covers after the erection-work in that particular
area is completed or when further work is not likely to be taken up for some time.
IN JASIDIH GSS VOL-II
Page 343
16.22
Contractor shall furnish three copies of the report on work carried out in a
particular week, indicating cable numbers, date on which laid, actual length and
route, testing carried out, terminations carried out, along with the marked up copy
of the cable schedule and interconnection drawing wherever any modifications are
made.
16.23
Contractor shall paint the tray identification number on each run of trays at an
interval of 10 m.
16.24
In case the outer sheath of a cable is damaged during handling/installation, the
Contractor shall repair it at his own cost to the satisfaction of the Owner. In case
any other part of a cable is damaged, the same shall be replaced by a healthy cable
at no extra cost to the Owner, i.e. the Contractor shall not be paid for installation
and removal of the damaged cable.
16.25
All cable terminations shall be appropriately tightened to ensure secure and
reliable connections. The Contractor shall cover the exposed part of all cable lugs
whether supplied by him or not with insulating tape, sleeve or paint.
16.26
Cable trays
i) The cable trays shall be of G.S.sheet and minimum thickness of sheet shall be
2mm.
ii) The Contractor shall perform all tests and inspection to ensure that material
and workmanship are according to the relevant standards. Contractor shall have to
demonstrate all tests as per specification and equipment shall comply with all
requirements of the specification.
a)
Test for galvanising (Acceptance Test)
The test shall be done as per approved standards.
b)
Deflection Test : (Type Test)
A 2.5 metre straight section of 300mm, 600mm wide cable tray shall be simply
supported at two ends. A uniform distributed load of 76 kg/m shall
be applied along the length of the tray. The maximum deflection at the mid-span
shall not exceed 7mm.
16.27
Conduits, Pipes and Duct Installation
16.27.1
Contractor shall supply and install all rigid conduits, mild steel pipes,flexible
conduits, hume pipes etc. including all necessary sundry materials such as tees,
elbows, check nuts, bushing, reducers, enlargers, coupling cap, nipples, gland
sealing fittings, pull boxes etc as specified and to be shown in detailed drawing.
The size of the conduit/pipe shall be selected on the basis of 40% fill criterion.
IN JASIDIH GSS VOL-II
Page 344
16.27.2
Contractor shall have his own facility for bending, cutting and threading the
conduits at site. Cold bending should be used. All cuts & threaded ends shall be
made smooth without leaving any sharp edges. Anticorrosive paint shall be
applied at all field threaded portions.
16.27.3
All conduit/pipes shall be extended on both sides of wall/floor openings. The
fabrication and installation of supports and the clamping shall be included in the
scope of work by Contractor.
16.27.4
When two lengths of conduits are joined together through a coupling, running
threads equal to twice the length of coupling shall be provided on each conduit to
facilitate easy dismantling of two conduits.
16.27.5
Conduit installation shall be permanently connected to earth by means of special
approved type of earthing clamps. GI pull wire of adequate size shall be laid in all
conduits before installation.
16.27.6
Each conduit run shall be painted with its designation as indicated on the
drawings such that it can be identified at each end.
16.27.7
Embedded conduits shall have a minimum concrete cover of 50 mm.
16.27.8
Conduit run sleeves shall be provided with the bushings at each end.
16.27.9
Metallic conduit runs at termination shall have two locknuts and a bushing for
connection. Flexible conduits shall also be suitably clamped at each end with the
help of bushings. Bushings shall have rounded edges so as not to damage the
cables.
16.27.10
Where embedded conduits turn upwards from a slab or fill, the termination
dimensions shown on the drawings, if any, shall be taken to represent the position
of the straight extension of the conduit external to
IN JASIDIH GSS VOL-II
Page 345
and immediately following the bend. At least one half of the arc length of the bend shall be
embedded.
16.27.11
All conduits/pipes shall have their ends closed by caps until cables are pulled.
After cables are pulled, the ends of conduits/pipes shall be sealed in an approved
manner to prevent damage to threaded portions and entrance of moisture and
foreign material.
16.27.12
For underground runs, Contractor shall excavate and back fill as necessary.
16.27.13
Contractor shall supply, unload, store and install conduits required for the lighting
installation as specified. All accessories/fittings required for making the
installation complete, including but not limited to pull out boxes, ordinary and
inspection tees and elbow, checknuts, male and female bushings (brass or
galvanised steel), caps, square headed male plugs, nipples, gland sealing fittings
,pull boxes, conduits terminal boxes, gaskets and box covers, saddle terminal
boxes, and all steel supporting work shall be supplied by the Contractor. The
conduit fittings shall be of the same material as conduits.
16.27.14
All unarmoured cables shall run within the conduits from lighting panels to
lighting fixtures, receptacles etc.
16.27.15
Size of conduit for lighting shall be selected by the Contractor during detailed
engineering.
16.27.16
Exposed conduits shall be run in straight lines parallel to building columns, beams
and walls. Unnecessary bends and crossings shall be avoided to present a neat
appearance.
16.27.17
Conduit supports shall be provided at an interval of 750mm for horizontal runs
and 1000mm for vertical runs.
16.27.18
Conduit supports shall be clamped on the approved type spacer plates or brackets
by saddles or U- bolts. The spacer plates or brackets in turn, shall be securely
fixed to the building steel by welding and to concrete or brick work by grouting or
by nylon rawl plugs. Wooden plug inserted in the masonary or concrete for
conduit support is not acceptable.
16.27.19
Embedded conduits shall be securely fixed in position to preclude any movement.
In fixing embedded conduit, if welding or brazing is used, extreme care should be
taken to avoid any injury to the inner surface of the conduit.
IN JASIDIH GSS VOL-II
Page 346
16.27.20
Spacing of embedded conduits shall be such as to permit flow of concrete
between them.
16.27.21
Where conduits are placed alongwith cable trays, they shall be clamped to
supporting steel at an interval of 600mm.
16.27.22
For directly embedding in soil, the conduits shall be coated with an asphalt-base
compound. Concrete pier or anchor shall be provided wherever necessary to
support the conduit rigidly and to hold it in place.
16.27.23
Conduit shall be installed in such a way as to ensure against trouble from trapped
condensation.
16.27.24
Conduits shall be kept, wherever possible, at least 300mm away from hot pipes,
heating devices etc. when it is evident that such proximity may reduce the service
life of cables.
16.27.25
Slip joints shall be provided when conduits cross structural expansion joints or
where long run of exposed conduits are installed, so that temperature change will
cause no distortion due to expansion or contraction of conduit run.
16.27.26
For long conduit run, pull boxes shall be provided at suitable intervals to facilitate
wiring.
16.27.27
Conduit shall be securely fastened to junction boxes or cabinets, each with a lock
nut inside and outside the box.
16.27.28
Conduits joints and connections shall be made thoroughly water-tight and rust
proof by application of a thread compound which insulates the joints. White lead
issuitable for application on embedded conduit and red lead for exposed conduit.
16.27.29
Field bends shall have a minimum radius of four (4) times the conduit diameter.
All bends shall be free of kinks, indentations of flattened surfaces. Heat shall not
be applied in making any conduit bend. Separate bends may be used for this
purpose.
16.27.30
The entire metallic conduit system, whether embedded or exposed, shall be
electrically continuous and thoroughly grounded. Where slip joints are used,
suitable bounding shall be provided around the joint to ensure a continuous
ground circuit.
IN JASIDIH GSS VOL-II
Page 347
16.27.31
After installation, the conduits shall be thoroughly cleaned by compressed air
before pulling in the wire.
16.27.32
Lighting fixtures shall not be suspended directly from the junction box in the
main conduit run.
17.0
JUNCTION BOX
a)
The Contractor shall supply and install junction boxes complete with
terminals as required. The brackets, bolts, nuts, screws etc required for
erection are also included in the scope of the Contractor.
b)
Junction boxes having volume less than 1600 cubic centimeters may be
installed without any support other than that resulting from connecting
conduits where two or more rigid metallic conduits enter and accurately
position the box. Boxes shall be installed so that they are level, plumb and
properly aligned to present a pleasing appearance.
c)
Boxes with volumes equal to or greater than 1600 cubic cm, and smaller
boxes terminating on less than two rigid metallic conduits or for other
reasons not rigidly held, shall be adequately supported by auxiliary steel of
standard steel shapes or plates to be fabricated and installed. The
Contractor shall perform all drilling, cutting, welding, shimming and
bolting required for attachment of supports.
18.0
TESTING AND COMMISSIONING
18.1
An indicative list of tests for testing and commissioning is given below.
Contractor shall perform any additional test based on specialities of the items as
per the field Q.P./instructions of the equipment Contractor or Owner without any
extra cost to the Owner. The Contractor shall arrange all equipments instruments
and auxiliaries required for testing and commissioning of equipments alongwith
calibration certificates and shall furnish the list of instruments to the Owner for
approval.
18.2
GENERAL CHECKS
(a)
Check for physical damage.
(b)
Visual examination of zinc coating/plating.
(c)
Check from name plate that all items are as per order/specification.
IN JASIDIH GSS VOL-II
Page 348
18.3
18.4
(d)
Check tightness of all bolts, clamps and connecting terminals using torque
wrenches.
(e)
For oil filled equipment, check for oil leakage, if any. Also check oil level
and top up wherever necessary.
(f)
Check ground connections for quality of weld and application of zinc rich
paint over weld joint of galvanised surfaces.
(g)
Check cleanliness of insulator and bushings.
(h)
All checks and tests specified by the manufacturers in their drawings and
manuals as well as all tests specified in the relevant code of erection.
(i)
Check for surface finish of grading rings (Corona control ring).
(j)
Pressure test on all pneumatic lines at 18.5 times the rated pressure shall be
conducted.
STATION EARTHING
a)
Check soil resistivity
b)
Check continuity of grid wires
c)
Check earth resistance of the entire grid as well as various sections of the
same.
d)
Check for weld joint and application of zinc rich paint on galvanised
surfaces.
e)
Dip test on earth conductor prior to use.
‘MOOSE’ ACSR STRINGING WORK, TUBULAR BUS WORK(NOT
APPLICABLE FOR TEHTA) AND POWER CONNECTORS
a)
Physical check for finish
b)
Electrical clearance check
c)
Testing of torque by torque wrenches on all bus bar power connectors and
other
accessories.
IN JASIDIH GSS VOL-II
Page 349
18.5
d)
Millivolt drop test on all power connectors.
e)
Sag and tension check on conductors.
ALUMINIUM TUBE WELDING
a)
Physical check
b)
Millivolt drop test on all joints.
c)
Dye penetration test & Radiography test on 10% sample basis on weld
joints.
c)
18.6
Test check on 5% sample joints after cutting the weld piece to observe
any voids etc.
INSULATOR
Visual examination for finish, damage, creepage distance etc.
18.7
All pre/commissioning activities and works work for substation
equipment
shall
be
carried
out
as
per
specifications.
IN JASIDIH GSS VOL-II
Page 350
ANNEXURE “A”
Testing Procedure for ACSR ‘MOOSE’ Conductor
1.0
UTS Test on Stranded Conductor
Circles perpendicular to the axis of the conductor shall be marked at two places
on a sample of conductor of minimum 5 m length suitably compressed with dead
end clamps at either end. The load shall be increased at a steady rate upto 80 kN
and held for one minute. The circles drawn shall not be distorted due to Relative
movement of strands. Thereafter the load shall be increased at a steady rate to
161.2 kN and held for one minute. The applied load shall then be increased until
the failing load is reached and the value recorded.
2.0
Corona Extinction Voltage Test
Two samples of conductor of 5m length shall be strung with a spacing of 450 mm
between them at a height not exceeding 8.0 m above ground. This assembly shall
be tested as per Annexure-C, Corona extinction voltage shall not be less than 320
KV (RMS) Line to ground.
3.0
Radio Interference Voltage Test
The sample assembly similar to that specified under (2.0) above shall be tested as
per Annexure - C . Maximum RIV level (across 300 ohm resistor at 1 MHz) at
305 KV (RMS) line to ground voltage shall be 1000 micro volts.
4.0
D.C Resistance Test on Stranded Conductor
On a conductor sample of minimum 5 m length two contact clamps shall be fixed
with a pre-determined bolt torque. The resistance shall be measured by a Kelvin
double bridge by placing the clamps initially zero metre and subsequently one
metre apart. The test shall be repeated at least five times and the average value
recorded. The value obtained shall be corrected to the value at 20°C as per clause
no. 12.8 of IS:398 (Part V)-1982. The resistance corrected at 20°C shall conform
to the requirements of this specification.
5.0
Chemical Analysis of Zinc
IN JASIDIH GSS VOL-II
Page 351
Samples taken from the zinc ingots shall be chemically/spectrographically
analysed. The same shall be in conformity to the requirements stated in this
specification.
6.0
Chemical Analysis of Aluminium and Steel
Samples taken from the Aluminium ingots/coils/strands shall be
chemically/spectrographically analysed. The same shall be in conformity to the
requirements stated in this specification.
7.0
Visual Check for Joints, Scratches etc.
Conductor drums shall be rewound in the presence of the inspector. The inspector
shall visually check for scratches, joints, etc. and that the conductor generally
conform to the requirements of this specification. The length of conductor wound
on the drum shall be measured with the help of counter meter during rewinding.
8.0
Dimensional Check for Steel and Aluminium Strands.
The individual strands shall be dimensionally checked to ensure that they conform
to the requirements of this specification.
9.0
Check for Lay-ratios of various Layers.
The lay-ratios of various layers shall be checked to ensure that they conform to
the requirements of this specification and clause no. 9.4 and 9.5 of IS-398 (Part V) 1982.
10.0
Galvanising Test
The test procedure shall be as specified in IS:4826-1968. The material shall
conform to the requirements of this specification.
11.0
Torsion and Elongation Tests on Steel Strands
The test procedures shall be as per relevant clause of IS:398 (Part V), 1982. In
torsion test, the number of complete twists before fracture shall not be less than
18 on a length equal to 100 times the standard diameter of the strand before
stranding & 16 after stranding. In case test sample length of less or more than 100
times the standard diameter of the strand, the minimum number of twist will be
proportionate to the length and if number comes in the fraction then it will be
rounded off to next
IN JASIDIH GSS VOL-II
Page 352
higher whole number. In elongation test, the elongation of the strand shall not be
less than 4% for a gauge length of 200 mm.
12.0
Breaking load test on welded Aluminium strand:
Two Aluminium wires, shall be welded as per the approved quality plan and shall
be subjected to tensile load. The welded point of the wire shall be able to
withstand the minimum breaking load of the individual strand guaranteed by the
bidder.
IN JASIDIH GSS VOL-II
Page 353
ANNEXURE “B”
Testing procedure for Galvanised Steel Earthwire
1.
UTS TEST
Circles perpendicular to the axis of the earthwire shall be marked at two places on
a sample of earthwire of minimum 5m length suitably compressed with dead end
clamps at either end. The load shall be increased at steady rate upto 34 KN and
held for one minute. The circles drawn shall not be distorted due to relative
movement of strands. Thereafter, the load shall be increased at a steady rate of
68.4 KN and held for one minute. The earthwire sample shall not fail during this
period. The applied load shall then be increased until the failing load is reached
and value recorded.
2.
D.C. RESISTANCE TEST
On an earthwire sample of minimum 5m length, two contact clamps shall be fixed
with a predetermined Bolt torque. The resistance shall be measured by a Kelvin
double-bridge by placing the clamps initially zero meter and subsequently one
meter apart. the test shall be repeated at least five times and the average value
recorded. The value obtained shall be corrected to the value at 20°C shall conform
to the requirements of this specification.
3.
Visual check for joints, scratches etc. and length of earthwire
Earthwire drums shall be rewound in the presence of the inspector. The inspector
shall visually check for joints, scratches etc. and see that the earthwire generally
conforms to the requirements of this specification. The length of earthwire wound
on the drum shall be measured with the help of counter meter during rewinding.
4.
TORSION AND ELONGATION TESTS
The test procedure shall be as per relevant clause of IS:398 (Part-V). The
minimum number of twists which a single steel strand shall withstand during
torsion test shall be eighteen for a length equal to 100 times the standard diameter
of the strand. In case the test sample length is less or more than 100 times the
standard diameter of the strand, the minimum number of twists will be
proportionate to the length and if number comes in the fraction then it will be
rounded off to next higher whole number. In
IN JASIDIH GSS VOL-II
Page 354
elongation test, the elongation of the strand shall not be less than 64% or a gauge
length of 200 mm.
5.
DIMENSIONAL CHECK
The individual strands shall be dimensionally checked to ensure that they conform
to the requirements of this specification.
6.
LAY LENGTH CHECK
The lay length shall be checked to ensure that they conform to the requirements of
this specification.
7.
GALVANISING TEST
The test procedure shall as specified in IS:4826-1968. The material shall conform
to the requirements of this specification.
8.
CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING
Samples taken from zinc ingots shall be chemically/spectrographically analysed.
The same shall be in conformity to the requirements stated in this specification.
9.
CHEMICAL ANALYSIS OF STEEL
Samples taken from steel ingots/coils/strands shall be chemically/
spectrographically analysed. The same shall be in conformity to the requirements
stated in this specification.
IN JASIDIH GSS VOL-II
Page 355
ANNEXURE-C
CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) TEST
1.
General
Unless otherwise stipulated, all equipment together with its associated connectors,
where applicable, shall be tested for external corona both by observing the voltage
level for the extinction of visible corona under falling power frequency voltage and
by measurement of radio interference voltage (RIV).
2.
Test Levels:
The test voltage levels for measurement of external RIV and for corona extinction
voltage are listed under the relevant clauses of the specification.
3.
Test Methods for RIV:
3.1
RIV tests shall be made according to measuring circuit as per International SpecialCommittee on Radio Interference (CISPR) Publication 16-1(1993) Part -1. The
measuring circuit shall preferably be tuned to frequency with 10% of 0.5 Mhz but
other frequencies in the range of 0.5 MHz to 2 MHz may be used, the measuring
frequency being recorded. The results shall be in microvolts.
3.2
Alternatively, RIV tests shall be in accordance with NEMA standard Publication No.
107-1964, except otherwise noted herein.
3.3
In measurement of, RIV, temporary additional external corona shielding may be
provided. In measurements of RIV only standard fittings of identical type supplied
with the equipment and a simulation of the connections as used in the actual
installation will be permitted in the vicinity within 3.5 meters of terminals.
3.4
Ambient noise shall be measured before and after each series of tests to ensure that
there is no variation in ambient noise level. If variation is present, the lowest ambient
noise level will form basis for the measurements. RIV levels shall be measured at
increasing and decreasing voltages of 85%, 100%, 115% and 130% of the specified
RIV test voltage for all equipment unless otherwise specified. The specified RIV test
voltage for 400 kV, 220 KV is listed in the detailed specification together with
maximum permissible RIV level in microvolts.
3.5
The metering instruments shall be as per CISPR recommendation or equivalent
device so long as it has been used by other testing authorities.
3.6
The RIV measurement may be made with a noise meter. A calibration
IN JASIDIH GSS VOL-II
Page 356
procedure of the frequency to which noise meter shall be tuned shall establish the
ratio of voltage at the high voltage terminal to voltage read by noisel meter.
4.
Test Methods for Visible Corona
The purpose of this test is to determine the corona extinction voltage of apparatus,
connectors etc. The test shall be carried out in the same manner as RIV test described
above with the exception that RIV measurements are not required during test and a
search technique shall be used near the onset and extinction voltage, when the test
voltage is raised and lowered to determine their precise values.The test voltage shall
be raised to 130% of RIV test voltage and maintained there for five minutes. In case
corona inception does not take place at 130%, test shall be stopped, otherwise test
shall be continued and the voltage will then be decreased slowly until all visible
corona disappears. The procedure shall be repeated at least 4 times with corona
inception and extinction voltage recorded each time. The corona extinction voltage
for purposes of determining compliance with the specification shall be the lowest of
the four values at which visible corona (negative or positive polarity) disappears.
Photographs with laboratory in complete darkeness shall be taken under test
conditions, at all voltage steps i.e. 85%, 100%, 115% and 130%. Additional
photographs shall be taken at corona inception and extinction voltages. At least two
views shall lbe photographed in each case using Panchromatic film with an ASA
daylight rating of 400 with an exposure of two minutes at a lens aperture of f/5.6 or
equivalent. The photographic process shall be such that prints are available for
inspection and comparison with conditions as determined from direct observation.
Photographs shall be taken from above and below the level of connector so as to
show corona on bushing, insulators and all parts of energised connectors. The
photographs shall be framed such that test object essentially, fills the frame with no
cut-off.
In case corona inception does not take place at 130%, voltage shall not be increased
further and corona extinction voltage shall be considered adequate.
4.1
The test shall be recorded on each photograph. Additonal photograph shall be taken
from each camera position with lights on to show the relative position of test object
to facilitate precise corona location from the photographic evidence.
4.2
In addition to photographs of the test object preferably four photographs shall be
taken of the complete test assembly showing relative positions of all the test
equipment and test objects. These four photographs shall be taken from four points
equally spaced around the test arrangement to show its features from all sides.
Drawings of the laboratory and test set up locations
IN JASIDIH GSS VOL-II
Page 357
shall be provided to indicate camera positions and angles. The precise location of
camera shall be approved by Purchaser’s inspector, after determining the best camera
locations by trial energisation of test object at a voltage which results in corona.
4.3
The test to determine the visible corona extinction voltage need not be carried out
simultaneously with test to determine RIV levels.
4.4
However, both test shall be carried out with the same test set up and as little time
duration between tests as possible. No modification on treatment of the sample
between tests will be allowed. Simultaneous RIV and visible corona extinction
voltage testing may be permitted at the discretion of Purchaser’s inspector if, in his
opinion, it will not prejudice other test.
5.
Test Records:
In addition to the information previously mentioned and the requirements specified
as per CISPR or NEMA 107-1964 the following data shall be included in test report:
a)
Background noise before and after test.
b)
Detailed procedure of application of test voltage.
c)
Measurements of RIV levels expressed in micro volts at each level.
d)
Results and observations with regard to location
interference sources detected at each step.
e)
Test voltage shall be recorded when measured RIV passes through 100
microvolts in each direction.
f)
Onset and extinction of visual corona for each
be recorded.
and type of
of the four tests required shall
IN JASIDIH GSS VOL-II
Page 358
ANNEXURE – D
SHORT CIRCUIT FORCES AND SPACER SPAN FOR 400kV GANTRY STRUCTURE
Sl.No.
Max. Conductor
Ph-Ph
Span Configuration Spacing
Short circuit
force per
Phase
5.64 T
Normal
Tension
Spacer
Span
1.
54 Mtr
QUAD
7 mtr
4T
2.
54 Mtr
QUAD
6 mtr
4T
5.1
T
5 mtr
3.
70 Mtr
TWIN
7 mtr
4T
5.64 T
5 mtr
4.
70 Mtr
TWIN
6 mtr
4T
5.1 T
5 mtr
SHORT CIRCUIT
220 kV GANTRY STRUCTURE
Sl.No.
6 mtr
FORCES AND SPACER SPAN FOR
Max. Conductor
Ph-Ph
Normal Short circuit Spacer
Span Configuration Spacing
Tension
force per
Span
Phase
1.
54 Mtr
QUAD
4.5 mtr
4T
5 T
2.5 mtr
2.
54 Mtr
QUAD
4.0 mtr
4T
5.7 T
2.5 mtr
3.
54 Mtr
TWIN
4.5 mtr
2T
3.5 T
2.5 mtr
4.
54 Mtr
TWIN
4.0 mtr
2T
3.5 T
2.5 mtr
5.
74 Mtr
TWIN
4.5 mtr
4T
5
T
2.5 mtr
6.
74 Mtr
TWIN
4.0 mtr
4T
5.7 T
2.5 mtr
However, the above details shall be finalized during detail
engineeineering after order
IN JASIDIH GSS VOL-II
Page 359
16. INSTRUMENT TRANSFORMERS
INSTRUMENT TRANSFORMERS
IN JASIDIH GSS VOL-II
Page 360
1.0
GENERAL :
1.1
The instrument transformers and accessories shall conform to the latest
version of the standards specified below except to the extent explicitly
modified in the specification and shall be in accordance with the requirements
in specification and as per following IEC/ISS:
Current transformers IEC:44-1 (or IS:2705)
Voltage transformers IEC:186/358 (or IS:3156)
1.2
The instrument transformers shall be complete with its terminal box and a
common marshalling box for a set of 3 instrument transformers.
1.3
The instrument transformer tank along with top metallics shall be hot dip
galvanized.
1.4
The impregnation details along with tests/checks to ensure successful
completion of impregnation cycle shall be furnished for approval.
1.5
The instrument transformers shall be designed for use in geographic and
meteorological conditions as given in specification.
2.0
CONSTRUCTION FEATURES :
The features and constructional details of instrument transformers shall be in
accordance with requirements stipulated hereunder :
2.1
Bushing/Insulators:
a)
Instrument transformers shall be of 145 kV class, oil filled/SF6 gas
filled, with shedded porcelain/composite bushings/Insulators suitable
for outdoor service and upright mounting on steel structures.
b)
Bushings/Insulators shall conform to requirements stipulated in
specification. The bushing/insulator for CT shall be one piece without
any metallic flange joint.
c)
Bushings shall be provided with oil filling and drain plugs, oil sight
glass of CT and for electromagnetic unit of CVT, etc. The
bushing/insulator of instrument transformer shall have a cantilever
strength of not less than 350 kg for 145 kV Instrument transformers or
as per the value obtained vide Chapter-GTR, whichever is higher. Oil
filling and drain plugs are not required with SF6 gas filled CT.
IN JASIDIH GSS VOL-II
Page 361
d)
Instruments transformers shall be hermetically sealed units. Bidder/
Manufacturer shall furnish details of the arrangements made for the
sealing of instrument transformers along with the bid.
Bidder/Manufacturer shall also furnish the details of site tests to check
the effectiveness of hermetic sealing for approval.
e)
2.2
Polarity marks shall indelibly be marked on each instrument
transformer and at the lead terminals at the associated terminal block.
Terminal box/Marshalling box :
Terminal box shall conform to the requirements of specification.
2.3
2.4
Insulating Oil :
a)
Insulating oil to be used for instrument transformers shall be of EHV
grade and shall conform to IS: 335 (required for first filling).
b)
The SF6 gas shall comply with IEC-60376, 60376A and 60376B and
shall be suitable in all respects for use in the switchgear under operating
conditions.
Name Plate :
Name plate shall conform to the requirements of IEC incorporating the year
of manufacture. The rated current, extended current rating in case of current
transformers and rated voltage, voltage factor in case of voltage transformers
shall be clearly indicated on the name plate. The rated thermal current in case
of CT shall also be marked on the name plate.
The intermediate voltage in case of capacitor voltage transformer shall be
indicated on the name plate.
3.0
CURRENT TRANSFORMERS :
a) Current transformers shall have single primary either ring type, or hair pin
type and suitably designed for bringing out the secondary terminals in a
weather proof (IP 55) terminal box at the bottom. These secondary
terminals shall be terminated to stud type non disconnecting terminal
blocks inside the terminal box. In case “Bar primary” inverted type current
transformers are offered the manufacturer will meet following additional
requirements :
(i) The secondaries shall be totally encased in metallic shielding
providing a uniform equipotential surface for even electric field
distribution.
(ii) The lowest part of the insulation assembly shall be properly secured
to avoid any risk of damage due to transportation stresses.
(iii) The upper part of insulation assembly resting on primary bar shall
be properly secured to avoid any damage during transportation
IN JASIDIH GSS VOL-II
Page 362
due to relative movement between insulation assembly & top
dome.
(iv) Nitrogen if used for hermetic sealing (in case of live tank design)
should not come in direct contact with oil.
(v) Bidder/Manufacturer shall recommend whether any special storage
facility is required for spare CT.
b)
Different ratios specified shall be achieved by secondary taps only and
primary reconnection shall not be accepted.
c)
Core lamination shall be of cold rolled grain oriented silicon steel or
other equivalent alloys. The cores used for protection shall produce
undistorted secondary current under transient conditions at all ratios
with specified CT parameters.
d)
The expansion chamber at the top of the porcelain insulators should be
suitable for expansion of oil.
e)
Facilities shall be provided at terminal blocks in the marshalling box for
star delta formation, short circuiting and grounding of CT secondary
terminals.
f)
Current transformer’s guaranteed burdens and accuracy class are to be
intended as simultaneous for all cores.
g)
For 245kV / 145 kV class CTs, the rated extended primary current shall
be 120% (or 150% if applicable) on all cores of the CTs as specified in
the specification.
h)
For 245kV /145 kV current transformer, characteristics shall be such as
to provide satisfactory performance of burdens ranging from 25% to 100%
of rated burden over a range of 10% to 100% of rated current in case of
metering CTs and up to the accuracy limit factor/knee point voltage in
case of relaying CTs.
i) The current transformer shall be suitable for horizontal transportation. It
shall be ensured that the CT is able to withstand all the stresses imposed on
it while transporting and there shall be no damage in transit the Contractor
shall submit the details of packing design to the Purchaser for review.
j) For 245kV /145 kV CTs the instrument security factor at all ratios shall be
less than five (5) for metering core. If any auxiliary CTs/reactor are used in
the current transformers then all parameters specified shall have to be met
treating auxiliary CTs as an integral part of the current transformer. The
auxiliary CTs/reactor shall preferably be inbuilt construction of the CTs. In
case these are to be mounted separately these shall be mounted in the
central marshalling box suitably wired upto the terminal blocks.
k) The wiring diagram plate for the interconnections of the three single phase
CTs shall be provided inside the marshalling box. The Bidder/Manufacturer
shall strictly adhere to it and deviations, if any, in this regard shall be
IN JASIDIH GSS VOL-II
Page 363
brought out with justification for Purchaser’s review.
l) The current transformers should be suitable for mounting on lattice support
structure to be provided by the Contractor in accordance with stipulations
of specification.
m) The CT shall be designed as to achieve the minimum risks of explosion in
service. Bidder/Manufacturer shall bring out in his offer, the measures
taken to achieve this.
n) 245kV /145 kV current transformers shall be suitable for high speed auto
reclosing.
4.0
VOLTAGE TRANSFORMERS :
a)
245kV /145 kV Voltage transformers shall be capacitor voltage
divider type with electromagnetic units and shall be suitable for carrier
coupling.
b)
Voltage transformers secondaries shall be protected by HRC cartridge
type fuses for all the windings. In addition fuses shall be provided for
the protection and metering windings for fuse monitoring scheme.
Thesecondary terminals of the CVTs shall be terminated to the stud type
non - disconnecting terminal blocks in the individual phase secondary
boxes via the fuse.
c)
CVTs shall be suitable for high frequency (HF) coupling required for
power line carrier communication. Carrier signal must be prevented
from flowing into potential transformer (EMU) circuit by means of a RF
choke/reactor suitable for effectively blocking the carrier signals over
the entire carrier frequency range i.e. 40 to 500 KHz. Details of the
arrangement shall be furnished along with the bid. H.F. terminal of the
CVT shall be brought out through a suitable bushing and shall be easily
accessible for connection to the coupling filters of the carrier
communication equipment, when utilised. Further earthing link with
fastener to be provided for HF terminal.
d)
The electromagnetic unit comprising compensating reactor,
intermediate transformer and protective and damping devices should
have separate terminal box with all the secondary terminals brought out.
e)
The damping device which should be permanently connected to one of
the secondary windings, should be capable of suppressing the
ferroresonance oscillations.
f)
The accuracy of 0.2 on secondary III should be maintained through out
the entire burden range upto100VA for 245 KV CT’s and upto 50 VA
for 145 kV CVTs on all the windings without any adjustments during
operation.
g)
245kV /145 kV CVTs shall be suitable for mounting on tubular GI pipe
in accordance with stipulations of specification or approved by JUSNL.
h)
It should be ensured that access to secondary terminals is without any
IN JASIDIH GSS VOL-II
Page 364
danger of access to high voltage circuit.
5.0
i)
A protective surge arrester shall be provided to prevent breakdown of
insulation by incoming surges and to limit abnormal rise of terminal
voltage of shunt capacitor/primary winding, tuning reactor/RF choke
etc. due to short circuit in transformer secondaries. In case of an
alternate arrangement, bidder shall bring out the details in the bid.
j)
The wiring diagram for the interconnection of the three single phase
CVTs shall be provided inside the marshalling box in such a manner
that it does not deteriorate with time. The Bidder/Manufacturer shall
strictly adhere to it and deviations, if any, in this regard shall be brought
out with justification for Purchaser’s review.
TERMINAL CONNECTORS :
The terminal connectors shall meet the requirements as given in specification.
6.0
TESTS :
6.1
In accordance with the requirements in specification, Current and Voltage
Transformers should have been type tested and shall be subjected to routine
tests in accordance with IEC:44-1/IS:2705 and IEC:186/IS:3156 respectively.
6.2
The test reports of the type tests and the following additional type tests shall
also be submitted for the Purchaser’s review.
a)
Current transformers :
i)
Radio interference test as per Annexure-A of specification.
ii)
Seismic withstand test as per Annexure-B of specification.
iii)
Thermal stability test, i.e. application of rated voltage and rated
extended thermal current simultaneously by synthetic test circuit.
iv)
Thermal co-efficient test i.e. measurement of tan delta as a oo
function of temperature (at ambient and between 80 C & 90 C)
and voltage (at 0.3, 0.7, 1.0 and 1.1 Um/√3)
v)
The current transformer shall be subjected to Fast Transient test by
any one of the following two methods given below to assess the
CT performance in service to withstand the high frequency over
voltage generated due to closing & opening operation of isolators.
Alternatively, method as per IEC:44-1 may be followed:
Method I: 600 negative polarity lightning impulses chopped on crest will be
applied to current transformer. The opposite polarity amplitude must be
limited to 50% of crest value when the wave is chopped. Impulse crest values
will be 1000 kVp for 420 kV CTs. One impulse per minute shall be applied
and every 50 impulse high frequency currents form the windings and total
current to earth will be recorded and be compared with reference currents
recorded applying one or more (max 20) reduced chopped impulses of 50% of
test value.
IN JASIDIH GSS VOL-II
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Oil samples will be taken before and 3 days after the test. Gas analysis must
not show appreciable rate of increase in various gases related with the results
of the analysis performed before test.
Total sum of crest values of current through secondaries must not exceed 5%
of the crest value of total current to earth. CT must withstand dielectric tests
after this test to pass the test.
Method II : 100 negative polarity impulses with a rise and fall time of less
than 0.25 microsecond having 950 kV for 420 kV CT corrected to
atmospheric condition shall be applied at one minute interval and total current
through insulation of earth will be recorded. The amplitude of first opposite
polarity should be limited to 50% of the chopped impulse crest value. Voltage
and total current wave shapes shall be recorded after every 10 impulses, and
will be compared with reference wave shapes recorded before test at 50% of
test values.
Oil sample shall be taken before and 3 days after the test and CT shall be
deemed to have passed the test if the increase in gas content before and after
test is not appreciable.
b)
Voltage transformers:
i)
High frequency capacitance and equivalent series resistance
measurement (as per IEC-358).
ii)
Seismic withstand test (as per Annexure-B of specification).
iii)
Stray capacitance and stray conductance measurement of the low
voltage terminal (as per IEC-358).
iv) Determination of temperature coefficient test (as per IEC-358).
v)
Radio interference test as per Annexure-A of specification.
vi) The Ferro-resonance type test shall be carried out on the complete
CVT.
6.3
The current and voltage transformer shall be subjected to the following
routine/site tests in addition to routine tests as per IEC/IS.
a)
CURRENT TRANSFORMERS :
ROUTINE TESTS:
i)
Measurement of Capacitance.
ii)
High voltage power frequency withstand test on Secondary Winding.
iii)
Over-voltage inter turn test (as per BS:3938).
iv) Oil leakage test.
v)
Measurement of tan delta at 0.3, 0.7, 1.0 and 1.1 Um/√3.
IN JASIDIH GSS VOL-II
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vi) Measurement of partial discharge shall be carried out as per IEC.
SITE TESTS: Dissolved gas analysis to be carried out at the time of
commissioning. CTs must have adequate provision for taking oil samples
from the bottom of the CT without exposure to atmosphere.
Bidder/Manufacturer shall recommend the frequency at which oil samples
should be taken and norms for various gases in oil after being in operation for
different durations. Bidder/Manufacturer should also indicate the total
quantity of oil which can be withdrawn from CT for gas analysis before
refilling or further treatment of CT becomes necessary.
b)
VOLTAGE TRANSFORMERS:
i)
Capacitance and loss angle measurement before and after voltage test
(as per IEC:358).
ii)
Partial discharge test on capacitor dividers (as per IEC-358).
iii)
7.0
Sealing test (as per IEC-358).
SPARE PARTS AND MAINTENANCE EQUIPMENT:
The Bidder shall include in his proposal spare parts equipment in accordance
with Section-Project.
IN JASIDIH GSS VOL-II
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8.0
A.
C8.1
TECHNICAL PARAMETERS :
245kV CURRENT TRANSFORMERS :
Rated Primary current
-600 A
C8.2
C8.3
C8.4
C8.6
Rated short time thermal current
Rated dynamic current
Maximum temperature rise over
design ambient temperature
One minute power frequency withstand
voltage sec. terminal & earth
Number of terminals
C8.7
Type of insulation
C8.5
31.5 kA for 1 sec.
80 kA (peak)
As per IEC:44-1
5 kV
All terminals of control circuits
are to be wired upto marshaling
box plus 20% spare terminals
evenly distributed on all TBs.
Class A
IN JASIDIH GSS VOL-II
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D.
Current transformers shall also comply with requirements of Table – IIC/ or
IID as applicable.
145 KV VOLTAGE TRANSFORMERS :
F8.1
F8.2
System fault level
Standard reference range
of frequencies for which
the accuracies are valid
31.5 kA for 1 second
96% to 102% for
protection and
99% to 101% for
measurement
IN JASIDIH GSS VOL-II
Page 369
F8.3
F8.4
F8.5
F8.6
High frequency capacitance
for entire carrier frequency
range
Within 80% to 150% of rated
capacitance
Equivalent series resistance
tance over the entire carrier
frequency range
Less than 40 ohms.
Stray capacitance and stray
conductance of the LV
terminal over entire carrier
frequency range
As per 1 IEC:358
One minute power frequency withstand voltage :
i) Between LV(HF) terminal
and earth terminal
ii)
F8.7
For secondary winding
10 kV (rms) for exposed terminals
and 4 KV (rms) for terminals
enclosed in a weather proof box
3 kV (rms)
Maximum temperature rise over
As per IEC:186
Design ambient temperature
F8.8
F8.9
Number of terminals in
control cabinet (interpole
pole cabling is to be
supplied by Purchaser)
All terminals of are wired upto
marshaling box plus 12 terminals
exclusively for Purchaser’s use.
Rated Total Thermal
burden (VA)
300 (100VA/winding)
Voltage Transformers shall also comply with the requirements of Table-IC of
this Chapter.
9.0
9.1
9.2
TESTING & COMMISSIONING
An indicative list of tests is given below. Contractor shall perform any
additional test based on specialties of the items as per the field
Q.P./Instructions of the equipment Supplier or Purchaser without any extra
cost to the Purchaser. The Contractor shall arrange all instruments required
for conducting these tests alongwith calibration certificates and shall furnish
the list of instruments to the Purchaser for approval.
Current Transformers
(a)
Insulation Resistance Test for primary and secondary.
(b)
Polarity test
IN JASIDIH GSS VOL-II
Page 370
9.3
(c)
Ratio identification test - checking of all ratios on all cores by primary
injection of current.
(d)
Dielectric test of oil (wherever applicable).
(e)
Magnetising characteristics test.
(f)
Tan delta and capacitance measurement
(g)
Secondary winding resistance measurement
Voltage Transformers/Capacitive Voltage Transformers
(a)
Insulation Resistance test for primary (if applicable) and secondary
winding.
(b)
Polarity test
(c)
Ratio test
(d)
Dielectric test of oil (wherever applicable).
(e)
Tan delta and capacitance measurement between :-(i)
HV - HF point
(ii) HF Point - Ground point of Intermediate Transformer.
(iii) HV - Ground point of Intermediate Transformer primary winding
(f)
Secondary winding resistance measurement.
IN JASIDIH GSS VOL-II
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TABLE - IC REQUIREMENTS OF 145 KV CAPACITIVE VOLTAGE
TRANSFORMERS
S.No.
PARTICULAR
DISCRIPTION
1.
Rated primary voltage (kV rms)
145
2.
Type
Single phase capacitor VT
3.
No. of secondaries
3
4.
Rated voltage factor
1.2 continuous
1.5 - 30 seconds
+ 20 minutes (For metering
5.
Phase angle error
core)
6.
Capacitance (pf)
8800
Secondary I
+ 10%/-5%
Secon- Secondary II dary III
7.
Voltage Ratio
132/0.11
132/0.11 132/0.11
8.
Application
Protection
Protection
Metering
9.
Accuracy
3P
3P
0.2
10.
Output burden (VA) (minimum)
50
50
50
IN JASIDIH GSS VOL-II
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TABLE- II B REQUIREMENTS FOR 145 KV CURRENT TRANSFORMER
No. Core Application Current Outpur Accuracy
of
No.
Ratio Burden Class as
Cores
(VA)
per IEC
44.1
5
1
2
3
4
5
BUS DIFF
CHECK
600300150/1-11-1-1 A
BUS DIFF
600MAIN
300150/1-11-1-1 A
METERING 60020
300150/1-11-1-1 A
TRANS
600BACK
300UP/LINE
150/1-1PROTN
1-1-1 A
TRANS.
600DIFF/LINE 300/1
PROTN
Minimun
Knee Pt.
Voltage Vk
Max CT
Max.
Sec.
Excitation
Winding
Current at
Resistance Vk (in mA)
(Ohms)
600/300/150 6/3/1.5
30 on-600/1
60 on-300/1
Tap
600/300/150 Tap
6/3/1.5
0.2
30 on-600/1
60 on-300/1
Tap
30 on-600/1
60 on-300/1
Tap
600/300/150 6/3/1.5
600/300/150 6/3/1.5
30 on 600/1
Taps
60 on 300/1
Tap
30 on
600/1
Tap
60 on
300/1
Tap
All relative CTs shall be of accuracy class PS as per IS: 270
IN JASIDIH GSS VOL-II
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17.
Sub-Station Structure
IN JASIDIH GSS VOL-II
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TECHNICAL SPECIFICATION
SECTION:
SECTION: STRUCTURE
Table of contents
1.0 GENERAL
2.0 DESIGN REQUIREMENTS FOR STRUCTURES NOT COVERED IN STANDARDISED
LIST
3.0 DESIGN DRAWINGS, BILL OF MATETRIALS AND DOCUMENTS
4.0 FABRICATION OF STEEL MEMBERS
5.0 PROTO-ASSEMBLY
6.0 BOLTING
7.0 WELDING
8.0 FOUNDATION BOLTS
9.0 STABILITY OF STRUCTURE
10.0 GROUTING
11.0 GALVANISING
12.0 TOUCH-UP PAINTING
13.0 INSPECTION BEFORE DISPATCH
14.0 TEST CERTIFICATE
15.0 ERECTION
16.0 MODE OF MEASUREMENT
17.0 SAFETY PRECAUTIONS
IN JASIDIH GSS VOL-II
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SECTION: STRUCTURES
1.0 GENERAL
1.1 The scope of specification covers fabrication, proto-assembly, supply and erection of galvanised
steel structures for towers, girders, lightning masts and equipment support structures. Towers, girders
and lightning masts shall be lattice type structure fabricated from structural steel conforming to IS
2062 (latest). All equipment support structures shall be fabricated from GI pipe conforming to YST 22
or of higher grade as per IS 806 except for 132kV and below for which the equipment structure shall
be of Lattice type.
Line diagrams of Towers, girders, Lightning mast, equipment support structures for standard
400kV/220kVstructures are enclosed with the tender document. The fabrication drawings alongwith
BOM shall be provided to the successful bidder after the award. Contractor shall only use these
standard drawings for fabrication. Support structure for circuit breaker is not standardized and shall be
designed by the Contractor and approved by the owner. Any other structures of 400kV/220kV class
necessary to suit the layout for a particular substation to complete the work in all its requirements shall
be designed by the owner at detailed Engineering stage. Design & drawing of structure other than
400kV/220kV class shall also be prepared by the owner at detailed engineering stage.
It is the intent of the owner to provide structures which allow interchangeability of equipments at a
later stage. Accordingly equipment support structure standardization has been carried out with the
provision of stool. Stools shall be provided by the Contractor between the equipment and its support
structure to match the bus bar height. The top of stool shall be connected to the equipment and the
bottom of the stool shall be connected to the support structure. Details of the stools shall be submitted
to Owner for approval.
The scope shall include supply and erection of all types of structures including bolts, nuts, washers,
hangers, shackles, clamps anticlimbing devices, bird guards, step bolts, inserts in concrete, gusset
plates, equipment mounting bolts, structure earthing bolts, foundation bolts, spring washers, fixing
plates, ground mounted marshalling boxes (AC/DC Marshalling box & equipment control cabinets),
structure mounted marshalling boxes and any other items as required to complete the job.
The connection of all structures to their foundations shall be by base plates and embedded
anchor/foundation bolts. All steel structures and anchor/foundation bolts shall be fully galvanized. The
weight of the zinc coating shall be at least 0.610 kg/m2 for anchor bolts / foundation bolts and for
structural members. One additional nut shall be provided below the base plate which may be used for
the purpose of leveling.
Suitable modification shall be carried out in the drawings of equipment support structures by the
Contractor in order to suit fixation of accessories such as marshalling boxes, MOM boxes, Control
Cabinets, Junction box, surge counter, etc. in the standard structure fabrication drawings. Drawings of
fixing of such accessories shall be submitted by the Contractor for approval.
2.0 DESIGN REQUIREMENTS FOR STRUCTURES NOT COVERED
IN STANDARDISED LIST
2.1 For design of steel structures loads such as dead loads, live loads, wind loads etc. shall be based on
IS:875,Parts I to V.
2.2 For materials and permissible stresses IS:802,Part-I,Section-2 shall be followed in general.
However, additional requirements given in following paragraphs shall be also considered.
2.3 Minimum thickness of galvanized tower member shall be as follows :
Members Minimum thickness (mm)
Leg members, Ground wire Peak members/Main members 5 Other members 4
Redundant members 4
IN JASIDIH GSS VOL-II
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2.4 Maximum slenderness ratios for leg members, other stressed members and redundant members for
compression force shall be as per IS-802.
2.5 Minimum distance from hole center to edge shall be 1.5 x bolt diameter. Minimum distance
between center to center of holes shall be 2.5 x bolt diameter.
2.6 All bolts shall be M16 or higher as per design requirement.
2.7 Step Bolts
In order to facilitate inspection and maintenance, the structures shall be provided with climbing
devices. Each tower shall be provided with M16 step bolts 175mm long spaced not more than 450mm
apart, staggered on faces on one leg extending from about 0.5 meters above ground level to the top of
the tower. The step bolt shall conform to IS: 10238. Ladders along with safety guard shall be provided
for the Lightening Mast Tower.
2.8 Design Criteria (To be referred only for structures for which design is
included in the scope of the Contractor)
a) All structures shall be designed for the worst combination of dead loads, live loads, wind loads as
per code IS:875, seismic forces as per code IS:1893 (latest),Importance factor of 1.5, loads due to
deviation of conductor, load due to unbalanced tension in conductor, torsional
load due to unbalanced vertical and horizontal forces, erection loads, short circuit forces including
“snatch” in the case of bundled conductors etc. Short circuit forces shall be calculated considering a
fault level of 40.0 kA. IEC-865 may be followed for evaluation of
short circuit forces.
b) Switchyard gantry structures shall be designed for the two conditions i.e. normal condition and short
circuit condition. In both conditions the design of all structures shall be based on the assumption that
stringing is done only on one side i.e. all the three (phase) conductors broken on the other side. Factor
of safety of 2.0 under normal conditions and 1.5 under short circuit condition shall be considered on all
external loads for the design of switchyard structures.
c) Vertical load of half the span of conductors/string and the earth wires on either side of the beam
shall be taken into account for the purpose of design. Weight of man with tools shall be considered as
150 kgs. for the design of structures.
d) Terminal/line take off gantries shall be designed for a minimum conductor tension of 4 metric
tonnes per phase for 400 kv and 2 metric tonnes per phase for 220 kv, 1 tonne per phase for 132 kV or
as per requirements whichever is higher . The distance between terminal gantry and dead end tower
shall be taken as 200 metres.
The design of these terminal gantries shall also be checked considering +/- 30 deg deviation of
conductor in both vertical and horizontal planes. For other gantries the structural layout
requirements shall be adopted in design.
e) The girders shall be connected with lattice columns by bolted joints.
f) All Pipe support used for supporting equipments shall be designed for the worst combination of dead
loads, erection load. Wind load/seismic forces, short circuit forces and operating forces acting on the
equipment and associated bus bars as per IS:806. The material specification shall be as per IS:1161
read in conjunction with IS:806.
g) If luminaries are proposed to be fixed on gantries/towers, then the proper loading for the same shall
be considered while designing. Also holes for fixing the brackets for luminaries should be provided
wherever required.
h) Foundation bolts shall be designed for the loads for which the structures are designed.
i) Lightning Mast shall be 50m in height (47.5m lattice structure plus 2.5m pipe) and designed for
diagonal wind condition.
IN JASIDIH GSS VOL-II
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Lightning masts shall be provided with a structural steel ladderwithin its base up to a height of 25
metre. The ladder shall beprovided with protection rings. Two platforms shall be providedone each at
12.5m and 25.0m height for mounting of lighting fixtures. The platforms shall also have protection
railing. Thedetails of lighting fixtures would be as per the approved drawings.
3.0 DESIGN DRAWINGS, BILL OF MATETRIALS AND
DOCUMENTS
3.1 FOR STANDARD STRUCTURES
3.1.1 Towers, girders, lightning masts, equipment support structures etc of 400/220kV class have all
been standardized by the owner and fabrication drawings (structure assembly drawing) alongwith Bill
of Material shall be provided by the owner for all these standard structures to the successful bidder
after the letter of award based on which structures shall be
supplied.
3.1.2 Contractor shall however not be relieved of his responsibility for the safety of the structure and
good connections and any loss or damage occurring due to defective fabrication, erection or
workmanship shall be borne by the Contractor.
3.2 FOR STRUCTURES DESIGNED BY CONTRACTOR (To be referred only for structures for
which design is included in the scope of the Contractor)
3.2.1 The Contractor shall furnish design, drawing and BOMs and shop manufacturing drawings for
every member to the owner after award of the Contract. The design drawing should indicate not only
profile, but section, numbers and sizes of bolts and details of typical joints. In case owner feels that
any design drawing, BOM are to be modified even after its approval, Contractor shall modify the
designs & drawings and resubmit the design drawing, BOM as required in the specification.
3.2.2 The fabrication drawings to be prepared and furnished by the Contractor shall be based on the
design approved by the owner. These fabrication drawings shall indicate complete details of
fabrication and erection including all erection splicing details and typical fabrication splicing details,
lacing details, weld sizes and lengths. Bolt details and all customary details in accordance with
standard structural engineering practice whether or not given by the owner. The fabrication drawings
shall be submitted to the owner. Proto shall be made only after approval of fabrication drawings.
3.2.3 Such approval shall, however, not relieve the Contractor of his responsibility for the safety of the
structure and good connections and any loss or damage occurring due to defective fabrication, design
or workmanship shall be borne by the Contractor.
3.3 The Mass fabrication work shall start only after the final approval to the proto corrected
Fabrication drawing is accorded by the owner. Protoassembly shall be required to be carried out only
for those structures that have not been proto-assembled by the same fabricators for this contract or for
earlier contracts from POWERGRID. Wherever proto-assembly is not to be repeated, proto-corrected
drawings shall be submitted directly with a note on the drawing stating that proto-assembly has been
carried out under a particular previous contract.
4.0 FABRICATION OF STEEL MEMBERS
4.1 The fabrication and erection works shall be carried out generally in accordance with IS 802. A
reference however may be made to IS 800 in case of non-stipulation of some particular provision in IS
802. All materials shall be completely shop fabricated and finished with proper connection material
and erection marks for ready assembly in the field.
5.0 PROTO-ASSEMBLY
i) The component parts shall be assembled in such a manner that they are neither twisted nor otherwise
damaged and shall be so prepared that the specified camber, if any, is provided. In order to minimize
IN JASIDIH GSS VOL-II
Page 378
distortion in member the component parts shall be positioned by using the clamps, clips, dogs, jigs and
other suitable means and fasteners (bolts and welds) shall be placed in a balanced pattern. If the
individual components are to be bolted, paralleled and tapered drifts shall be used to align the part so
that the bolts can be accurately positioned.
ii) Sample towers, beams and lightning masts and equipment support structures shall be trial
assembled in the fabrication shop and shall be inspected and cleared by Contractor based on the
approved fabrication drawing before mass fabrication. Owner may opt to witness such trial assembly.
For all structures, B.O.Ms along with proto corrected fabrication drawings shall be prepared and
submitted to owner as document for information. Such BOM, which shall be duly certified by the
Contractor for its conformity to the drawings issued by Owner, shall be the basis for owner to carry out
inspection.
6.0 BOLTING
i) Every bolt shall be provided with a washer under the nut so that no part of the threaded portion of
the bolt is within the thickness of the parts bolted together.
ii) All steel items, bolts, nuts and washers shall be hot dip galvanised.
iii) 2.0% extra nuts and bolts shall be supplied for erection.
7.0 WELDING
The work shall be done as per approved fabrication drawings which shall clearly indicate various
details of joints to be welded, type of weld, length and size of weld, whether shop or site weld etc.
Symbols for welding on erection and shop drawings shall be according to IS:813. Efforts shall be
made to reduce site welding so as to avoid improper joints due to constructional difficulties.
8.0 FOUNDATION BOLTS
8.1 Foundation bolts for the towers and equipment supporting structures and elsewhere shall be
embedded in first stage concrete while the foundation is cast. The Contractor shall ensure the proper
alignment of these bolts to match the holes in the base plate.
8.2 The Contractor shall be responsible for the correct alignment and leveling of all steel work on site
to ensure that the towers/structures are plumb.
8.3 All foundation bolts for lattice structure, pipe structure are to be supplied by the Contractor.
8.4 All foundation bolts shall be fully galvanised so as to achieve 0.61 kg. per Sq.m. of Zinc Coating
as per specifications.
8.5 All foundation bolts shall conform to IS 5624 but the material, however shall be MS conforming to
IS:2062.
9.0 STABILITY OF STRUCTURE
The Supplier shall be responsible for the stability of the structure at all stages of its erection at site and
shall take all necessary measures by the additions of temporary bracings and guying to ensure adequate
resistance to wind and also to loads due to erection equipment and their operations.
10.0 GROUTING
The method of grouting the column bases shall be subject to approval ofowner and shall be such as to
ensure a complete uniformity of contact over the whole area of the steel base. The Contractor will be
fully responsible for the grouting operations.
IN JASIDIH GSS VOL-II
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11.0 GALVANISING
11.1 All structural steel works and pipe supports shall be galvanised after fabrication.
11.2 Zinc required for galvanising shall have to be arranged by the manufacturer. Purity of zinc to be
used shall be 99.95% as per IS:209.
11.3 The Contractor shall be required to make arrangement for frequent inspection by the owner as
well as continuous inspection by a resident representative of the owner, if so desired for fabrication
work.
12.0 TOUCH-UP PAINTING
The touch up primers and paints shall consist of Red Oxide / Zinc chromate conforming to the
requirements of IS:2074 with a pigment to be specified by the owner.
13.0 INSPECTION BEFORE DISPATCH
Each part of the fabricated steel work shall be inspected as per approved quality plans and certified by
the owner or his authorised representative as satisfactory before it is dispatched to the erection site.
Such certification shall not relieve the Contractor of his responsibility regarding adequacy and
completeness of fabrication.
14.0 TEST CERTIFICATE
Copies of all test certificates relating to material procured by the Contractor for the works shall be
forwarded to the owner.
15.0 ERECTION
The Contractor should arrange on his own all plant and equipment, welding set, tools and tackles,
scaffolding, trestles equipments and all other accessories and ancillaries required for carrying out
erection without causing any stresses in the members which may cause deformation and permanent
damage.
16.0 MODE OF MEASUREMENT
The measurement of the standard lattice and pipe structures for towers, beams, equipment support
structure etc. shall be made in numbers for each type of structures. This will include foundation bolts
and nuts and therefore no separate payment shall be made for the same. The unit rate quoted for each
type of structure shall be inclusive of supply, fabrication, galvanizing, erection, nuts, bolts, wastages
etc. complete. Nothing extra shall be payable for substitution necessitated due to non-availability of
sections indicated in the standard drawing. Nothing extra shall be payable for modifications or steel
added to suit the contractors fixing arrangements for accessories etc.
The measurement of the non-standard lattice and pipe structure of tower structure, beam, equipment
structure etc. shall be measured in MT including the weight of foundation bolt. . The unit rate quoted
shall be inclusive of supply, fabrication, galvanizing, erection, nuts, bolts, (excluding foundation
bolts), washers, wastages etc complete.
17.0 SAFETY PRECAUTIONS
The Contractor shall strictly follow at all stages of fabrication, transportation and erection of steel
structures, raw materials and other tools and tackles, the stipulations contained in Indian Standard
Code for Safety during erection of structural steel work-IS:7205.
18.0 All tests mentioned in standard field quality plans have to be carried out and conformity of
materials and workmanship shall be ascertained.
IN JASIDIH GSS VOL-II
Page 380
IN JASIDIH GSS VOL-II
Page 381
18. CLAMPS AND CONNECTORS.
GENERAL TECHNICAL REQUIREMENTS FOR CLAMPS AND CONNECTORS.
IN JASIDIH GSS VOL-II
Page 382
1.
SCOPE
This section of the specification covers design, manufacture, testing at
manufalcturer's works before despatch followed by supply and delivery of power
connectors, bus bar, clamps etc for 132/33 KV grid s/ s complete in all
respects.
2.
STANDARDS
2.1
The clamps, spacers and connectors covered under this specification shall conform
strictly to the provisions of the following Indian Standard Specifications as
amended up to date except where specified otherwise in the specification:
a) IS: 5561-1970- Specification for electric power connector.
b) IS:2121-1981- Specification for fitting for Aluminium as amended Part-I & II
and Steel cored Aluminium conductors for over head power lines. up-,to-date
c) IS:2633-1972- Methods for testing uniformity of coating on Zinc coated
articles.
d) IS:2629-1966- Recommended practice for hot dip galvanising for Iron and
Steel.
e) IS:617-1975- Specification for Aluminium and Aluminium alloy materials.
I)
1S: 1963-1967- Specification for Steels. g) IS.:1367-1961- Bolts and Nuts.
3
RATING
3.1
Normal current rating at the specified temperature of 50 degree C shall not be less
than Current rating of moose condicutor
3.2
The minimum rated Short Time Current rating shall be taken as 31.5 KA for 1 sec
for 132 KV. The connectors has to withstand the above current successfully for
which test certificates from C.P.R.I, Bangalore or any other testing Laboratory
recognised by Government has to be furnished with the tender. The current
density to be considered in design shall not be more than 1.25-A per mm square.
4.
MATERIAL:
4.1
All Aluminium and Aluminium alloy used in the manufacture shall conform to
IS: 617-1975 (as amended upto date).
4.2
All bolts, nuts & washers shall be made from non-magnetic stainless steel and
shall have bright finish: The holes of plain washer shall be reasonably concentric
IN JASIDIH GSS VOL-II
Page 383
with outer perphery. All sharp edges shall be removed. Spring washers shall be
supplied in natural finish.
4.3
The materials offered shall be of best quality and workmanship, free of blow holes
and cracks, well finished and of approved design. The materials used in
manufacture of the clamps and connectors should have high current carrying
capacity, high corrosion resi$tar ee. The purity and composition of the materials
shall have to be indicated in the tender. All connectors or its components to be
connected with ACSR conductors shall have Aluminium purity not. less than
99.5% if these are compression type.
All bus bar camp shall be made preferably from forged Aluminium of purity not less than
99.5%. The thickness and-contact surface should be maintained in such way that the clamp
should conform to IS:5561-1970 or any latest revision thereof.
Any terminal connector or its components other than those as mentioned above
shall be manufactured from Aluminium Silicon alloy conforming to designation A6
of IS:6 17- 1 05O (latest version)
4.4
All ferrous metal parts except those made of stain less steel shall be protected
by hot-dip galvanising in accordance with IS:2629-1966, as amended uptodate.
Spring wsher where used shall be electro galvanised. The thread in nuts and in
tapped holes shall be cut before galvanising and if required should be re-turned
after galvanising.
5
DESIGN AND CONSTRUCTION:
5.1
The connectors shall be designed and proportioned so that they are capable of
safely with standing' the stresses to which they may be subjected including those
due to short circuits (Dynamic Force upto 300 Kg during short circuit) and
stresses, due to climatic conditions, wind load etc. The effect of vibration both on the
conductor and connectors itself shall be minimum. The correctors shall be designed,
manufactured and finished to avoid sharp radii of curvature, ridges,
exerscences which might lead to localised pressure or damage to the conductor
and connectors in service.
5.2
Supplier should provide Cold Rolled Aluminium Copper, himetalic strip between the copper
and Aluminium portion of the connection. The sheet thickness shall not be less than 2 mm.
IN JASIDIH GSS VOL-II
Page 384
5.3
Sufficient contact pressure should be maintained at the joint by provision of
required number of bolts and nuts and other fixing arrangement. But the contact
pressure should not be so great as to cause relaxation of the joint by cold flow.
The joint should be such that the pressure is maintained within the range under all
conditions of service. To avoid excessive local pressure, the contact pressure
.should be evenly distributed by use of pressure plates, washers or suitable saddles of adequate area and thickness.
5.4
The current carrying parts shall be designed and manufactured such that contact
resistance is reduced to the minimum. The resistance of the joint should be less
than that of an equal length of conductor when measured i11d ivid uwilly. Test
Report showing the mdli volt drop lest and rc sist.irice should be enclosed with the
tender.
5.5
All connectors shall be so designed and manufactured as 10 offer ease of
installation as these are to be used in over head installations. Design of the
connector will be such that full tightening of nuts & bolts should be possible
without the use of double wrench.
The connectors shall be such as to avoid local corona sound or visible discharge.
6.
TEMPERATURE RISE:
The temperature rise of power connectors while carrying the rated current shall
not exceed 35 degree C over the ambient temperature of 50 degree C prevailing in
the substation site.
If the ambient temperature exceeds as specified above, the permissible temp rise
shall be reduced by an amount equal to the excess ambient temperature.
7.
TEST
Following acceptance tests and routine tests shall be c«rried out on the clamps &.
connectors as per IS:55C~ 1 ~c. lS:2633 in the works of manufacturer-. .
a) Routine test:
i)
Visual Inspection test.
h)Acceptance test:
ii)
Dimensional check.
a)
Tensile test.
IN JASIDIH GSS VOL-II
Page 385
b)
Resistance test.
c)
Dimensional check.
d)
Galvanising test.
It type list has been already been lone &-in case required by B.S.E.B, type test
indicated below may also be performed for which Board may pay actual charges.
Type:
i)
Tensile test
ii)
resistance test
iii)
Temperature rise test.
iv)
Short time Current test.
v)
Salt spray test,
vi)
Galvanising test for Galvanised ferrous items.
vii)
Visual Corna discharge test
viii)
Dimensional test.
.
The reports of all the above mentioned tests carried out on each items shall be
submitted for approval.
The Tenderers should have adequate testing facilities at their works to conduct all
acceptanc dc and routine tests as required by relevant ISS at their costs. The
tenderer may have to arrange type testing of clamps/connectors before finalisation
of the tender at their cost.
Acceptance and routine test certificates as mutually agreed between the
purchaser and the contractor based on any national standard will have to be
furnished by the tenderer. These certificates will have to be got approved by the
tenderer before supply of materials.
8.
DRAWINGS:
8.1
Each tender shall be accompained with four sets of detailed dimensional
drawings of the connectors offered. The drawings should show the elevation,
crossection, longitudinal-section and plan of each item, tendered. The materials of
each part to be manufactured shall be clearly indicated in the drawing. All
dimensions must be in metric units, Schedule of drawings must accompany the
tender.
IN JASIDIH GSS VOL-II
Page 386
8.2
The successfull tenderer will have to submit six sets of approved drawings and
manuals for the use of the purchaser. Out of these sets, one set must be in the form
of reproducible tracing.
8.3
Any manufacturing done prior to the approval of the drawings will be at the
suppliers risk. The purchaser shall have the right to request the supplier to make
any change in the design which may be necessary in his opinion to make the
equipments conform to the stated provisions and intent of these specifications
without additional cost to the purchaser.
9.
INTERCHANGEABILITY
Corresponding parts of similar clamps & connectors shall be interchangeable in
every respects.
10.
INSTRUCTION BOOKS/ CATALOGUES:
Applicable parts list, catalogues, operating and maintenance instructions in
English/Hindi language especially prepared to cover all the equipment supplied
under this specification which many be needed for assembling, Disassembling, repairs, identification of parts for ordering replacements, operation and
maintenance, shall be collected in a common cover and submitted in twelve
copies for each equipment to the purchaser free of cost. Such instruction
booklelts shall be supplied at least two months before actual despatch of the
equipment.
11.
SAMPLES:
The tenderer will have to submit sample of each item for approval to BSEB
before effecting supply and delivery of the ordered quantity of all items,
12.
MARKING:
The equipment shall be eligibly and itidaliably marked with Trade mark of the
manufacturer, country of manufacture and suitable identification mark as
13.S.E.Board.
All lables to be used on wooden boxes containing the clamp and connectors,
shall be of tin securely bound with wire and shall have the descriptive marking
stamped thereon.
IN JASIDIH GSS VOL-II
Page 387
13.
SPECIFIC
TECHNICAL
PARTICULARS
FOR
THE
CONNECTOR/
P.G.CLAMPS/BUS SUPPORT CONNECTORS.
1.
Rated current -
Equivalent of current rating
of moose conductor.
2.
Rated frequency -
50 Hz
3.
Rated short time current.
25 KA for 3 sec (minimum)
4.
Aluminium Alloy to be used must conform to
IS617 :1975
(amended up to date)
5.
Stainless steel Bolts & NUTs conforming to
IS 1363 : 1967 &IS 13671961 (as amended up to
date)
6.
o
Temp. rise of connectors and clamps above 50 C 35oC
ambient temp. shall not exceed
7.
Protection against corrosion.
All parts shall either be inherently
resistant to atmospheric condition or
suitably protected against corrosion both
during storage and in service.
8.
Tensile load Test.
A tensile load of 55 kg shall be applied
and the conductor shall be
A) For connector
marked in such a way that movement
relative to the connectors shall be tested.
B) For Tension clamps
without any subsequent adjustment on the
connector, the load shall be steadily
increased to 110Kg. This load shall be
maintained for one minute. There shall be
no movement of the conductor due to slip
during this one minute period and no
failure of the connector.
9.
Material
Forged
Al.
Alloy
IS:617-1959
(As
amended upto date)
10.
Make of bolts & nuts.
Tested Non magnetic stainless steel of
requited make.
IN JASIDIH GSS VOL-II
Page 388
14.
OFFER FOR COMPRESSION TYPE JOINTS/CLAMPS & CONNECTOR
Clamps and connectors may be fixed by means of hydraulic tools with suitable dies. These dies should
be manufactured from heat treated alloy steel. Dies will be supplied in line with the sizes of the
conductors to be used i.e., ACSR "Moose" and "Panther" conductors.
The clamps & connectors should be made of forged Al. alloy suitable to with stand the load and
stresses. Conductivity should not be less than the same length of the conductor.
IN JASIDIH GSS VOL-II
Page 389
19. HARDWARE FITTINGS
IN JASIDIH GSS VOL-II
Page 390
GENERAL TECHNICAL SPECIFICATION AND TERMS & ONDITIONS OF
SUPPLY FOR HARDWARE FITTINGS FOR MOOSE CONDUCTOR
1.
SCOPE :
This section of the specification covers the technical specification and other terms &
condition design, manufacture, testing and supply of conductor/Earth wire accessories
and hardware fittings as per details in specification.
2
PREQUALIFICATION REQUIREMENTS :
Tenderers quoting against this tender must be financially sound and have
adequateexperience of manufacture and supply of material under tender. They should
have their own manufacturing unit and adequately equipped testing laboratory.
Tenderers having ISI certification will be preferred.
3 STANDARD :
Design, Manufacture, Galvanized and Testing of conductor/Earth wire Accessories and
hardware fittings shall conform to the following Indian Standard Specification as
amended up to date.
i)
IS:2121 – Specification for fittings for Aluminium and Steel cored Aluminium
conductors.
ii) IS:2486 – Specification for insulator fittings for over head power lines.
iii) IS:209 – Specification for Zinc.
iv) IS:2629 - Recommended practice for hot dip galvanized for Iron & Steel.
v) IS:2633 – Method for testing uniformity of zinc coating on hot dip zinc coated
articles.
vi) IS:9708 – Specification for Vibration dampers.
vii) IS:2141 – (Part-II) Mid span compression joint.
viii) IS:2141 – (Part-II) Specification for vibration damper.
4. TECHNICAL PARTICULARS :
(A) GENRAL REQUIREMENTS
Material offered shall be of best quality and workmanship. All casting shall be free from
blow-holes, flaws, cracks or other defects and shall be smooth, close grained and of true
forms and dimensions. All machined surfaces shall be true, smooth and well finished.
Metal fittings or drop forged steel or heat treated malleable cast iron for insulator
string hardware shall have excellent mechanical and electrical properties, such as
strength, toughness and high corrosion resistance and free from corona formation. The
material employed in the manufacture of accessories, viz aluminum, aluminum alloys,
malleable iron, forged steel and stainless steel depending on the types of application,
shall be corrosion resistant and machinable. Fittings and accessories shall be supplied
complete in all respects, suitable for the proposed attachment and for the size of
conductor and Earth wire for which they are to be used. All bolts, nuts, screw heads shall
be of the whit worth standard thread. Bolt heads and nuts shall be hexagonal. If required
the nuts and tapped holes shall be cut out after galvanizing and shall be well
lubricated/greased. All other threads shall be cut out before galvanizing. The bolt threads
shall be under cut to take care increase in diameter due to galvanizing. Washers shall be
electro galvanized.
Bolts, nuts, washers split pins, security clip etc. shall be supplied
as per actual requirement plus 2.5% extra. The general design of hardware shall be such
as to ensure uniformity, high strength, free from corona formation.
All hooks, eyes,
pins, bolts, suspension clamps and other fittings for attaching insulators to the towers or
IN JASIDIH GSS VOL-II
Page 391
to the line conductors shall be so designed as to reduce to minimum the damage to
conductors, insulators or the fittings arising from the conductor vibrations. Adequate
bearing area between fittings shall be provided and point or line contact shall not be
there. All fittings shall be resistant to atmospheric corrosion and shall be suitably
protected against corrosion both in storage and service. The accessories shall be such as
to avoid local corona formation or discharge likely to cause interference to either sound
or vision transmission. Visible corona voltage of conductor accessories shall be greater
than 11% or maximum line to neutral voltage of the line.
B)
CONDUCTOR FITTINGS:
I)
Compression type Mid span Joints.
Compression type mid span straight joints offered shall conform to technical
particulars.
II)
REPAIR SLEEVES:
Compression type repair sleeves shall be made of extruded aluminium and shall
be suitable to provide reinforcement for conductor with broken or damaged
aluminium strands. The repair sleeves shall be designed to make good conductor
of which not more than 1/6 of the strands in the outer most layer are
damaged/severed. The repair sleeves after compression should present smooth
surface. The repair sleeves shall be so designed that conductivity of the joint shall
not be less that 100% of that of conductor. Other details will be as per drawings
and of technical particulars.
III) PREFORMED ARMOUR RODS:
Helically twisted formed armour rods offered shall be suitable for ACSR
Moose/Panther conductors to provide rigidity an protection to the conductor at all
the suspension points due to vibrations.
Armour rods shall be made of 99.6%
pure electrolytic Aluminium or Aluminium alloy depending on the type of
construction. The armour rods shall be marked in the centre suitable to indicate the
commencement point of applying armour rods. No joint shall be permitted in the
rods except those made in base rods before drawing. The armour rods shall be
capable or being fixed by hand on the conductor without the aid of any tools or
implements. The direction of spiral shall be the same as that of the conductor. The
wires of the outer most layer of aluminium strands of the conductor shall have right
hand lay. The loading stress of armour rods on the conductor shall be evenly
distributed over the entire length and there shall be no tendency of loosening at the
ends. Preformed armour rods shall not loose their resilience even after two or three
applications. The rods should be capable of providing high self retaining strength
and protection against vibration damage and fatigue failure of conductor. The ends
should be properly ball ended. So that the danger of corona formation is avoided.
The surface of the armour rods when filled on the conductor, shall be smooth and
free from protection cuts and abrasions etc. Dimentional sketch of the armour rod is
enclosed with this specification.
IV) STOCK BRIDGE VIBRATION DAMPERS.
A dimensional sketch or the stock bridge 4R type vibration damper is attached with
this specification Calculation and complete details of design, weight etc. of the
damper shall be furnished with the tender together with the damping characteristics
and energy dissipation curves of the dampers and guaranteed of their effectiveness
for the specified conductor. For the purpose of these calculations, the design data
shall be given in this specification. The offer is liable to be rejected in absence of
IN JASIDIH GSS VOL-II
Page 392
the above details.The vibration damper shall be of approved design. The clamp of
the vibration damper shall be made of aluminium alloy, so designed as to prevent
any damage to or chaffing of the conductor during erection or continued operation.
If there is any chance of the clamp chaffing, the conductor while in service suitable
aluminium liners, shall be provided. The messenger cable shall be made of high
tensile strength steel strands and preformed in order to prevent subsequent drop of
weights in service. The damper weight made of cast iron shall be attached to
messenger cable by approved methods, clamping bolt shall be provided with self
locking nuts.
All ferrous parts including the messenger cable, shall be hot dip
galvanized. The ends of the messenger cable shall be effectively sealed to prevent
corrosion. The vibration damper and its attachments shall have smooth surface, to
avoid corona formation. The clamp of the stock bridge vibration damper shall be so
designed that in case of loosening of the bolt or changing free part of the clamp it
does not allow damper to disengage from the conductor.
C)
INSULATOR HARDWARE FITTINGS :
The insulator hardware fittings for suspension and tension towers shall generally
constitute of following components :i)
Anchor shackle for ball hook for attachment or the suspension strings to tower
hanger and tension strings to tower strain plates.
ii) Suitable yoke assembly for double suspension and double tension fittings.
iii) Suitable arching horns and fittings.
iv)
Suspension/tension clamps.
v) Sag adjustment plates for dead end assembly.
vi) Other fittings i.e. eye links, chain link, ball clevises, socket clevis, eye clavicle,
clevises etc.
vii) Bolts and nuts, washers split pins etc
CLAMPS
SUSPENSION CLAMPS
Suspension clamps offered shall be made of high strength aluminium alloy suitable for
use with conductor with armour rod. The design shall be such as to avoid hot spot,
Kicks cuts, Grooves projectors etc. Which are likely to damage conductor or lead to
localized pressure, Clamps shall have satisfactory corona performance, no sharp radius
or curvatures, ridge and excrescence etc, cotter pins, cotter bolts, U. Bolts, nuts,
washers, etc. shall be made of galvanized steel. Split pins of suitable size and strength
shall be made of brass. The clamps shall permit the conductor to slip before failure of
the conductor and shall have sufficient slipping strength to resist conductor tension
under broken wire conditions. It shall have sufficient contact surface to minimize
damage due to fault current.
TENSION CLAMPS :
Tension clamps shall be made of aluminium alloy and shall be of proper type. The
clamps shall not permit, slip of any damage to or failure of the conductor at a load of
less than 95% of the ultimate strength of conductor. Mechanical efficiency of the clamp
shall not be affected by method of erection involved. Come along or similar clamp
during stringing operations.
IN JASIDIH GSS VOL-II
Page 393
5.
6.
7.
8.
9.
ARCHING HORN :
the Insulator hardware assembly shall have provision for fixing a set of arcing horns on
the Insulator hardware fittings.
VIBRATION DAMPERS :
Vibration damper shall be of stock bridge type having an aluminium alloy clamp
compressed on the steel messenger strand between counter weights made of cast iron
and shall be suitable for use on the overhead ground wire.
RAW MATERIALS :
Procurement of all raw materials for execution of this contract shall be done by the
supplier at their own cost.
DRAWINGS :
The tenderer shall submit fully dimensioned drawings to scale indicating the materials
of each part for dimension all under supply. The complete string drawing, both
suspension and tension, shall indicate the over all length with its variations when
subjected to tension as also the sparkover distance. The following arrangement of
complete insulator strings and their component parts shall be clearly indicated.
i) Attachment to the tower hanger or strain plate.
ii) Arcing Horn attachments.
iii) Suitable ball and socket type fittings for interconnecting insulator units to the top
and bottom clamps.
iv) Detailed drawings of suspension and tension clamps indicating design adopted for
preventing damage to the conductor & earthwire.
The material offered shall be in conformity with the purchaser’s drawings attached with
this specification. Any deviation from those drawings conforming to any other standard
quoted by the tenderer will be subject to technical scrutiny by the Purchaser who shall
have every right to accept or reject the same without assigning any reason thereof.
GALVANISING :
All ferrous metal parts except those made of stainless steel shall be galvanized in
accordance with latest issue of IS:2629 or any other equivalent authoritative standard.
The weight of zinc coating shall conform to latest issue of IS:2633. The zinc used for
galvanization shall conform to grade Zn-98 as per latest issue of IS:209. Spring
washers, where used, shall be electro galvanized.
INTER CHANGEABILITY :
All hardware fitting and conductor accessories shall be of standard design and made to
gauge of jig and shall be interchangeable in all respects with similar items.
TESTS/REPORTS :
Conductor accessories and hardware fittings will be subjected to all tests as per relevant
Indian Standard Specification. The tests will be categorized in three grades, normally (i)
Type. (ii) Acceptance Tests and (iii) Routine Tests.
TYPE TESTS :
Type Tests are normally carried out once and is not required to be carried out against all
orders. Tenderers are, therefore to submit along with their offer reports in respect of
Type Tests carried out as per provision of Indian Standard Specification by a
reputed/recognized testing laboratory.
IN JASIDIH GSS VOL-II
Page 394
ACCEPTANCE TESTS :
These are such tests which are carried out for acceptance of material. This will
constitute al tests as prescribed in the relevant Indian Standard Specification.
ROUTINE TESTS :
These are such tests which will apply to all fittings.
Reports n respect of all tests carried out during manufacture as per Indian Standard
specification will be submitted to department for approval at the time material is offered
for inspection. Tenderers shall clearly state in their tender about testing facilities
available in the laboratories at their works to confirm their ability to carry out all tests as
per Indian Standard Specification.
Costs in carrying out any/all tests as above will be borne by the tenderer and will be
included in their quoted price.
TECHNICAL PARTICULAR FOR HARDWARE FITTINGS:
1.
2.
Technical particular of ACSR Moose/Panther/Zebra conductor and Earthwire for which
accessories and hardware fittings are required.
a)
ACSR CONDUCTOR FOR TRANSMISSION LINE
ACSR panther conductor of composition 30/3.00 mm AL
b)
EARTHWIRE
+ 7/3.00 st conforming in all respect to IS 398
+7/9 SWGGSS Earthwire of 110Kgf/mm2 quality conforming in all respect to IS:2141
Conductor accessories and hardware fitting for ACSR panther conductor (for use in 132 KV
Line).
a)
M.S. comp. Joint.
i)
Physical Dimension
As per approved drawing
ii)
Material specification
-doiii)
Minimum Failing strength 100% of UTS of ACSR
panther conductor.
iv)
Slipping strength
95% of UTS of
conductor.
v)
Electrical resistance
Expressed as percentage
Of measured resistance of
Equivalent length of
Conductor.
75%
b)
i)
REPAIR SLEEVE:
Physical dimension
ii)
iii)
Material a specification
Electrical Resistance
Expressed as percentage
of measured resistance of
equivalent length of
conductor
iv)
Minimum failing strength
As per approved
drawing/type test reports
-do-
-
75%
-
95% of U.T.S
IN JASIDIH GSS VOL-II
Page 395
of ACSR panther
c)
i)
ii)
a)
b)
iii)
a)
b)
iv)
a)
b)
v)
vi)
vii)
viii)
ix)
x)
d)
i)
ii)
iii)
iv)
v)
VIBRATION DAMPER
Physical Dimension
As per type test reports
Material – a) Clamp
Aluminium alloy
Messenger cable
High strength steel wire.
Weight
Cast Iron
Galvaniastion.
Spring washers etc.
Electro galvanized.
Other ferrous parts
Hot dip galvanised.
SLIP STRENGTH OF DAMPER CLAMP.
Before fatigue test
Not less than 250 Kg
After fatigue test
Not less than 200 Kg
Maximum permissible dynamic
strain on conductor with damper
150 Micro strain
Minimum no. of cycles for
fatigue performance.
Ten Million
Amplitude for fatigue
+1 MM at the highest
resonance frequency.
With velocity range for
effectiveness of the damper Upto 30 KV
Claimpul torque
Normal span
Preformed armour rod
Physical dimension
Reference
Material
Tensile strength
Conductivity
-
Approx 6 Kg meter
350 Mtrs
-
as per approved drawing
-do99.6% Pure electrolytic
A! or a1 alloy.
50,000 PSI
39% of inter national
annealed copper strands.
e)
i)
i)
ii)
iii)
iv)
2.
i)
ii)
iii)
iv)
v)
i)
ii)
iii)
Insulator hardware fittings
Specification of disc insulator for which Hardware fittings should match
Suspension
Tension
Type
Ball and socket
Ball and socket
Ball size
16 mm
16 mm
Disc Size
255 x 145 mm 255 x 145 mm
E.R. Strength
70 KN
90 KN
Insulator string Arrangment.
Material
Dimension
String arrangement Mechanical Strength
(E.M Strength)
Reference Drawing
Single suspension
Double suspension
Single tension
As per approved drawing
As per approved drawing
As per approved drawing
-
As per a approved drawing
As per approved drawing
-do-doIN JASIDIH GSS VOL-II
Page 396
iv)
3.
i)
ii)
iii)
iv)
a)
b)
v)
Double Tension
-doCLAMPS.
Material
As per approved drawing
Dimension
-doMechanical strength
-doSlipping strength
Suspension
25% of UTS of Conductor
Tension
95% of UTS of Conductor
Angle of Inclination of
Jumper terminal
300
3.Accessories and fitting for 7/9 SWG Earthwire.
a) M.S. compression joint.
i) Physical Dimension
As per approved drawing
ii) Material
As per approved drawing
iii) Minimum Failing strength
UTS of 7/9 SWG earth wire of 110 kgf/mm2
quality.
iv) Reference drawing
As per approved drawing
b) Vibration dumper.
i) Physical dimension material.
As per approved drawing
c) Suspension/Tension clamps with Flexible copper bond for 7/9 SWG earth wire.
i) Physical dimension
ii) Material
iii) Slipping strength
a) Suspension
b) Tension
iv) Minimum Failing load
a) Suspension
b) Tension
v) Reference Draiwn.
Suspension clamp
Tension clamp
As per approved drawing
-do25% UTS of E/W
95% UTS of E/W
UTS of E/W
UTS of E/W
- As per approved drawing
-do-
IN JASIDIH GSS VOL-II
Page 397
20. POST INSULATOR
IN JASIDIH GSS VOL-II
Page 398
GENERAL
TECHNICAL
INSULATORS.
1.
REQUIREMENT
FOR
POST
SCOPE :
This specification covers the design manufacture. Testing at
manufacturers works, supply and delivery F.O.R. destination of POST
INSULATORS for use in outdoor grid substations of JUSNL.
2.
STANDARDS :
The insulators covered under this specification shall comply with the
requirements of latest edition of IS:2644-1973 or IEC-168-1964 (as
amended upto date) except where specified otherwise in the
specification.
3.1.
DRAWINGS :
Drawings in quadruplicate incorporating the following particulars shall
be submitted by each tenderer with the tender for the purpose of
preliminary study.
i) General outline drawing showing al dimension, net weights,
shipping weights etc.
ii) A copy of catalogue giving full details for the insulators.
iii) Sectional views showing the general constructional features.
3.2
Within 15 days of the receipt of the order the tenderer shall submit the
following drawings in quadruplicate for approval of the purchaser:
a)
b)
3.3
Drawing showing details of insulators with dimensions.
Assembly drawing showing the complete stacks/erected as desired
for 132 kV systems, with full dimensions and accessories.
Tenderer may furnish any other drawing found necessary in addition to
those stated above.
4.
DESIGN AND GENERAL REQUIREMENT:
4.1
The post insulator unit shall have two metal parts, a cap partially
embracing and insulating component and pedestal cemented into a recess
in the insulating component. The cap shall have holes for retaining
attachment bolts may pass.The post insulator one unit or a number of
units bolted together shall be designed to support and insulate high
voltage busbars and isolators. These shall be designed to with stand
tensile, torsional cantilever and compressive loads as specified in this
specification.Normally theses insulators shall be mounted uprist but in
some cases other mounting arrangements may also be required for which
the insulator shall also be designed.
4.2
The insulators shall be fabricated by the wet process. The insulating
porcelain and the metal parts shall be assembled together with such
materials and in such manner that any thermal expansion of the meal and
the porcelain part through out the range of prating temperature shall not
IN JASIDIH GSS VOL-II
Page 399
lesson the parts or create under stress adversely effecting the electrical
and mechanical strength specified in the specification.
4.3
4.4
5.
The post insulators shall be designed and manufactured in such a
manner that the following are avoided:
a)
Stresses due to expansion and contraction which may lead to
deterioration in use.
b) Stress concentration due to direct engagement of the porcelain with
metal fitting.
c)
Shapes which do not facilitate easy cleaning by normal methods.
PORCELAIN:
The porcelain shall be sound, free from defects thoroughly vitrified and
smoothly glazed. The glaze shall be brown in colour. The glaze shall
cover all the exposed porcelain parts except those areas which serve as
supports during firing or are required to be left unglazed. The unglazed
part shall not have a total area exceeding.
MARKING :
Each insulator shall be legibly and indelibly market to show the
following:
a)
b)
c)
6.
7.
8.
8.1
8.2.
8.3.
Name of trademark of the manufacturer.
Month and year of manufacture.
Country of manufacture.
Marking on porcelain shall be printed and shall be applied before
firing. In case in the insulators posses any ISI mark, the same shall
also be printed.
CREEPAGE DISTANCE:
The tenderer shall specify in tender the creepage distance of the
insulators.The minimum distance, for insulators is specified in
specification.
MECHANICAL LOADS:
The insulator shall be suitable for minimum failing loads specified in
specification. Load shall be applied axially to the insulator stanch.
TEST:
TYPE TEST:
Type test are intended to demonstrate compliance of the design of the
insulator with the requirements of specification. An insulator subjected to
type tests may be unsuitable for subsequent use in service. Type tests
shall be made on an insulator that has passed the routine test.
VISIBLE
DISCHARGE
TEST
(POWER
FREQUENCY
VOLTAGE)
The test room shall be darkened and a period of five minutes shall be
allowed for the observer to become accustomed to darkness. A power
frequency test voltage specified in specification, shall be applied and
maintained at this value for five minutes. During this test observation
shall be made and there shall be no sign of visible corona.
IMPULSE VOLTAGE WITH STAND TEST:
IN JASIDIH GSS VOL-II
Page 400
8.4.
8.5.
8.6
The post insulator or post insulator units shall be tested dry with both
positive and negative polarity unless it is known which polarity gives the
lowest withstand value, in which case it is sufficient to test with that
polarity. The value of impulse voltage shall be as specified in
specification and shall be corrected for the atmospheric conditions given
at section-III. Five consecutive impulse voltage waves shall be applied. If
flash over or puncture does not occur, the insulator shall be considered to
have passed the test. If during these five waves puncture occur or if two
of the applied waves cause flashover through air, the insulator shall be
considered to have failed. If only one of applied waves causes flash over
through air, ten additional test waves should be applied. The insulator
shall be considered to have passed this test only if flashover through
air/or puncture does not occur for any of these additional 10 waves.
IMPULSE VOLTAGE FLASH OVER TEST:
The impulse generator shall be adjusted to deliver the require impulse
wave. The 50 per cent impulse flash over voltage shall then be
determined. At least 20 application near the required value shall be made
to determine it with reasonable accuracy. The polarity shall then the
reversed and 50 per cent flashover voltage for the opposite polarity
measured in a similar manner.
The insulator shall not be damaged by these tests but slight marking on
the surface of the insulating parts or obippug of the cement used for
assembly shall be permitted.
The impulse flashover voltage to be recorded shall be the positive and
negative 50 per cent impulse flashover voltage measured in accordance
with and corrected in accordance with reference atmospheric condition.
DRY ONE MINUTE POWER FREQUENCY WITH STAND TEST:
The post insulator or post insulator units shall be tested at the value of
test voltage specified in section-III. Suitable correction shall be done
taking into account the atmospheric condition. The test voltage shall be
applied for one minute. The insulator shall not flashover or puncture
during the test.
WET ONE MINUTE POWER FREQUENCY WITHSTAND TEST:
The test object shall be subjected to a spray of water of prescribed
resistivity given in the characteristics of the spray indicated below. The
spray consisting of small drops shall fall on the test object at an angle of
approximately 450 to the vertical as determined by visual observations, or
by measurements of the vertical and horizontal components of the spray.
These components shall be measured with a collecting vessel having a
horizontal opening of area 100 to 750 Sq. cm. when both vertical and
horizontal components are required, the horizontal components shall be
measured with a collecting vessels having a similar vertical opening,
located on the side of the test object facing the spraying nozzles and as
close to the test object as is possible without collecting splases from it.
The test object should be sprayed for at least one minute before the
application of the voltage.
IN JASIDIH GSS VOL-II
Page 401
8.7
8.8
8.9
8.10
The characteristics of the spray shall be as given below:
Precipitation rate.
(mm/min/vertical component) 3 10%
Resistivity of water
(Ohm. Cm.)
10,000 10%
Temperature of water (0C)
Ambient 15
The value of test voltage to be applied has been specified in section-III.
Taking into account the atmospheric conditions, the test voltage shall be
applied for one mounte. The insulator shall not flashover or puncture
during the test.
The test voltaged shall then be gradually increased from about to per cent
of the net one minute withstand voltage value to reach the flashover
voltage in not less than 5 seconds.
POWER FREQUENCY PUNCTURE WITHSTAND TEST:
The insulators, after having been cleanded and dried, shall be completely
immersed in a tank containing a suitable insulating medium to prevent
surface discharges on them. If the tank be made of metal, its dimensions
shall be such that the shortest distance between any part of the insulator
and side of the tank is not less than 13 times the diameter of the largest
insulator shed.The test voltage shall be applied between those parts
which normally have the operating voltage between them. During
immersion in the insulation medium precautions shall be taken to avoid
air pockets under the sheds of the insulator. The voltage shall be
increased rapidly to the specified dry one minute power frequency test
voltage and then rapidly increased at a rate of about 100 volts per second
until the puncture withstand voltage is reached. No puncture shall occur
at this voltage for the minimum time necessary to measure it.
MECHANICAL STRENGTH TEST:
Test post insulator or post insulator units shall be attached to the
mounting face of the testing machine by its normal method of mounting.
The mechanical strength test of the post insulator or post insulator units
shall in general consists of the test given in specification unless otherwise
specified the test given shall be made.
BENDING TEST:
The load shall be applied to the free end of the post insulator or post
insulator units. The direction of loading shall pass through the axis of the
insulator and shall be at right angles to it. The load shall be applied
gradually starting from a value not greater than half the specified
minimum failing load and shall be increased until the specified minimum
failing load is reached. The insulator shall pass the test if there is no
failure it this load.
TORSION TEST:
The post insulator or post insulator unit shall be subjected to a tensional
load avoiding all bending moment. The torsion test and load shall be
applied gradually starting from a value not greater than half the specified
minimum failing load and failure shall not take place below the specified
IN JASIDIH GSS VOL-II
Page 402
minimum failing load. The load may then be increased to the failing load,
which may be noted for information.
8.11
TENSILE OR COMPRESSION TEST:
The post insulator or post insulator units shall be subjected to a tensional
or compression load along its axis. The tensile or compression load shall
be applied gradually starting from a value not greater than half the
specified minimum failing load. The load may then be incensed to the
failing load which may be noted for information.
9.
SAMPLE TEST:
Suitable number of individual post insulators and complete units or one
unit solid core shall be subjected to tests as per IS-2544-1973 or any
other equivalent authoritative standard.
The insulators after having withstand the routine test shall be subjected to
the following tests in order as indicated below:
10.
VERIFICATION OF DIMENSIONS:
It shall be verified that the post insulator or post insulator units in
accordance with the relevant drawings tolerance of
(0.3d 0.3) mm
shall be allowed for all dimension and the dimension should be in
millimeters.
11.
TEMPERNTURE CYCLE TEST:
The insulator shall be completely an quickly immersed in a water bath
maintained at a temperature of the degree centigrade given in the table
above that of the cold water and left submerged for T minutes where T
(15
0.7M) M being the mass of the insulator in Kg. It shall then be
withdrawn and quickly and completely immersed without being placed in
an intermediate container in a bath of cold water or the same period to T
minutes.
Table Temp, difference in degree.
Volume
D2 L
Temperature
Up to over 23
23 Up to 26
60
55
Difference
over 26 up
to 32
55
55
Up to 0.164 over
0.410/0.164 up to 55
over
0.655/0.410 up to 50 50
50
over
0.900/0.655 up to 45
45
over
1.105/0.900 up to 40
40
over
Over 1.150
35
35
L = The greatest external diameter of the insulators.
L = The height of the insulator.
T deg. For
Over 32 up
to 36
50
50
Thickness
Over 36 up
to 43
45
45
Over 40
45
40
35
35
50
45
35
35
45
45
40
35
40
40
40
35
35
35
35
35
Notes :-
The thickness shall be the greatest thickness of the insulator as defind
as the diameter of the biggest section through the axis of the insulator.
12.
The completes test shall comprise five transfer cold to hot, hot to cold,
cold to hot, hot to cold, cold to hot. The time taken to transfer the
insulator from one bath to the other shall be as short as possible and
shall not exceed 30 second. The quantity of water in the test tank shall
IN JASIDIH GSS VOL-II
Page 403
be large enough not to cause a temperature variation of more than 50 in
the water when the insulator is immersed.
After the completion of immersion, the insulator shall be examined to
verify that the immolating parts have not cracked nor the fittings are
loosened and that the glass is undamaged.
13.
14.
15.
16.
POWER FREQUENCY PUNCTURE WITHSTAND TEST:
The test given in 8.7 shall be carried out. If one or more samples fail to
comply with the requirement of this test, a test in accordance with 16
shall be made.
POROSITY TEST:
Porcelain fragments from the insulator or by agreement from
representative pieces of porcelain fired adjacent to them, shall be
immersed in one per cent alcoholic solutions of funchumim (ig funchsin
in 100g of methylated spirit) under a pressure of notless than 150
Kg/Cm2 for a period such that the product of test duration in hour and
the test pressure in Kg/Cm2 is not less than 1800.
The fragments shall then be removed from the solution, washed, grid
and broken, Examination with naked eye of the fresh broken surface
shall not reveal any dye penetration. Ponetration in small cracks formed
during the intial breaking shall be neglected.
GALVANISATION TEST:
The galvanized metal fittings of the insulator shall comply with the test
given in IS 728-1956 method of determination of weight thickness and
uniformity of coating on galvanized articles other than wire and sheets.
If one or more samples fail to.
If one or more samples fail to comply with the requirement of this test a
retest in accordance with 2.21.16 shall be made.
RETEST AND REJECTION:
If only one insulator or meta part fails to comply with anyone of the
tests given in specification a new quantity equal to twice the first
quantity shall be subjected to retesting. The retesting shall comprise the
test in which failure occurred preceded by those tests which may be
considered to have influenced the result of the original tests. If no
failure occurs, the lot shall be O.K.
If two or more insulators or metal parts fail to comply with any of the
tests given in specification or if any failure occurs on insulators or metal
parts subjected to retesting as in specification, complete lot shall be
with drawn for the further examination by the manufacturer after which
the lot or may part thereof may be resubmitted for tests. The number
then selected shall be three times the first quantity chosen for test. This
retesting shall comprise the test in which the failure occurred preceded
by those test which may be considered to have influenced. There sults
or the original tests.
17.
ROUTINE TEST:
IN JASIDIH GSS VOL-II
Page 404
18.
Routine tests shall be conducted on every insulator as per the order
given below:
VISUAL EXAMINATION:
A visual examination of the insulator shall be made. The insulator shall
be free from physical distortion of shape and the vitrified glaze shall be
hard and smooth and free from cracks or any other defect likely to be
prejudicial to satisfactory performance in service, with exception of
area serving as supports during firing are left unglazed for the purpose
of assembly the unglazed face shall not come a total area exceeding.
DL
1+
Cm. Square.
1000
Where
D = greatest external diameter.
L = Height of the insulator.
Also the area of any single defect shall not exceed:
DL
Cm. Square.
1000
Such unglazed area shall be already shown in the drawing submitted by
the manufacturer.
MECHANICAL TEST:
Every post insulator unit shall be subjected to a mechanical test at a
load not less than 10 per cent of the specified tensile failing load of the
unit. The load shall be maintained for at least 3 Sec. minimum without
damage to the insulator or loosening of fitting. Insulators with broker
whose metal parts are fractured or become detached during the test shall
be rejected. If it exceeds 5 per cent of the lot, the lot shall be rejected.
ELECTRICAL TEST:
Post insulator unit shall be subjected to the power frequency. The test
voltage shall be such as to produce frequent flashover (every few secs).
The voltage shall be maintained for a minimum period of five minutes
or if failures occur for five minute after the last punctured piece has
been removed. Insulators which
0.5 +
19.
20.
are damaged during the test shall be rejected stream or pattern formed
during electrical tests may be observable, but it shall not disqualify the
insulator for acceptance.
SPECIFIC TECHNICAL REQUIREMENTS FOR POST INSULATORS
21.
22.
SCOPE :
The section covers the specific technical particulars, system particular suiting to
which the post insulators shall be offered as per the General Technical
Specifications given in Section-II of this specification and schedule of
requirements specified herein
TYPE AND RATING :
IN JASIDIH GSS VOL-II
Page 405
22.1
The insulators offered shall be stacking type post insulator with cap and
pedestal
suitable for 220KV, 132KV, 33 KV system.
22.2 The insulators offered shall fulfil the following technical requirements :-
1. Type
Stacking type post insulator with cap and
pedestal.
Effectively Earthed.
50 CPS
2. System Earthing
3. Rated system frequency
4. Nominal system voltage in KV
(RMS)
33
22
5.Highest system voltage in KV (RMS)
36
24
6. Basic insulation level in KVP
200
170
7. Minium creepage distance in mm
(i) Total
850
430
(ii) Protected
425
215
Cantilever strength in Kg.
(i) Up right
3200
920
(ii) Inverted
1820
680
8. Tensile strength in Kg
9100
4500
9. Torsional strength in Kgfm
520
92
10. Height of each insulator (minimum) 368
254
in mm
11. Bolt circle diameter in mm
127
76
12. Visible discharge test voltage
(Power frequency) in KV (RMS)
27
18
13. One minute power frequency with stand test voltage in KV (RMS)
(i) Dry
130
90
(ii) Wet
85
56
14. Impulse voltage with stand test
voltage in KVP
210
125
3.19.3 Technical Particulars of 33KV Post Insulator's to be used in 132 KV system
Stacking Type
1.
(i)
(ii)
(iii)
(iv)
(i)
(ii)
Dimensions For
Height of mm for each insulator
Height of insulator stack in mm. (Solid dore)
Bolt Circle Diameter in mm
Creepage distance in mm
Total
Protected
132 KV System
368
1472
127
3400
1700
IN JASIDIH GSS VOL-II
Page 406
(v)
(i)
(ii)
(iii)
(iv)
(v)
Cantilever strangth in kg.
Upright
550
Inverted
400
Tensile strength in kg
9100
Torsional strength
520
Power Frequency flashover
Dry
275
Voltage in KV (RMS)
Wet
275
(vi) Impulse flash over in KV (peak)
750
(vii) Visible discharge Test Voltage power frequency in
KV (rms)
105
(viii) Number of Insulators to
4 Unit
Be used for stacking type.
Stack
IN JASIDIH GSS VOL-II
Page 407
AUTO/ POWER TRANSFORMERS
IN JASIDIH GSS VOL-II
Page 408
GENERAL TECHNICAL SPECIFICATION FOR 150 MVA 220/132/33 KV AUTO
TRANSFORMERS.
1.1
SCOPE :
1.1.1 This Section provides for design, manufacture, assembly, Inspection and testing at
manufactures works before despatch, packing, supply and delivery of Auto
Transformers at destination sub station complete with all fittings, first filling of
Transformer oil and 10% extra Tr. Oil, accessories and associated equipment for
efficient and trouble free operation as specified herein after.
1.1.2 It is not easy to specify completely herein all details of the design and manufacture
of the equipment. However, the equipment shall conform in all respect to the
standards of engineering, design & workmanship listed in clause no. 2.3 and shall be
capable of performing continuous commercial operation in a manner acceptable to
the purchaser who shall have power to reject the material which in his judgement, is
not in accordance therewith.
1.1.3 The equipment offered shall be complete with all components in all respects. All
such components shall be deemed to be within the scope of supply irrespective of
whether those are specifically mentioned in this specification and / or the
commercial order or not.
1.1.4 The scope of work shall also include supervision of erection, testing and
commissioning of all the equipment to be supplied against this tender.
1.2
PARALLEL OPERATION
The subject transformer has to be run in parallel with the existing 150 MVA Auto
Transformer. The transformer should be offered taking in to account the parameters
of the existing transformer as given below:
Parameters of existing Auto Transformers (150 MVA)
a) % impedance – 9.61% / 9.58% (+ 10% tolerance)
b) Vector Group
–
Yvodll
c) Rated voltage at no load (d) rated current
HV – 220 kV
HV –
196.8 – 275.6 – 393.6 A
LV – 132 kV
LV –
328.0 – 459.3 – 656.1 A
TV – 33 kV
TV
874.8
d) Normal voltage Ratio:High Voltage winding
–
220 kV Rated voltage Rate
Intermediate winging
–
132 kV
Low Voltage winding
–
33 kV
220/132/33
IN JASIDIH GSS VOL-II
Page 409
2.2
ELIGIBILITY :
2.2.1 Tenders of those firms only shall be considered who are themselves manufacturers
of the equipment offered and whose engineering organisation is capable of
undertaking the manufacture, supply, testing and putting into services of such
equipment. The tenderer must be ISO 9001: 2000 company.
2.2.2 The offered equipment must be in successful operation for atleast three consecutive
years as on date of bid opening. The tenderers shall furnish alongwith Part I of the
tenders, the list of past supplies executed for the offered item and performance
reports from their users. Tender (Part-I) must accompany with Earnest Money as
specified in NIT.
2.3
STANDARDS :
2.3.1 The transformers, accessories and associated equipment shall conform to the
latest revision and amendments of standards as given below, except to the extent
explicitly modified in the specifications.
Indian
Standard
No.
Title
International &
Internationally
Recognized Standard.
IS-325
Three phase Induction Motors.
IEC – 34
IS – 335
Insulating oils for transformers and
Switch gear.
IEC – 296
BS- 148
IS – 778
Gun metal gate, globe and check valves
for general purpose.
IS – 1886
Code of Practice for installation and
maintenance of transformers.
IS – 2026
Auto Transformers
IEC – 76
IS – 2099
Bushings for alternating voltage
Above 1000 V
IEC – 137
BS – 223
IS – 2117
Degrees of protn. Pro vided by
enclosures for low, voltage switchgear
& control gear.
IS – 2705
Current Transformers
IS – 3203
Code of practice of climatic proofing
IES – 185
IN JASIDIH GSS VOL-II
Page 410
Of electrical ecuipments.
IS – 3347
IS – 3401
IS – 3637
IS – 3639
IS – 4253
IS – 5561
IS – 5578
IS – 11353
IS – 6272
IS – 6600
IS – 9434
Dimension for porcelain transformer
Bushings.
Silica gel.
Gas operated relays
Fittings & Accessories for auto
Transformers.
Cork and rubber.
Electric Power connector.
Marking & arrangements for
Switchgera, bus bars, Main
Connections and auxiliary wiring.
Industrial cooling fans
Guide for loading of oil immersed
transformers
Guide for sampling and analysis of
Dissolved gas in oil filled equipments.
BSCP - 0160
IS – 12676
Oil impregenated paper insulated
condensor bushing dimension and
requirements.
Insulation Co- ordination
IEC – 71
Indian Electricity Rules, 1956
2.3.2 The standards mentioned above are available from
Standard
Name and address
IS
IEC
BUREAU OF INDIAN STANDARD
Manak Bhawan,
9, Bahadur Shah Zafer park,
New Delhi 1100001
India.
INTERNATIONAL ELECTRO TECHNICAL
COMMISSION
Bureau Central dela Commission Electro Technique
International, I, ruo de Verembe,
Coneva, SWITZERLAND
2.3.4 Equipment meeting with the requirements of other authoritative International
standards which insure equal of better performance than the standards mentioned
above shall also be considered. When the equipment offered by the supplier
conforms to other standards, salient points of difference between standards
adopted and the standards specified in this specification shall be clearly brought out
in the offer. Two copies of such standards with authentic translation in English shall
be furnished alongwith the offer.
IN JASIDIH GSS VOL-II
Page 411
2.4
DRAWINGS :
2.4.1 The tenderers shall furnish alongwith their tenders following particulars/
dimensional drawings of the transformers and other accessories for the purpose of
preliminary study:a)
General out line drawings.
b)
Sectional views, showing the general construction features and disposition of
various fittings.
c)
G.A. drawings of cooler control cabinet and RTCC panel.
d)
Schematic drawing of OLTC, RTCC and cooler control, etc.
e)
Foundation drawings.
f)
Bushing drawings showing the full details of construction of condenser
bushing and other relevant data.
g)
Demand on of the largest parts to be shipped and the position in which these
are to be transported.
h)
Technical literatures on Tap changer control, cooling system, Relays, Motors,
and general constructional features for winding, temperature indicator,
Buchholz Relay, Oil Temp. Indicator etc.
i)
Type Test Reports.
2.4.2 All drawings should be in ink and suitable for micro filming. The drawings shall
include the following information’s.
i)
Dimensions and Tolerance on dimensions.
ii)
Material designation used for different components with reference to
standards.
iii)
Fabrication details such as welds, finishes and coatings.
iv)
Catalogue or part number for each component and the total assembly with
bill of materials.
v)
Identification Marking.
vi)
Weight of individual components and total assembled weight.
vii)
All dimension and data shall be in S.I. Units.
2.4.3 Within 30 (thirty) days after placement of the order, the supplier shall furnish six sets
of the following drawings for the approval of the purchaser.
IN JASIDIH GSS VOL-II
Page 412
i)
G.A. drawing showing front, side elevations and plan of the transformer and
all accessories with detailed dimensions, position of centre of Gravity.
ii)
Detailed foundation Drawings.
iii)
Drawings of each type of bushings, lifting dimensions, clearance between H.T.
& L.T. terminals and ground, quantity of insulating oil, name plate, details etc.
iv)
Large scale drawing of high & low tension windings of the transformer
showing the nature and arrangement of insulators and terminal connectors.
v)
Control wiring diagrams and drawings showing temperature indicators, alarm
circuits etc.
vi)
Drawing showing construction and mounting details of marshalling Box.
vii)
Schematic diagrams showing the flow of oil in the cooling system as will as
ench limb and winding longitudinal and corss sectional view showing the duct
size, cooling pipes etc. for the transformer heat exchange or drawing to scale
shall be furnished.
viii)
Detailed drawing showing wheel loading and ordinates of centre of gravity.
ix)
Crane requirements for assembling and dismantling of transformers.
x)
Dimensional drawing for terminal connectors.
2.4.4 The purchaser shall communicate his approved/comment on the drawings to the
supplier within reasonable period. In case any modification is required according to
the purchasers comments the supplier shall modify the drawing and resubmit six
copies of the modified drawings for purchasers approval within two weeks from the
date of communications of comments on the drawings.
2.4.5 The manufacturing of the equipment shall be strictly in accordance with the
approved drawings and no deviations shall be permitted without written approval of
the purchaser. All manufacturing & fabrication prior to the approval of the drawings
shall be at the suppliers risk.
INSTRUCTION MANUALS:
The supplier shall furnish 06 (Six) copies of operation, maintenance and erection manual per
unit of transformer to the office of the
Chief Engineer (Transmission),
Jharkhand Urja Sancharan Nigam
Limited. The manuals shall be bound
volumes and shall contain the following
documents / Information.
i)
Instructions regarding erection, Testing & commissioning, operationmaintenance of the equipment.
IN JASIDIH GSS VOL-II
Page 413
ii)
All relevant information and drawings pertaining to the main equipment as
well as auxiliary devices.
iii)
Marked erection drawings identifying the component parts of the equipment
as shipped to enable the purchaser to carry out the erection of the
equipment with his own personnel.
iv)
Detailed dimensions, assembly and description of all the components.
v)
Apart from the above, each manual shall also contain one set of all the
approved drawings, Type test reports as well as acceptance of test reports
and routing test reports of the corresponding consignment dispatched.
Note:- These manuals shall be invariably furnished to the office of the Chief Engineer
(Transmission) Jharkhand Urja Sancharan Nigam Limited, Ranchi before
dispatch of the transformers.
2.6
DESIGN AND CONSTRUCTIONAL DETAILS:
2.6.1 The transformer and the accessories shall be designed to facilitate inspection,
cleaning, and repair and for operation where continuity of supply is primary
consideration. All components shall 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.
2.6.2
All materials used shall be of Prime quality and workmanship which should be
of the class most suitable for working under the conditions specified and shall
withstand the variations of temperature and atmospheric conditions arising
under working conditions without undue distortion or deterioration or the
setting up of undue stresses in any part and also without affecting the
strength and suitability of the various parts for the work which they have to
perform.
2.6.3
All outdoor apparatus including bushing insulators with their mountings shall
be designed so as to avoid pockets in which matter may be collected. All
connections and contacts shall be of simple cross sections and surfaces for
carrying continuously the specified current without undue heating and fixed
connections shall be secured by bolts or set of screws of sample size,
adequately locked. Lock nuts shall be used on stud connections carrying
current.
2.6.4
The transformers and all its accessories like CTs, if any, etc. shall be designed
to with stand without injury, the thermal and mechanical affects of any
external short circuit to earth and of short circuits at the terminals of winding
for a period of 2 sec.
2.6.5
The transformer shall be capable of being loaded upto loads of 150% in
accordance with IS : 6600. There shall be no limitation imposed by bushing
Tap changer, etc.
IN JASIDIH GSS VOL-II
Page 414
2.6.6
The transformer shall be so designed that it should be capable of being
operated without danger on any tapping to the voltage at that tapping at the
rented MVA with voltage partition of 10% corresponding to the voltage at
that tapping.
2.6.7
The transformers shall be designed with particular attention to suppression
of maximum harmonic voltage. Specially, the third and fifth so as to minimize
the interference with communication system.
2.6.8
Transformer shall be capable of operating under the natural cooled condition
upto the specified load. The forced cooling equipment shall come into
operation by present contacts of winding temperature indicator and the
transformer shall operate as a forced cooled unit, initially as ONAF upto the
specified load and then as OFAF. Cooling shall be so designed that during
total failure of power supply to cooling fans and oil pumps, the transformer
shall be capable to operate at full load for at least 10 (ten) minutes without
the calculated winding hottest spot temperature exceeding 140oC. Also
stopping of one or two cooling fans should not have any effect on the cooling
system.
2.6.9
Transformer shall be capable of with standing thermal and mechanical stress
caused by symmetrical or asymmetrical faults on any winding.
2.6.10
Transformer shall accept without injurious heating, combined voltage and
frequency fluctuation, which produces the following over fluxing condition.
i)
130% for 1 minute.
144% for 5 Seconds.
ii)
Over fluxing with stand characteristics upto 170% shall be submitted
alongwith the bid by the tenderers.
2.7
TANK :
2.7.1
Tank shall be of welded construction and fabricated from tested quality low
carton steel of adequate thickness.
All seams and those jointing not required to be opened at site, shall be factory welded and
wherever possible they shall be before painting, dye penetration test shall be
carried out on welded parts of jacking because, lifting lugs and all load
bearing member. The requirement of post weld heat treatment for
tank/press relieving parts shall be based on recommendations of BS : 5500
table 4.4.3.1.
2.7.2
Tank transformer shall be projected for general rigidity and these shall be
designed to prevent retention of water.
IN JASIDIH GSS VOL-II
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2.7.3
The transformer shall be of bell type tank construction with the joint at about
500 mm above the bottom of the tank. In case the joint is welded it shall be
provided with flanges suitable for repeated welding the joint shall be
provided with a suitable gasket to prevent any unwanted materials in the
tank. Proper tank welding shall be done to prevent excessive temperature
rise of the joint.
2.7.4
The tanks shall be designed to withstand:
i)
Mechanical shocks during transportation.
ii)
Vacuum filling of oil.
iii)
Continuous internal pressure of 35 KN/M2 over normal hydrostatic pressure
of oil.
iv)
Short circuit forces.
2.7.5
Wherever possible the transformer tank and its accessories shall be designed
without pocket wherein gas may be collected. Where pockets can not be
avoided, pipes shall be provided to vent the gas into the main expansion
pipes.
2.7.6
Adequate space shall be provided at the bottom of the tank for collection of
sediments.
2.7.7
The base of each tank shall be so designed that it shall be possible to move
the complete unit by skidding in any direction without injury when using
plates or rails.
2.7.8
Tank shield shall be such that no magnetic field shall exist outside the tank.
They shall be of magnetically permeable material. If required impermeable
shields shall be provided at the coil ends. Tank shield shall not resonnic when
excited at the natural frequency of the equipment. Bidder may confirm about
use of tank shield in the schedule of additional information.
2.7.9
Suitable guides shall be provided in the tank for positioning the core and coil
assembly.
2.7.10
Each tank shall be provided with.
i)
Lifting lugs suitable for lifting the equipment complete with oil
without any damage or distortion.
ii)
A minimum four jacking pads in accessible position at 500mm height to enable the
transformer complete will oil, to be raised or lowered using hydraulic or
screw jacks.
iii)
Suitable haulage holes shall be provided.
IN JASIDIH GSS VOL-II
Page 416
2.7.11
The tank shall be provided with two suitable copper alloy or lugs or any other
suitable materials for the purpose of grounding.
2.7.12
The tank shall be equipped with the following valves with standard screw
connections for external piping:i)
One drain and lower filter valve located on the low voltage side of the
transformer and placed to completely drain the tank. The tenderer may
furnish in addition to the above a large valve with eccentric reducer. If
considered necessary by him for draining the tank. The valve shall be
equipped with a small cock.
ii)
One filter valve located at the top of the high voltage side. The opening of this
valve shall be baffled to prevent separation of the oil.
iii)
One filter valve located on the high voltage side of the transformer above the
bottom of the tank.
iv)
One relief valve to operate at a pressure below the test pressure of the tank.
TANK COVER:
2.8.1 The tank cover shall be sloped to prevent retention of rain water and shall not
distort when lifted.
2.8.2 Al least two adequately sized manhole / inspection openings, one at each end of the
tank shall be provided for any access to the lower ends of the bushings and earth
connections. The inspection covers shall not weight more than 25 kg. The inspection
covers shall be provided with two handles.
2.8.3 The tank covers shall be fitted with pockets at the position of maximum oil
temperature of MCR (Maximum continuous rating) for bulbs of oil and winding
temperature indicators. It shall be possible to remove these bulbs without lowering
the oil in the tank.
2.8.4 Bushings, turrets, covers of inspection openings, thermometer, pockets etc. shall be
designed to prevent ingress of water into or leakage of oil from the tank.
2.8.5 All bolted construction shall be fitted with weather proof hot oil resistant gasket in
between, for complete oil tightness. If gasket is compressible, metallic stops shall be
provided to prevent over-compression.
AXLES AND WHEELS:
2.9.1
The transformers are to be provided with flanged bi-directional wheels and axles.
These shall be so designed as not to deflect excessively to interfere with the
movement of the transformer. Wheels shall be provided with suitable bearings
which shall be must and corrosion resistant. Fittings for lubrication shall also be
provided.
IN JASIDIH GSS VOL-II
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2.9.2
Suitable locking arrangement alongwith foundation bolts shall be provided for the
wheels to prevent accidental movement of transformer.
2.9.3
The wheels are required to swivel and they shall be arranged as that they can be
turned, through an angle of 90o when the tank is jacked up to clear of rails. Means
shall be provided for locking the swivel movement in position parallel to and at right
angles to the longitudinal axis of the tank.
2.9.4 The rail track gauge shall be 5’ 6” (1676 mm) along longer axis as well as along
shorter axis.
ANTI EARTHQUAKE CLAMPING DEVICE:
The prevent transformer movement during earthquake clamping device shall be provide for
fixing transformer to the foundation. The Bidder shall supply necessary bolts for embedding
in the concrete foundation. The arrangements shall be such that the transformer can be
fixed to or unfastened from these bolts as desired. The fixing of the transformers to the
foundations shall be designed to withstand seismic events to the extent that a static co
efficient of 0.3g, applied in the direction of leanest resident to the loading will not cause the
transformer or clamping devices as well as bolts to be over stressed.
The details of the device used and its adequacy shall be brought out in the additional
information schedule.
CONSERVATOR TANK:
The conservator tank shall have adequate capacity between highest and
lowest visible levels to meet the requirement of expansion of the total cold
oil volume in the transformer and cooling equipment from minimum ambient
temperature to 100oC. Conservator shall be with volumetric capacity at least
7 ½ % of a total volume of oil in the main tank of the transformer.
The conservator shall be provided with air bag cell to prohibit the direct contact of oil with
the atmosphere.
2.12
b)
The conservator tank shall be bolted into position so that it can be removed
for cleaning purpose.
c)
The conservator shall be fitted with magnetic oil level gauge with low level
electrically instated alarm contact.
d)
Conservator shall be provided in such a position as not to obstruct the
connection to the transformer.
e)
Separate conservator tank/ compartment in the main conservator shall be
provided for OLTC.
BREATHER
Conservator shall be fitted with dehydrating filter breather. It shall be so designed that:
IN JASIDIH GSS VOL-II
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a)
Passage of air is through a dust filter and silicagel.
b)
Silicagel is isolated from atmosphere by an oil seal.
c)
Moisture absorption indicated by a change in colour of the tinted crystals can
be easily observed from a distance.
d)
Breather is mounted not more than 1400 mm above rail top level.
e)
Minimum quantity of silicagel to be 1 kg for every 3500 litres of oil in the
tank.
f)
It should be colorless.
PRESSURE RELIEF DEVICE:
Adequate no. of pressure relief devices may be provided at suitable locations which
shall be of sufficient size for rapid release of any pressure that may be generated in
the tank and which may result in damage to the equipment. The device shall operate
at static pressure of less than the hydraulic test pressure of transformer tank. It shall
be mounted direct on the tank. One set of electrically insulated contacts shall be
provided for alarm/tripping, alongwith the recommended settings.
2.14
BUCHHOLZ RELAY:
A double float type Buchholz relay shall be provided. All the gases evolved in the
transformer shall collect in this relay. The relay shall be provided with a test cock
suitable for a flexible pipe connection for checking its operation and taking gas
sample. A copper or stainless steel tube, shall be connected from the gas collector to
a valve located about 1200mm above ground level to facilities sampling, with the
transformer in service. The device shall be provided with two electrically
independent ungrounded contacts, one for alarm on gas accumulation and the other
for tripping on sudden rise of pressure.
2.15
TEMPRATURE INDICATOR :
2.15.1 Oil Temperature Indicator (OTI) :
All Transformers shall be provided with a 150mm dial type thermometer for top oil
temperature indication. The thermometer shall have adjustable, electrically
independent ungrounded alarm & trip contacts, maximum reading pointer and
resetting device mounted in the cooler control cabinet. A temperature sensing
element suitable located in a pocket on top oil shall be furnished. This shall be
connected to OTI by means of capillary tubes. Accuracy class of OTI shall be +/- 1.5%
or better.
2.15.2 WINDING TEMPERATURE INDICATOR (WTI) :
A device for measuring the hot spot temperature of each of the windings shall be
provided (HV, IV, LV). It shall comprise of following :-
IN JASIDIH GSS VOL-II
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a)
Temperature sensing element
b)
Image coil
c)
Auxiliary CTs, if required to match the image coil, shall be furnished and mounted in
the cooler cabinet.
d)
150mm dial local indicating instrument with maximum reading pointer mounted in
cooler control cabinet and with two adjustable electrically independent ungrounded
contacts (besides that required for control of cooling equipment), one for high winding
temperature alarm and other for trip.
e)
Calibration device
f)
In addition to the above, the following indication equipment shall be provided for each
winding :
i)
Remote winding temperature indicator. It shall be suitable for flush mounting on RTCC
panel. The difference between local and remote WTI indication at any given time shall
not exceed 1o C. One RWTI shall be provided for each winding in the middle phase
(HV,IV,LV).
g)
Auxiliary supply if required, at owner’s panel for RWTI shall be 110/220 V DC only.
h)
Accuracy class of WTI shall be +/- 1.5 % or better.
i)
Any special cables required for shielding purpose for connection between cooler
control cabinet and remote winding temperature indicator control circuit shall be in
supplier’s scope of work.
2.15.3
Along with the OTI /WTI the transformer shall also be equipped with Fiber
Optic based direct temperature measurement system as per below technical
specifications:a)
System shall be of fiber optic rugged. The probes shall be directly installed in each
phase of Power transformer to measure the winding hotspot and top oil temperature.
There will be total number of at least 8 probes inside the transformer, out of which 1
probe should be installed in top of the transformer for the measurement of top oil
temperature. 1 Probe for Core temperature. The remaining 6 will be for Winding
temperature measurement.
b)
Temperature range of the system should be -30 degree C to +200 degree C and
accuracy of + 2 degree C with no recalibration required and should use LED as source
of light.
c)
Probe shall be all silica, double PFA Teflon Jacketed, Kevlar cabled fiber with
perforated outer jacketed to allow complete oil filling and white Teflon protective
Helix wrap for improved visibility and mechanical strength.
IN JASIDIH GSS VOL-II
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2.15.3.1
The measuring unit shall be capable to retain
temperature data for at least 90 days at 1 minute interval for all channels and shall
have facility to download these data. The system shall have following key features:
a)
Fixing arrangement of sensor at suitable location of the winding in such a way that it
will be mechanically protected allowing efficient and secure mounting of sensor tip in
the winding in compliance with the annexure E of IEC 60076-2.
b) The temperature recording of the monitor channels will be obtained in RTCC Panel in
control room through repeater.
c) Alarm output with programmable set points as per user’s choice.
d) IEC 61850 Protocol on RS 485 or RS 232 ports.
e) User friendly software to allow easy configuration to monitor for data logging and
retrieval.
2.15.3.2
Location of optical temperature sensors inside the transformer shall be
finalised during detailed engineering.
2.16 EARTHING TERMINALS:
a)
Two (2) earthing pads (each complete with two (2) Nos. taped holes, M 10 bolts, plain
and spring washers) suitable for connection to 100x12mm copper/brass grounding
unit shall be provided each at position close to the two (2) diagonally bottom corners
of tank. Earthing strip upto the ground level shall be provided by the Bidder.
b)
Two earthing terminals suitable for connection to 50x6 mm galvanised steel flat shall
also be provided on cooler, marshalling box and any other equipment mounted
separately.
2.17 CORE:
i) The core shall be constructed from high grade non-ageing cold rolled super grain
oriented silicon steel laminations having high permeability and low hysteresis loss.
The bidder should offer the CORE for inspection & approval by the purchaser during
the manufacturing stage. Bidder’s call notice for this purpose should be accompanied
with the following documents, as applicable, as proof towards use of primary CORE
material:
a)
Invoice of supplier
b)
Mill’s test certificate
c)
Packing list
d)
Bill of lading
e) Bill of entry certificate by customs CORE material should be directly procured either
from the manufacturer or through their accredited marketing organisation of repute and
not through any agent.
ii)
The design of the magnetic circuit shall be such as to avoid static discharges,
development of short circuit paths within itself or to the earthed clamping
IN JASIDIH GSS VOL-II
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structure and production of flux component at right angles to the plane of
laminations which may cause local heating.
iii)
Conventional core construction/clamping drives a hole through core
laminations.
This weakens the core.
As such a method of
construction/clamping should be adopted so that hole through core
laminating is avoided. ‘Boltless CORE’ or belting arrangement will be
preferred. The clamping of core by belting should ensure adequate
mechanical strength and the core and winding shall be capable of
withstanding the vibration and shock during transportation, installation,
service and also prevent movement of core and winding relative to tank
during the above conditions. However Bidders may quote as per their own
design also.
iv)
Core and winding shall be capable of withstanding the shock during transport
installation service and adequate provision shall be made to prevent
movement of core and winding relative to tank during these conditions.
v)
All steel section used for supporting the core shall be thoroughly sand blasted
after cutting drilling and welding.
vi)
When bell type tank construction is offered, suitable projecting guides shall
be provided on core-assembly to facilitate removal of tank.
vii)
Each core lamination shall be insulated with a material that will not
deteriorate due to pressure and hot oil. The nature of insulation should be
specified in the tender.
viii)
The supporting frame work of core shall be so designed as to avoid presence
of pockets which would prevent complete emptying of the tank through
drain valve or cause trapping of air during oil filling.
ix)
Manufacturer must have in-house availability of Numerically Controlled
Automatic Core Cutting Plant. This must bring following advantages :
a) Ensure dimensional accuracy with respect to Cross Sectional area of Built
Core
b) Ensure proper monitoring & control on quality
c) Avoid any possibility of mixing of prime material with defective / second
grade material, which would ultimately affect the quality and life of
transformers.
The
maximum flux density in any part of the core and yoke at rated MVA,
voltage and frequency at any tap shall not exceed 1.6 tesla.
WINDINGS :
IN JASIDIH GSS VOL-II
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2.18.1 The windings shall be so designed that all coil assemblies of identical voltage ratings
shall be interchangeable and field repairs to the winding can be made readily
without special equipment. The coil shall be supported between adjacent sections of
insulating spacers, and the barriers, brushings and other insulation used in the
assembly of the windings shall be arranged to ensure a free circulation of the oil and
to reduce a hot spot in the windings.
2.18.2 The insulation of the coils shall be such as to develop the full electrical strength of
the windings, All materials used in the insulation and assembly of the windings shall
be insoluble, non-catalytic, and chemically inactive in the hot transformer oil, and
shall not soften or there wise be adversely officiated under the operating conditions.
2.18.3 All threaded connections shall be provided with locking facilities. All loads from the
winding to the terminal board and bushing shall be rigidly supported in prevent
injury from vibration. Guide tubes shall be used where practicable.
2.18.4 The windings shall be clamped securely in place so that they are not displaced or
deformed during short circuits. The assembled core and windings shall be vacuum
dried by vapor phase drying process only and suitably impregnated before removal
from the treating. The tenderer must confirm the type of drying to be used
alongwith the offer. The copper conductors used in the coil structure shall be best
suited to the requirements and all permanent current carrying points in the windings
and the leads shall be welded or braced.
2.19 STABILISING WINDING:
The transformer shall be provided with delta connected stabilizing windings at the
specified voltage and shall be suitably rated to with stand the stresses due to short
circuit in the system.
Coils shall be pressed before assembly to avoid loosening while in service. The coils
shall be clamped by adjustable push bolts at the tap end. The force shall be uniformly
distributed to the winding by using sturdy end-rings.
2.19.3 The coils and insulation shall be perfectly dried vapor phase drying process and then
oil impregnated at a high degree of vacuum followed by keeping for a period at
vacuum, in order to draw put all traces or air. Continuously transposed conductor
transposed at sufficient intervals shall be used for the entire windings in order to
minimize eddy currents & to equalize the distribution of currents and temp along the
winding. The winding shall be helical with center surge shield.
2.19.4 The winding voltage shall be of 12.1 KV class as specified in the section III of this
specification. The product of the number of turns of the stabilizing winding and crosssectional area of one turn of such winding shall not be less than 33.33 percent of the
corresponding product for the untapped main windings.
2.19.5 The tenderer shall give recommended protection scheme in detail for the protection
to the stabilizing windings both under loaded and unloaded conditions. The tenderer
shall furnish in the tender one second short circuit with stand test value.
2.19.6 Winding of the tertiary shall be done with conductors having as large a depth to
thickness ratio as to commensurate with practicability of winding and conductor
manufacturer.
IN JASIDIH GSS VOL-II
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2.19.7 The tertiary delta shall be wound on strong cylinder preferably fiber glass. The end of
the winding shall be supported with a fiber glass and collars.
It shall be ensured that free end of the winding (Loads) are fixed strongly in position
and made in capable of movement in radial direction.
2.20 INSULATING OIL:
2.20.1 The quality of the oil supplied with transformer shall conform to the oil parameters
specified in this clause. No inhibitors shall be used in the oil. The samples will be
drawn as follows:i)
Prior to filling
ii)
Before and after heat run test.
iii)
Before energisation.
All tests as per IS : 335 shall be conducted on oil samples.
2.20.2 The insulating oil shall be subjected to testing in the oil manufacturer’s works before
supply, in the presence of the representative of the transformer manufacturer.
2.20.3 Sufficient quantity of oil necessary for first filling of all tanks, coolers and radiator at
the proper level alongwith 10% extra oil by weight for topping up shall be supplied in
non-returnable steel containers suitable for outdoor storage.
2.20.4 The tenderer shall furnish following information in his offer to enable the purchaser
to placed order/s for oil at the option of the purchaser.
i)
Required technical parameters of oil.
ii)
Quantity required for first filling each rating and voltage class of transformer.
iii)
List of manufacturers of oil who are preferred by the tenderer for the
transformers offered by them.
2.20.5 The supplier shall dispatch the transformer of rating 150 MVA and above in an
atmosphere of Nitrogen. The Bidder shall lake care of the weight limitation on
transport and handling facility at site. In the latter case necessary arrangement shall
be ensured by the supplier to take care of pressure drop of nitrogen during transit
and storage till completion of oil filling during erection. A gas pressure testing valve
with necessary pressure gauge and adapter valve shall be provided.
Auto transformer below 150 MVA rating shall be supplied with oil.
2.20.6 The Bidder shall warrant that characteristic of oil furnished shall comply with the
requirements specified in IS – 335, 1993 (Fourth Revision) with the Intent
amendment/ revision expiation specified here under and shall be suitable for MVA
grade transformers.
IN JASIDIH GSS VOL-II
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2.20.7 The oil shall have the following main characteristics or equivalent (the requirement
indicated is determined in accordance with the test method adopted by IS :
335/1972 amended up to date).
Sl. No.
1.
Characteristic
Appearance
Requirement
The oil shall be clear and
transparent and free from
suspended matter or
sediment
2.
Density at
27oC Maximum
0.89 gm/cm
IS:1448(P-16)1967
or equivalent authoritative
Standard.
3.
Kinetics
Viscosity
at 27oC max.
27 CST
IS:1448(P-20)1960
or equivalent authoritative
standard.
4.
Inter facial tension
at 27oC min.
0.04N/M
IS : 6104/1971 or equivalent
authoritative standard.
5.
Flash point
140oC
IS : 1448 (P-25) 1960
Equivalent authoritative
Standard.
6.
Pour Point, Max.
(-) 10oC
IS : 1118 (P-25) 1970
equivalent authoritative
Standard.
7.
Neutralization
value (Total
Acidity ) max.
0.03 mg
KOH/ gm
IS : 335/1972 equivalent
authoritative standard.
8.
Corrosive
Non-corrosive
(in terms of classification
copper strip)
IS : 335-1972 appendix
A or equivalent authoritative
standard.
9.
a)
Electric strength
(Breakdown volt.)
New untreated oil
IS : 6792-1972 or equivalent
authoritative standard.
b)
After treatment
10.
Dielectric dissipation
Min
40 KV (R.M.S.) If the
above value is not
attained the oil shall
be treated.
60 KV (rms)
0.005
Method of test
A representative sample
of the oil shall be in a
100 mm thick layer,
ambient temperature
IS: 6262-1971 or equivalent
IN JASIDIH GSS VOL-II
Page 425
factor (tan delta at
90oC) mix.
11.
authoritative standard.
a)
Specific Resistance
Resistively
At 90oC min
35x1012 ohm cm
b)
At 27oC min.
1500x1012 ohm cm min.
12.
Oxidation stability
a)
Neutralization
value after
oxidation.
Max. Total sludge
after oxidation
0.02mg/koh/gm
13.
Presence of
oxidation
inhibitor
The oil shall not contain IS: 335-1972 appendix-D or
anti oxidant additives.
Equivalent authoritative
standard.
14.
Water content
30ppm
15.
Oxidation Ageing
test with copper
catalyst for 96 hours
as per
ASTM – D – 1934
a) Resistively
at 27oC Min
b) At 90oC Min
c) Total acidity
(Maxm.)
d) Total sludge
(Maxm )
e) Tan delta at
90oC (Maxm.)
b)
IS : 6103-1971 or equivalent
authoritative standard.
IS: 335-1972 appendix-C or
equivalent authoritative
0.05 percent
by weight.
IS:2362-1963 or
equivalent authoritative
standard.
2.5x1012 ohm-cm
0.20x1012 ohm-cm
0.05 mg/koh/gm
0.05
0.20
2.21
DIAPHRAGM SEAL TYPE CONSTANT OIL PRESSURE SYSTEM:
a)
In this system contact of the oil with atmosphere shall be prohibited by using a flexible
or nitrite rubber reinforced with nylon cloth air cell.
b)
Diaphragm used shall be suitable for continuous operation in all atmosphere of 100oC
to which transformer oil is likely to rise.
IN JASIDIH GSS VOL-II
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c)
The connection of the air cell to the reservoir shall be by an air proof seal promotion
entrance of air into the cell only.
d)
The Diaphragm of the conservator shall with stand the vacuum during installation and
maintenance. Otherwise provision shall be made to isolate the conservator from main
tank during vacuum by providing vacuum sealing valve in the pipe connecting main
tank with the conservator.
2.22
TAP CHANGING MECHANISM:
2.22.1 On load tap changer.
Each transformer shall be provided with an on load tap changing mechanism. This shall
be designed suitable for remote control operation from switch boards installed in the
control room in addition to lying capable of local as well as local electrical operation.
2.22.2 The on load changers shall include the followings.
a)
An oil immersed tap selector and arcing switch or are suppressing tap selection
provided with reactor or resistor for reduction of make and break arcing
voltage and short circuits.
b)
Motor driven mechanism.
c)
Control and protection devices.
d)
Local tap changer position indicator.
e)
Manual operating device.
2.22.3 The on load tap changer shall be designed so that the contacts do not interrupt ARC
within the main tank of the transformer. The tap selector and arcing switch or ARC
suppressing tap selector switch shall be located in one or more all filled compartments.
The compartment shall be provided with means of releasing the gas produced by the
arcing. It shall be designed so as to prevent the oil in the tap selector compartment,
from mixing with the oil in the transformer tank. Bucholtz relay shall therefore be
provided by indicate the accumulation of gas alarm.
2.22.4 The tap change shall be capable of permitting parallel operation with other transformer
of the same type.
2.22.5 The transformer shall give full load output on all taps. The manual operating device
shall be solicitude on the transformer that it can be operated by a man standing at the
level of the transformer track. It shall be strong and robust in construction.
2.22.6 The control scheme for the tap changer shall be provided for independent control of
the tap changers when the transformers are in independent service. In addition,
provision shall be made to enable parallel control also at time so that the tap changer
will be operated simultaneously when one unit is in parallel with another so that under
normal conditions the tap changer will not become out of step and this will eliminate
IN JASIDIH GSS VOL-II
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circulating current. Additional feature like master/ follower and visual indication during
the operation of motor shall also be incorporated.
2.22.7 Necessary interlock blocking independent control when the units are in parallel shall be
provided.
2.22.8 Under abnormal conditions such may occur if the contactor controlling out load tap
changer sticks, the arrangement must be such as to switch off supply to the motor so
that an out of step condition of limited to one tap difference between the units. Details
of out of step protection provided for the taps should be furnished in the tender.
2.22.9 The contactors and associated gear for the tap change driving motors shall be housed
in local kiosk mounted adjacent to or on the transformer. The motors shall be suitable
for operation with 3 phase, 415 volts 50 cycles external power supply.
2.22.10 The supplier shall include in scope of supply in addition to the equipment above, the
following accessories mounted on a separate panel to be installed on the R.T.C.C. panel
to be supplied with each transformer.
i)
Tap raise and lower push bottom switch.
ii)
Remote tap position indicator or other required devices and indication lamps
etc.
iii)
An indication lamp showing tap changing in progress, audible out of step alarm.
iv)
Name plate for each component.
v)
Remote winding temperature indicator one no.
vi)
Cooler control switch.
vii)
Hot oil temperature indicator one no.
2.22.11 Complete particular of the tap changing gear including the capacity of the motor shall
be stated in the tender.
2.23
OIL PRESERVING EQUIPMENT:
2.23.1 Oil preserving equipment shall be inert gas system of conservator or expansion tank
type. If the conservator or expansion tank type in provided, oil level in the conservator
or expansion tank shall not be below the level of the bushing flanges.
2.23.2 If conservator or expansion tank type in offered the conservator or expansion tank shall
have two filter valve one at bottom at one end and the other at the top on the
opposite end in addition to the valve specified in accessories for the main tank. The
conservator or expansion tank shall also have shut off valve and sump with a small
IN JASIDIH GSS VOL-II
Page 428
drain valve and sampling cock, the latter no gagged as not to interfere with oil lines.
The oil level gauge shall be mounted on the conservator or expansion tank.
2.23.3 If an inert gas pressure system is offered gas cylinder filled with high pressure gas, and
automatic reducing valve, a breathing regulator, and mechanical relief valve shall be
furnished. Sufficient gas for blowing out and displacing the air in the transformer shall
be supplied in addition to the full initial supply of gas required for initial operation. The
system proposed shall be automatic in operation, shall provide for expansion and
contraction of oil through a temperature range of 20oC without discharging gas, and
shall seal the interior from atmosphere within the limits provided in this specification.
The oil level in the transformer and in the auxiliary expansion tanks, If required, shall be
located below the level of the busing flanges.
A bracket for attaching block and tackle shall be provided to assist in removal of the gas
cylinder.
2.23.4 The tenderer my offer other arrangement which in his opinion is considered to be
better than the one mentioned above. The proposal shall be supported with sufficient
explanatory notes, operational data etc.
2.24
TRANSFORMER BUSHINGS:
2.24.1 The bushings shall have high factors of safety against leakage to ground and shall be so
located as to provide adequate electrical clearance between bushings and grounded
parts. Bushings of identical voltage rating shall be interchangeable. The bushing shall
be equipped with suitable terminals of approved type and size and shall be suitable for
bimetallic conductor. The insulation class of the high voltage neutral busing shall be
properly coordinated with the insulation class of the neutral of the high voltage
winding.
2.24.2 All main winding and neutral leads shall be brought out through out door type bushing
which shall be so located that the full flashover strength will be utilized and the
adequate phase clearance shall be realized.
Each bushing shall be so coordinated with the transformer insulation, that all flashover
will occur outside the tank.
2.24.3 All porcelain used in bushing shall be of the wet process, homogeneous and free from
cavities or other flaws. The glazing shall be uniform in colour and free from blisters
burns and other deicely.
The creepage distance of the busing shall be suitable for use in highly polluted
atmosphere.
2.24.4 The bushings for 220 KV shall be of oil filled condenser type preferable hermetically
cooled and shall conform to the latest edition of IS:2090 of IEC publication No. 137 & IS
3347 (per III/Section – I as ended upto date.) The characteristics of the oil used in the
bushings shall be the as that the oil in the transformers.
IN JASIDIH GSS VOL-II
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2.24.5 All bushings shall have puncture strength greater than the dry flash over value.
2.24.6 Main terminals shall be soldier less and shall be suitable for connection to ACSR
conductor. The spacing between the bushing must be adequate to prevent flash over
between phases under all condition of operation.
2.24.7 Special adjustable arcing horn may also be provided for the bushing as per
IS:3716/1966 or IEC publication No. 71 A.
2.24.8 The tenderer shall given the guaranteed with stand voltage for the above and also
furnish calibration curve with different settings of the co-ordination gaps to enable
purchaser to decide the actual gap setting. Tenderer’s recommendations are also
invited in this respect.
2.25 COOLING
2.25.1 Cooling units shall be of radiator types. The radiators for transformers shall be
detachable type and shall be provided with removal valves at the top and bottom so as
to enable the removal of radiators without drawing the oil from the transformer tank.
The radiator bank shall be designed for name pressure and vacuum conditions as
specified for main tank.
2.25.2 Each transformer shall be provided with two cooling banks each of 50% capacity and
each cooling bank shall be provided with its pump having 100% capacity, fans, valves
and other necessary and necessary inter connection as such in case of failure of any of
the two pumps, one pump can be utilized for full 100% capacity and can pump oil to
both the cooling banks.
2.25.3 The cooling system shall be so designed that the transformer shall be capable of
operating under the natural cooled condition upto specified load and winding
temperature. The forced cooling equipment shall come into operation automatically at
the preset value of the winding temperature contacts.
2.25.4 All cooling units shall be se designed and attached to and mounted on the transformer
tank as to be accessible for cleaning and painting to prevent any accumulation of water
on the outer surfaces to completely drain oil and to ensure against formation of gas
pockets when the tank is being filled.
2.25.5 Cooler units shall be connected to the tank by machined steel flanges welded to the
cooling units and the cooling banks/ tank and provided with gaskets. At each cooling
unit connections, an indicative shut off valve shall be provided which can be fastened in
either open or close position. A separate oil tight blank flange shall be provided for
each tank connection for use when the cooler unit is detached. Each cooling unit shall
have a lifting eye, an oil drain at the bottom and a vent at the tap.
2.25.6 Fans or blowers for air blast cooling shall be mounted so as to ensure that no damage
to the coolers occurs due to vibrations of the fans, Wire mesh screens shall be fitted to
prevent accidental contact with the blades, the mesh being not greater then 1 inch or
IN JASIDIH GSS VOL-II
Page 430
2.5 dm. Also fans shall be so located that they are readily accessible for inspection and
repair.
2.25.7 In case of ONAN/ONAF cooling system, the transformer shall be capable for giving
continuous output of at least 80% of the rated output with all these artificial cooling
out of service and without exceeding the prescribed temperature rise.
2.26
COOLER CONTROL
2.26.1 Cooler units shall be suitable for operation with a 415 volts, 3 phase, 50 Hz, external
power supply.
2.26.2 The pumps and fan motor controls including all relays, starters, switches and wiring
shall be furnished. Each motor circuit shall have overload and short circuit protection.
2.26.3 Control equipment for fan motors shall be mounted in a marshalling cabinet adjacent
to the transformer and shall include the necessary contractors with automatic control
and annunciation system and provision for manual and remote operation with
indication shall be provided.
2.26.4 A single metal enclosed main isolating suitable with HRC fuses shall be provided for
incoming supply.
2.26.5 The switching IN or OUT of the cooling arrangement shall be controlled by winding
temperature and there shall be provision for automatic switching IN or OUT at preset
temperature levels which should be capable of adjustment & setting at well.
2.26.6 In case of ONAN/ONAF cooled transformers, provision of automatic change over from
main supply to stand by auxiliary supply should be available in case of failure of main
supply. Necessary alarm etc for this also may be provided.
2.26.7 The pumps shall preferably be provided with flow indication showing the condition and
direction of oil flow.
2.27 CONTROL CABINET:
2.27.1 All controls alarms, indication and relaying device provided with the transformer shall
be wired upto the terminal blocks inside the control cabinet. Not more than two wires
shall be connected to one terminal. 10% spare terminals shall be provided.
2.27.2 All devices and terminal blocks within the control cabinet shall be clearly identified by
symbols corresponding to those used on applicable schematic or wiring diagrams.
2.28
CENTRE OF GRAVITY:
The center of gravity of the transformer shall below and as near the vertical center line
as possible. The transformers shall be stable with or without oil. If the center of gravity
is eccentric relative to track either with or without oil its location shall be shown on the
drawing.
IN JASIDIH GSS VOL-II
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2.29
FREQUENCY:
The transformer shall be suitable for continuous operation with a frequency variation
of five percent from normal of 50Hz without exceeding the specified temperature rise.
2.30
PARALLEL OPERATION:
the similar ration transformer shall operation factory in parallel with each other if
connected between high voltage and low voltage busters. Also, wherever specified the
transformers shall be suitable for parallel operation with existing transformer, if
required by the purchaser.
2.31
IMPEDANCE:
Suppliers shall indicate the guaranteed impedance and tolerances and also the upper
and lower limits of impedance which can be offered without an increase in the quoted
price. Impedances shall include positive and zero sequence and shall be expressed in
terms of the branches of the star connected equivalent diagrams, all on the same KVA
base and the range shall be given for each branch of the equivalent circuit in turn. The
transformer impedance shall be as specified in section III of this specification.
2.31
2.33
NEUTRAL EARTHING ARRANGEMENT:
a)
The neutral terminals of the star connected windings shall be brought to the
ground level by a copper grounding bar which shall be supported from the tank
by procession insulators of highest system voltage of 24 KV.
b)
The end of the copper bar shall be brought to the ground level, at a convenient
point, for connection to purchaser’s ground network through two (2)
100x12mm galvanized stool flats. The connection shall be made by using two (2)
bolted neutral grounding terminals with necessary accessories.
c)
Suitable flexible copper strip connection of adequate size shall be provided for
connecting to neutral bushing terminals to avoid terminal load on the bushings.
INSULATION
The dielectric strength of winding insulation and of the bushing shall conform to the
values given in IS: 2026-1982 (as amended upto date (or I.E.C. publication no. 76).
For rated system voltage of 220 kV & 132 kV the following impulse test voltages may be
offered.
voltage
System voltage
Impulse test voltage
Power Frequency withstand test
HV 220 KV
950 KVP
395 kV RMS
IV 132 KV
650 KVP
230 kV RMS
IN JASIDIH GSS VOL-II
Page 432
LV 33 KV
250 KVP
Neutral
95 kV RMS
95 KVP
38 kV RMS
The H.V. winding of the transformers shall have graded insulation. The insulation class
of the neutral end of the winding shall be graded to 95 KV (impulse) and 38 KV (Power
frequency with stand.)
2.34
TEMPERATURE:
The transformer shall be installed outdoor without any protection from sum and rain.
The maximum temperature (specified in section – III of this specification) of hot spot
shall be limited to 105oC with class A insulation. Each transformer shall be capable of
operating continuously at its normal rating without exceeding the temperature rise
limits specified belowTemperature rise oC
45oC for ONAN/ONAF.
Winding (measured by resistance).
50oC for OFAF
Top oil (Measured by thermometer).
35oC
Cores
Not to exceed that permitted for the
adjacent part of the winding.
Note: The reference ambient temperature for the purpose of temperature rise shall be 50oC.
If the ambient temperature is in excess of this value the temperature rise shall be
reduced by an amount equal to the excess ambient temperature.
The transformer shall be free from abnormal noise (other than humming) and
vibration.
2.35
ACCESSORIES
Each transformer shall be provided with the following accessories:
i)
Dial type thermometers for oil
For ONAN/ONAF/OFAF Transformer.
a)
A dial type thermometer for indicating oil temperature fitted with
maximum pointer adjustable alarm and trip contacts.
b)
The dial type indicating thermometer of robust pattern mounted on the
side of the transformer at convenient height to roads the temperature in
the hottest part of the oil and fitted with alarm and trip contacts and
IN JASIDIH GSS VOL-II
Page 433
contacts for switching in and switching out the cooling system at
predetermined temperatures.
ii)
One winding hot spot temperature detector in one winding of each phase as
described below:It shall be indicating type responsive to the combination of top temperature
and winding current, calibrated to follow the hot test spot temperature of the
transformer winding. The winding temperature detector shall operate a remote
alarm and trip at predetermined independent temperature in the event of the
hottest spot temperature approaching dangerous value and in the case of
ONAN/ONAF/OFAF type transformer shall automatically actuate the fan.
iii)
One magnetic type oil level gauge with low level alarm contacts and a dial
showing minimum, maximum and normal oil levels. The gauge shall be readable
from the transformer base level. A low gas pressures electric alarm device shall
also be provided if the transformer is equipped with inert gas pressure
equipment.
iv)
One oil filling valve (inlet).
v)
One oil drain valve.
vi)
One filter valve located at the top of the tank of the H.V. side.
vii)
One filter valve located near bottom of the tank of the H.V. side of the
transformer.
viii)
Oil sampling device.
ix)
Pressure relief device.
A safety valve of the chimney type with an equalizer pipe interconnecting the
top
of the conservator and uppermost part of the safety valve should be
provided to prevent rise of oil in the safety valve pipe. A stop cock should also
be provided in the inter connecting pipe. A air release cock shall also be fitted in
a convenient position. The safety valve pipe shall preferably take of from the
side of the transformer tank near to the tank cover not from the top of tank
cover. This is with a view to prevent the gases forming in the tank from rising
into the safety valve pipe and thereby passing the bucholtz relay defeating its
purpose and for avoiding the necessity for providing a bottom diaphragm for
the safety valve off from the tank cover.
x)
One double float gas detector relay (Buchholz relay with alarm and tripping
contacts) to detect accumulation of gas and sudden change of oil pressure
complete with two shut off valves and flange couplings to permit, easy removal
without lowering oil level in the main tank, bleed valve for gas venting and a
test valve.
IN JASIDIH GSS VOL-II
Page 434
2.36
xi)
Radiators complete with fans, etc. described in clause.
xii)
Air cell bag type conservator along with its supporting bracket to be mounted
on tank or independent structure, as the case may be (in case of independent
structure mounting, the structure shall be within the scope of transformer
supplier).
xiii)
Eye bolts and lugs on all parts for case of handling.
xiv)
Two grounding terminals.
xv)
Diagram and rating plate.
xvi)
One set of equipment for control, protection indication and annunciation for
each transformer comprising motor contractors, detecting elements or devices,
indicating apparatus, instruments, relays, enunciators, etc.
xvii)
Suitable weather proof cubicles for housing the control equipment, terminal
blocks, etc (one for each transformer) one number indoor cubicle (RTCC panel)
detailed as under clause 2.18.2.10 for each transformer for remote control of
cooler fans, on load tap changer, alarm and indicating devices.
xviii)
One set consisting of 4 nos of lifting cum traversing hydraulic jacks. (common to
all the transformer per substation). Price of jacks should be quoted separately.
xix)
Ladder for access to top cover. The equipment and accessories furnished with
the transformer shall be suitably mounted on the transformer for case of
operation, inspection and maintenance and the mounting details shall be
subject to the approval of the purchase. All valves shall be provided either with
blind companion flanges or with pipe plugs for protection.
xx)
Indication, alarm and relay equipment shall have contacts suitable for operation
with 250 volts D.C supply. Any other necessaries or appliances recommended
by the manufacturer for the satisfactory operation of the transformer together
with their prices, shall be given in the tender.
TERMINALS:
2.36.1 The bushing shall be equipped with terminals suitable for connection with ACSR
“ZEBRA” conductor having ever all diameter 28.62 mm.
2.37
TERMINALS MARKING
2.37.1 Each terminal (including the neutral) shall be distinctly marked on both the primary and
secondary side in accordance with the diagram of connection supplied with the
transformers.
2.38
CONDUIT AND WIRING:
IN JASIDIH GSS VOL-II
Page 435
2.38.1 All secondary or control wiring from current transformers, temperature detectors and
alarm contacts. Shall be enclosed in metal conduits and shall be carried to the weather
proof cubicle box mounted on the side of transformers or located closely. Terminal
Board shall be installed in the cubicle to provide for ready connections to the control
cables.
2.39
EVALUATION OF LOSSES
2.39.1 The no load losses and load losses for the purpose of evaluation of the tenders shall be
capitalized at the following rates:
No load losses
Rs. 162000.00 per KW
Load losses and Aux. losses.
Rs. 81500.00 per KW
The bidder should fill each component of losses strictly as per schedule, Otherwise
J.S.E.B. has right to accept or reject the offer of bidder.
The guaranteed loss at rated voltage for each equipment shall be corrected in
accordance with IEC-76 for the purpose of comparison of guaranteed losses with
measured losses for levy of liquidated damages. However, the equipment under no
circumstances shall be accepted if the measured losses are more than +15% of the
guaranteed losses at rated voltage.
Sl. No.
Equipment
Parameter to be Value of F in Indian Rupees
taken for applying (applicable for each item/ unit of
differential
price the facilities) per unit of
factor
parameter differential per KW
1
150 MVA 220/132/3 Differential Iron loss Rs. 162000/- (Rupees One Lac Sixty
kV Auto Transformer (kW)
Two Thousand) only
Differential copper Rs. 81500/- (Rupees Eighty One
and aux. loss (kW)
Thousand Five Hundred) only
The amount of liquidated damages so recoverable shall be as per the aforesaid ceiling
and shall not prejudice the contractor’s other liabilities under the Contract in any
manner. The liquidated damages for shortfall in guaranteed parameters and for delay
in completion are independent of each other and shall be levied separately and
concurrently.
2.40 TOLERANCE:
No positive tolerance is acceptable. Any changes in the figures assigned for transformer
losses shall not be permitted after opening of bids and bid evaluation shall be carried
out on the basis of information made available at the time of bid opening.
2.41
CLEANING AND PAINTING
2.41.1 Before painting of filling with oil or compound, all un-galvanized parts shall be
completely clean and free from rust, scale and grease and all external rough surface in
castings, shall be filled by metal deposition. The interior of all transformer tanks and
other oil filled cambers and internal structural steel work shall be cleaned of all scale
and rust by sand blasting or other approved method. These surfaces shall be painted
with an oil resisting varnish or paint unexposed welds need not be painted.
IN JASIDIH GSS VOL-II
Page 436
2.41.2 Except for nuts, bolts and washer which may have to be removed for maintenance
purpose, all external surfaces shall receive a minimum of three coats of paints, the
primary coat shall be applied immediately after cleaning. The second coat shall be of oil
paint of weather resisting nature and of a shade or colour easily distinguishable from
the primary, and the second and the final coats shall be applied after the primary coat
has been touched up where necessary. The final cost shall be of a glossy, oil and
weather resisting non-fading paint.
2.41.3 All interior surface of mechanism chambers and kiosks except these which have
received anticorrosion treatment shall receive three coats of paints applied to the
thoroughly cleaned metal surfaces. The final coat shall be of light coloured anti
condensation mixture, any damage to paint work incurred during. The transport and
erection shall be made good by thoroughly checking the damaged portion and applying
the full number of coat appoints that had been applied before damaged was caused.
2.42
TESTS:
2.42.1 The supplier shall carry out all type tests and routine test of the transformers as per the
relevant latest IEC standard. Type tests and special tests, if any shall be carried out on
one transformer while routine test shall be conducted on all transformers. All external
components and fittings that are likely to effect the performance of the transformer
during the test shall be in place.
Where it is, required test results shall be corrected to a reference temperature of 75oC.
2.43
TYPE TESTS:
2.43.1 All type tests in accordance with IEC as amended upto date shall be carried out on one
unit of transformer by the successful tenderers. In case the tenderers furnish the Latest
test reports of those tests carried out on similar transformers, the purchaser at his
discretion may wave off necessity of carrying out these tests.
2.44
ROUTINE TESTS & FACTORY TESTS:
2.44.1 All standard routine tests in accordance with IEC (amended upto date) alongwith
dielectric tests shall be carried out on which transformer.
2.44.2 All double welds shall be tested for leaks with air transformer oil to EHV grade
transformer oil at a pressure not less than normal pressure plus 35 KN/M2 measured at
the base of the tank. The pressure shall be maintained for a period not less than 12
hours for oil and one hour for hour during which no leakage shall occur.
2.44.3 All tanks, single welds, cooling coils, radiator valves and other parts necessary
for complete transformer filled with oil to a pressure corresponding to twice the
normal head of oil or to the normal pressure plus 35 FM per meter square whichever is
lower will be measured at the base of the tank and will be maintained for one hour. If
leak occur, the tests shall be conducted again after all the leaks have been stopped.
IN JASIDIH GSS VOL-II
Page 437
2.44.4 The following tests shall be made on the transformer unless otherwise stated in the
schedule of requirement.
2.45
i)
Resistance of each winding at all taps.
ii)
Turn ratio for all sets of windings on each tap.
iii)
Polarity and phase rotation.
iv)
Excitation losses at 90%, 100% and 110% of rated voltage measured by the
average voltage voltmeter method. The excitation losses given the test report
shall be those measured after the implies tests are completed.
v)
Impedance between each pair of winding.
vi)
‘Zero’ and positive phase sequence impedance on 3 phase transformer.
vii)
Regulation at rated load and at unity, 0.9 and 0.8 lagging power factor.
viii)
Load losses at rated frequency by applying a primary voltage sufficient to
produce rated current in the windings with the secondary windings short
circuited.
ix)
Separate source voltage withstand test.
x)
Temperature rise tests at an equivalent to rated load. The current required for
the auxilliaries shall be stated in the test reports.
xi)
Induced voltage withstand test.
xii)
Impulse tests on one limb of the transformer.
xiii)
Tan-Delta Test.
xiv)
Dissolved Gas Analysis.
TEST AT SITE
After erection at site, the transformer shall be subject to the following tests:-
2.46
i)
Insulation resistance test.
ii)
Ratio and polarity test.
iii)
Dielectric test on oil.
iv)
Any other tests specified by the purchaser and manufacturers mutually agreed.
TESTS ON TRANSFORMER TANK
IN JASIDIH GSS VOL-II
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2.46.1 In addition to the routine tests on welds of the tank, the following tests shall be carried
out on one of the transformer tanks.
i)
VACUM TEST
The transformer tank without oil shall be subject to an internal vacuum of 760
mm of mercury for one hour. The permanent deflection of the flats plates after
the vacuum has been released shall not exceed the values specified below:-
Horizontal length of flat pleas (in mm)
Permanent deflection (in mm)
Upto & including 750
5.0
751 to 12.50
6.5
1251 to 1750
8.0
1751 to 2000
9.5
2001 to 2200
11.0
2251 to 2500
12.5
2501 to 3000
16.0
above 3000
19.0
ii)
PRESSURE TEST
Transformer tank alongwith its radiators, conservator and other fittings shall be
subjected to a pressure corresponding to twice the normal head of oil in the
transformer or to the normal pressure plus 35 KN/M2 which ever is lower,
measured at the base of the tank and maintained for one hour. The permanent
defection of the flat plates after the excess pressure has been released shall not
exceed the figures specified above for vacuum test.
iii)
2.47
An explosion vent with its diaphragm in position shall be subjected to as
increasing oil pressure. This vent shall operate before reaching the pressure
specified in the pressure test as above.
TESTS ON LOAD TAP CHANGER
2.47.1 The various routine and type tests as specified in the IEC publication 214-1906
amended upto date shall be carried out.
Type test certificates and copies of oscillogramme as called for in IEC publication 214
shall be furnished.
2.47.2 After the tap change is fully assembled on the transformer, the following operation
tests shall be performed without failure at 100% of the rated auxiliary supply voltage.
IN JASIDIH GSS VOL-II
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2.48
i)
Eight complete operation cycles with the transformer not energized.
ii)
One complete operating cycle with the transformer not energized with 85% of
the rated auxiliary supply voltage (exceptional).
iii)
One complete operating cycle with the transformer energized at rated voltage
and frequency at no load.
iv)
Ten tap change operations with steps on either side of the principle tapping
with as far as possible the rated current of the transformer with one winding
short circuited. After the transformer is on the transformer, a power frequency
test shall be applied to the auxiliary circuit for auxiliary circuits insulation test.
FURTHER TESTS/ SPECIAL TESTS:
The purchaser reserves the right having any other reasonable tests carried out their
own expenses either before shipment or at site to ensure that the transformer
complies with the requirements of this specification.
2.49
INSPECTION/ ACCESSORIES TESTS:
2.49.1 The purchaser shall have access at times to the works and all other places of
manufacture where the transformers are being manufactured and the supplier shall
provided all facilities for unrestricted inspection of the supplier works, raw materials,
manufacture of all the accessories and for conducting necessary tests.
2.49.2 The supplier ladder shall keep the purchaser informed in advance of the time of
starting and of the progress of manufacture of equipment in its various stages so that
arrangements could be made for inspection.
2.49.3 No material shall be dispatched from its point of manufacture unless the material had
been satisfactorily inspected, tested, approved, and dispatch clearance given by the
JUSNL.
2.49.4 The acceptance of any quantity of equipment shall in no way relieve the supplier of his
responsibility for meeting all the requirement of this specification and shall not prevent
subsequent rejection of such equipment are later found to be defective.
2.49.5 The supplier shall inform the purchaser at least thirty days in advance, about the
manufacturing program so that arrangement can be made for inspection.
2.49.6 The purchaser reserves the right to insist for witnessing the acceptance/routine testing
of bought out items. The supplier shall communicate in the purchaser the details of
such testing program at least three weeks in advance. The testing shall not be
postponed even if the purchaser is unable to depute his representative for witnessing
the testing.
2.50
TEST REPORTS:
2.50.1 After all the test have been completed the following test reports shall be furnished.
IN JASIDIH GSS VOL-II
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i)
Copies of routine test reports. All records of routine tests reports as well as all
test reports for the test conducted during manufacture shall be maintained by
the supplier. These shall be produced for verification as & when requested by
the purchaser.
ii)
Six copies of test reports for the tests carried out on the ancillary apparatus
shall be furnished.
iii)
All auxiliary equipment shall be tested as per the relevant standard. Test
certificates shall be submitted for all brought out items.
iv)
Six copies of acceptance test reports and type test reports duly witnessed by
the JUSNLs inspector shall be furnished to the purchaser. One copy of the test
reports will be returned to the supplier duly approved by the purchaser and
only thereafter the material shall be dispatch.
2.50.2 Each test reports shall indicate the following information’s:a)
Complete identification the date of testing including the serial number of the
transformer.
b)
Method of application, where applied, duration and interpretation of results for
each test.
c)
Temperature rise graded to 75oC including ambient temperature.
Note:- One copy of all test imports shall be provided in the instruction manual to be furnished
as per clause no. 2.05 of this specification.
2.51
PACKING AND FORWARDING:
2.51.1 The equipment to be supplied against this tender shall be packed for shipment in such
a manner as may facilitate easy handling and avoiding any damage during transit.
2.51.2 The equipment shall be packed in crates suitable for vertical/horizontal transport as
the case may be and suitable in withstand handling during transportation and outdoor
storage. The supplier shall be wholly responsible for any damage to the equipment
during transit due to improper and inadequate packing. The easily damageable items
shall be carefully packed and marked with the appropriate caution symbol. Wherever
necessary, proper arrangement for lifting such as lifting books etc. shall be provided.
Any material, found short inside the packing cases, shall be supplied by the supplier
without any extra cost.
2.51.3 Each consignment shall be accompanied by a detailed packing list containing the
following information’s:i)
Name of the consignee.
ii)
Name of consignment.
IN JASIDIH GSS VOL-II
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iii)
Destination.
iv)
Total weight of the consignment.
v)
Sign showing upper/lower side of the crates.
vi)
Handling and packing instructions.
vii)
Bill of material indicating contents of each package.
2.51.4 The transformer shall be shipped filled with oil/inert gas (whichever may be desired by
the purchaser depending on the size, etc.)
2.51.5 All parts shall be adequately marked to facilitate field erection. Boxes and crates shall
be marked with the contract number and shall have a packing list enclosed showing the
parts contained therein.
2.51.6 In case synthetic resin bonded paper type bushing is offered (S.R.B.P.) the lower parts
not being oil filled, special attention shall be paid in packing so as to avoid moisture.
The details of bushing and method of packing shall be stated in the tender.
2.52
LABELS
2.52.1 Labels shall be provided for all apparatus such as relays, switches, fuse contained in any
cubicles or marshalling kiosk.
2.52.2 Descriptive labels for mounting indoor or inside cubicles and kiosk shall be of material
that will ensure permanency of the lettering. Matter satin finish shall be provided to
avoid dazzle from reflected light. Labels mounted on dark surfaces shall have white
lettering on a black background. Danger notice shall have red lettering on a white
background.
All plates shall be of material which will not be corroded.
2.52.3 Labeling shall be clear, concise and adequate.
2.52.4 Labels shall be supplied as far as possible in the following four standard sizes:
a)
Labels for fuses and links shall measure approximately 28mm to 45mm by
13mm to 19mm and lettering of 3mm to 6mm. shall be used according to the
amount of inscription required.
b)
Labels for relays, contactors thermal devices and similar apparatus shall
measure 65mm by 20mm and shall have lettering as specified in above.
c)
Labels for controllers and changed ever switches shall measure 70mm and
where practicable have 20mm letter alongwith 1.5 mm stocks.
IN JASIDIH GSS VOL-II
Page 442
d)
Labels for the doors of junction boxes, marshalling kiosks and similar equipment
shall measure 125mm by 50mm and have 13mm lettering with 1.5mm wide
stocks.
2.52.5 The labels for mounting outdoors shall be weather and corrosion proof. The letters/
diagrams thereon, shall be formed by etching any other such process which will ensure
permanency of the lettering/marking.
2.53
SUPERVISION OF ERECTION, TESTING AND COMMISSIONING
2.53.1 The tenderer shall arrange for the services of the supervisor for the supervision of
erection, testing and commissioning of the equipment. The tenderer shall quote his
charges for the above services. The general terms and conditions for erection and
supervise services is given in section IV of this specification.
2.54
SPARE PARTS & MAINTENANCE EQUIPMENT:
2.54.1 The tenderer shall quote separately for mandatory spares as specified in the schedule
of requirement section III of this specification. The make and type of such spares
offered shall be same as these offered alongwith the main transformer and inter
changeable with the similar items.
The price offered for supply of these spares shall be taken into consideration for the
purpose of bid evaluation.
2.54.2 The tender shall also indicate his proposal and quote their rates for any other spares
recommended for the trouble free operation of the equipment for five years. The
prices for such optional spares shall be quoted. separately. The price of these optional
spares shall not taken into consideration for the purpose of bid evaluation.
The purchaser shall decide the actual quantities of spare parts to be included in the
order on the basis of this list and the item wise price of spare parts.
2.55
ERECTION AND MAINTENANCE TOOLS
2.55.1 The tenderer shall separately list out in their tender the sets of tools required for initial
erection and subsequent maintenance for the auto transformer and the associated
equipments. Item wise unit price for such tools shall be quoted in schedule F, Section V
of this specification. The prices quoted for such tools shall not be taken into
consideration for the purpose of bid evaluation.
2.56
BASIS OF AWARD
2.56.1 The tenderer shall quote for complete equipment required for auto transformer as
specified in the schedule of requirements. The purchaser reserves the right to split up
and award the contract on any all the firms without assigning any reasons.
2.57
GUARANTEED TECHNICAL PARTICULARS:
2.57.1 The tenderer shall furnish all guaranteed technical particulars.
IN JASIDIH GSS VOL-II
Page 443
Particulars which are subject to guarantee shall be clearly marked. Tender without
information’s in this respect may not be considered.
2.58
GUARANTEE:
2.58.1 The transformer alongwith all fittings and accessories supplied shall carry performance
guarantee for the satisfactory performance of the equipment supplied for a period of
12 months from the date of commissioning of the equipment or 18 months from the
date of receipt of the last consignment at site/stores, whichever is earlier.
2.58.2 If any defects develop during this period in any part of the equipment, the supplier
shall replace or repair the same to the satisfaction of the purchaser expeditiously free
of cost.
2.58.3 The tenderer shall also indicate whether facilities shall be made available by him at site
for repair to transformers, on load Tap changers and the accessories offered by them
after the guarantee period it so desired by the purchaser.
2.59
DEVIATION FROM SPECIFICATION
2.59.1 The tenderers are required to furnish the tenders as per terms and conditions laid
down in the specification. However the deviations, if any from the specification shall be
separately spelt out, in the absence of which it will be presumed that the provisions of
the specification are compiled by the tenderer.
IN JASIDIH GSS VOL-II
Page 444
SPECIFIC TECHNICAL REQUIREMENTS FOR 150 MVA
220/132/33 KV AUTO TRANSFORMER
IN JASIDIH GSS VOL-II
Page 445
SPECIFIC TECHNICAL REQUIREMENT FOR 150 MVA 220/132/33 KV AUTO TRANSFORMERS.
3.1
SCOPE
3.1.1 This section of the specification covers the specific technical particulars, climate and
Isoceraunic condition, system particulars suiting which auto transformers shall be
offered as per the General Technical Requirements given in the Section II.
3.1.2 The specific Technical Requirements and the schedule of requirements are specified
hereunder:3.2
CLIMATE AND ISOCERAUNIC CONDITIONS:
3.2.1
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
The climate and Isoceraunic conditions at the site are given below:Maximum ambient temperature in shade50oC
Minimum ambient temperature in shade4oC
Maximum daily average ambient temperature35oC
Maximum yearly average ambient temperature30oC
Maximum relative humidity
150%
Average number of thunder storm days per annum.
80
Average rainfall per annum.
125cm.
Maximum wind pressure
150 kg/m2
Height above sea level
Not exceeding
1500m.
Earthquake acceleration.
0.05x2 g.
TYPE AND RATING
x)
3.3
3.3.1 The equipment offered shall be suitable for continuous operation at full rated capacity
under the conditions specified in clause no. 3.2 above, the type and rating of the
transformers proposed for procurement against the tender are specified in Annexure I.
3.4
PARALLEL OPERATION
3.4.1 The transformer proposed for procurement against the tender are also required to
operate in parallel with the existing transformers.
3.5
AUXILIARY POWER SUPPLY
3.5.1 The purchase will make separate arrangements of providing low tension A.C. and D.C.
supply for auxiliary equipment and control use. All the auxiliary electrical
equipment/Accessories shall be suitable for operation on the following supply system:
(i)
For auxiliaries
(a)
(b)
Tolerance:
(ii)
Frequency-
VoltageFor control alarm and
240 volts, single phase 50HZ, neutral grounded
A.C. supply.
415 volts, three phase 50HZ, Netural grounded
A.C. supply.
between 90% and 105% of normal frequency of
50 HZ.
from 110% to 85% of the normal voltage.
250 V available from the station battery.
IN JASIDIH GSS VOL-II
Page 446
Protective devices.
The D.C. supply is subject to a variation of 10%
3.6
EVALUATION OF LOSSES
3.6.1 The no load losses and load losses for the purpose of evaluation of the tenders shall be
capitalized at the following rates:
No load losses
Rs. 162000.00 per KW
Load losses and Aux. losses.
Rs. 81500.00 per KW
The bidder should fill each component of losses strictly as per schedule, Otherwise
J.S.E.B. has right to accept or reject the offer of bidder.
The guaranteed loss at rated voltage for each equipment shall be corrected in
accordance with IEC-76 for the purpose of comparison of guaranteed losses with
measured losses for levy of liquidated damages. However, the equipment under no
circumstances shall be accepted if the measured losses are more than +15% of the
guaranteed losses at rated voltage.
Sl. No.
Equipment
Parameter to be Value of F in Indian Rupees
taken for applying (applicable for each item/ unit of
differential
price the facilities) per unit of
factor
parameter differential per KW
1
150 MVA 220/132/3 Differential Iron loss Rs. 162000/- (Rupees One Lac Sixty
kV Auto Transformer (kW)
Two Thousand) only
Differential copper Rs. 81500/- (Rupees Eighty One
and aux. loss (kW)
Thousand Five Hundred) only
The amount of liquidated damages so recoverable shall be as per the aforesaid ceiling
and shall not prejudice the contractor’s other liabilities under the Contract in any
manner. The liquidated damages for shortfall in guaranteed parameters and for delay
in completion are independent of each other and shall be levied separately and
concurrently.
3.7
NEUTRAL C.T.
3.7.1 The tenderer may quote separately for one Multi-Ratio bushing/turret mounted
current transformer of suitable ratio class PS as per IS 2705 for providing one common
neutral lead for the purpose of restricted earth fault protection.
3.8
REQUIREMENT AND DESIRED DELIVERY.
3.8.1 The quantity proposed for procurement and the desired delivery and detailed in the
schedule of requirement and desired delivery enclosed as Annexure II of this
specification.
3.8.2 The quantity mentioned in the schedule is tentative and are subject to increase or
decrease by 15% the time of finalization of tender and placement of order at the
direction of the purchaser.
3.9
EARTH QUAKE & WIND DESIGN LOAD
IN JASIDIH GSS VOL-II
Page 447
3.9.1 The equipment offered shall be so designed to withstand repeated earthquake
acceleration of 0.05x2g and wind load 150 kg/M2 in the projected are simultaneous
without damage to component part and without treatment of operation.
IN JASIDIH GSS VOL-II
Page 448
ANNEXURE I
TYPE & RATING OF THE TRANSFORMERS
The type, rating and the specific guaranteed technical particulars for 150 MVA 220/132/33 KV
Auto Transformers will be as under.
150 MVA
Core type construction
Oil immersed
i)
Type
ii)
No. of Phase
3 (three)
iii)
Service
Out door
iv)
Reference standard
v)
Rated Frequency
50 HZ
vi)
Rated Voltage
a) High voltage winding
b) Low voltage winding
c) Tertiary winding
220 KV
132 KV
33 KV
vii)
Normal Ratio
viii)
Highest voltage system
a) High voltage
b) Low voltage
c) Tertiary winding
ix)
Capacity
x)
Type of Cooling
xi)
Connections
a) High Voltage winding
b) Low voltage winding
c) Tertiary winding
d) Vector group reference
xii)
Insulation level withstand value.
a) 1.2x50 Micro second impulse
Voltage, KV (Peak).
b) Power frequency withstand
voltage, KV R.M.S.
IS 2026
220/132/33 KV
245 KV
145 KV
36 KV
75 MVA/ 105 MVA/ 150 MVA
ONAN/ONAF/ OFAF
Star
Star
Delta
Yna0 d11 (Auto)
950/95/650/250 KVP
395/38/230/95 kV RMS
IN JASIDIH GSS VOL-II
Page 449
xiii)
17
xiv)
Percentage impedance
Tap 1
+ IS Tolerance
HV – IV
IV - LV
HV – LV
Tap Changer on HV winding
a) Type
b) Location
c) Number of taps
d) Range of tap
e) Voltage variation that
each tap to provide.
Type of core material
xvi)
Flux density of normal
voltage and frequency.
xvii) Over voltage withstand.
xviii) System of earthing.
a) High voltage.
b) Low voltage.
xix)
xx)
–
–
11.38%
27.96%
42.45%
Tap
11.33%
–
–
High speed transition
Resister, ON-LOAD type
High voltage winding.
17 tap position
(+) 10% to (–) 10% on rated HV voltage 230 kV
f) Control
xv)
11.62%
Tap 5
Creepage distance (in mms)
a) Total
Voltage
Tap Position
1
–
2
–
3
–
4
–
5N
–
6
–
7
–
8
–
9A
–
In step of 1.25%
variation.
Local (Manual/
electrical)
Remote/Auto
Cold Rolled super
grain oriented
silicon steel
lamination.
(As per Cl. No.2.17 of section-II)
1.6 Tesla
110% for 3(three)
minutes.
Effectively earthed
Effectively earthed
6125/ 3625/ 900
Voltage (in kV)
231.00
228.25
225.50
222.75
220.00
217.25
214.50
211.75
209.00
IN JASIDIH GSS VOL-II
Page 450
xxi)
9B
9C
10
11
12
13
14
15
16
17
kV (No Load)
HV
IV
LV
–
–
–
–
–
–
–
–
–
–
–
–
–
209.00
209.00
206.25
203.50
200.75
198.00
195.25
192.50
189.75
187.00
220 kV
132 kV
33 kV
IN JASIDIH GSS VOL-II
Page 451
ANNEXURE II
BILL OF QUANTITY FOR 150 MVA AUTO TRANSFORMER
Sl. No. Description of equipment
Qnty in Nos.
1.
Three phase 50 Hz ONAN/ONAF/ OFAF
2 No.
150 MVA, 220/132/33 KV
Auto transformer with OLTC, RTCC, bushings, connectors
& other fittings, Control equipment etc. with first filling of oil
Plus 10% extra oil.
2.
Spare parts
i) H.V. Bushing
1 No.
ii) L.V. Bushing
1 No.
iii) Neutral Bushing
1 No.
iv) Set of gaskets
1 No.
v) Buchholz relay
1 No.
vi) Magnetic oil guage
1 No.
vii) Buchhols Relay for OLTC
1 No.
viii) Winding temp. Indicator
1 No.
ix) Oil temp indicator
1 No.
x) Silicagel breather
1 No.
xi) Pressure relief device
1 No.
xii) Fan.
1 No.
xiii) Contactor for fan.
1 No.
xiv) Contactor for tap changer.
1 No.
xv) Hydraulic jack
1 Set
(One set comprises of four nos. of Hydraulic jack)
3.
Type test to be carried out
Lightning Impulse test
Temperature Rise test
Dissolve gas Analysis test
Capacitance & tan delta test
Zero phase sequence test
Vacuum test on tank
Pressure test on tank
Measurement of power taken by cooling equipment
Measurement of accostic noise level
IN JASIDIH GSS VOL-II
Page 452
GENERAL TECHNICAL SPECIFICATION FOR 50 MVA 132/33 KV
POWER TRANSFORMERS.
1.3
SCOPE :
1.3.1 This Section provides for design, manufacture, assembly, Inspection and testing at
manufactures works before despatch, packing, supply and delivery of Power
Transformers at destination sub station complete with all fittings, first filling of
Transformer oil and 10% extra Tr. Oil, accessories and associated equipment for
efficient and trouble free operation as specified herein after.
1.3.2 It is not easy to specify completely herein all details of the design and manufacture
of the equipment. However, the equipment shall conform in all respect to the
standards of engineering, design & workmanship listed in clause no. 2.3 and shall be
capable of performing continuous commercial operation in a manner acceptable to
the purchaser who shall have power to reject the material which in his judgement, is
not in accordance therewith.
1.3.3 The equipment offered shall be complete with all components in all respects. All
such components shall be deemed to be within the scope of supply irrespective of
whether those are specifically mentioned in this specification and / or the
commercial order or not.
1.3.4 The scope of work shall also include supervision of erection, testing and
commissioning of all the equipment to be supplied against this tender.
2.3
ELIGIBILITY :
2.3.1 Tenders of those firms only shall be considered who are themselves manufacturers
of the equipment offered and whose engineering organisation is capable of
undertaking the manufacture, supply, testing and putting into services of such
equipment. The tenderer must be ISO 9001: 2000 company.
2.3.2 The offered equipment must be in successful operation for atleast three consecutive
years as on date of bid opening. The tenderers shall furnish alongwith Part I of the
tenders, the list of past supplies executed for the offered item and performance
reports from their users. Tender (Part-I) must accompany with Earnest Money as
specified in NIT.
2.4
STANDARDS :
2.4.1 The transformers, accessories and associated equipment shall conform to the
latest revision and amendments of standards as given below, except to the extent
explicitly modified in the specifications.
Indian
Standard
No.
IS-325
Title
Three phase Induction Motors.
International &
Internationally
Recognized Standard.
IEC – 34
IN JASIDIH GSS VOL-II
Page 453
IS – 335
Insulating oils for transformers and
Switch gear.
IEC – 296
BS- 148
IS – 778
Gun metal gate, globe and check valves
for general purpose.
IS – 1886
Code of Practice for installation and
maintenance of transformers.
IS – 2026
Power Transformers
IEC – 76
IS – 2099
Bushings for alternating voltage
Above 1000 V
IEC – 137
BS – 223
IS – 2117
Degrees of protn. Pro vided by
enclosures for low, voltage switchgear
& control gear.
IS – 2705
Current Transformers
IS – 3203
Code of practice of climatic proofing
Of electrical ecuipments.
IS – 3347
Dimension for porcelain transformer
Bushings.
IS – 3401
Silica gel.
IS – 3637
Gas operated relays
IS – 3639
Fittings & Accessories for power
Transformers.
IS – 4253
Cork and rubber.
IS – 5561
Electric Power connector.
IS – 5578
Marking & arrangements for
IS – 11353
Switchgera, bus bars, Main
Connections and auxiliary wiring.
IS – 6272
Industrial cooling fans
IS – 6600
Guide for loading of oil immersed
transformers
IES – 185
BSCP - 0160
IN JASIDIH GSS VOL-II
Page 454
IS – 9434
Guide for sampling and analysis of
Dissolved gas in oil filled equipments.
IS – 12676
Oil impregenated paper insulated
condensor bushing dimension and
requirements.
Insulation Co- ordination
IEC – 71
Indian Electricity Rules, 1956
2.3.2 The standards mentioned above are available from
Standard
Name and address
IS
BUREAU OF INDIAN STANDARD
Manak Bhawan,
9, Bahadur Shah Zafer park,
New Delhi 1100001
India.
IEC
INTERNATIONAL ELECTRO TECHNICAL
COMMISSION
Bureau Central dela Commission Electro Technique
International, I, ruo de Verembe,
Coneva, SWITZERLAND
2.3.5 Equipment meeting with the requirements of other authoritative International
standards which insure equal of better performance than the standards mentioned
above shall also be considered. When the equipment offered by the supplier conforms
to other standards, salient points of difference between standards adopted and the
standards specified in this specification shall be clearly brought out in the offer. Two
copies of such standards with authentic translation in English shall be furnished
alongwith the offer.
2.5 DRAWINGS :
2.5.1 The tenderers shall furnish along with their tenders following particulars/ dimensional
drawings of the transformers and other accessories for the purpose of preliminary
study:j)
General out line drawings.
k) Sectional views, showing the general construction features and disposition of various
fittings.
l)
G.A. drawings of cooler control cabinet and RTCC panel.
m) Schematic drawing of OLTC, RTCC and cooler control, etc.
n) Foundation drawings.
o) Bushing drawings showing the full details of construction of condenser bushing and
other relevant data.
p) Demand on of the largest parts to be shipped and the position in which these are to be
transported.
IN JASIDIH GSS VOL-II
Page 455
q)
Technical literatures on Tap changer control, cooling system, Relays, Motors, and
general constructional features for winding, temperature indicator, Buchholz Relay, Oil
Temp. Indicator etc.
r)
Type Test Reports.
2.5.2 All drawings should be in ink and suitable for micro filming. The drawings shall include
the following information’s.
i)
Dimensions and Tolerance on dimensions.
viii) Material designation used for different components with reference to standards.
ix) Fabrication details such as welds, finishes and coatings.
x)
Catalogue or part number for each component and the total assembly with bill of
materials.
xi) Identification Marking.
xii) Weight of individual components and total assembled weight.
xiii) All dimension and data shall be in S.I. Units.
2.5.3 Within 30 (thirty) days after placement of the order, the supplier shall furnish six sets
of the following drawings for the approval of the purchaser.
i)
G.A. drawing showing front, side elevations and plan of the transformer and all
accessories with detailed dimensions, position of centre of Gravity.
xi) Detailed foundation Drawings.
xii) Drawings of each type of bushings, lifting dimensions, clearance between H.T. & L.T.
terminals and ground, quantity of insulating oil, name plate, details etc.
xiii) Large scale drawing of high & low tension windings of the transformer showing the
nature and arrangement of insulators and terminal connectors.
xiv) Control wiring diagrams and drawings showing temperature indicators, alarm circuits
etc.
xv) Drawing showing construction and mounting details of marshalling Box.
xvi) Schematic diagrams showing the flow of oil in the cooling system as will as ench limb
and winding longitudinal and corss sectional view showing the duct size, cooling pipes
etc. for the transformer heat exchange or drawing to scale shall be furnished.
xvii) Detailed drawing showing wheel loading and ordinates of centre of gravity.
xviii) Crane requirements for assembling and dismantling of transformers.
xix) Dimensional drawing for terminal connectors.
2.5.4 The purchaser shall communicate his approved/comment on the drawings to the
supplier within reasonable period. In case any modification is required according to
the purchasers comments the supplier shall modify the drawing and resubmit six
copies of the modified drawings for purchasers approval within two weeks from the
date of communications of comments on the drawings.
2.5.5 The manufacturing of the equipment shall be strictly in accordance with the approved
drawings and no deviations shall be permitted without written approval of the
purchaser. All manufacturing & fabrication prior to the approval of the drawings shall
be at the suppliers risk.
2.5 INSTRUCTION MANUALS:
The supplier shall furnish 06 (Six) copies of operation, maintenance and erection manual per
unit of transformer to the office of the Chief Engineer (Trans.), JHARKHAND URJA
SANCHARAN NIGAM LIMITED. The manuals shall be bound volumes and shall contain
the following documents / Information.
IN JASIDIH GSS VOL-II
Page 456
i)
Instructions regarding erection, Testing & commissioning, operation- maintenance of
the equipment.
vi) All relevant information and drawings pertaining to the main equipment as well as
auxiliary devices.
vii) Marked erection drawings identifying the component parts of the equipment as
shipped to enable the purchaser to carry out the erection of the equipment with his
own personnel.
viii) Detailed dimensions, assembly and description of all the components.
ix) Apart from the above, each manual shall also contain one set of all the approved
drawings, Type test reports as well as acceptance of test reports and routing test
reports of the corresponding consignment dispatched.
Note:- These manuals shall be invariably furnished to the office of the Chief Engineer
(Trans.) JHARKHAND URJA SANCHARAN NIGAM LIMITED, Ranchi before despatch of
the transformers.
2.7 DESIGN AND CONSTRUCTIONAL DETAILS:
2.7.1 The transformer and the accessories shall be designed to facilitate inspection,
cleaning, and repair and for operation where continuity of supply is primary
consideration. All components shall 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.
2.6.2 All materials used shall be of Prime quality and workmanship which should be of the
class most suitable for working under the conditions specified and shall withstand the
variations of temperature and atmospheric conditions arising under working
conditions without undue distortion or deterioration or the setting up of undue
stresses in any part and also without affecting the strength and suitability of the
various parts for the work which they have to perform.
2.6.3 All outdoor apparatus including bushing insulators with their mountings shall be
designed so as to avoid pockets in which matter may be collected. All connections and
contacts shall be of simple cross sections and surfaces for carrying continuously the
specified current without undue heating and fixed connections shall be secured by
bolts or set of screws of sample size, adequately locked. Lock nuts shall be used on
stud connections carrying current.
2.6.4 The transformers and all its accessories like CTs, if any, etc. shall be designed to with
stand without injury, the thermal and mechanical affects of any external short circuit
to earth and of short circuits at the terminals of winding for a period of 2 sec.
2.6.5 The transformer shall be capable of being loaded upto loads of 150% in accordance
with IS : 6600. There shall be no limitation imposed by bushing Tap changer, etc.
2.6.6 The transformer shall be so designed that it should be capable of being operated
without danger on any tapping to the voltage at that tapping at the rated MVA with
voltage partition of 10% corresponding to the voltage at that tapping.
2.6.7 The transformers shall be designed with particular attention to suppression of
maximum harmonic voltage. Specially, the third and fifth so as to minimize the
interference with communication system.
2.6.8 Transformer shall be capable of operating under the natural cooled condition upto the
specified load. The forced cooling equipment shall come into operation by present
contacts of winding temperature indicator and the transformer shall operate as a
IN JASIDIH GSS VOL-II
Page 457
forced cooled unit, initially as ONAN upto the specified load and then as ONAF. Cooling
shall be so designed that during total failure of power supply to cooling fans, the
transformer shall be capable to operate at full load for at least 10 (ten) minutes
without the calculated winding hottest spot temperature exceeding 140oC. Also
stopping of one or two cooling fans should not have any effect on the cooling system.
2.6.9 Transformer shall be capable of with standing thermal and mechanical stress caused
by symmetrical or asymmetrical faults on any winding.
2.6.10
Transformer shall accept without injurious heating,
combined voltage and frequency fluctuation, which produces the following over
fluxing condition.
i)
130% for 1 minute.
144% for 5 Seconds.
iii) Over fluxing with stand characteristics upto 170% shall be submitted alongwith the bid
by the tenderers.
2.7 TANK :
2.7.1 Tank shall be of welded construction and fabricated from tested quality low carton
steel of adequate thickness.
All seams and those jointing not required to be opened at site, shall be factory welded and
wherever possible they shall be before painting, dye penetration test shall be carried
out on welded parts of jacking because, lifting lugs and all load bearing member. The
requirement of post weld heat treatment for tank/press relieving parts shall be based
on recommendations of BS : 5500 table 4.4.3.1.
2.7.2 Tank transformer shall be projected for general rigidity and these shall be designed to
prevent retention of water.
2.7.3 The transformer shall be of bell type tank construction with the joint at about 500 mm
above the bottom of the tank. In case the joint is welded it shall be provided with
flanges suitable for repeated welding the joint shall be provided with a suitable gasket
to prevent any unwanted materials in the tank. Proper tank welding shall be done to
prevent excessive temperature rise of the joint.
2.7.4 The tanks shall be designed to withstand:
i)
Mechanical shocks during transportation.
Vacuum filling of oil.
Continuous internal pressure of 35 KN/M2 over normal hydrostatic pressure of oil.
Short circuit forces.
2.7.5 Wherever possible the transformer tank and its accessories shall be designed
without pocket wherein gas may be collected. Where pockets can not be avoided,
pipes shall be provided to vent the gas into the main expansion pipes.
2.7.6 Adequate space shall be provided at the bottom of the tank for collection of
sediments.
2.7.7 The base of each tank shall be so designed that it shall be possible to move the
complete unit by skidding in any direction without injury when using plates or rails.
2.7.8 Tank shield shall be such that no magnetic field shall exist outside the tank. They
shall be of magnetically permeable material. If required impermeable shields shall be
provided at the coil ends. Tank shield shall not resonnic when excited at the natural
frequency of the equipment. Bidder may confirm about use of tank shield in the
schedule of additional information.
IN JASIDIH GSS VOL-II
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2.7.9 Suitable guides shall be provided in the tank for positioning the core and coil
assembly.
2.7.10 Each tank shall be provided with.
i)
Lifting lugs suitable for lifting the equipment complete with oil without any
damage or distortion.
A minimum four jacking pads in accessible position at 500mm height to enable the
transformer complete will oil, to be raised or lowered using hydraulic or screw jacks.
Suitable haulage holes shall be provided.
2.7.11 The tank shall be provided with two suitable copper alloy or lugs or any other
suitable materials for the purpose of grounding.
2.7.12 The tank shall be equipped with the following valves with standard screw
connections for external piping:i)
One drain and lower filter valve located on the low voltage side of the transformer
and placed to completely drain the tank. The tenderer may furnish in addition to the
above a large valve with eccentric reducer. If considered necessary by him for
draining the tank. The valve shall be equipped with a small cock.
One filter valve located at the top of the high voltage side. The opening of this valve shall be
baffled to prevent separation of the oil.
One filter valve located on the high voltage side of the transformer above the bottom of the
tank.
One relief valve to operate at a pressure below the test pressure of the tank.
2.8
TANK COVER:
2.8.1 The tank cover shall be sloped to prevent retention of rain water and shall not
distort when lifted.
2.8.2 Al least two adequately sized manhole / inspection openings, one at each end of the
tank shall be provided for any access to the lower ends of the bushings and earth
connections. The inspection covers shall not weight more than 25 kg. The inspection
covers shall be provided with two handles.
2.8.3 The tank covers shall be fitted with pockets at the position of maximum oil
temperature of MCR (Maximum continuous rating) for bulbs of oil and winding
temperature indicators. It shall be possible to remove these bulbs without lowering
the oil in the tank.
2.8.4 Bushings, turrets, covers of inspection openings, thermometer, pockets etc. shall be
designed to prevent ingress of water into or leakage of oil from the tank.
All bolted construction shall be fitted with weather proof hot oil resistant gasket in
between, for complete oil tightness. If gasket is compressible, metallic stops shall be
provided to prevent over-compression.
2.9
AXLES AND WHEELS:
2.9.1 The transformers are to be provided with flanged bi-directional wheels and axles.
These shall be so designed as not to deflect excessively to interfere with the
movement of the transformer. Wheels shall be provided with suitable bearings
which shall be must and corrosion resistant. Fittings for lubrication shall also be
provided.
2.9.2 Suitable locking arrangement alongwith foundation bolts shall be provided for the
wheels to prevent accidental movement of transformer.
IN JASIDIH GSS VOL-II
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2.9.3 The wheels are required to swivel and they shall be arranged as that they can be
turned, through an angle of 90o when the tank is jacked up to clear of rails. Means
shall be provided for locking the swivel movement in position parallel to and at right
angles to the longitudinal axis of the tank.
The rail track gauge shall be 5’ 6” (1676 mm) along longer axis as well as along shorter axis.
2.10 ANTI EARTHQUAKE CLAMPING DEVICE:
The prevent transformer movement during earthquake clamping device shall be provide for
fixing transformer to the foundation. The Bidder shall supply necessary bolts for
embedding in the concrete foundation. The arrangements shall be such that the
transformer can be fixed to or unfastened from these bolts as desired. The fixing of
the transformers to the foundations shall be designed to withstand seismic events to
the extent that a static co efficient of 0.3g, applied in the direction of leanest
resident to the loading will not cause the transformer or clamping devices as well as
bolts to be over stressed.
The details of the device used and its adequacy shall be brought out in the additional
information schedule.
2.11 CONSERVATOR TANK:
a)
The conservator tank shall have adequate capacity between highest and lowest
visible levels to meet the requirement of expansion of the total cold oil volume in
the transformer and cooling equipment from minimum ambient temperature to
100oC. Conservator shall be with volumetric capacity at least 7 ½ % of a total volume
of oil in the main tank of the transformer.
The conservator shall be provided with air bag cell to prohibit the direct contact of oil with
the atmosphere.
The conservator tank shall be bolted into position so that it can be removed for cleaning
purpose.
The conservator shall be fitted with magnetic oil level gauge with low level electrically
instated alarm contact.
Conservator shall be provided in such a position as not to obstruct the connection to the
transformer.
Separate conservator tank/ compartment in the main conservator shall be provided for
OLTC.
BREATHER
Conservator shall be fitted with dehydrating filter breather. It shall be so designed that:
a)
Passage of air is through a dust filter and silicagel.
b)
Silicagel is isolated from atmosphere by an oil seal.
c)
Moisture absorption indicated by a change in colour of the tinted crystals can be
easily observed from a distance.
d)
Breather is mounted not more than 1400 mm above rail top level.
e)
Minimum quantity of silicagel to be 1 kg for every 3500 litres of oil in the tank.
f)
It should be color less.
2.13 PRESSURE RELIEF DEVICE:
Adequate no. of pressure relief devices may be provided at suitable locations which shall be
of sufficient size for rapid release of any pressure that may be generated in the tank
IN JASIDIH GSS VOL-II
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and which may result in damage to the equipment. The device shall operate at static
pressure of less than the hydraulic test pressure of transformer tank. It shall be
mounted direct on the tank. One set of electrically insulated contacts shall be
provided for alarm/tripping, alongwith the recommended settings.
2.14 BUCHHOLZ RELAY:
A double float type Buchholz relay shall be provided. All the gases evolved in the
transformer shall collect in this relay. The relay shall be provided with a test cock
suitable for a flexible pipe connection for checking its operation and taking gas
sample. A copper or stainless steel tube, shall be connected from the gas collector to
a valve located about 1200mm above ground level to facilities sampling, with the
transformer in service. The device shall be provided with two electrically independent
ungrounded contacts, one for alarm on gas accumulation and the other for tripping
on sudden rise of pressure.
TEMPRATURE INDICATOR:
2.15.1 Oil Temperature Indicator (OTI):
All Transformers shall be provided with a 150mm dial type thermometer for top oil
temperature indication. The thermometer shall have adjustable, electrically
independent ungrounded alarm & trip contacts, maximum reading pointer and
resetting device mounted in the cooler control cabinet. A temperature sensing
element suitable located in a pocket on top oil shall be furnished. This shall be
connected to OTI by means of capillary tubes. Accuracy class of OTI shall be +/- 1.5%
or better.
WINDING TEMPERATURE INDICATOR (WTI) :
A device for measuring the hot spot temperature of each of the windings shall be provided
(HV, LV). It shall comprise of following:Temperature sensing element
Image coil
Auxiliary CTs, if required to match the image coil, shall be furnished and mounted in the
cooler cabinet.
150mm dial local indicating instrument with maximum reading pointer mounted in cooler
control cabinet and with two adjustable electrically independent ungrounded
contacts (besides that required for control of cooling equipment), one for high
winding temperature alarm and other for trip.
Calibration device
In addition to the above, the following indication equipment shall be provided for each
winding :
Remote winding temperature indicator. It shall be suitable for flush mounting on RTCC
panel. The difference between local and remote WTI indication at any given time shall
not exceed 1o C. One RWTI shall be provided for each winding in the middle phase
(HV,LV).
Auxiliary supply if required, at owner’s panel for RWTI shall be 110/220 V DC only.
Accuracy class of WTI shall be +/- 1.5 % or better.
IN JASIDIH GSS VOL-II
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Any special cables required for shielding purpose for connection between cooler control
cabinet and remote winding temperature indicator control circuit shall be in
supplier’s scope of work.
Along with the OTI /WTI the transformer shall also be equipped with Fiber Optic
based direct temperature measurement system as per below technical
specifications:System shall be of fiber optic rugged. The probes shall be directly installed in each phase of
Power transformer to measure the winding hotspot and top oil temperature. There
will be total number of at least 8 probes inside the transformer, out of which 1 probe
should be installed in top of the transformer for the measurement of top oil
temperature. 1 Probe for Core temperature. The remaining 6 will be for Winding
temperature measurement.
Temperature range of the system should be -30 degree C to +200 degree C and accuracy of
+ 2 degree C with no recalibration required and should use LED as source of light.
Probe shall be all silica, double PFA Teflon Jacketed, Kevlar cabled fiber with perforated
outer jacketed to allow complete oil filling and white Teflon protective Helix wrap for
improved visibility and mechanical strength.
2.15.3.1
The measuring unit shall be capable to retain temperature data for at least 90
days at 1 minute interval for all channels and shall have facility to download these
data. The system shall have following key features:
a) Fixing arrangement of sensor at suitable location of the winding in such a way that it
will be mechanically protected allowing efficient and secure mounting of sensor tip in
the winding in compliance with the annexure E of IEC 60076-2.
b) The temperature recording of the monitor channels will be obtained in RTCC Panel in
control room through repeater.
c) Alarm output with programmable set points as per user’s choice.
d) IEC 61850 Protocol on RS 485 or RS 232 ports.
e) User friendly software to allow easy configuration to monitor for data logging and
retrieval.
2.15.3.2
Location of optical temperature sensors inside the transformer shall be
finalised during detailed engineering.
WINDING TEMPERATURE INDICATOR (WTI) :
A device for measuring the hot spot temperature of each of the windings shall be provided
(HV, IV, LV). It shall comprise of following :Temperature sensing element
Image coil
Auxiliary CTs, if required to match the image coil, shall be furnished and mounted in the
cooler cabinet.
150mm dial local indicating instrument with maximum reading pointer mounted in cooler
control cabinet and with two adjustable electrically independent ungrounded
contacts (besides that required for control of cooling equipment), one for high
winding temperature alarm and other for trip.
Calibration device
In addition to the above, the following indication equipment shall be provided for each
winding :
Remote winding temperature indicator. It shall be suitable for flush mounting on RTCC
panel. The difference between local and remote WTI indication at any given time shall
IN JASIDIH GSS VOL-II
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not exceed 1o C. One RWTI shall be provided for each winding in the middle phase
(HV,IV,LV).
Auxiliary supply if required, at owner’s panel for RWTI shall be 110/220 V DC only.
Accuracy class of WTI shall be +/- 1.5 % or better.
Any special cables required for shielding purpose for connection between cooler control
cabinet and remote winding temperature indicator control circuit shall be in
supplier’s scope of work.
2.16 EARTHING TERMINALS:
Two (2) earthing pads (each complete with two (2) Nos. taped holes, M 10 bolts, plain and
spring washers) suitable for connection to 100x12mm copper/brass grounding unit
shall be provided each at position close to the two (2) diagonally bottom corners of
tank. Earthing strip upto the ground level shall be provided by the Bidder.
Two earthing terminals suitable for connection to 50x6 mm galvanised steel flat shall also be
provided on cooler, marshalling box and any other equipment mounted separately.
2.17 CORE:
i)
The core shall be constructed from high grade non-ageing cold rolled super
grain
oriented silicon steel laminations having high permeability and low hysteresis
loss.
The bidder should offer the CORE for inspection & approval by the purchaser
during the manufacturing stage. Bidder’s call notice for this purpose should be
accompanied with the following documents, as applicable, as proof towards use of
primary CORE material:
Invoice of supplier
Mill’s test certificate
Packing list
Bill of lading
Bill of entry certificate by customs
CORE material should be directly procured either from the manufacturer or through their
accredited marketing organisation of repute and not through any agent.
The design of the magnetic circuit shall be such as to avoid static discharges, development
of short circuit paths within itself or to the earthed clamping structure and production
of flux component at right angles to the plane of laminations which may cause local
heating.
Conventional core construction/clamping drives a hole through core laminations. This
weakens the core. As such a method of construction/clamping should be adopted so
that hole through core laminating is avoided. Boltless CORE or belting arrangement
will be preferred. The clamping of core by belting should ensure adequate mechanical
strength and the core and winding shall be capable of withstanding the vibration and
shock during transportation, installation, service and also prevent movement of core
and winding relative to tank during the above conditions. However Bidders may
quote as per their own design also.
IN JASIDIH GSS VOL-II
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Core and winding shall be capable of withstanding the shock during transport installation
service and adequate provision shall be made to prevent movement of core and
winding relative to tank during these conditions.
All steel section used for supporting the core shall be thoroughly sand blasted after cutting
drilling and welding.
When bell type tank construction is offered, suitable projecting guides shall be provided on
core-assembly to facilitate removal of tank.
Each core lamination shall be insulated with a material that will not deteriorate due to
pressure and hot oil. The nature of insulation should be specified in the tender.
The supporting frame work of core shall be so designed as to avoid presence of pockets
which would prevent complete emptying of the tank through drain valve or cause
trapping of air during oil filling.
Manufacturer must have in-house availability of Numerically Controlled Automatic Core
Cutting Plant. This must bring following advantages :
Ensure dimensional accuracy with respect to Cross Sectional area of Built Core
Ensure proper monitoring & control on quality
Avoid any possibility of mixing of prime material with defective / second grade material,
which would ultimately affect the quality and life of transformers.
The maximum flux density in any part of the core and yoke at rated MVA, voltage and
frequency at any tap shall not exceed 1.6 tesla.
2.18 WINDINGS :
The windings shall be so designed that all coil assemblies of identical voltage ratings shall be
interchangeable and field repairs to the winding can be made readily without special
equipment. The coil shall be supported between adjacent sections of insulating
spacers, and the barriers, brushings and other insulation used in the assembly of the
windings shall be arranged to ensure a free circulation of the oil and to reduce a hot
spot in the windings.
2.18.2 The insulation of the coils shall be such as to develop the full electrical strength of the
windings, All materials used in the insulation and assembly of the windings shall be
insoluble, non-catalytic, and chemically inactive in the hot transformer oil, and shall
not soften or there wise be adversely officiated under the operating conditions.
2.18.3 All threaded connections shall be provided with locking facilities. All loads from the
winding to the terminal board and bushing shall be rigidly supported in prevent injury
from vibration. Guide tubes shall be used where practicable.
The windings shall be clamped securely in place so that they are not displaced or deformed
during short circuits. The assembled core and windings shall be vacuum dried by
vapor phase drying process only and suitably impregnated before removal from the
treating. The tenderer must confirm the type of drying to be used alongwith the offer.
The copper conductors used in the coil structure shall be best suited to the
requirements and all permanent current carrying points in the windings and the leads
shall be welded or braced.
2.19 INSULATING OIL:
2.19.1 The quality of the oil supplied with transformer shall conform to the oil parameters
specified in this clause. No inhibitors shall be used in the oil. The samples will be
drawn as follows:i)
Prior to filling
IN JASIDIH GSS VOL-II
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ii)
Before and after heat run test.
iii)
Before energisation.
All tests as per IS : 335 shall be conducted on oil samples.
2.19.2 The insulating oil shall be subjected to testing in the oil manufacturer’s works before
supply, in the presence of the representative of the transformer manufacturer.
2.19.3 Sufficient quantity of oil necessary for first filling of all tanks, coolers and radiator at
the proper level alongwith 10% extra oil by weight for topping up shall be supplied in
non-returnable steel containers suitable for outdoor storage.
2.19.4 The tenderer shall furnish following information in his offer to enable the purchaser
to placed order/s for oil at the option of the purchaser.
i)
Required technical parameters of oil.
Quantity required for first filling each rating and voltage class of transformer.
List of manufacturers of oil who are preferred by the tenderer for the transformers offered
by them.
2.19.5 The supplier shall dispatch the transformer of rating 50 MVA and above in an
atmosphere of Nitrogen. The Bidder shall lake care of the weight limitation on
transport and handling facility at site. In the latter case necessary arrangement shall
be ensured by the supplier to take care of pressure drop of nitrogen during transit
and storage till completion of oil filling during erection. A gas pressure testing valve
with necessary pressure gauge and adapter valve shall be provided.
Power transformer below 50 MVA rating shall be supplied with oil.
2.19.6 The Bidder shall warrant that characteristic of oil furnished shall comply with the
requirements specified in IS – 335, 1993 (Fourth Revision) with the Intent
amendment/ revision expiation specified here under and shall be suitable for MVA
grade transformers.
2.20 The oil shall have the following main characteristics or equivalent (the requirement
indicated is determined in accordance with the test method adopted by IS : 335/1972
amended up to date).
Sl. No.
1.
Characteristic
Appearance
Requirement
The oil shall be clear and
transparent and free from
suspended matter or
sediment
Method of test
A representative sample
of the oil shall be in a
100 mm thick layer,
ambient temperature
2.
Density at
27oC Maximum
0.89 gm/cm
IS:1448(P-16)1967
or equivalent authoritative
Standard.
3.
Kinetics
Viscosity
at 27oC max.
27 CST
IS:1448(P-20)1960
or equivalent authoritative
standard.
4.
Inter facial tension
at 27oC min.
0.04N/M
IS : 6104/1971 or equivalent
authoritative standard.
5.
Flash point
140oC
IS : 1448 (P-25) 1960
IN JASIDIH GSS VOL-II
Page 465
Equivalent authoritative
Standard.
6.
Pour Point, Max.
(-) 10oC
IS : 1118 (P-25) 1970
equivalent authoritative
Standard.
7.
Neutralization
value (Total
Acidity ) max.
0.03 mg
KOH/ gm
IS : 335/1972 equivalent
authoritative standard.
8.
Corrosive
Non-corrosive
(in terms of classification
copper strip)
IS : 335-1972 appendix
A or equivalent authoritative
standard.
9.
a)
Electric strength
(Breakdown volt.)
New untreated oil
IS : 6792-1972 or equivalent
authoritative standard.
b)
After treatment
10.
Dielectric dissipation
factor (tan delta at
90oC) mix.
12.
a)
Specific Resistance
Resistively
At 90oC min
35x1012 ohm cm
b)
At 27oC min.
1500x1012 ohm cm min.
12.
Oxidation stability
a)
Neutralization
value after
oxidation.
Max. Total sludge
after oxidation
0.02mg/koh/gm
13.
Presence of
oxidation
inhibitor
The oil shall not contain IS: 335-1972 appendix-D or
anti oxidant additives.
Equivalent authoritative
standard.
14.
Water content
30ppm
b)
Min
40KV (R.M.S.) If the
above value is not
attained the oil shall
be treated.
60 KV (rms)
0.005
IS: 6262-1971 or equivalent
authoritative standard.
IS : 6103-1971 or equivalent
authoritative standard.
IS: 335-1972 appendix-C or
equivalent authoritative
0.05 percent
by weight.
IS:2362-1963 or
equivalent authoritative
IN JASIDIH GSS VOL-II
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standard.
15.
2.21
e)
f)
g)
h)
Oxidation Ageing
test with copper
catalyst for 96 hours
as per
ASTM – D – 1934
a) Resistively
at 27oC Min
b) At 90oC Min
c) Total acidity
(Maxm.)
d) Total sludge
(Maxm )
e) Tan delta at
90oC (Maxm.)
2.5x1012 ohm-cm
0.20x1012 ohm-cm
0.05 mg/koh/gm
0.05
0.20
DIAPHRAGM SEAL TYPE CONSTANT OIL PRESSURE SYSTEM:
In this system contact of the oil with atmosphere shall be prohibited by using a flexible
or nitrite rubber reinforced with nylon cloth air cell.
Diaphragm used shall be suitable for continuous operation in all atmosphere of 100oC
to which transformer oil is likely to rise.
The connection of the air cell to the to of the reservoir shall be by an air proof seal
promotion entrance of air into the cell only.
The Diaphragm of the conservator shall with stand the vacuum during installation and
maintenance. Otherwise provision shall be made to isolate the conservator from main
tank during vacuum by providing vacuum sealing valve in the pipe connecting main
tank with the conservator.
2.22 TAP CHANGING MECHANISM:
2.22.1 On load tap changer.
Each transformer shall be provided with an on load tap changing mechanism. This shall
be designed suitable for remote control operation from switch boards installed in the
control room in addition to lying capable of local as well as local electrical operation.
2.22.2 The on load changers shall include the followings.
f)
An oil immersed tap selector and arcing switch or are suppressing tap selection
provided with reactor or resistor for reduction of make and break arcing
voltage and short circuits.
g)
Motor driven mechanism.
h)
Control and protection devices.
i)
Local tap changer position indicator.
j)
Manual operating device.
2.22.3 The on load tap changer shall be designed so that the contacts do not interrupt ARC
within the main tank of the transformer. The tap selector and arcing switch or ARC
suppressing tap selector switch shall be located in one or more all filled compartments.
The compartment shall be provided with means of releasing the gas produced by the
arcing. It shall be designed so as to prevent the oil in the tap selector compartment,
IN JASIDIH GSS VOL-II
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from mixing with the oil in the transformer tank. Bucholtz relay shall therefore be
provided by indicate the accumulation of gas alarm.
2.22.4 The tap change shall be capable of permitting parallel operation with other transformer
of the same type.
2.22.5 The transformer shall give full load output on all taps. The manual operating device
shall be solicitude on the transformer that it can be operated by a man standing at the
level of the transformer track. It shall be strong and robust in construction.
2.22.6 The control scheme for the tap changer shall be provided for independent control of
the tap changers when the transformers are in independent service. In addition,
provision shall be made to enable parallel control also at time so that the tap changer
will be operated simultaneously when one unit is in parallel with another so that under
normal conditions the tap changer will not become out of step and this will eliminate
circulating current. Additional feature like master/ follower and visual indication during
the operation of motor shall also be incorporated.
2.22.7 Necessary interlock blocking independent control when the units are in parallel shall be
provided.
2.22.8 Under abnormal conditions such may occur if the contactor controlling out load tap
changer sticks, the arrangement must be such as to switch off supply to the motor so
that an out of step condition of limited to one tap difference between the units. Details
of out of step protection provided for the taps should be furnished in the tender.
2.22.9 The contactors and associated gear for the tap change driving motors shall be housed
in local kiosk mounted adjacent to or on the transformer. The motors shall be suitable
for operation with 3 phase, 415 volts 50 cycles external power supply.
2.22.10 The supplier shall include in scope of supply in addition to the equipment above, the
following accessories mounted on a separate panel to be installed on the R.T.C.C. panel
to be supplied with each transformer.
i)
Tap raise and lower push bottom switch.
viii)
Remote tap position indicator or other required devices and indication lamps
etc.
ix)
An indication lamp showing tap changing in progress, audible out of step alarm.
x)
Name plate for each component.
xi)
Remote winding temperature indicator one no.
xii)
Cooler control switch.
xiii)
Hot oil temperature indicator one no.
2.22.11 Complete particular of the tap changing gear including the capacity of the motor shall
be stated in the tender.
2.23 OIL PRESERVING EQUIPMENT:
2.23.1 Oil preserving equipment shall be inert gas system of conservator or expansion tank
type. If the conservator or expansion tank type in provided, oil level in the conservator
or expansion tank shall not be below the level of the bushing flanges.
2.23.2 If conservator or expansion tank type in offered the conservator or expansion tank shall
have two filter valve one at bottom at one end and the other at the top on the
opposite end in addition to the valve specified in accessories for the main tank. The
conservator or expansion tank shall also have shut off valve and sump with a small
drain valve and sampling cock, the latter no gagged as not to interfere with oil lines.
The oil level gauge shall be mounted on the conservator or expansion tank.
IN JASIDIH GSS VOL-II
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2.23.3 If an inert gas pressure system is offered gas cylinder filled with high pressure gas, and
automatic reducing valve, a breathing regulator, and mechanical relief valve shall be
furnished. Sufficient gas for blowing out and displacing the air in the transformer shall
be supplied in addition to the full initial supply of gas required for initial operation. The
system proposed shall be automatic in operation, shall provide for expansion and
contraction of oil through a temperature range of 20oC without discharging gas, and
shall seal the interior from atmosphere within the limits provided in this specification.
The oil level in the transformer and in the auxiliary expansion tanks, If required, shall be
located below the level of the busing flanges.
A bracket for attaching block and tackle shall be provided to assist in removal of the gas
cylinder.
2.23.5 The tenderer my offer other arrangement which in his opinion is considered to be
better than the one mentioned above. The proposal shall be supported with sufficient
explanatory notes, operational data etc.
2.24 TRANSFORMER BUSHINGS:
2.24.1 The bushings shall have high factors of safety against leakage to ground and shall be so
located as to provide adequate electrical clearance between bushings and grounded
parts. Bushings of identical voltage rating shall be interchangeable. The bushing shall
be equipped with suitable terminals of approved type and size and shall be suitable for
bimetallic conductor. The insulation class of the high voltage neutral busing shall be
properly coordinated with the insulation class of the neutral of the high voltage
winding.
2.24.2 All main winding and neutral leads shall be brought out through out door type bushing
which shall be so located that the full flashover strength will be utilized and the
adequate phase clearance shall be realized.
Each bushing shall be so coordinated with the transformer insulation, that all flashover
will occur outside the tank.
2.24.3 All porcelain used in bushing shall be of the wet process, homogeneous and free from
cavities or other flaws. The glazing shall be uniform in colour and free from blisters
burns and other deicely.
The creepage distance of the busing shall be suitable for use in highly polluted
atmosphere.
2.24.4 The bushings for 132 KV shall be of oil filled condenser type preferable hermetically
cooled and shall conform to the latest edition of IS:2090 of IEC publication No. 137 & IS
3347 (per III/Section – I as ended upto date.) The characteristics of the oil used in the
bushings shall be the as that the oil in the transformers.
2.24.5 All bushings shall have puncture strength greater than the dry flash over value.
2.24.6 Main terminals shall be soldier less and shall be suitable for connection to ACSR
conductor. The spacing between the bushing must be adequate to prevent flash over
between phases under all condition of operation.
2.24.7 Special adjustable arcing horn may also be provided for the bushing as per
IS:3716/1966 or IEC publication No. 71 A.
2.24.8 The tenderer shall given the guaranteed with stand voltage for the above and also
furnish calibration curve with different settings of the co-ordination gaps to enable
purchaser to decide the actual gap setting. Tenderer’s recommendations are also
invited in this respect.
IN JASIDIH GSS VOL-II
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2.25 COOLING
2.25.1 Cooling units shall be of radiator types. The radiators for transformers shall be
detachable type and shall be provided with removal valves at the top and bottom so as
to enable the removal of radiators without drawing the oil from the transformer tank.
The radiator bank shall be designed for name pressure and vacuum conditions as
specified for main tank.
2.25.2 Each transformer shall be provided with two cooling banks each of 50% capacity and
each cooling bank shall be provided with its pump having 100% capacity, fans, valves
and other necessary and necessary inter connection as such in case of failure of any of
the two pumps, one pump can be utilized for full 100% capacity and can pump oil to
both the cooling banks.
2.25.3 The cooling system shall be so designed that the transformer shall be capable of
operating under the natural cooled condition upto specified load and winding
temperature. The forced cooling equipment shall come into operation automatically at
the preset value of the winding temperature contacts.
2.25.4 All cooling units shall be se designed and attached to and mounted on the transformer
tank as to be accessible for cleaning and painting to prevent any accumulation of water
on the outer surfaces to completely drain oil and to ensure against formation of gas
pockets when the tank is being filled.
2.25.5 Cooler units shall be connected to the tank by machined steel flanges welded to the
cooling units and the cooling banks/ tank and provided with gaskets. At each cooling
unit connections, an indicative shut off valve shall be provided which can be fastened in
either open or close position. A separate oil tight blank flange shall be provided for
each tank connection for use when the cooler unit is detached. Each cooling unit shall
have a lifting eye, an oil drain at the bottom and a vent at the tap.
2.25.6 Fans or blowers for air blast cooling shall be mounted so as to ensure that no damage
to the coolers occurs due to vibrations of the fans, Wire mesh screens shall be fitted to
prevent accidental contact with the blades, the mesh being not greater then 1 inch or
2.5 dm. Also fans shall be so located that they are readily accessible for inspection and
repair.
2.25.8 In case of ONAN/ONAF cooling system, the transformer shall be capable for giving
continuous output of at least 80% of the rated output with all these artificial cooling
out of service and without exceeding the prescribed temperature rise.
2.26 COOLER CONTROL
2.26.1 Cooler units shall be suitable for operation with a 415 volts, 3 phase, 50 Hz, external
power supply.
2.26.2 The pumps and fan motor controls including all relays, starters, switches and wiring
shall be furnished. Each motor circuit shall have overload and short circuit protection.
2.26.3 Control equipment for fan motors shall be mounted in a marshalling cabinet adjacent
to the transformer and shall include the necessary contractors with automatic control
and annunciation system and provision for manual and remote operation with
indication shall be provided.
2.26.4 A single metal enclosed main isolating suitable with HRC fuses shall be provided for
incoming supply.
IN JASIDIH GSS VOL-II
Page 470
2.26.5 The switching IN or OUT of the cooling arrangement shall be controlled by winding
temperature and there shall be provision for automatic switching IN or OUT at preset
temperature levels which should be capable of adjustment & setting at well.
2.26.6 In case of ONAN/ONAF cooled transformers, provision of automatic change over from
main supply to stand by auxiliary supply should be available in case of failure of main
supply. Necessary alarm etc for this also may be provided.
2.26.8 The pumps shall preferably be provided with flow indication showing the condition and
direction of oil flow.
2.27 CONTROL CABINET:
2.27.1 All controls alarms, indication and relaying device provided with the transformer shall
be wired upto the terminal blocks inside the control cabinet. Not more than two wires
shall be connected to one terminal. 10% spare terminals shall be provided.
2.27.3 All devices and terminal blocks within the control cabinet shall be clearly identified by
symbols corresponding to those used on applicable schematic or wiring diagrams.
2.28
CENTRE OF GRAVITY:
The center of gravity of the transformer shall below and as near the vertical center line
as possible. The transformers shall be stable with or without oil. If the center of gravity
is eccentric relative to track either with or without oil its location shall be shown on the
drawing.
2.29
FREQUENCY:
The transformer shall be suitable for continuous operation with a frequency variation
of five percent from normal of 50Hz without exceeding the specified temperature rise.
2.30
PARALLEL OPERATION:
the similar ratio transformer shall operate satisfactory in parallel with each other if
connected between high voltage and low voltage busters. Also, wherever specified the
transformers shall be suitable for parallel operation with existing transformer, if
required by the purchaser.
2.31
IMPEDANCE:
Suppliers shall indicate the guaranteed impedance and tolerances and also the upper
and lower limits of impedance which can be offered without an increase in the quoted
price. Impedances shall include positive and zero sequence and shall be expressed in
terms of the branches of the star connected equivalent diagrams, all on the same KVA
base and the range shall be given for each branch of the equivalent circuit in turn. The
transformer impedance shall be as specified in section III of this specification.
2.31
NEUTRAL EARTHING ARRANGEMENT:
d)
The neutral terminals of the star connected windings shall be brought to the
ground level by a copper grounding bar which shall be supported from the tank
by procession insulators of highest system voltage of 24 KV.
e)
The end of the copper bar shall be brought to the ground level, at a convenient
point, for connection to purchaser’s ground network through two (2)
IN JASIDIH GSS VOL-II
Page 471
f)
2.33
100x12mm galvanized stool flats. The connection shall be made by using two (2)
bolted neutral grounding terminals with necessary accessories.
Suitable flexible copper strip connection of adequate size shall be provided for
connecting to neutral bushing terminals to avoid terminal load on the bushings.
INSULATION
The dielectric strength of winding insulation and of the bushing shall conform to the
values given in IS: 2026-1982 (as amended upto date (or I.E.C. publication no. 76).
For rated system voltage of 132KV, 33 KV the following impulse test voltages may be
offered.
System voltage
i) 132 KV
ii) 33 KV
Impulse test voltage
550 KV
170 KV
The H.V. winding of the transformers shall have graded insulation. The insulation class
of the neutral end of the winding shall be graded to 95 KV (impulse) and 38 KV (Power
frequency with stand.)
2.34
TEMPERATURE:
The transformer shall be installed outdoor without any protection from sum and rain.
The maximum temperature (specified in section – III of this specification) of hot spot
shall be limited to 105oC with class A insulation. Each transformer shall be capable of
operating continuously at its normal rating without exceeding the temperature rise
limits specified belowTemperature rise oC
Winding (measured by resistance).
45oC for ONAN/ONAF.
50oC for OFAF
Top oil (Measured by thermometer).
35oC
Cores
Not to exceed that permitted for the
adjacent part of the winding.
Note: The reference ambient temperature for the purpose of temperature rise shall be 50oC.
If the ambient temperature is in excess of this value the temperature rise shall be
reduced by an amount equal to the excess ambient temperature.
The transformer shall be free from abnormal noise (other than humming) and
vibration.
2.35
ACCESSORIES
Each transformer shall be provided with the following accessories:
i)
Dial type thermometers for oil
For ONAN/ONAF Transformer.
c)
A dial type thermometer for indicating oil temperature fitted with
maximum pointer adjustable alarm and trip contacts.
d)
The dial type indicating thermometer of robust pattern mounted on the
side of the transformer at convenient height to roads the temperature in
the hottest part of the oil and fitted with alarm and trip contacts and
IN JASIDIH GSS VOL-II
Page 472
xxi)
xxii)
xxiii)
xxiv)
xxv)
xxvi)
xxvii)
xxviii)
xxix)
xxx)
xxxi)
xxxii)
xxxiii)
xxxiv)
contacts for switching in and switching out the cooling system at
predetermined temperatures.
One winding hot spot temperature detector in one winding of each phase as
described below:It shall be indicating type responsive to the combination of top temperature
and winding current, calibrated to follow the hot test spot temperature of the
transformer winding. The winding temperature detector shall operate a remote
alarm and trip at predetermined independent temperature in the event of the
hottest spot temperature approaching dangerous value and in the case of
ONAN/ONAF type transformer shall automatically actuate the fan.
One magnetic type oil level gauge with low level alarm contacts and a dial
showing minimum, maximum and normal oil levels. The gauge shall be readable
from the transformer base level. A low gas pressures electric alarm device shall
also be provided if the transformer is equipped with inert gas pressure
equipment.
One oil filling valve (inlet).
One oil drain valve.
One filter valve located at the top of the tank of the H.V. side.
One filter valve located near bottom of the tank of the H.V. side of the
transformer.
Oil sampling device.
Pressure relief device.
A safety valve of the chimney type with an equalizer pipe interconnecting the
top
of the conservator and uppermost part of the safety valve should be
provided to prevent rise of oil in the safety valve pipe. A stop cock should also
be provided in the inter connecting pipe. A air release cock shall also be fitted in
a convenient position. The safety valve pipe shall preferably take of from the
side of the transformer tank near to the tank cover not from the top of tank
cover. This is with a view to prevent the gases forming in the tank from rising
into the safety valve pipe and thereby passing the bucholtz relay defeating its
purpose and for avoiding the necessity for providing a bottom diaphragm for
the safety valve off from the tank cover.
One double float gas detector relay (Buchholz relay with alarm and tripping
contacts) to detect accumulation of gas and sudden change of oil pressure
complete with two shut off valves and flange couplings to permit, easy removal
without lowering oil level in the main tank, bleed valve for gas venting and a
test valve.
Radiators complete with fans, etc. described in clause.
Air cell bag type conservator along with its supporting bracket to be mounted
on tank or independent structure, as the case may be (in case of independent
structure mounting, the structure shall be within the scope of transformer
supplier).
Eye bolts and lugs on all parts for case of handling.
Two grounding terminals.
Diagram and rating plate.
IN JASIDIH GSS VOL-II
Page 473
xxxv) One set of equipment for control, protection indication and annunciation for
each transformer comprising motor contractors, detecting elements or devices,
indicating apparatus, instruments, relays, enunciators, etc.
xxxvi) Suitable weather proof cubicles for housing the control equipment, terminal
blocks, etc (one for each transformer) one number indoor cubicle (RTCC panel)
detailed as under clause 2.18.2.10 for each transformer for remote control of
cooler fans, on load tap changer, alarm and indicating devices.
xxxvii) One set consisting of 4 nos of lifting cum traversing hydraulic jacks (common to
all the transformer per substation). Price of jacks should be quoted separately.
xxxviii) Ladder for access to top cover. The equipment and accessories furnished with
the transformer shall be suitably mounted on the transformer for case of
operation, inspection and maintenance and the mounting details shall be
subject to the approval of the purchase. All valves shall be provided either with
blind companion flanges or with pipe plugs for protection.
xxxix) Indication, alarm and relay equipment shall have contacts suitable for operation
with 250 volts D.C supply. Any other necessaries or appliances recommended
by the manufacturer for the satisfactory operation of the transformer together
with their prices, shall be given in the tender.
2.36 TERMINALS:
2.36.2 The bushing shall be equipped with terminals suitable for connection with ACSR
“ZEBRA” conductor having ever all diameter 28.62 mm.
2.37 TERMINALS MARKING
2.37.2 Each terminal (including the neutral) shall be distinctly marked on both the primary and
secondary side in accordance with the diagram of connection supplied with the
transformers.
2.38 CONDUIT AND WIRING:
2.38.1 All secondary or control wiring from current transformers, temperature detectors and
alarm contacts. Shall be enclosed in metal conduits and shall be carried to the weather
proof cubicle box mounted on the side of transformers or located closely. Terminal
Board shall be installed in the cubicle to provide for ready connections to the control
cables.
2.39 EVALUATION OF LOSSES:
2.39.1 The measured losses of each transformer shall not exceed the values indicated in the
tender by more than the tolerances admissible as per standards. The fixed losses shall
be as low as is consistent with modern design, technique, reliability and economical use
of material. For the purpose of comparison of bids, the capitalized costs of iron and
copper losses at the rates given in section III of this specification shall be added to the
quoted price of the transformer.
2.39.2 The no load loss in killowatts at rated voltage and rated frequency and the total losses
in kilowatts at rated output, rated voltage and rated frequency shall be guaranteed
under penalty for each transformer. For the purpose of penalty computations, the test
figures of the no load and the total lesses shall be earmarked with the corresponding
guaranteed figures.
IN JASIDIH GSS VOL-II
Page 474
2.39.3 The penalties shall be separately evaluated from (I) the excess of the test figures of the
no load loss in kilowatts over the corresponding guaranteed value, and (II) the excess of
the difference between the test values of the total losses and the no-load loss, in
kilowatts over the difference of the corresponding guaranteed values. No tolerance
shall be permitted over the test figures of the losses.
2.39.4 The penalties shall be calculated for the excess of no. load less and for the excess of the
difference in the total and no load losses at the rates specified in the section III of this
specification. For fraction of the kilowatt, the penalties shall be applied prorata. If the
test figures of losses are less than the guaranteed values, no bonus will be allowed.
2.39.5 The tenderer should note that the values assigned for capitalization of losses are based
on the present worth factor and therefore capitalization of investment shall not be
made separately.
2.40 TOLERANCE:
2.40.1 Since Indian standards allow certain tolerance for the acceptance of the transformer no
load and load losses, the bidders are requested to indicate whether the figures given
for the guaranteed losses in schedule of Guaranteed technical particulars are with or
without such tolerances. If tolerances and are applicable, the limits for the same should
be indicated. In the absence of any information to this effect, the figures for no load
and load losses excluding auxiliary loss shall be increased as provided in Indian
Standard. Any changes in the figures assigned for transformer losses shall not be
permitted after opening of the bids and bid evaluation shall be carried out on the basis
of information made available at the time of bid opening.
2.41 CLEANING AND PAINTING
2.41.1 Before painting of filling with oil or compound, all un-galvanized parts shall be
completely clean and free from rust, scale and grease and all external rough surface in
castings, shall be filled by metal deposition. The interior of all transformer tanks and
other oil filled cambers and internal structural steel work shall be cleaned of all scale
and rust by sand blasting or other approved method. These surfaces shall be painted
with an oil resisting varnish or paint unexposed welds need not be painted.
2.41.2 Except for nuts, bolts and washer which may have to be removed for maintenance
purpose, all external surfaces shall receive a minimum of three coats of paints, the
primary coat shall be applied immediately after cleaning. The second coat shall be of oil
paint of weather resisting nature and of a shade or colour easily distinguishable from
the primary, and the second and the final coats shall be applied after the primary coat
has been touched up where necessary. The final cost shall be of a glossy, oil and
weather resisting non-fading paint.
2.41.4 All interior surface of mechanism chambers and kiosks except these which have
received anticorrosion treatment shall receive three coats of paints applied to the
thoroughly cleaned metal surfaces. The final coat shall be of light coloured anti
condensation mixture, any damage to paint work incurred during. The transport and
erection shall be made good by thoroughly checking the damaged portion and applying
the full number of coat appoints that had been applied before damaged was caused.
2.42
TESTS:
IN JASIDIH GSS VOL-II
Page 475
2.42.1 The supplier shall carry out all type tests and routine test of the transformers as per the
relevant latest IEC standard. Type tests and special tests, if any shall be carried out on
one transformer while routine test shall be conducted on all transformers. All external
components and fittings that are likely to effect the performance of the transformer
during the test shall be in place.
Where it is, required test results shall be corrected to a reference temperature of 75oC.
2.43 TYPE TESTS:
2.43.2 All type tests in accordance with IEC as amended upto date shall be carried out on one
unit of transformer by the successful tenderers. In case the tenderers furnish the Latest
test reports (within 5 years) of those tests carried out on similar transformers, the
purchaser at his discretion may wave off necessity of carrying out these tests.
2.44 ROUTINE TESTS & FACTORY TESTS:
2.44.1 All standard routine tests in accordance with IEC (amended upto date) alongwith
dielectric tests shall be carried out on which transformer.
2.44.2 All double welds shall be tested for leaks with air transformer oil to EHV grade
transformer oil at a pressure not less than normal pressure plus 35 KN/M2 measured at
the base of the tank. The pressure shall be maintained for a period not less than 12
hours for oil and one hour for hour during which no leakage shall occur.
2.44.4 All tanks, single welds, cooling coils, radiator valves and other parts necessary
for complete transformer filled with oil to a pressure corresponding to twice the
normal head of oil or to the normal pressure plus 35 FM per meter square whichever is
lower will be measured at the base of the tank and will be maintained for one hour. If
leak occur, the tests shall be conducted again after all the leaks have been stopped.
2.44.4 The following tests shall be made on the transformer unless otherwise stated in the
schedule of requirement.
i)
Resistance of each winding at all taps.
xv)
Turn ratio for all sets of windings on each tap.
xvi)
Polarity and phase rotation.
xvii) Excitation losses at 90%, 100% and 110% of rated voltage measured by the
average voltage voltmeter method. The excitation losses given the test report
shall be those measured after the implies tests are completed.
xviii) Impedance between each pair of winding.
xix)
‘Zero’ and positive phase sequence impedance on 3 phase transformer.
xx)
Regulation at rated load and at unity, 0.9 and 0.8 lagging power factor.
xxi)
Load losses at rated frequency by applying a primary voltage sufficient to
produce rated current in the windings with the secondary windings short
circuited.
xxii) Separate source voltage withstand test.
xxiii) Temperature rise tests at an equivalent to rated load. The current required for
the auxilliaries shall be stated in the test reports.
xxiv) Induced voltage withstand test.
xxv) Impulse tests on one limb of the transformer.
xxvi) Tan-Delta Test.
xxvii) Dissolved Gas Analysis.
IN JASIDIH GSS VOL-II
Page 476
2.45
TEST AT SITE
After erection at site, the transformer shall be subject to the following tests:i)
Insulation resistance test.
v)
Ratio and polarity test.
vi)
Dielectric test on oil.
vii)
Any other tests specified by the purchaser and manufacturers mutually agreed.
2.46 TESTS ON TRANSFORMER TANK
2.46.1 In addition to the routine tests on welds of the tank, the following tests shall be carried
out on one of the transformer tanks.
i)
VACUM TEST
The transformer tank without oil shall be subject to an internal vacuum of 760
mm of mercury for one hour. The permanent deflection of the flats plates after
the vacuum has been released shall not exceed the values specified below:Horizontal length of flat pleas (in mm)
Permanent deflection (in mm)
Upto & including 750
5.0
751 to 12.50
6.5
1251 to 1750
8.0
1751 to 2000
9.5
2001 to 2200
11.0
2251 to 2500
12.5
2501 to 3000
16.0
above 3000
19.0
ii)
PRESSURE TEST
Transformer tank alongwith its radiators, conservator and other fittings shall be
subjected to a pressure corresponding to twice the normal head of oil in the
transformer or to the normal pressure plus 35 KN/M2 which ever is lower,
measured at the base of the tank and maintained for one hour. The permanent
defection of the flat plates after the excess pressure has been released shall not
exceed the figures specified above for vacuum test.
iii)
An explosion vent with its diaphragm in position shall be subjected to as
increasing oil pressure. This vent shall operate before reaching the pressure
specified in the pressure test as above.
2.47 TESTS ON LOAD TAP CHANGER
2.47.1 The various routine and type tests as specified in the IEC publication 214-1906
amended upto date shall be carried out.
Type test certificates and copies of oscillogramme as called for in IEC publication 214
shall be furnished.
2.47.2 After the tap change is fully assembled on the transformer, the following operation
tests shall be performed without failure at 100% of the rated auxiliary supply voltage.
i)
Eight complete operation cycles with the transformer not energized.
v)
One complete operating cycle with the transformer not energized with 85% of
the rated auxiliary supply voltage (exceptional).
vi)
One complete operating cycle with the transformer energized at rated voltage
and frequency at no load.
IN JASIDIH GSS VOL-II
Page 477
vii)
2.48
Ten tap change operations with steps on either side of the principle tapping
with as far as possible the rated current of the transformer with one winding
short circuited. After the transformer is on the transformer, a power frequency
test shall be applied to the auxiliary circuit for auxiliary circuits insulation test.
FURTHER TESTS/ SPECIAL TESTS:
The purchaser reserves the right having any other reasonable tests carried out their
own expenses either before shipment or at site to ensure that the transformer
complies with the requirements of this specification.
2.49 INSPECTION/ ACCESSORIES TESTS:
2.49.1 The purchaser shall have access at times to the works and all other places of
manufacture where the transformers are being manufactured and the supplier shall
provided all facilities for unrestricted inspection of the supplier works, raw materials,
manufacture of all the accessories and for conducting necessary tests.
2.49.2 The supplier ladder shall keep the purchaser informed in advance of the time of
starting and of the progress of manufacture of equipment in its various stages so that
arrangements could be made for inspection.
2.49.3 No material shall be dispatched from its point of manufacture unless the material had
been satisfactorily inspected, tested, approved, and dispatch clearance given by the
JUSNL.
2.49.4 The acceptance of any quantity of equipment shall in no way relieve the supplier of his
responsibility for meeting all the requirement of this specification and shall not prevent
subsequent rejection of such equipment are later found to be defective.
2.49.5 The supplier shall inform the purchaser at least thirty days in advance, about the
manufacturing program so that arrangement can be made for inspection.
2.49.6 The purchaser reserves the right to insist for witnessing the acceptance/routine testing
of bought out items. The supplier shall communicate in the purchaser the details of
such testing program at least three weeks in advance. The testing shall not be
postponed even if the purchaser is unable to depute his representative for witnessing
the testing.
2.50 TEST REPORTS:
2.50.1 After all the test have been completed the following test reports shall be furnished.
i)
Copies of routine test reports. All records of routine tests reports as well as all
test reports for the test conducted during manufacture shall be maintained by
the supplier. These shall be produced for verification as & when requested by
the purchaser.
v)
Six copies of test reports for the tests carried out on the ancillary apparatus
shall be furnished.
vi)
All auxiliary equipment shall be tested as per the relevant standard. Test
certificates shall be submitted for all brought out items.
vii)
Six copies of acceptance test reports and type test reports duly witnessed by
the JUSNLs inspector shall be furnished to the purchaser. One copy of the test
reports will be returned to the supplier duly approved by the purchaser and
only thereafter the material shall be dispatch.
2.50.2 Each test reports shall indicate the following information’s:-
IN JASIDIH GSS VOL-II
Page 478
d)
Complete identification the date of testing including the serial number of the
transformer.
e)
Method of application, where applied, duration and interpretation of results for
each test.
f)
Temperature rise graded to 75oC including ambient temperature.
Note:- One copy of all test imports shall be provided in the instruction manual to be furnished
as per clause no. 2.05 of this specification.
2.51 PACKING AND FORWARDING:
2.51.1 The equipment to be supplied against this tender shall be packed for shipment in such
a manner as may facilitate easy handling and avoiding any damage during transit.
2.51.2 The equipment shall be packed in crates suitable for vertical/horizontal transport as
the case may be and suitable in withstand handling during transportation and outdoor
storage. The supplier shall be wholly responsible for any damage to the equipment
during transit due to improper and inadequate packing. The easily damageable items
shall be carefully packed and marked with the appropriate caution symbol. Wherever
necessary, proper arrangement for lifting such as lifting books etc. shall be provided.
Any material, found short inside the packing cases, shall be supplied by the supplier
without any extra cost.
2.51.3 Each consignment shall be accompanied by a detailed packing list containing the
following information’s:i)
Name of the consignee.
viii)
Name of consignment.
ix)
Destination.
x)
Total weight of the consignment.
xi)
Sign showing upper/lower side of the crates.
xii)
Handling and packing instructions.
xiii)
Bill of material indicating contents of each package.
2.51.4 The transformer shall be shipped filled with oil/inert gas (whichever may be desired by
the purchaser depending on the size, etc.)
2.51.5 All parts shall be adequately marked to facilitate field erection. Boxes and crates shall
be marked with the contract number and shall have a packing list enclosed showing the
parts contained therein.
2.51.7 In case synthetic resin bonded paper type bushing is offered (S.R.B.P.) the lower parts
not being oil filled, special attention shall be paid in packing so as to avoid moisture.
The details of bushing and method of packing shall be stated in the tender.
2.52 LABELS
2.52.1 Labels shall be provided for all apparatus such as relays, switches, fuse contained in any
cubicles or marshalling kiosk.
2.52.2 Descriptive labels for mounting indoor or inside cubicles and kiosk shall be of material
that will ensure permanency of the lettering. Matter satin finish shall be provided to
avoid dazzle from reflected light. Labels mounted on dark surfaces shall have white
lettering on a black background. Danger notice shall have red lettering on a white
background.
All plates shall be of material which will not be corroded.
2.52.3 Labeling shall be clear, concise and adequate.
IN JASIDIH GSS VOL-II
Page 479
2.52.4 Labels shall be supplied as far as possible in the following four standard sizes:
e)
Labels for fuses and links shall measure approximately 28mm to 45mm by
13mm to 19mm and lettering of 3mm to 6mm. shall be used according to the
amount of inscription required.
f)
Labels for relays, contactors thermal devices and similar apparatus shall
measure 65mm by 20mm and shall have lettering as specified in above.
g)
Labels for controllers and changed ever switches shall measure 70mm and
where practicable have 20mm letter alongwith 1.5 mm stocks.
h)
Labels for the doors of junction boxes, marshalling kiosks and similar equipment
shall measure 125mm by 50mm and have 13mm lettering with 1.5mm wide
stocks.
2.52.6 The labels for mounting outdoors shall be weather and corrosion proof. The letters/
diagrams thereon, shall be formed by etching any other such process which will ensure
permanency of the lettering/marking.
2.53 SUPERVISION OF ERECTION, TESTING AND COMMISSIONING
2.53.2 The tenderer shall arrange for the services of the supervisor for the supervision of
erection, testing and commissioning of the equipment. The tenderer shall quote his
charges for the above services. The general terms and conditions for erection and
supervise services is given in section IV of this specification.
2.54 SPARE PARTS & MAINTENANCE EQUIPMENT:
2.54.1 The tenderer shall quote separately for mandatory spares as specified in the schedule
of requirement section III of this specification. The make and type of such spares
offered shall be same as these offered alongwith the main transformer and inter
changeable with the similar items.
The price offered for supply of these spares shall be taken into consideration for the
purpose of bid evaluation.
2.54.2 The tender shall also indicate his proposal and quote their rates for any other spares
recommended for the trouble free operation of the equipment for five years. The
prices for such optional spares shall be quoted. separately. The price of these optional
spares shall not taken into consideration for the purpose of bid evaluation.
The purchaser shall decide the actual quantities of spare parts to be included in the
order on the basis of this list and the item wise price of spare parts.
2.55 ERECTION AND MAINTENANCE TOOLS
2.55.2 The tenderer shall separately list out in their tender the sets of tools required for initial
erection and subsequent maintenance for the power transformer and the associated
equipments. Item wise unit price for such tools shall be quoted in schedule F, Section V
of this specification. The prices quoted for such tools shall not be taken into
consideration for the purpose of bid evaluation.
2.56 BASIS OF AWARD
2.56.2 The tenderer shall quote for complete equipment required for power transformer as
specified in the schedule of requirements. The purchaser reserves the right to split up
and award the contract on any all the firms without assigning any reasons.
IN JASIDIH GSS VOL-II
Page 480
2.57 GUARANTEED TECHNICAL PARTICULARS:
2.57.1 The tenderer shall furnish all guaranteed technical particulars as called for in annexure
- III of this specification.
Particulars which are subject to guarantee shall be clearly marked. Tender without
information’s in this respect may not be considered.
2.58 GUARANTEE:
2.58.1 The transformer alongwith all fittings and accessories supplied shall carry performance
guarantee for the satisfactory performance of the equipment supplied for a period of
24 months from the date of commissioning of the equipment or 30 months from the
date of receipt of the last consignment at site/stores, whichever is earlier.
2.58.2 If any defects develop during this period in any part of the equipment, the supplier
shall replace or repair the same to the satisfaction of the purchaser expeditiously free
of cost.
2.58.4 The tenderer shall also indicate whether facilities shall be made available by him at site
for repair to transformers, on load Tap changers and the accessories offered by them
after the guarantee period it so desired by the purchaser.
2.59 DEVIATION FROM SPECIFICATION
2.59.1 The tenderers are required to furnish the tenders as per terms and conditions laid
down in the specification. However the deviations, if any from the specification shall be
separately spelt out, in the absence of which it will be presumed that the provisions of
the specification are compiled by the tenderer.
IN JASIDIH GSS VOL-II
Page 481
SECTION-III
SPECIFIC TECHNICAL REQUIREMENTS FOR 50 MVA
132/33 KV POWER TRANSFORMERS
IN JASIDIH GSS VOL-II
Page 482
SPECIFIC TECHNICAL REQUIREMENT FOR 50 MVA 132/33 KV POWER TRANSFORMERS.
3.1
SCOPE
3.1.1 This section of the specification covers the specific technical particulars, climate and
Isoceraunic condition, system particulars suiting which power transformers shall be
offered as per the General Technical Requirements given in the Section II.
3.1.3 The specific Technical Requirements and the schedule of requirements are specified
hereunder:3.2
3.2.1
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
CLIMATE AND ISOCERAUNIC CONDITIONS:
The climate and Isoceraunic conditions at the site are given below:Maximum ambient temperature in shade50oC
Minimum ambient temperature in shade4oC
Maximum daily average ambient temperature35oC
Maximum yearly average ambient temperature30oC
Maximum relative humidity
100%
Average number of thunder storm days per annum.
80
Average rainfall per annum.
125cm.
Maximum wind pressure
150 kg/m2
Height above sea level
Not exceeding
1000m.
Earthquake acceleration.
0.05x2 g.
3.3
TYPE AND RATING
3.3.2 The equipment offered shall be suitable for continuous operation at full rated capacity
under the conditions specified in clause no. 3.2 above, the type and rating of the
transformers proposed for procurement against the tender are specified in Annexure I.
3.4
PARALLEL OPERATION
3.4.1 The transformer proposed for procurement against the tender are also required to
operate in parallel with the existing transformers.
3.5
AUXILIARY POWER SUPPLY
3.5.1 The purchase will make separate arrangements of providing low tension A.C. and D.C.
supply for auxiliary equipment and control use. All the auxiliary electrical
equipment/Accessories shall be suitable for operation on the following supply system:
(i)
For auxiliaries
(a)
240 volts, single phase 50HZ, neutral grounded
A.C. supply.
(b)
415 volts, three phase 50HZ, Netural grounded
A.C. supply.
Tolerance:
Frequency- between 90% and 105% of normal frequency of
50 HZ.
Voltagefrom 110% to 85% of the normal voltage.
(ii)
For control alarm and
250 V available from the station battery.
Protective devices.
The D.C. supply is subject to a variation of 10%
IN JASIDIH GSS VOL-II
Page 483
3.6
EVALUATION OF LOSSES
3.6.1 The no load losses and load losses for the purpose of evaluation of the tenders shall be
capitalized at the following rates:
No load losses
Rs. 162000.00 per KW
Load losses and cooler losses.
Rs. 81000.00 per KW
3.7
NEUTRAL C.T.
3.7.2 The tenderer may quote separately for one Multi-Ratio bushing/turret mounted
current transformer of suitable ratio class PS as per latest IS for providing one common
neutral lead for the purpose of restricted earth fault protection. The GTP will be
approved by JUSNL after award.
3.8
REQUIREMENT AND DESIRED DELIVERY.
3.8.1 The quantity proposed for procurement and the desired delivery detailed in the
schedule of requirement enclosed as Annexure II of this specification.
3.8.2 The quantity mentioned in the schedule is tentative and are subject to increase or
decrease by 15% the time of finalization of tender and placement of order at the
direction of the purchaser.
3.9
EARTH QUAKE & WIND DESIGN LOAD
3.9.1 The equipment offered shall be so designed to withstand repeated earthquake
acceleration of 0.05x2g and wind load 150 kg/M2 in the projected are simultaneous
without damage to component part and without treatment of operation.
IN JASIDIH GSS VOL-II
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ANNEXURE I
TYPE & RATING OF THE TRANSFORMERS
The type, rating and the specific guaranteed technical particulars for 50MVA 132/33 KV Power
Transformers will be as under.
50 MVA
Core type construction
Oil immersed
i)
Type
ii)
No. of Phase
03 (three)
iii)
Service
Out door
iv)
Reference standard
v)
Rated Frequency
50 HZ
vi)
Rated Voltage
a) High voltage winding
b) Low voltage winding
132 KV
33 KV
vii)
Normal Ratio
viii)
Highest voltage system
a) High voltage
b) Low voltage
ix)
Capacity
x)
Type of Cooling
xi)
Connections
a) High Voltage winding
b) Low voltage winding
xii)
Insulation level withstand value.
a) 1.2x50 Micro second impulse
Voltage, KV (Peak).
b) Power frequency withstand
voltage, KV R.M.S.
xiii)
Percentage impedance
xiv)
Tap Changer
a) Type
IS 2026/ IEC – 76 (Latest)
132/33 KV
145 KV
36 KV
40MVA/ 50MVA
ONAN/ONAF 40/50 MVA
Star
Star
550/170
230/70
15% ± IS Tolerence
High speed transition
Resister, ON-LOAD type
IN JASIDIH GSS VOL-II
Page 485
b) Location
c) Number of taps
d) Range of tap
e) Voltage variation that
each tap to provide.
f) Control
xv)
Type of core material
xvi)
Flux density of normal
voltage and frequency.
xvii) Over voltage withstand.
xviii) System of earthing.
a) High voltage.
b) Low voltage.
On high voltage side.
15
(+) 4.288% to (-) 15.575%
In step of 1.429%
variation.
Local (Manual/
electrical)
Remote/Auto
Cold Rolled super
grain oriented
silice steel
iamination.
(As per Cl. No.2.17 of section-II)
1.6 Tesla
130% for 3(three)
minutes.
Effectively earthed
Effectively earthed
xix)
Creepage distance (in mms)
a) Total
b) Protected
xx)
Percentage impendence at extreme taps between H.V. & L.V. at 750C and 50 MVA base.
Lowest tap
–
14.0%
Highest tap
–
15.4%
Normal tap
–
15%
Voltage
Tap Position
Voltage
1
–
138600 Volt
2
–
136700 Volt
3
–
134800 Volt
4
–
132900 Volt
5
–
131100 Volt
6
–
129200 Volt
7
–
127300 Volt
8
–
125400 Volt
9
–
123500 Volt
10
–
121600 Volt
11
–
119700 Volt
xxi)
3625/900
1700/425
IN JASIDIH GSS VOL-II
Page 486
12
13
14
15
–
–
–
–
117900 Volt
116000 Volt
114100 Volt
112200 Volt
OR
Nos. of taps – 17,
Normal tap – 05
Normal tap voltage –132000 V
Note: This transformer may be run in parallel with existing transformer, no. of taps and
normal taps, impedance etc. will be decided at the time of approval of drawings.
IN JASIDIH GSS VOL-II
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ANNEXURE II
BILL OF QUANTITY FOR 50 MVA POWER TRANSFORMERS
Sl. No. Description of equipment
1.
Three phase 50 Hz ONAN/ONAF
50 MVA, 132/ 33 KV
Power transformer with OLTC, RTCC, fitting &
Control equipment etc. with first filling of oil
Plus 10% extra oil.
2.
Spare parts
i) H.V. Bushing
ii) L.V. Bushing
iii) Neutral Bushing
iv) Set of gaskets
v) Buchholz relay
vi) Magnetic oil guage
vii) Buchhols Relay for OLTC
viii) Winding temp. Indicator
ix) Oil temp indicator
x) Silicagel breather
xi) Pressure relief device
xii) Fan.
xiii) Contactor for fan.
xiv) Contactor for tap changer.
xv) Hydraulic jack
(One set comprises of four nos. of Hydraulic jack)
Qnty in Nos.
02 Nos.
01 No.
01 No.
01 No.
01 No.
01 No.
01 No.
01 No.
01 No.
01 No.
01 No.
01 No.
01 No.
01 No.
01 No.
01 Set
IN JASIDIH GSS VOL-II
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23. CIVIL WORK
1.
GENERAL :
The details of scope of civil work related to the completion of construction of
220/132/33KV Grid Sub- Station at JUSNL.. This detailed scope of work will include all those
works which are not specifically mentioned here but are technically or otherwise required
and unavoidable for the commissioning of the Grid Sub Station.
2. SCOPE OF WORK
The Scope of work broadly covers the works as detailed under s and scope of work detailed
under Vol.I. These works include design and engineering to be done by the Contractor for
all new works including Civil works of C/R, offices, all Roads, drains, store sheds, Pump
House, Check Post and all foundation etc including Planning, Survey, Design, Construction
including all cost of lobour, material complete in all respect for commissioning of the Grid
Sub station.
Ordering authority reserves the full right to change or alter any scope of work at any time
without assigning any reason.
All the clearances related to performing all the scope of works shall be obtained by the
tenderer/contractor and the Board shall extend all necessary help in this regard.
3. SITE CONDITIONS
The tenderer/Contractor shall familiarize himself with site conditions, general arrangements
at Grid Sub- Stations and Schemes etc. JUSNL shall assist the Contractor to the extent
possible in obtaining the required information but it shall not be binding on the Board to
provide the same. The tenderers are necessarily required to visit the Sub- Station sites to
acquaint themselves with the topography, infrastructure, design and to collect the required
inputs so as to access the requirement of total work for completion of the specified scope.
The tenderer shall be fully responsible for providing all equipments, materials, systems and
services specified or otherwise which are required to complete the work, construction and
successful commissioning, operation and maintenance of the specified work in all respects.
4. All materials required for Civil Construction, installation and commissioning works,
including the supply of all labour and materials viz
Cement, Steel, aggregate and Bricks etc for the above works, shall be supplied by
the Contractors and shall be of best quality.
5. The complete design and detail engineering shall be done by the Contractor based
on the best prevalent technology and practices. All the works and structure shall be
able to be utilized and meet the requirements.
6. The Contractors shall be responsible for the overall co-ordinations with Boards
officials, internal/external agencies, Project management, training of the Boards
manpower, loading, unloading, handling, storing including Board's supplied
materials (if applicable) for successful construction erection, testing and
commissioning of the Sub- Station/Switchyard.
7. Design of all works at Sub-Station and its associated Civil, Electrical & Mechanical
auxiliaries includes preparation of single line diagrams and electrical layouts,
IN JASIDIH GSS VOL-II
Page 489
8.
erection key diagrams, electrical and physical clearance diagrams, design
calculations for all structures, earth mat (40 KA for 1 sec. for 220 KV and 31.5 KA for
1 sec for 132 KV) will be minimum values to be considered for design purposes),
Direct Stroke lightning System (as and where specified), Bus bars, Spacers, Control
and protection Schematics, wiring and termination schedules cabling works, design
of fire fighting system, complete drainage of the entire Grid area matching to the
topography of the locality including design and drawings of all civil works and
structures, drawings for Sub- Station Structures, indoor and outdoor
lighting/illumination, and all other relevant drawings & documents required for
engineering of all facilities to be provided under this contract, are covered in the
scope of work of the contractor.
QUANTITIES
The requirement of various items/equipments and civil works are indicated in
the . For some equipments/items and Civil works, bill of quantity has been indicated
in the . However, wherever the quantities of items/works are not indicated, the
bidder is required to estimate the quantity of each item of work required for entire
execution and completion of that particular item/works and incorporate the price in
respective s with quantity. However, the tenderer shall furnish supplementary
schedules for all such items/works.
9. The earth mat design shall be based on measurement of Soil resistivity to be taken by
the contractor in the adjoining/near by vacant area since correct soil resistivity value
can not be obtained in the existing switchyard area. Earth mat shall be designed for
area as and where specified.
10. Making provision of new channels/angle frames for installation Of C & R Panels,
PLCC Panels etc. including making good the floor after the work, shall also be
considered included in the scope of work of this contract.
11. Wherever quantity and unit are indicated, the actual quantity erected shall be
considered for payment purpose and wastage shall not be considered.
12. OTHER CIVIL WORKS
12.1 All civil works shall be carried out as per design/drawings standardized by the
JUSNL/approved by the JUSNL. In case any item is not covered under specification then
the same shall be carried out as per CPWD and or PWD specification and schedule of
rate, standards and codes. Any item for which specification is not provided herein and
is not covered under CPWD/PWD specification, shall be executed as per Engineer- incharge guidelines. All materials shall be of the best quality conforming to relevant
Indian Standards and Codes. In case of any conflict between Standards/ Codes and
Technical Specification, the provisions of Technical Specification or approval of the
Engineer in charge shall prevail.
The Contractor shall furnish all labour, tools, equipments, materials, temporary work
shops, constructional plant and machinery, fuel supply, transportation and all other
incidental items not shown or specified but as may be required for complete
performance of the works in accordance with drawings, specifications and direction of
Engineer in charge.
All materials including Cement, reinforcement steel and structural Steel etc. shall be
arranged by the contractor. All testing equipments shall be arranged by the
contractor at his own cost and coneyance.The bidder shall fully apprise himself of
the prevailing conditions at the proposed site.Climatic conditions including Monsoon
IN JASIDIH GSS VOL-II
Page 490
patterns, local conditions including law and order and contingent measures in the
bid, including those, which may not have been specifically brought out in the
specifications.
12.2 CONTROL ROOM BUILDING.DRAWINGS
All construction drawings of double storey control room building will be prepared by
tenderer for approval of concerned JUSNL officials. The building should be
earthquake resitant frame structure having granite floor. The control of and battery
room shall be kept at ground floor. Complete drawing and design conforming to
existing soil conditions should be furnished.
One sample drawing of control room is enclosed for indicating the general
arrangement of control room.
12.3
FIREFIGHTING PUMP HOUSE BUILDING WITH TANK;
As per CBIP mannual
12.4 Tower & equipment foundations with cable trenches.
All construction drawings for towers and equipments foundations shall conform to
JUSNL’s Design.Drawings for any non-standard tower or equipment foundation, if
required, shall be designed by the Contractor and made available to the Board during
detailed Engineering. Foundations for any miscellaneous requirements like electric
poles, the Contractor shall engineer kiosks etc. and the design and drawings shall be
submitted for owner's approval.
CABLE TRENCHES
All the cable trenches have to be constructed with 6" thick minimum R.C.C. wall
having 6" wide 6 mm thick mild steel plate lugs fixed in the walls @ 3 meter c/c to
support the cable trays. The entire length of the trench shall be covered with 6" thick
R.C.C. (M-20) cover having at least 75 mm bearing each side over the trench wall of
6" thickness. The top of trench and cover slab should be flushed to give monolithic
look. M.S. Gratings should be provided over trenches after every 10 covers slabs. In
case of any deviations from the Boards Standard design and drawing, Prior approval
for the same may be taken. In case the site conditions warrant any special type of
foundation for any equipment to be used, the same shall be designed and taken in to
the scope of work during detailed engineering.
12.5 Tower and equipment structures.
The structures shall conform to JUSNL’s approved design and drawings suitable
modification shall be carried out in the drawings of equipment support structures by
the contractor in order to suit fixation of accessories such as marshalling boxes,
MOM boxes, control cabinets, junction box, surge counter etc. in the standard
structure fabrication drawings. The contractor shall submit drawings of fixing of such
accessories for approval.
12.6 Roads and rail Road.
All construction drawings for road as well as rail cum road shall be furnished by the
tenderer for the Board's approval. An indicative drawing for road is enclosed.
12.7.1 Anitweed treatment in the entire area of Grid Sub Station with stone spreading is to
be provided in the Switchyard area.
12.8.1 Scope for miscellaneous works.
IN JASIDIH GSS VOL-II
Page 491
This clause covers the execution of the work for site preparation, such as clearing
of the site, the supply and compaction of fill material, excavation and
compaction of backfill for foundation, road construction, drainage, trenches and
final toping by approved quality of stone aggregates (broken hard stone).
12.8.2. Levelling dressing of the entire G/S/S/ area office and store zones, disposal of
unwarranted wastages, garbage etc. alongwith cleaning of bushes and jungles
including finishing painting of all civil and electrical installations to give a fresh
look with hygienic conditions of all the areas of G/S/S/ all as per direction and
satisfaction of Engineer-in-Charge.
12.8.3 Providing and building the ground profile of entire area of G/S/S/ including switch
yard, control room office, stores and remaining area of switchyard in such a way
that no water logging takes place in any case. The ground profile should be
shaped in a way to give a good look of land escaping having sufficient grass over
stapes flower beds with ornamental plants in gabions all as per directions and
satisfaction of engineer-in-charge.
12.8.4 GENERAL
1.
Material unsuitable for construction shall be removed and
replaced by suitable fill material after obtaining approval of the owner.
2.
Backfill material around foundation or other works shall be suitable for the
purpose for which it is used and compacted to the density described
under
compaction. Excavated material not suitable or not required for backfill shall be
disposed off in area's as directed by owner up to a maximum lead of 2 km.
12.8.5 EXCAVATION AND BACKFILL
(A) Excavation and backfill for foundations shall be in accordance with the
relevant code.
(B) Whenever water table is met during the excavation, it shall be dewatered
and water table shall be maintained below the bottom of the excavation level
during excavation, concreting and backfilling.
(C) When embankments are to be constructed on slopes of 15% or greater,
benches or steps with horizontal and vertical faces shall be cut in the original
slope prior to placement of embankment material. Vertical faces shall
measure not more than 1 m in height.
(D)Embankments adjacent to abutments, culverts, retaining walls and similar
structures shall be constructed by compacting the material in successive uniform
horizontal layers not exceeding 15 cm in thickness (of loose material before
compaction). Each layer shall be compacted as required by means of mechanical
tampers approved by the owner. Rocks larger than 10 cm in any direction shall
not be placed in embankment adjacent to structures.
(E) Earth embankments of roadways and site areas adjacent to building shall be
placed in successive uniform horizontal layers not exceeding 20 cm in thickness
in loose stage measurement and compacted to the full width specified. The
upper surface of the embankment shall be shaped so as to provide complete
drainage of surface water at times.
12.8.6 COMPACTION
a) The density to which fill materials shall be compacted shall be as per
relevant IS code and as per direction of owner. All compacted sand filling
shall be confined as far as practicable. Backfilled earth shall be compacted
IN JASIDIH GSS VOL-II
Page 492
to minimum 05% of the Standard Proctor's density at OMC. Cohesion less
materials sub grade shall be compacted to 70% relative density
(minimum).
b) At all times unfinished construction shall have adequate drainage. Upon
completion of the road's surface course, adjacent shoulders shall be given
a final shaping, true alignment and grade.
c) Each layer of earth embankment when compacted shall be as close to
optimum moisture content as practicable. Embankment material which
does not contain sufficient moisture to obtain proper compaction shall be
wetted. If the materials contain any excess moisture, then it shall be
allowed to dry before rolling. The rolling shall begin at the edges
overlapping half the width of the roller each time and progress to the
center of the road or towards the building as applicable. Rolling will also
be required on rock fills. No compaction shall be carried out in rainy
weather.
12.8.7. REQUIREMENT FOR FILL MATERIAL UNDER FOUNDATION.
The thickness of fill material under the foundation shall be such that the
maximum pressure from the footing, transferred through the fill material and
distributed on to the original undisturbed soil will not exceed the allowable
soil bearing pressure of the original undisturbed soil. For expansive soils the
fills materials and other protections etc. to be used under the foundation is
to be got approved by the owner.
12.9
ANTIWEED TREATMENT & STONE SPREADING
12.10 SCOPE OF WORK
The Contractor shall furnish all labour, equipment and materials required for
complete performance of the work in accordance with the drawings,
specification and direction of the owner. Stone spreading 6"above 4" cement
concrete layer shall be done in the areas of the switchyard under present
scope of work. However, the stone spreading along with cement concrete
layer in future areas within fenced area shall also be provided.
12.10.1
GENERAL REQUIREMENT
The material required for site surfacing/stone filling shall be free from all
types of organic materials and shall be of standard quality, and as approved
by the owner.
12.10.2 The material to be used for stone filling/site shall be uncrushed/crushed/broken
stone of 40 mm nominal size (ungraded single size) conforming to Table 2 of
IS:383 courses are given below:
(a) Sieve Analysis limits (Gradation)
(IS:383 - Table - 2)
Sieve Size
% passing by weight
63 mm
100
40 mm
85 – 100
20 mm
0 – 20
10 mm
0-5
"One Test" shall be conducted for every 500 cu.m.
IN JASIDIH GSS VOL-II
Page 493
(b) Hardness
Abrasion, value CDS: 2386-IV- not more than 40% impact value (IS:2386 PartIV) not more than 30% and frequency shall be one test per 500 cu.m. with a
minimum of one test per source.
(c) Flakiness Indx
One test shall be conducted per 500 cu.m. of aggregate as per IS:2386 Part – I
and maximum value is 25%.
12.10.3 After all the structures/equipments are erected, antiweed treatment shall be
applied in the switchyard where ever stone spreading along with cement
concrete is to be done and the area shall be thoroughly de-weeded including
removal of roots. The recommendation of local agriculture or horticulture
department may be sought where ever feasible while choosing the type of
chemical to be used. The antiweed chemical shall be procured from reputed
manufacturers. The doses and application of chemical shall be strictly done as
per manufacturer's recommendation. Nevertheless the effectiveness of the
chemical shall be demonstrated by the contractor in a test area of 10M X
10M(appx.) and shall be sprinkled with water at least once in the afternoon
everyday after forty-eight hours of application of chemical. The Engineer –in
– charge shall monitor the treated area over a period of two to three weeks
for any growth of weeds. Engineer in charge shall give the final approval
based on results.
12.10.01 The formation level of entire switchyard area shall be HFL+300 mm. Lean
concreting and stone spreading shall be done on the FGL above indicated. The
plinth of control room shall be 600 mm above the FGL.
12.10.2
12. 10.3
12.10.4
12.10.5
After antiweed treatment is complete, the surface for the switchyard area
shall be maintained, rolled/completed to the lines and grades as decided by
Engineer-In-Charge. The sub grade shall be consolidated by using half ton
roller with suitable water sprinkling arrangement to form a smooth and
compact surface. The roller shall run over the sub grade till the soil is evenly
and densely consolidated and behaves an elastic mass.
In areas that are considered by the Engineer-In-Charge to be too congested
with foundation and structures for proper rolling of the site surfacing
material by normal rolling equipments, the material shall be compacted by
hand, if necessary. Due care shall be execised so as not to damage any
foundation structures or equipment during rolling compaction.
The sub grade shall be in moist condition at the time while Cement concrete
is placed. If necessary, it should be staturated with water for not less than 6
hours but not exceeding 20 hours before placing of cement concrete. If it
becomes dry prior to the actual placing of cement concrete, it shall be
sprinkled with water and it shall be ensured that no pools of water or soft
patches are formed on the surface.
Over the prepares sub grade, 100 mm thick base layer of cement concrete in
1:5:10 (1 Cement : 5 fine / coarse sand : 10 burnt brick aggregate) shall be
provided in the area excluding roads, drains, cable trenches as per detailed
engineering drawing. For easy drainage of water, the slope of 1:100 is to tbe
proved from the ridge to the nearest drain. The ridge shall be suitably located
IN JASIDIH GSS VOL-II
Page 494
at the center of the area between the nearest drains. The above slope shall
be provided at the top of base layer of cement concrete in 1: 5: 10. A layer of
cement slurry of mix 1 : 6 (1 cement : 6 fine sand) shall be laid uniformly over
cement concrete layer. The cement consumption for cement slurry shall be
less than 150 Kgs. Per 100 sq.m.
12.10.6 A final layer of 150 mm thickness of uncrushed/crushed/broken stone of 40
mm nominal size (ungraded size) shall be spread uniformly over cement
concrete layer after curing is complete.
12.10.7 The drain should be designed to cater the need of switchyard area and the
slony area as well. Routing and termination of drains should be done
accordingly.
13.
PROJECT MANAGEMENT
The contractor shall be responsible for the overall management implementations of
all labour laws and their benifits and supervision of the works. The contractor shall establish
a suitable project office and facilities at site/Ranchi for performing the Project Management
function. The contractor shall provide experienced and knowledgeable personnel in this
office for the purposes of work. The said personnel shall be skilled and competent in all
phases of management of the project, the engineering and the construction and design
engineering for sub-station, and superstructures, electrical auxiliary systems,
communication systems and all other skills necessary for the proper completion of the
works. The contractor shall demonstrate to the purchaser, as may be required by purchaser
the contractor's staff assigned to the works, comply with the above staffers qualifications.
The contractor shall nominate a coordinator (projects manager) for this project who will be
responsible for the complete job. Correspondence for all technical/commercial matters will
be addressed to him. The above said staff, under the general direction of a project manger,
shall be authorized by the contractor.
a. To act with full authority on behalf of the contractor in respect of the
works.
b. To receive and respond to notices, instruction and direction from the
purchaser to the contractor.
c.
To manage control and facilitate the execution of the works in accordance
with the key dates set forth in the specification and contract.
d. To facilitate the provision and exchange of information data and other
communications between purchaser and the contractor.
e.
To provide as may be required by the Engineer, explanations of the
detailed design of the various parts and stagesof the works and keep the
Engineer informed of upto-date progress of the Engineering and other work
being performed by the contractor.
f.
To provide any documentation or information required by purchaser and
to cooperate with purchaser in accordance with the provision of the
specification to complete the proper execution of the Equipments and Substation. The contractor will be called upon to attend design coordination
meeting with the purchaser, other contractor and the consultants of the
purchaser during the period of the contract. The contractor shall attend such
meeting at his own cost at Ranchi or at mutually agreed venue as and when
IN JASIDIH GSS VOL-II
Page 495
14.
15.
required and fully cooperate with such person and agencies involved during
these discussion
ENGINEERING AND DETAILED DESIGN
a) The contractor shall be responsible for the engineering and detailed design of
the various works assigned to him for the grid sub-station. The detailed design
includes, but not limited to the following main items in accordance with
requirement of the specifications.
b) Design and specification of all structures, system and sub system related of
sub-stn works.
c)
Design of sub-station structures equipments and materials including all
electrical and civil engineering and construction and installation as per
specifications.
d) This shall include development of all necessary drawings for the complete work
and all drawings and design are to be submitted for approval before start of
the work.
CIVIL WORKS
The complete work is to be done which includes complete design and soil
investigation. The soil details of the foundation and the structural design of the civil
construction will be furnished by the contractor. The details shall include the
following technical details alongwith other details:
SOIL INVESTIGATION
1.Bore Hole Chart.
2.Soil Characteristic and type of soil.
3.Depth of foundation from firm ground level.
4.Bearing capacity of the soil below 1.5 M Depth and every additional 1
M
depth up to at least 5 M depth.
5.Structural design of the every components of the construction involved
in the work.
6.
7.
8.
DOUBLE STOREYED CONTROL ROOM
Foundation details shall be provided by the contractor. It should be designed on
under reamed pile foundation or as per recommendations in the report on sub-soil
investigation. The structure should be earthquake proof and frame structure.
The structural design of the superstructure of control room shall be furnished by the
contractor after obtaining the approval of floors plans drawing.
GA & DETAILS OF BOUNDARY WALL AND EXPANDED METAL FENCING.
The boundary/ retention wall shall be on under reamed pile foundations or as per
recommendation in the soil investigation report.
The entire area of Grid Sub-Station shall be provided with brick boundary wall. The
tenderer is required to construct and raise this wall at least to achieve a height of 8'
above the formation level over which 3' "Y" shaped' barbed wire fencing having
rows of barbed wire over it covering the entire area of Grid Sub Station. The top of
the boundary wall has to be capped with 4" thick R.C.C. band all along. In addition
IN JASIDIH GSS VOL-II
Page 496
to this a matching entrance gate with all required pillars, arches of projections with
iron gates as per approved design and drawing has to be provided.
9.
Depth of under reamed pile should not be less than 3.5 Meter or as per
recommendations in the soil investigation report.
10.
Length of one panel of boundary wall between two joints shall be furnished
with design calculation in conformity with soil investigation report.
11
The over hang to be provided beyond the pile adjoining the joints must be
clearly mentioned and should conform to design parameters and soil
investigation reports.
12.
There should be minimum air gap of 4" between GL and bottom of capping
beam.
13.
No cranking should be done in main reinforcement of capping beam.
14.
Length of panel between two expansion joints should be preferably between 35'-0"
to 40'-'0
15.
The formation level shall be indicated in the drawing. The formation level should be
HFL +300mm.
16.
The height of boundary wall( brick work) should be 8 feet above the formation level.
17.
Concrete used inR.C.C. should be M 20
18.
Reinforcement in the capping beam on both sides of expansion joint beyond piles
should be properly designed for cantilever portion.
19.
Minimum one-inch expansion joint should be given in running capping beam. Brick
work should be done on capping beam leaving the one inch gap in this brick
work.
20.
Brick work should be done with first class brick work in C.M (1.6) with sone sand of
F.M. 1.8 to 2.00
21.
ENTRANCE GATE COMPLEX
The gate has to be constructed 20' wide with all accessories and provision of an
accommodation to accommodate at least 6 watch guards has to be constructed
with all amenities of water, cooking, lavatory bath etc alongwith 6 beds, 6
mattresses and 6 pillows at the gate complex having its elevation and color
matching to the control room building. This complex should be provided
with a watch tower over it to enable the guard to have full view of the
grid
while on duty having protection from sun and rain.
22. Expanded metal fencing shall cover the entire switchyard & control room
where as the brick wall boundary will cover the entire land acquired for the
Grid sub Station.
23. All civil works shall be done as per PWD specifications of Jharkhand,
CPWD/CBIP recommendations, modern practices and IS specifications which
ever is agreed upon by B.S.E.B.
24. Design of foundation work for equipments shall be done considering all
technical parameters, recommendations of CBIP and manufacturer of
equipments and practices followed in B.S.E.B. as well as atmospheric
conditions detailed in the specifications.
25. Joint in the capping beam should be provided. Piles should be taken
minimum to 3.5 Meters depth or as recommended from the firm ground
level. Before taking up any construction, the site should be properly leveled.
After getting the site leveled the practical formation level is to be fixed at
IN JASIDIH GSS VOL-II
Page 497
least 300 mm above HFL so that no water logging takes place in the SubStation area.
26. Bricks laid in soling for casting of capping bream should be removed after
brick work above capping beam up to a minimum height of 8 feet has been
done to have 4” air gap between capping beam and ground level to avoid
failure of capping beam and brick work above due to upheaval pressure from
earth below.
27. Proper reinforcement on top in cantilever portion of expansion joint should
be laid.
28. No cranking of reinforcement to be done in main reinforcement of capping
beam.
29. The depth of pile should be measured minimum 11'6" from the firm ground
level and not the filled up ground level.
30. Drawings should be sent for approval after drawing to the scale.
FOR CONSTRUCTION OF CONTROL ROOM
1. The casting of piles should be done with the help of casing.
2. Depth of piles should be taken up from firm ground level.
3. The tie beam should be laid on existing ground level as per
drawing details.
4.The working drawings of tie beams showing longitudinal cross
section with schedule of bar-should be submitted
5.The working drawings of roof slabs, roof beams, floor slab and
floor beams with longitudinal section and schedule of bar should
be submitted.
6.Working drawing of foundation details of stair case should be submitted
7. Details of stair beam & stair slab with schedule of bar should
submitted.
8. Working drawing with specification of doors, window, brick work,
ventilators position, cable trench, oil tank in D.G. set room, shaft, w/c
& bath, septic tank, chamber, fixing of D.G. Set, pipe trench, cable
pits, aluminum shutters, grill, collapsable shutters should be
submitted.
9. Working drawing with specification of mono rail, ring for lifting
arrangement of panels should be submitted.
10. The plinth of control room should be made 600mm high from
formation level. (Minimum)
11. Working drawing of flooring showing specification of brick soling,
concrete, Granite stone, acid proof floor for battery room should be
submitted.
12. All floors of control room except battery room, cable room, D.G. set
room should be of granite stone.
13. Plinth of control room should be filled up with local sand.
14. Provision of anti-termite treatment should be made.
15. Plinth protection, around "the Control Room building with proper
drainage should be provided.
IN JASIDIH GSS VOL-II
Page 498
16.
The main hall of control room should be painted with oil bound
distemper/plastic paint.
17.
Remaining rooms, except, battery room, D.G. set room cable room
should be painted with dry distemper/oil bound distemper.
18.
Outer portion of control room should be painted with weather proof
paint of approved standard make.
19.
Front elevation, back elevation, side elevation of Control Room should
be submitted.
20.
Proper roof treatment should be done with water proof zel over and
above the R.C.C. roof to avoid any water leakage in due course.
21. SITE AND GENERAL SERVICES
Soil investigation work in the proposed work site & clearing etc. Site leveling,
Antiweed treatment and gravel filling. Cable trenches and road crossing for
cable trenches, in the sub-station area are included in the scope of work.
22.
DRAINS, FOUNDATION, ROADS & STRUCTURES OF SUB STATION.
All drains, foundation and roads and structures for the equipment system,
being supplied by the contractor required for the complete sub-station shall
be under the contractor's scope of work.
All roads of the G/S/S have to be constructed by the tenderer for which
relavent drawings and specifications should be submitted for approval by the
Board. Construction of road should be planned and executed in such a
each and every structure and equipment are attended easily in
way
that
due course.
IN JASIDIH GSS VOL-II
Page 499
24.
Fire protection system
IN JASIDIH GSS VOL-II
Page 500
TECHNICAL SPECIFICATION FOR FIRE PROTECTION SYSTEM
1.00.00 INTENT OF SPECIFICATION
This section covers the design and performance requirements of the following types
of fire protection systems;
a.
Hydrant System
b.
High Velocity Water (H.V.W) Spray System
c.
Fire Detection System
d.
Portable Fire Extinguishers
e.
Wheel/ Trolley mounted Fire Extinguishers
1.00.01
It is not the intent to completely specify all details of design and construction.
Nevertheless, the system design and equipment shall conform in all respects to high
standard of engineering, design and workmanship and shall be capable of performing
in continuous commercial operation in a manner acceptable to the Owner. The system
design shall also conform to TAC/ NFPA norms.
1.00.02
The scope of work include complete earthwork (i.e. excavation, backfilling
etc.) for the entire buried piping for the system, valve pits and pipe supports for
buried, entrenched and overground piping.
1.00.03
The equipment offered shall comply with the relevant Indian Standards. The
equipment conforming to any other approved international standards shall meet the
requirement called for in the latest revision of relevant Indian Standard or shall be
superior.
1.00.04
Ambient temperature for design of all equipment shall be considered as 50° C.
1.00.05
The piping and instruments diagram for Hydrant and HVW spray system for
400kV substations is enclosed at Appendix-III and for hydrant system for 220kV and
132kV substations is enclosed at Appendix-IV. The successful bidder shall prepare
detailed layout and piping drawing based on this drawing and also other drawing such
as road, drainage, cable trench, switch yard layout, etc. as furnished by the Employer
during detailed engineering.
1.00.06
Various equipment under the fire protection system should be supplied from
the suppliers approved by JUSNL.
2.00.00 DESIGN AND CONSTRUCTION
2.01.00 Hydrant System
Hydrant system of fire protection essentially consists of a large network of
pipe, both underground and over ground which feeds pressurised water to a number of
hydrant valves, indoor as well as outdoor. These hydrant valves are located at
strategic locations near buildings, Transformers and Reactors. Hose pipes of suitable
length and fitted with standard accessories like branch pipes, nozzles etc., are kept in
Hose boxes. In case of emergency, these hoses are coupled to the respective hydrant
valves through instantaneous couplings and jet of water is directed on the equipment
on fire. Hydrant protection shall be provided for the following in the substation.
a)
Control room building
b)
D.G. set building
c)
L.T. Transformer area.
d)
Fire Fighting pump House.
e)
Stores
f)
Transformers
g)
Shunt Reactors/ Bus Reactors.
2.01.01
A warning plate shall be placed near the hydrant points for the transformers
and reactors and the pump in 220kV substations to clearly indicate that water shall be
IN JASIDIH GSS VOL-II
Page 501
sprayed only after ensuring that the power to the transformer/reactor which is on fire
is switched off and there are no live parts within 20metres of distance from the
personnel using the hydrant.
2.02.00. HIGH VELOCITY WATER (H.V.W) SPRAY SYSTEM
H.V.W. spray type fire protection essentially consists of a network of
projectors and an array of heat detectors around the Transformer/Reactor to be
protected. On operation of one or more of heat detectors, Water under pressure is
directed to the projector network through a Deluge valve from the pipe network laid
for this system. This shall be provided for transformers and reactors in 400kV
substations. Wet detection initiation system shall be employed for automatic
operation. The system shall be designed in such a way that the same can be extended
to protect additional Transformer/ Reactor to be installed in future. However, for the
purpose of design it shall be assumed that only one Transformer/Reactor will be on
fire. The system shall be designed to have a pressure of 5.5kg/cm2 at 350m3/hr. at the
farthest transformer/ reactor location as identified in the tender drawings.
2.02.01
The Electrical clearance between the Emulsifier system pipe work and live
parts of the protected equipment shall not be less than the values given below :
1.
420 kV bushing 3500 mm
2.
245 kV bushing 2150 mm
3.
145 kV bushing 1300 mm
4.
52 kV bushing 630 mm
5.
36 kV bushing 320 mm
2.02.02
Minimum water pressure available at the farthest and/or highest projector
(H.V.W spray system) on the equipment protected shall be 3.5 kg/cm2(g). However,
water pressure available at any projector shall not exceed 5.00kg/cm2(g). Water shall
be applied at a rate of 10.2 LPM/M2 of the surface area of the entire transformer /
Reactor including radiator, conservator, etc. (including bottom surface for
transformer)
2.02.03 Deluge Valve
Deluge Valve shall be water pressure operated manual reset type. The Deluge
valve shall be closed water tight when water pressure in the heat detector pipe work is
healthy and the entire pipe work shall be charged with water under pressure upto the
inlet of the Deluge valve. On fall of water pressure due to opening of one or more heat
detectors, the valve shall open and water shall rush to the spray water network
through the open Deluge valve. The valves shall be manually reset to initial position
after completion of operation. Each Deluge Valve shall be provided with a water
motor gong which shall sound an alarm when water after passing through the Deluge
valve, is tapped through the water motor. Each Deluge valve shall be provided with a
local panel from which will enable manual electrical operation of the valve. In
addition to this, each valve shall be provided with local operation latch. Test valves
shall simulate the operation of Deluge valves and shall be of quick opening type. The
general construction shall conform to requirements under clause no.7.00.00 for
piping, valves and specialities.
2.02.04 High Velocity Spray Nozzles (Projectors)
High velocity spray system shall be designed and installed to discharge water
in the form of a conical spray consisting of droplets of water travelling at high
velocity, which shall strike the burning surface with sufficient impact to ensure the
formation of an emulsion. At the same time the spray shall efficiently cut off oxygen
supply and provide sufficient cooling.
IN JASIDIH GSS VOL-II
Page 502
2.02.05
Minimum set point of the heat detectors used in the HVW spray system shall
be 79oC. The optimum rating shall, however, be selected by the Bidder, keeping in mind the
maximum and minimum temperature attained at site.
2.03.00
Fire Detection System
This system shall be provided for 400kV substations.
2.03.01
Suitable fire detection system using smoke detectors and/or heat detectors
shall be provided for the entire control room building, including corridor and toilets.
Fire detectors shall be located at strategic locations in various rooms of the building.
The operation of any of the fire detectors/ manual call point should result in the
following;
1.
A visual signal exhibited in the annunciation panels indicating the area where
the fire is detected.
2.
An audible alarm sounded in the panel, and
3.
An external audible alarm sounded in the building, location of which shall be
decided during detailed engineering.
4.
If the zone comprises of more than one room, a visual signal shall be exhibited
on the outer wall of each room.
5.
A signal shall be given to air conditioning system for its shut down.
2.03.02
Each zone shall be provided with two zone cards in the panel so that system
will remain healthy even if one of the cards becomes defective.
2.03.03
Fire detectors shall be provided on ceiling as well as on false ceiling in
conference room, on false ceiling in control room and relay room and on ceiling in all
other areas. Coverage area of each smoke detector shall not be more than 80 m2 and
that of heat detectors shall not be more than 40 m2. Ionisation type smoke detectors
shall be provided in all areas except AHU Room where heat detectors shall be
provided. If a detector is concealed, a remote visual indication of its operation shall be
provided. Manual call points (Break glass Alarm Stations) shall be provided at
strategic locations in the control room building. All cabling shall be done through
concealed conduits.
2.04.00
Portable and Wheel/ Trolley mounted Fire Extinguishers
2.04.01
Portable Fire Extinguishers
Adequate number of portable fire extinguishers of pressurised water, dry chemical
powder, and Carbon dioxide type shall be provided in suitable locations in control
room building and DG set & FF building. These extinguishers will be used during the
early phases of fire to prevent its spread and costly damage. The design, construction
& testing of pressurised water type, dry chemical powder type and Carbon dioxide
type portable fire extinguishers shall meet the requirements as per clause 10.00.00.
2.04.02
Wheel/ Trolley mounted Fire Extinguishers Wheel/ Trolley mounted fire
extinguishers shall be provided for the protection of transformers in 200kV and
132kV substations. Dry chemical powder (DCP) type and Carbon dioxide (CO2) type
of 22.5kg capacity shall be provided. Each 220kV or 132kV transformer shall be
provided with 2 nos. of DCP type and 2 nos. of CO2 type extinguishers. The design,
construction & testing of Dry chemical powder (DCP) type and Carbon dioxide (CO2)
type of 22.5kg capacity shall meet the requirements of relevant IS codes and clause
10.00.00 of this specification. 2.05.00 Water Supply System
2.05.01
For 400kV substations.
Water for hydrant & HVW system shall be supplied by one electrical motor
driven pump with another pump, driven by diesel engine, shall be used as standby.
Two nos. water storage tanks of total capacity 420 cu.m. shall be provided. Pumps
shall work under positive suction head. Annunciations of the hydrant & HVW spray
IN JASIDIH GSS VOL-II
Page 503
systems shall be provided in fire water pump house and repeated in 400 kV control
room. The outdoor piping for the system in general shall be laid above ground on
concrete pedestals with proper clamping. However, at road/rail crossings, in
front/access of buildings, places where movement of cranes/vehicles is expected and
at any other place where above ground piping is not advisable, the pipes shall be laid
underground as per Cl.no.7.04.05. Such locations shall be finalised during detailed
engineering. The whole system will be kept pressurised by providing combination of
air vessel and jockey pumps. The capacity of air vessel shall not be less than 3m3.
Minor leakage will be met by Jockey pump. One additional jockey pump shall be
provided as standby. The pumps and air vessel with all auxiliary equipment will be
located in firewater pump house. Operation of all the pumps shall be automatic and
pumps shall be brought into operation at preset pressure. Fire pumps shall only be
stopped manually. Manual start/stop provision shall be provided in local control
panel.
2.05.02
For 220kV and 132kV substations.
Water for hydrant system shall be supplied by one Diesel engine driven pump of 96
m3/hr. capacity at 56MWC discharge pressure. A R.C.C. tank of 100 m3 size shall be
provided for water storage. The tank shall be provided with all accessories such as
drain, overflow and filling connection with float valve etc. The hydrants shall be
provided for all buildings, store yard and each transformer/ reactor. The pump shall
work on positive suction and the operation will be manual. The pump shall be located
in the DG set room
2.05.03
The design and construction of horizontal centrifugal pumps alongwith drives
and accessories shall be in line with the requirements of Tariff Advisory Committee
of India.
2.05.04
The technical specification of the diesel engine driven fire pump and electric
motor driven fire pumps shall meet requirements as set in Data Sheet. The general
design of the fire fighting pump sets shall meet the requirements under clauses
no.5.00.00 for Horizontal centrifugal pumps and 12.00.00 for Electrical motors.
2.05.05
Each pump shall be provided with a nameplate indicating suction lift/delivery
head, capacity and number of revolutions per minute.
2.05.06
Design, construction, erection, testing and trial operation of piping, valves,
strainers, hydrant valves, hoses, nozzles, branch pipes, hose boxes, expansion joints
etc. shall conform to the requirements of clause no.7.00.00.
2.06.00 Instrumentation and Control System
2.06.01
All instruments like pressure indicators, differential pressure indicators,
pressure switches, level indicators, level switches, temperature indicators, alarms and
all other instruments and panels as indicated in the specification and drawings and
those needed for safe and efficient operation of the whole system shall be furnished
according to the requirements of clause 11.00.00.
2.06.02 Control Panel
Power feeder for motors will be from switchgear board located in control
building but control supply for all local control panels, annunciation panels, battery
charger units, space heaters etc. shall be fed from the AC and DC distribution boards
located in pump house. These AC & DC distribution boards will be fed from the
switchgears and DCDBs located in control building.
a)
Panel for motor driven fire water Pump
The panel shall be provided with :
1.
TPN switch 1 No.
IN JASIDIH GSS VOL-II
Page 504
2.
Auto/manual switch 1 No.
3.
Start/Stop Push buttons 1 Set with indication lamp
4.
DOL starter with 1 Set thermal O/L relay
5.
Indicating lamp showing 1 Set power ON
6.
Indication lamp with drive 1 Set ON/OF
7.
Indication lamp showing 1 No. Motor Trip
Main power cable from breaker feeder of main switchboard shall be terminated in this
panel and another cable shall emanate from this panel which shall be terminated at
motor terminals.
b)
Panel for Two nos. Jockey Pump 1No.
The panel shall be provided with the following :
1.
Fuse-switch unit for Jockey pumps 1 Set for each pump
2.
Auto/manual switch for 1 No. each Jockey Pumps
3.
Selector switch for 1 No. selecting either jockey pump
4.
D.O.L. starter with overload 1 No. each relay self-resetting type, for all the
drives.
5.
Start/stop push button for 1 Set for each Jockey Pump with indication jockey
pump lamp with pad-locking arrangements in stop position
6.
Indication lamp for trip 1 No. each for indication all the drives.
c)
Panel for 2 Nos. battery charger 1 No. & Diesel Engine driven fire water pump
The panel shall be provided with the following :
1.
Auto/Manual switch for Diesel Engine driven pump 1 No.
2.
Start/Stop push buttons 1 Set with indication lamp
3.
Indicating lamp showing 1 Set drive ON/OFF
4.
D.C. Voltmeter/Ammeter in the battery charger circuit
5.
Battery charger will be as per specification described
6.
Selector switch for selecting either of battery chargers for the battery sets.
7.
Selector switch for selecting either set of batteries for Diesel engine starting.
8.
Selector switch for boost charging/Trickle charging of battery set.
d)
Individual local control panel is to be considered for each transformer/ Reactor
deluge system wherever these equipment are envisaged. This panel shall contain push buttons
with indicating lamps for spray ON/OFF operation in the valve operation circuit. Push
buttons shall be concealed behind glass covers, which shall be broken to operate the buttons.
Provision shall be made in the panel for the field signal for the annunciations such as spray
ON and fire in the Transformer/Reactor. A signal for spray ON shall also be provided in the
control room fire alarm panel for employer’s event logger.
2.06.03 Annunciation Panels
a) Location : Fire Water Pump House
i) Indicating lamps showing power supply "ON" and status indication lamps for each motor.
ii) Annunciation windows complete with buttons. Details are as follows :
_____________________________________________________
Sl.No. Description Number
_____________________________________________________
1. Electric motor driven fire water pump running 1
2. Electric motor driven fire water pump fails 1 to start
3. Diesel engine driven fire water pump running. 1
4. Diesel engine driven water pump fails 1 to start
5. Jockey pump-1 running 1
6. Jockey pump-1 fails to start 1
7. Jockey pump-2 running 1
IN JASIDIH GSS VOL-II
Page 505
8. Jockey pump-2 fails to start 1
9. Fire in Transformer/ Reactor 1 for each equipment
10. Deluge system operating for 1 for each Transformer/Reactor equipment
11. Fire fighting System in operation/ 1 Header pressure low
12. Fire in smoke detection system zone 1
13. Water storage tank water level 2 low
14. High speed diesel tank level low 1
15. Spare 10
----------------------------------------------------------------------------------------b) Location 400 kV Control Room
i) Indication lamp showing power supply 'ON'
ii) Provision shall be made in the panel for a signal for spray
ON for each Transformer/Reactor for owner's use for event
logger.
iii) Following annunciations shall be provided.
----------------------------------------------------------------------------------------Sl.No. Description Number
----------------------------------------------------------------------------------------1. Fire in Transformer/ Reactor 1 for each equipment
2. Diesel engine driven fire water 1 pump in operation
3. Motor driven fire water pump in operation 1
4. Fire fighting Water storage tank level Low 2
5. Fire/Fault 1+1(duplicate) For each zone as applicable
6. Spares 10
----------------------------------------------------------------------------------------c) Each annunciation panel shall be provided with a hooter.
d) Indication for fault in respective areas shall also be provided. Each annunciation window
shall exhibit 'FIRE’ and 'FAULT' conditions separately.
2.06.04 The control and interlock system for the fire protection system shall meet the
following requirements:
1. Electric Motor Driven Fire water Pump
Pump should start automatically under any of the following conditions:
a) HVW spray or Hydrant system header pressure low.
b) Operation of any deluge valve Pump should be stopped manually only. Pump should also
be started manually if required from local control panel.
2. Diesel Engine Driven Standby Pump
The pump should automatically start under any of the following conditions:
a) Header pressure low.
b) Electric motor operated fire water pump fails to start. - Pump should be stopped manually
only.
- Pump should also be started manually if required from the local control panel.
- The battery set which is connected for starting of Diesel engine shall not be subjected to
boost charge.
3. Jockey Pump
Jockey pump shall start automatically when water pressure in header falls below the set
value. Jockey pump shall stop automatically when the pressure is restored to its normal value.
Manual starting/stopping shall be possible from the local control panel.
3.00.00 SHOP AND SITE TESTS
3.01.00 Shop Tests
IN JASIDIH GSS VOL-II
Page 506
3.01.01 Shop tests of all major equipment centrifugal pumps, diesel engines, electrical drive
motors, piping, valves and specialties, pressure and storage vessels, MCC, electrical panels,
controls, instrumentation etc. shall be conducted as specified in various clauses and as per
applicable standards/codes.
3.01.02 Shop tests shall include all tests to be carried out at Contractor's works, works of his
sub-contractor and at works where raw materials supplied for manufacture of equipment are
fabricated. The tests to be carried out shall include but not be limited to the tests described as
follows :
a) Materials analysis and testing.
b) Hydrostatic pressure test of all pressure parts, piping, etc.
c) Dimensional and visual check.
d) Balancing test of rotating components.
e) Determination of performance characteristics of pumps, compressors, diesel engines,
electrical drive motors, etc.
f) Response characteristics of heat/smoke detectors.
g) Performance characteristics of HVW spray nozzles (projectors).
h) Temperature rating test on Heat detectors.
i) Flow rate and operational test on Flow control valves.
j) Operational test of alarm valve (water-motor gang).
k) Calibration tests on instruments and tests on control panel.
l) Destruction/burst tests on 2% or minimum one (1) no. of hoses and portable type fire
extinguishers for each type as applicable. Any fraction number shall be counted as next
higher integer.
m) Performance test on fire extinguishers as required in the code.
3.01.03 In the absence of any Code/Standard, equipment shall be tested as per mutually
agreed procedure between the supplier and the Employer.
3.01.04 A comprehensive visual and functional check for panels would be conducted and will
include a thorough check up of panel dimensions, material of construction, panel finish,
compliance with tubing and wiring specifications, quality of workmanship, proper tagging &
locations of instruments/accessories. The wiring check shall be complete point to point ring
out and check for agreement with installation drawings and equipment vendor prints of the
complete system and an inspection of all field connection terminals and leveling.
3.01.05 All test certificates and reports shall be submitted to the Employer for approval.
3.01.06 The Employer's representative shall be given full access to all tests. The
manufacturer shall inform the Employer allowing adequate time so that, if the Employer so
desires, his representatives can witness the test.
3.02.00 Site Tests
3.02.01 General
a) All piping and valves, after installation will be tested hydraulically at pressure of 1.5 times
that of the maximum attainable pressure in the system to check against leak tightness.
b) All manually operated valves/gates shall be operated throughout 100% of the travel and
these should function without any trouble whatsoever, to the satisfaction of the Employer.
c) All pumps shall be run with the specified fluid from shut off condition to valve wide open
condition. Head developed will be checked from the discharge pressure gauge reading.
During the test, the pumps and drives shall run smoothly without any undue vibration,
leakage through gland, temperature rise in the bearing parts, noise, flow pulsation etc.
d) All pressure vessels should be tested hydraulically at the specified test pressure, singly or
in the system.
IN JASIDIH GSS VOL-II
Page 507
e) Painting shall be checked by dry type thickness gauges.
f) Visual check on all structural components, welding, painting etc. and if doubt arises, these
will be tested again.
g) All test instruments and equipment shall be furnished by the Contractor to the satisfaction
of the Employer.
h) Automatic starting of all the fire pumps by operating the test valves.
i) Automatic operation of the Jockey pump
j) Operation of the automatic flow control valve by operating the test valve and remote
operating of the solenoid valve.
k) Operation of entire annunciation system.
3.02.02 After erection at site, the complete HVW spray protection and hydrant system shall
be subject to tests to show satisfactory performance for which detailed procedure shall be
submitted for Employer's approval. It shall be in line with standard Performance Guarantee.
3.02.03 All the detectors installed shall be tested for actuation by bringing a suitable source
of heat/smoke near the detector and creating a stream of hot air/ smoke over the detector. The
exact procedure of this test shall be detailed out by the Employer to the successful Bidder.
4.00.00 SPARE PARTS
The Contractor shall indicate in his scope of supply all the mandatory spares in the relevant
schedules. The list of mandatory spares is indicated in ‘Section - Projects’.
5.00.00 HORIZONTAL CENTRIFUGAL PUMPS
This clause covers the design, performance, manufacturing, construction features and testing
of horizontal centrifugal pumps used for the purpose of fire fighting.
5.01.00 The materials of the various components shall conform to the applicable IS/ BS/
ASTM/ DIN Standards.
5.01.01 In case of any contradiction with the aforesaid standards and the stipulations as per
the technical specification as specified hereinafter, the stipulations of the technical
specification shall prevail. In case of contradiction between this specification and "horizontal
centrifugal pump data specification sheets" enclosed, stipulations of the data specification
sheets will prevail.
5.02.00 General Performance Requirements
5.02.01 The pump set shall be suitable for continuous operation at any point within the
"Range of operation".
5.02.02 Pumps shall have a continuously rising head capacity characteristics from the
specified duty point towards shut off point, the maximum being at shut off.
5.02.03 Pumps shall be capable of furnishing not less than 150% of rated capacity at a head
of not less than 65% of the rated head. The shut off head shall not exceed 120% of rated
head. Range of operation shall be 20% of rated flow to 150% of rated flow.
5.02.04 The pump-motor set shall be designed in such a way that there is no damage due to
the reverse flow through the pump which may occur due to any maloperation of the system.
5.02.05 Drive Rating
The drive rating shall not be less than the maximum power requirement at any point within
the "Range of Operation" specified where the supply frequency is 51.5 Hz (and the motor is
running at 103% of its rated speed). During starting under reverse flow condition, the motor
shall be capable of bringing the pump to rated speed at normal direction with 90% rated
voltage
at motor terminals.
5.02.07 Pump set along with its drive shall run smooth without undue noise and vibration.
Acceptable peak to peak vibration limits shall generally be guided by Hydraulic Institute
Standards.
IN JASIDIH GSS VOL-II
Page 508
5.02.08 The Contractor under this specification shall assume full responsibility in the
operation of the pump and drive as one unit.
5.03.00 Design & Construction
5.03.01 Pump casing may be axially or radially split. The casing shall be designed to
withstand the maximum pressure developed by the pump at the pumping temperature.
5.03.02 Pump casing shall be provided with adequate number of vent and priming
connections with valves, unless the pump is made self-venting & priming. Casing drain, as
required, shall be provided complete with drain valves.
5.03.03 Under certain conditions, the pump casing nozzles will be subjected to reactions from
external piping. Pump design must ensure that the nozzles are capable of withstanding
external reactions not less than those specified in API-610.
5.03.04 Pump shall preferably be of such construction that it is possible to service the
internals of the pump without disturbing suction and discharge piping connections.
5.03.05 Impeller
The impeller shall be secured to the shaft and shall be retained against circumferential
movement by keying, pinning or lock rings. On pumps with overhung shaft impellers shall be
secured to the shaft by an additional locknut or cap screw. All screwed fasteners shall tighten
in the direction of normal rotation.
5.03.06 Wearing Rings
Replaceable type wearing rings shall be furnished to prevent damage to impeller and casing.
Suitable method of locking the wearing ring shall be used.
5.03.07 Shaft
Shaft size selected shall take into consideration the critical speed, which shall be at least 20%
away from the operating speed. The critical speed shall also be atleast 10% away from
runaway speed.
5.03.08 Shaft Sleeves
Renewable type fine finished shaft sleeves shall be provided at the stuffing boxes/mechanical
seals. Length of the shaft sleeves must extend beyond the outer faces of gland packing or seal
and plate so as to distinguish between the leakage between shaft & shaft sleeve and that past
the seals/gland.
5.03.09 Shaft sleeves shall be securely fastened to the shaft to prevent any leakage or
loosening. Shaft and shaft sleeve assembly should ensure concentric rotation.
5.03.10 Bearings
Bearings and hydraulic devices (if provided for balancing axial thrust) of adequate design
shall be furnished for taking the entire pump load arising from all probable conditions of
continuous operation throughout its "Range of Operation" and also at the shut-off condition.
The bearing shall be designed on the basis of 20,000 working hours minimum for the load
corresponding to the duty point. Bearings shall be easily accessible without disturbing the
pump assembly.
A drain plug shall be provided at the bottom of each bearing housing.
5.03.11 Stuffing Boxes
Stuffing box design shall permit replacement of packing without removing any part other
than the gland. Stuffing boxes shall be sealed/cooled by the fluid being pumped and
necessary piping, fittings, valves, instruments, etc. shall form an integral part of the pump
assembly.
5.03.12 Shaft Couplings
All shafts shall be connected with adequately sized flexible couplings of suitable design.
Necessary guards shall be provided for the couplings.
5.03.13 Base Plates & Sole Plate
IN JASIDIH GSS VOL-II
Page 509
A common base plate mounting both for the pump and drive shall be furnished. The base
plate shall be of rigid construction, suitably ribbed and reinforced. Base plate and pump
supports shall be so constructed and the pumping unit so mounted as to minimise
misalignment caused by mechanical forces such as normal piping strain, hydraulic piping
thrust etc. Suitable drain taps and drip lip shall be provided.
5.03.14 Balancing
All rotating components shall be statically and dynamically balanced at shop.
5.03.15 All the components of pumps of identical parameters supplied under this
specification shall be interchangeable.
5.03.16 Prime Mover
The design and construction of the electric drive motor shall be as specified in clause
12.00.00.
5.04.00 Tests and Inspection
5.04.01 The manufacturer shall conduct all tests required to ensure that the equipment
furnished conform to the requirements of this specification and are in compliance with the
requirements of applicable Codes and Standards. The particulars of the proposed tests and the
procedures for the tests shall be submitted to the Employer/Engineer for approval before
conducting the tests.
5.04.02 Where stage inspection is to be witnessed by Employer, in addition to above, the
Bidder shall submit to the Employer/Engineer at the beginning of the contract, the detailed
PERT-Chart showing the manufacturing programme and indicating the period where
Employer or his authorized inspecting agency are required at the shop.
5.04.03 Material of Construction
All materials used for pump construction shall be of tested quality. Materials shall be tested
as per the relevant standards and test certificates shall be made available to the
Employer/Engineer.
5.04.04 Where stage inspection is to be witnessed by Employer, all material test certificates
shall be correlated and verified with the actual material used for construction before starting
fabrication, by Employer's Inspector who shall stamp the material. In case mill test
certificates for the material are not available, the Contractor shall carry out physical and
chemical tests at his own cost from a testing agency approved by the Employer, as per the
requirements of specified material standard. The samples for physical and chemical tests shall
be drawn up in presence of Employer's inspector who shall also witness the tests.
5.04.05 Shaft shall be subjected to 100% ultrasonic test and machined portion of the impeller
shall be subject to 100% DP test. On finished shaft DP test will also be carried out.
5.04.06 Hydraulic test at shop
All pressure parts shall be subjected to hydraulic testing at a pressure of 150% of maximum
pressure generated by the pump at rated speed or 200% of total dynamic head whichever is
higher, for a period not less than one (1) hour.
5.04.07 Performance test at shop
Pumps shall be subjected to routine tests to determine the performance of the pumps. These
tests shall be conducted in presence of Employer/Engineer's representative as per the
requirements of the Hydraulic Institute Standards/ASME Power Test Code PTC 8.2/BS599/I.S.S., latest edition. Routine tests shall be done on all the pumps.
5.04.08 Performance tests shall be conducted to cover the entire range of operation of the
pumps. These shall be carried out to span 150% of rated capacity upto pump shut-off
condition. A minimum of five combinations of head and capacity are to be achieved during
testing to establish the performance curves, including the design capacity point and the two
extremities of the Range of operation specified.
5.04.09 Tests shall preferably be conducted alongwith the actual drives being supplied.
IN JASIDIH GSS VOL-II
Page 510
5.04.10 The Bidders shall submit in his proposal the facilities available at his works to
conduct performance testing. If because of limitations of available facilities, a reduced speed
test or model test has to be resorted to establish pump performance, the same has to be
highlighted in the offer.
5.04.11 In case of model testing, the stipulations of latest edition of Hydraulic Institute
Standards shall be binding. Prototype or model tests, however, shall be conducted with the
suction condition identical to the field conditions i.e. sigma values of prototype and model is
to be kept same.
5.04.12 Prior to conducting model testing, calculations establishing model parameters, sizes
and test procedure will be submitted to Employer/Engineer for approval.
5.04.13 All rotating components of the pumps shall be subjected to static and dynamic
balancing tests.
5.04.14 After installation, pumps offered may be subjected to testing at field also by
Employer. If the performances at field are not found to meet the requirement, then the
equipment shall be rectified by the Contractor without any extra cost. Prior to performance
testing, the procedure for such tests will be mutually agreed between Employer and
Contractor. The Contractor shall furnish all necessary instruments, accessories and personnel
for site testing. Prior to testing, the calibration curves of all instruments and permissible
tolerance limit of instruments shall be mutually agreed upon.
5.04.15 If desired by the Employer, the Contractor shall conduct necessary model test for
establishing optimum sump dimensions/flow correcting devices in existing sump, to suit the
pump offered.
5.04.16 The Employer or his authorised representative shall have full access to all tests. Prior
to performance tests, the Contractor shall intimate the Employer allowing adequate time so
that if the Employer so desires, his representative can witness the test.
5.04.17 Report and test certificates of the above tests shall be submitted to the
Employer/Engineer for approval.
6.00.00 DIESEL ENGINES
This Clause covers the design, performance, manufacturing construction features and testing
of compression ignition diesel engines, used primarily for driving centrifugal pumps, used for
the purpose of fire fighting.
6.01.00 Design and Construction
General
6.01.01 The diesel engine shall be of multicylinder type four-stroke cycle with mechanical
(airless) injection, cold starting type.
6.01.02 The continuous engine brake horse power rating (after accounting for all auxiliary
power consumption) at the site conditions shall be atleast 20% greater than the requirement at
the duty point of pump at rated RPM and in no case, less than the maximum power
requirement at any condition of operation of pump.
6.01.03 Reference conditions for rated output of engine shall be as per IS:10000, part II or
ISO:3046, part I.
6.01.04 The engine shall be designed with regard to ease of maintenance, repair, cleaning and
inspection.
6.01.05 All parts subjected to substantial temperature changes shall be designed and
supported to permit free expansion and contraction without resulting in leakage, harmful
distortion or misalignment.
6.01.06 Starting
IN JASIDIH GSS VOL-II
Page 511
The engine shall be capable of both automatic and manual start. The normal mode of starting
is automatic but in the event of failure of automatic
start or at the discretion of the operator, the engine can be started manually from the LCP.
Since the fire pumping unit driven by the diesel engine is not required to run continuously for
long periods and the operation will not be frequent, special features shall be built into the
engine to allow it to start within a very short period against full load even if it has remained
idle for a considerable period.
6.01.07 If provision for manual start (cranking) is provided, all controls/ mechanisms, which
have to be operated during the starting process, shall be within easy reach of the operator.
6.01.08 Automatic cranking shall be effected by a D.C. motor having high starting torque to
overcome full engine compression. Starting power will be supplied from either of the two (2)
sets of storage batters. The automatic starting arrangement shall include a 'Repeat Start'
feature. The battery capacity shall be adequate for 10 (ten) consecutive starts without
recharging with a cold engine under full compression.
6.01.09 The batteries shall be used exclusively for starting the diesel engine and be kept fully
charged all the time in position. Arrangement for both trickle and booster charge shall be
provided.
Diesel engine shall be provided with two (2) battery charger units of aircooled design. The
charger unit shall be capable of charging one (1) set of battery at a time. Provision shall,
however, be made so that any one of the charger units can be utilised for charging either of
the two (2) batteries.
6.01.10 For detail design of battery and battery charger, sub- section Electrical may be
referred to.
6.01.11 Governing System :
The engine shall be fitted with a speed control device, which will control the speed under all
conditions of load.
6.01.12 The governor shall offer following features :
a) Engine should be provided with an adjustable governor capable of regulating engine speed
within 5% of its rated speed under any condition of load between shut-off and maximum load
conditions of the pumps. The governor shall be set to maintain rated pump speed at maximum
pump load.
b) Engine shall be provided with an over speed shut- down device. It shall be arranged to
shut-down the engine at a speed approximately 20% above rated engine speed and for manual
reset, such that the automatic engine controller will continue to show an over speed signal
until the device is manually reset to normal operating position (Vol.II, NFPA, 1978).
6.01.13 The governor shall be suitable for operation without external power supply.
6.01.14 Fuel System
The diesel engine will run on High Speed Diesel.
6.01.15 The engine shall be provided with fuel oil tank having adequate capacity to hold
sufficient fuel oil for a minimum of six (6) hours of full load run. The fuel oil tank shall
preferably be mounted near the engine. No fuel oil tank will be provided by the Employer.
6.01.16 The fuel oil tank shall be of welded steel constructed to relevant standards for mild
steel drums. The outlet of the tank shall be above the inlet of fuel injection pump of the diesel
engine to ensure adequate pressure at suction of injection pump.
6.01.17 The fuel oil tank shall be designed in such a way that the sludge and sediment settles
down to the tank bottom and is not carried to the injection pump. A small sump shall be
provided and fitted with drain plug to take out sludge/sediment and to drain oil. Adequate
hand holes (greater than 80 mm size) shall be provided to facilitate maintenance.
6.01.18 Pipeline carrying fuel oil shall be gradually sloped from the tank to the injection
pump. Any valve in the fuel feed pipe between the fuel tank and the engine shall be placed
IN JASIDIH GSS VOL-II
Page 512
adjacent to the tank and it shall be locked in the open position. A filter shall be incorporated
in this pipeline, in addition to other filters in the fuel oil system. Pipe joints shall not be
soldered and plastic tubing shall not be used. Reinforced flexible pipes may also be used.
6.01.19 The complete fuel oil system shall be designed to avoid any air pocket in any part of
the pipe work, fuel pump, sprayers/injectors, filter system etc. No air relief cock is permitted.
However, where air relief is essential, plugs may be used.
6.01.20 A manual fuel pump shall be provided for priming and releasing of air from the fuel
pipelines.
6.01.21 Lubricating Oil System
Automatic pressure lubrication shall be provided by a pump driven by the crank shaft, taking
suction from a sump and delivering pressurised oil through cooler and fine mesh filters to a
main supply header fitted in the bed plate casing. High pressure oil shall be supplied to the
main and big end bearings, cam-shaft bearings, cam-shaft chain and gear drives, governor,
auxiliary drive gears etc. Valve gear shall be lubricated at reduced pressure through a
reducing valve and the cams by an oil bath.
6.01.22 Cooling Water System
Direct cooling or heat exchanger type cooling system shall be employed for the diesel engine.
Water shall be tapped from the fire pump discharge. This water shall be led through duplex
strainer, pressure breakdown orifice and then after passing through the engine, the water at
the outlet shall be taken directly to the sump through an elevated funnel.
6.02.00 Testing & Inspection
6.02.01 The manufacturer shall conduct all tests required, to ensure that the equipment
furnished conforms to the requirement of this sub-section and in compliance with
requirements of applicable codes. The particulars of the proposed tests and the procedure for
the tests shall be submitted to the Employer for approval before conducting the tests.
6.02.02 At manufacturer's works, tests shall be carried out during and after completion of
manufacture of different component/parts and the assembly as applicable. Following tests
shall be conducted.
6.02.03 Material analysis and testing.
6.02.04 Hydrostatic pressure testing of all pressure parts.
6.02.05 Static and dynamic balance tests of rotating parts at applicable over-speed and
determination of vibration level.
6.02.06 MPI/DPT on machined parts of piston and cylinder.
6.02.07 Ultrasonic testing of crankshaft and connecting rod after heat treatment.
6.02.08 Dimensional check of close tolerance components like piston, cylinder bore etc.
6.02.09 Calibration tests of all fuel pumps, injectors, standard orifices, nozzles, instruments
etc.
6.02.10 Overspeed test of the assembly at 120% of rated speed.
6.02.11 Power run test.
6.02.12 Performance test of the diesel engine to determine its torque, power and specific fuel
consumption as function of shaft speed. Performance test of the engine shall be carried for 12
hours out of which 1 hour at full load and one hour at 110% overload.
6.02.13 Measurement of vibration & noise.
(i) Measurement of vibration
The vibration shall be measured during full load test as well as during the overload test and
limit shall be 100 microns.
(ii) Measurement of noise level
The equivalent 'A' weighted sound level measured at a distance of 1.5 M above floor level in
elevation and 1.0 M horizontally from the base of the equipment, expressed in dB to a
reference of 0.0002 microbar shall not exceed 93 dBA.
IN JASIDIH GSS VOL-II
Page 513
6.02.14 Adjustment of speed governor as per BS:5514.
6.02.15 Diesel engine shall be subjected to routine tests as per IS:10000/BS:5514.
7.00.00 PIPING, VALVES AND SPECIALITIES
This clause covers the design, manufacture, shop testing, erection, testing and commissioning
of piping, valves and specialities.
7.02.00 Scope
The piping system which shall include but not be limited to the following :
7.02.01 Plain run of piping, bends, elbows, tees, branches, laterals, crosses, reducing unions,
couplings, caps, expansion joints, flanges, blank flanges, thrust blocks, anchors, hangers,
supports, saddles, shoes, vibration dampeners, sampling connections, hume pipes etc.
7.02.02 Gaskets, ring joints, backing rings, jointing material etc. as required. Also all welding
electrodes and welding consumables including special ones, if any.
7.02.03 Instrument tapping connections, stubs etc.
7.02.04 Gate and globe valves to start/stop and regulate flow and swing check valves for one
directional flow.
7.02.05 Basket strainers and Y-type strainers
7.02.06 Bolts, nuts, fasteners as required for interconnecting piping, valves and fittings as
well as for terminal points. For pipe connections into Owner's
R.C.C. works, Bidder will furnish all inserts.
7.02.07 Painting, anti-corrosive coatings etc. inside and outside pipes and equipment.
Adequate number of air release valves shall be provided at the highest points in the piping
system to vent any trapped air in the system.
7.03.00 Design
7.03.01 Material of construction of various pipes shall be as follows :
(a) Buried Pipes
Mild steel black pipes as per IS:1239, Part-I medium grade (for pipes of sizes 150 NB and
below) or IS:3589, Fe 410 grade (for pipes of sizes 200 NB and above) suitably lagged on the
outside to prevent soil corrosion, as specified elsewhere.
(b) Overground Pipes normally full of water
Mild steel black pipes as per IS:1239, Part-I medium grade (for pipes for sizes 150 NB and
below) or IS:3589, Fe 410 grade (for pipes of sizes 200 NB and above).
(c) Overground pipes normally empty, but periodic charge of water and for detector
line for HVW System.
Mild steel galvanised pipes as per IS:1239, Part-I medium grade (for pipes of sizes 150 NB
and below) or IS:3589, Fe 410 grade (for pipes of sizes 200 NB and above).
7.03.02 All fittings to be used in connection with steel pipe lines upto a size of 80 mm shall
be as per IS:1239. Part-II Mild steel tubulars and other wrought steel pipe fittings, Heavy
grade. Fittings with sizes above 80 mm upto 150 mm shall be fabricated from IS:1239 Heavy
grade pipes or steel plates having thickness not less than those of IS:1239 Part-I Heavy grade
pipes. Fittings with sizes above 150 mm shall be fabricated from IS:3589 Class-2 pipes. All
fitting used in GI piping shall be threaded type. Welding shall not be permitted on GI piping.
7.03.03 Pipelines carrying water, air etc. should be sized on the basis of following values of
allowable velocities based on the rated capacity of the pumps:
-----------------------------------------------------------------------------------------Service Description Velocity in M/Sec.
-----------------------------------------------------------------------------------------Pipe Size
-----------------------------------------------------------------------------------------Below 50-150 mm 200 mm &
IN JASIDIH GSS VOL-II
Page 514
50 mm upwards
-----------------------------------------------------------------------------------------(a) Pump suction _ 1.2-1.5 1.2-2.0
(b) Pump discharge 1.2-1.8 1.8-2.4 2.1-2.5
(c) Header _ 1.5-2.4 2.1-2.4
(d) Compressed air 15-20 20-30 25-35
below 2 kg/cm2(g)
(e) Compressed air 20-30 25-40 35-45
2 kg/cm2g and above
-----------------------------------------------------------------------------------------7.03.04 For steel pipeline, welded construction should be adopted unless specified otherwise.
7.03.06 All piping system shall be capable of withstanding the maximum pressure arising
from any condition of operation and testing including water hammer effects.
7.03.09 Gate/sluice valve will be used for isolation of flow in pipe lines and shall be as per
IS:778/BS-5150 (for size upto 40 mm), IS:780 (for sizes above 40 mm and upto 300 mm) and
IS:2906 (for sizes above 300 mm). Valves shall be of rising spindle type. PN 1.6 class valves
shall be provided.
7.03.10 Gate Valves shall be provided with the following :
(a) Hand wheel.
(b) Position indicator.
(c) Draining arrangement of valve seat.
(d) Locking facility (where necessary).
7.03.11 Gate valves shall be provided with back seating bush to facilitate gland removal
during full open condition.
7.03.12 Globe valves shall be provided with contoured plug to facilitate regulation and
control of flow. All other requirements should generally follow those of gate valve.
7.03.13 Non-return valves shall be swing check type. Valves will have a permanent "arrow"
inscription on its body to indicate direction of flow of the fluid.
These valves shall generally conform to IS:5312.
7.03.14 Whenever any valve is found to be so located that it cannot be approached manually
from the nearest floor/gallery/platform handwheel with floor stand or chain operator shall be
provided for the same.
7.03.15 Valves below 50 mm size shall have screwed ends while those of 50 mm and higher
sizes shall have flanged connections.
7.03.14 Strainers
Basket Strainer
a) Basket strainers shall be of 30mesh and have the following materials of construction :
Body Fabricated mild steel as per IS:2062 (Tested Quality).
Strainer Wires of stainless steel (AISI : 316), 30 SWG, suitably reinforced.
b) Inside of basket body shall be protected by two (2) coats of heavy duty bitumastic paint.
c) Strainers shall be Simplex design. Suitable vent and drain connections with valves shall be
provided.
d) Screen open area shall be at least 4 times pipe cross sectional area at inlet.
e) Pressure drop across strainer in clean condition shall not exceed 1.5 MWC at 410 M3/hr
flow.
7.03.15 Y-type On-line Strainer
Body shall be constructed of mild steel as per IS:2062 (tested quality).
Strainer wires shall be of stainless steel AISI:316, 30 SWG, 30 mesh.
Blowing arrangement shall be provided with removable plug at the outlet.
IN JASIDIH GSS VOL-II
Page 515
Screen open area shall be atleast 4 times pipe cross-sectional area at inlet.
7.03.16 Hydrant Valve (Outdoor) and Indoor Hydrant Valves (Internal
Landing Valves).
The general arrangement of outdoor stand post assembly, consisting of a column pipe and a
hydrant valve with a quick coupling end shall be as per TAC requirement.
Materials of construction shall be as follows :
a) Column pipe M.S. IS:1239 med. grade.
b) Hydrant Valve
i) Body Gun metal.
ii) Trim Leaded tin bronze as per IS:318, Grade-2.
iii) Hand Wheel Cast Iron as per IS:210, Grade- 20.
iv) Washer, gasket Rubber as per IS:638. etc.
v) Quick coupling Leaded tin bronze as per connection IS:318, Grade-2.
vi) Spring Phosphor Bronze as per IS:7608.
vii) Cap and chain Leaded tin bronze as per IS:318, Grade-2.
The general design of hydrant valve shall conform to IS:5290.
7.03.17 Hoses, Nozzles, Branch pipes and Hose boxes
(a) Hose pipes shall be of unlined flax canvas/reinforced rubber-lined canvas construction as
per IS:4927/type A of IS:636 with nominal size of 63 MM (2 1/2") and lengths of 15 metre or
7.5 metre, as indicated elsewhere. All hoses shall be ISI marked.
(b) Hosepipes shall be capable of withstanding an internal water pressure of not less than 35
kg/cm2 without bursting. It must also withstand a working pressure of 8.5 kg/cm2 without
undue leakage or sweating.
(c) Each hose shall be fitted with instantaneous spring lock type couplings at both ends. Hose
shall be fixed to the coupling ends by copper rivets and the joint shall be reinforced by 1.5
mm galvanized mild steel wires and leather bands.
(d) Branch pipes shall be constructed of copper and have rings of leaded tin bronze (as per
IS:318 Grade-2) at both ends. One end of the branch pipe will receive the quick coupling
while the nozzles will be fixed to the other end.
(e) Nozzles shall be constructed of leaded tin bronze as per IS:318, Grade-2.
(f) Suitable spanners of approved design shall be provided in adequate numbers for easy
assembly and dismantling of various components like branch pipes, nozzles, quick coupling
ends etc.
(g) Hose pipes fitted with quick coupling ends, branch pipes, nozzles spanner etc. will be kept
in a hose box, which will be located near point of use. The furnished design must meet the
approval of Tariff Advisory Committee.
(h) All instantaneous couplings, as mentioned under clause Nos.3.03.19, 3.03.20 and 3.03.21
above shall be of identical design (both male and female) so that any one can be interchanged
with another. One male, female combination shall get locked in by mere pushing of the two
halves together but will provide leak tightness at a pressure of 8 kg/cm2 of water. Designs
employing screwing or turning to have engagement shall not be accepted.
7.04.00 Fabrication & Erection
7.04.01 The contractor shall fabricate all the pipework strictly in accordance with the related
approved drawings.
7.04.02 End Preparation
(a) For steel pipes, end preparation for butt welding shall be done by machining.
(b) Socket weld end preparation shall be sawing/machining.
(c) For tees, laterals, mitre bends, and other irregular details cutting templates shall be used
for accurate cut.
IN JASIDIH GSS VOL-II
Page 516
7.04.03 Pipe Joints
(a) In general, pipes having sizes over 25 mm shall be joined by butt welding. Pipes having
25 mm size or less shall be joined by socket welding/screwed connections. Galvanised pipes
of all sizes shall have screwed joints. No welding shall be permitted on GI pipes. Screwed
joints shall have tapered threads and shall be assured of leak tightness without using any
sealing compound.
(b) Flanged joints shall be used for connections to vessels, equipment, flanged valves and
also on suitable straight lengths of pipe line of strategic points to facilitate erection and
subsequent maintenance work.
7.04.04 Overground Piping
(a) Piping to be laid overground shall be supported on pipe rack/supports. Rack/supports
details shall have to be approved by Employer/Engineer.
(b) Surface of overground pipes shall be thoroughly cleaned of mill scale, rust etc. by wire
brushing. Thereafter one (1) coat of red lead primer shall be applied. Finally two (2) coats of
synthetic enamel paint of approved colour shall be applied.
7.04.05 Buried Pipe Lines
(a) Pipes to be buried underground shall be provided with protection against soil corrosion by
coating and wrapping with two coats of coal tar hot enamel paint and two wraps of reinforced
fibre glass tissue. The total thickness of coating and wrapping shall not be less than 3 mm.
Alternatively corrosion resistant tapes can also be used for protection of pipes against
corrosion.
(b) Coating and wrapping shall be in line with IS:10221.
(c) Buried pipelines shall be laid with the top of pipe one meter below ground level.
(vi) At site, during erection, all coated and wrapped pipes shall be tested with an approved
Holiday detector equipment with a positive signalling device to indicate any fault hole breaks
or conductive particle in the protective coating.
7.05.00 General Instruction for Piping Design and Construction
7.05.01 While erecting field run pipes, the contractor shall check, the accessibility of valves,
instrument tapping points, and maintain minimum headroom requirement and other necessary
clearance from the adjoining work areas.
7.05.02 Modification of prefabricated pipes, if any, shall have to be carried out by the
contractor at no extra charge to the Employer.
7.05.03 Welding
(i) Welding shall be done by qualified welders only.
(ii) Before welding, the ends shall be cleaned by wire brushing, filing or machine grinding.
Each weld-run shall be cleaned of slag before the next run is deposited.
(iii) Welding at any joint shall be completed uninterrupted. If this cannot be followed for
some reason, the weld shall be insulated for slow and uniform cooling.
(iv) Welding shall be done by manual oxyacetylene or manual shielded metal arc process.
Automatic or semi-automatic welding processes may be done only with the specific approval
of Employer/ Consultant.
(v) As far as possible welding shall be carried out in flat position. If not possible, welding
shall be done in a position as close to flat position as possible.
(vi) No backing ring shall be used for circumferential butt welds.
(vii) Welding carried out in ambient temperature of 5°C or below shall be heat-treated.
(viii) Tack welding for the alignment of pipe joints shall be done only by qualified welders.
Since tack welds form part of final welding, they shall be executed carefully and shall be free
from defects. Defective welds shall be removed prior to the welding of joints. Electrodes size
for tack welding shall be selected depending upon the root opening.
(ix) Tacks should be equally spaced as follows :
IN JASIDIH GSS VOL-II
Page 517
for 65 NB and smaller pipes : 2 tacks
for 80 NB to 300 NB pipes : 4 tacks
for 350 NB and larger pipes : 6 tacks
(x) Root run shall be made with respective electrodes/filler wires. The size of the
electrodes/filler wires. The size of the electrodes shall not be greater than 3.25 mm (10 SWG)
and should preferably be 2.3 mm (12 SWG). Welding shall be done with direct current values
recommended by the electrode manufacturers.
(xi) Upward technique shall be adopted for welding pipes in horizontally fixed position. For
pipes with wall thickness less than 3 mm, oxyacetylene welding is recommended.
(xii) The root run of butt joints shall be such as to achieve full penetration with the complete
fusion of root edges. The weld projection shall not exceed 3 mm inside the pipe.
(xiii) On completion of each run craters, weld irregularities, slag etc. shall be removed by
grinding or chipping.
(xiv) Fillet welds shall be made by shielded metal arc process regardless of thickness and
class of piping. Electrode size shall not exceed 10 SWG. (3.25 mm). At least two runs shall
be made on socket weld joints.
7.06.00 Tests at Works
7.06.01 Pipes
(i) Mechanical and chemical tests shall be performed as required in the codes/standards.
(ii) All pipes shall be subjected to hydrostatic tests as required in the codes/standards.
(iii) 10% spot Radiography test on welds of buried pipes shall be carried out as per ASME
VIII.
7.06.02 Valves
(i) Mechanical and chemical tests shall be conducted on materials of the valve as required in
the codes/standards.
(ii) All valves shall be tested hydrostatically for the seat as well as required in the
code/standards for a period of ten minutes.
(iii) Air test shall be conducted to detect seat leakage.
(iv) Visual check on the valve and simple operational test in which the valve will be operated
thrice from full open to full close condition.
(v) No repair work on CI valve body, bonnet or wedge shall be allowed.
7.06.03 Strainers
(i) Mechanical and chemical tests shall be conducted on materials of the strainer.
(ii) Strainers shall be subjected to a hydrostatic test pressure of 1.5 times the design pressure
or 10 kg/cm2g whichever is higher for a period of one hour.
(iii) Pressure drop test on one strainer of each size/type shall be conducted.
7.06.04 Hydrant valves and Indoor Hydrant Valves (Internal Landing Valves)
(i) The stand post assembly along with the hydrant valve (valve being open and outlet closed)
shall be pressure tested at a hydrostatic pressure of 21 kg/cm2g to detect any leakage through
defects of casting.
(ii) Flow test shall be conducted on the hydrant valves at a pressure of 7 kg/cm2g and the
flow through the valve shall not be less than 900 litres/min.
(iii) Leak tightness test of the valve seat shall be conducted at a hydrostatic test pressure of 14
kg/cm2g.
7.06.05 Hoses, Nozzles, Branch Pipes and Hose Boxes
Unlined flax/reinforced rubber-lined canvas hoses shall be tested hydrostatically. Following
tests shall be included as per IS:4927/IS:636.
a) Percolation test
IN JASIDIH GSS VOL-II
Page 518
b) Pressure test at 21 kg/cm2g
c) Burst test at 32 kg/cm2g (minimum)
The branch pipe, coupling and nozzles shall be subjected to a hydrostatic test pressure of 21
kg/cm2g to detect any leakage through defects of casting. Dimensional checks shall be made
on the hose boxes and nozzle spanners.
8.00.00 AIR VESSELS
8.01.00 Air vessels shall be designed and fabricated of mild steel as class-II vessels as per
IS:2825.
8.02.00 Inside surface of the tank shall be protected by anti-corrosive paints/coatings/linings
as required.
8.03.00 Outside surfaces of the vessels shall be provided with one (1) coat of red lead primer
with two (2) coats of synthetic enamel paint of approved colour and characteristics.
8.04.00 Tests & Inspection
8.04.01 Air vessels shall be hydraulically tested at 1.5 times design pressure or 2 times the
working pressure, which