KARNATAKA SOLAR POWER DEVELOPMENT CORPORATION
LIMITED
KSPDCL/SP/F-29/2015-16/02 dated 09-12-2015
BIDDING DOCUMENTS FOR
Establishing 4 nos of
2 x 150 MVA,
220/66kV
stations at
Nagalamadike Hobli in Pavagada Taluk, Tumkur District along with
connected Transmission lines and Terminal Bays on Total Turnkey
Basis,in two lots ( Lot1 & Lot 2 ) in respect of the proposed 2000 MW
Pavagada Solar Park in Tumkur District, Karnataka including supply
of all Materials,Erection (including Civil Works ),Testing and
commissionig.
BID DOCUMENTS CONSIST OF THE FOLLOWING VOLUMES
VOLUME- I
CONDITIONS OF CONTRACT
VOLUME-IIA (Part 1 of 3) ↔ |
(Part 2 of 3) ↔ | TECHNICAL SPECIFICATIONS
(Part 3 of 3) ↔ |
DRAWINGS
VOLUME- IIIA
TECHNO-COMMERCIAL SHEETS
AND
PRICE SHEETS
(BID PROPOSAL SHEETS)
Page 1 of 382
KARNATAKA SOLAR POWER DEVELOPMENT CORPORATION
LIMITED
KSPDCL/SP/F-29/2015-16/02 dated 09-12-2015
BIDDING DOCUMENTS FOR
Establishing 4 nos of
2 x 150 MVA,
220/66kV
stations at
Nagalamadike Hobli in Pavagada Taluk, Tumkur District along with
connected Transmission lines and Terminal Bays on Total Turnkey
Basis,in two lots ( Lot1 & Lot 2 ) in respect of the proposed 2000 MW
Pavagada Solar Park in Tumkur District, Karnataka including supply
of all Materials,Erection (including Civil Works ),Testing and
commissionig.
VOLUME - IIA
(PART 3 OF 3)
TECHNICAL SPECIFICATION
------------------------------------------------------------------------------------------------------------
ISSUED BY
The Chief Executive Officer,
KSPDCL
BANGALORE-560 001
Page 2 of 382
THIS BID DOCUMENT CONTAINS FOLLOWING VOLUMES:
VOLUME - IlA
(Part 3 of 3)
TECHNICAL SPECIFICATIONS
OTHER VOLUMES CONTAIN THE FOLLOWING:
VOLUME - I
CONDITIONS OF CONTRACT
VOLUME-IIA
(Part 1 of 3)
TECHNICAL SPECIFICATIONS
VOLUME-IIA
(Part 2 of 3)
TECHNICAL SPECIFICATIONS
VOLUME- III
TECHNO-COMMERCIAL SHEETS
AND
PRICE SHEETS
(BID PROPOSAL SHEETS)
Page 3 of 382
VOLUME IIA (PART 3 OF 3)
TECHNICAL SPECIFICATION
SECTION
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
DESCRIPTION
1.1KV GRADE POWER AND CONTROL CABLE
415 / 240 VOLTS PANEL
AC OUT DOOR DISTRIBUTION BOX
BATTERY
BATTERY CHARGER
LT TRANSFORMER
FIRE FIGHTING
DG SET
11KV UG CABLE
SWITCH YARD ERECTION
STRUCTURES
CIVIL WORKS
RELAY & PROTECTION PANELS
PLCC EQUIPMENTS
FURNITURE
EARTH MATERIAL
11KV SWITCH GEAR
CAPACITOR BANK
11KV SPECIAL GOS
TESTING AND COMMISSIONING
Page 4 of 382
SECTION-5.1
1.1 kV GRADE POWER & CONTROL CABLE
VOLUME - IIA
Section 5. 1 (1. 1 KV Grade Power & Control Cables)
1.
REQUIREMENTS FOR 1.1 KV GRADE CABLES:
1.0
Qualifying Requirement :
Please refer Volume - 1 Section IFB Clause 11.0
1.1 GENERAL:
The bidder shall quote for cables for entire scope of work. Following are the
preferred sizes of cables to be used in the project and the cable vis a vis the purpose f or
which to be used in indicated in part I of 3 of
volume - II i.e., Technical specifications.
PVC POWER CABLES (ALUMINUM CABLES):
4C x 95mm²
4C x 25 mm²
2C x 10mm²
PVC CONTROL CABLES (STANDARD COPPER CABLES):
2C x 2.5 mm²
10C x 2.5 mm²
19C x 2.5 mm²
4C x 6 mm²
4C x 10 mm²
4C x 25 mm²
1.2
Successful bidder shall prepare entire laying and termination schedules in accordance
with criteria stipulated at Clause 1.3 below along with final cable quantities required
and the same shall be submitted in advance for Owner's approval.
1.3
CRITERIA FOR SELECTION OF POWER & CONTROL CABLES:
1.3.1
Aluminum conductor P V C insulated armoured power cables shall be used for main
power supply purpose from L T Aux. Transformers to control room.
Page 5 of 382
1.3-2 Aluminum conductor P V C insulated armoured power cables
various other applications in
switchyard area / control room
protection purposes.
shall be used for
except for control /
1.3.3
For all control / protection instrumentation purposes P V C insulated armoured
control cables of minimum 2.5 sq. mm. size with stranded copper conductors shall be
used.
1.3.4
The size of the Power & Control and power cables for various purposes have been
indicated in part 1 of 3 of Technical specifications. The bidder has to asses the quantities
and indicate in the bid proposal sheets. In some cases tentative quantities have been
indicated. These can be reassessed and indicated by bidder.
The Bidder may offer other than sizes specified, 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 and short circuit consideration of system.
Relevant calculation shall be submitted by the bidder during detailed engineering for Purchaser
approval.
The successful bidder has to finalize the cable schedules based on the site conditions and
the schemes quoted, which are to be approved by owner payment for control and power cables
will be made quantities of both power and control cables indicated in the bid proposal sheets
and quantities finalized as per cable schedules WHICHEVER is LOWER
1.3.5
While preparing cables schedules for control / protection purposes following shall
be ensured :
Separate cables shall be used for AC & DC
Separate cables shall be used for DC1 & DC2 (only for 220KV Station)
For different cores of CT, CVT, & VTs separate cables shall be used.
At least one (1) core shall be kept as spare in each copper control cables up to 9C size where as
minimum no of spare cores shall be two (2) for control cables of 10 cores or higher size.
For control cabling, 2.5 sq. mm copper cables shall be used for connections. For CT & VT
circuits 6 &10 sq. mm copper control cables shall be used, respectively.
2.0
TECHNICAL:
2.1.0
CODES & STANDARDS
The design manufacture testing and performance of cables
covered under this specification shall comply with latest
edition of the following standards including amendments:
IS:7098
XLPE insulated PVC sheathed cables
(Part-I) for working voltage up to & including 1100 Volts .
ISS130 Conductors for insulated electrical cables & flexible cords.
Page 6 of 382
IS:5831
PVC insulation & sheath of electrical cables.
IS:3975
Mild steel wires strips & tapes for arm armoring of cables .
IS:10418
Specification of drums for electric cables
IS: 1554
ASTMD
PVC insulated (heavy duty) electric cables for working
voltage (part-I) up to and including 1100 V.
Measuring & minimum oxygen concentration to
support 2683 candle like combustion of plastic(oxygen index).
2.1.2
Cables complying with other internationally accepted standards such as IEC,
VDE, JPCEA etc., will also be considered if they ensure performance &
constructional features equivalent or superior to standards listed above In such a
case.The Bidder shall clearly indicate the standard / standards adopted and furnish a
copy of English version of the latest revision of the standard(s) along with the tender &
shall clearly bring out the salient features for comparison.
2.1.3
In case of any conflict between the referred specifications codes or standards & this
technical specifications, the latter shall prevail to the extent of such difference.
2.1.4
1.1 KV grade power & control cables to be supplied under this package shall be ISI
approved & marked as such. Non-compliance of above shall not be accepted.
2.1.5
However, if cables to be, supplied under this package are manufactured outside India
confirm to other internationally accepted equivalent or superior standards the above
specification not be applicable .
2.1.6
The Indian Standards mentioned in Clause 2.1 can be
obtained from: Bureau of Indian Standards
Manak Bhavan,
9. Bahadur Shah Zafar Marg,
NewDelhi - 110002.
INDIA.
2.2.0
TECHNICAL REQUIREMENTS:
2.2.1
GENERAL
2.2.1.1
The cables shall be suitable for laying in racks, ducts, trenches, conduits &
underground buried installation with uncontrolled back fill & chance of flooding
by water.
2.2.1.2
They shall be designed to withstand all mechanical, electrical & thermal
stress under steady & transient operating conditions.
Page 7 of 382
2.2.1.3
The Aluminum / Copper wires used for manufacturing the cables shall be true
circular in shape before stranding should be uniformly of good quality, free from
defects . All aluminum used in the cable shall be of H2 grade.
2.2.1.4
The fillers & inner sheath shall be of non-hygroscopic, & shall be softer than
insulation The outer sheath must be fill reluctant suitable for the operating
temperature of the cable.
2.2.1.5
Progressive sequential marketing of the length of the cable in meters. Every onemeter shall be provided on the outer sheath of all cables.
2.2.1.6
Only galvanized round steel wire armour shall be used for multicore cables.
G.S.strip armour shall not be accepted for these cables.
2.2.1.7
The cables shall have outer sheath of a material with an oxygen index of not
less than 29 & a temperature index of not less than 250º C.
2.2.1.8
All the cables shall pass fire resistance test as per IS:1554(part-1).
2.2.1.9
The P V C cables insulated cables shall be capable
conductor temperature of 160º C during a short circuit.
2.2-1-10
Repaired cables shall not be accepted.
2.2-1-11
Allowable tolerance on the overall diameter of the cables shall
be plus or minus 2 mm.
2.2-1-12
The normal current rating of PVC insulated cables shall be as per IS 3961.
2.3
of withstand
in a
L.T. PVC Power Cables.
The P V C ( 70ºC ) insulated 1100V grade power cables shall be of FR type clause
category, conforming to IS:1554 (part-I ) its amendments, read along with this specification
& shall
be suitable for steady conductor temperature 70 º C. The conductor
shall be stranded Aluminum. The
insulation shall be extruded P V C to type-A of
IS : 5831. A
distinct inner sheath shall be provided in all multi-core cables. For
multicore armored cables, the inner sheath shall be of extruded P V C. The, outer sheath shall
be extruded PVC to type ST-1 of IS : 5831 for all cables . Where armouring is specified for
single core cables the same shall be of aluminium wires /strips.
2.4
L.T. PVC Control Cables:
2-4. 1 The 1100 grade 70° C control cables shall be of FR type Clause category confirming to
IS : 1554 ( Part-I ) & its amendments, read along with this specification The conductor
shall
be stranded copper. The insulation shall be extruded PVC to type A of
IS:5831. A distinct extruded inner
sheath shall be provided in all cables. The fire
retardant over sheath shall be extruded P V C to type ST-1 of IS : 5831 & shall be
grey in color except where specifically advised by the owner to be black.
2.4.2
Cores shall be identified as per IS:554 for the cables up to five (5) cores & for cables
with more than five(5) cores the identification of cores
shall done by printing legible
Hindu Arabic Numerals on all cores as per clause 10.3 of IS :1554(Part-1).
Page 8 of 382
2.6.0
CABLE DRUMS
2.6.1
Cables shall be supplied non-returnable wooden or steel drums of heavy construction &
drum shall be properly seasoned sound & free from defects. Wood preservative shall be
applied to the entire drum.
2.6.2
Standard lengths for each size on power & control cables to be supplied by bidder shall be
500/1000 meters. The cable length per drum shall be subject to a tolerance of plus or
minus 5% of the standard length. The owner shall have the option of rejecting cable
drums with Shorter lengths. However, the total quantity of cables after taking into
consideration of all cable drum of each size shall be within tolerance of 2%.
2.6.3
A layer of waterproof paper shall be applied to the surface of the drums over the outer
most cable layer.
2.6.4
A clear space of atleast 40 mm shall be left between the cables & the lagging.
2.6.5
Each drum shall carry the manufacture's name, the owner's name,
address,
contract
number & type, size & length of the cable, net & gross weight stenciled on both sides of
drum. A tag containing the same information shall be attached to the
leading end of
the cable An arrow &. suitable accompanying wording shall be mark-ed on one end of the
reel indicating the direction in which it should be rolled.
2.6.6
Packing shall be sturdy & adequate to protect the cables, from any injury due - to
mishandling or other conditions
encountered during transportation, handling &
storage. Both cables ends shall be scaled with good quality heat shrinkable caps so as to
eliminate ingress of water during transportation & erection.
2.7.0
TYPE TESTS
2.7.1
All cables shall conform to all type routine & acceptance tests listed in the relevant-IS.
2.7.2
The type tests on cables shall be conducted on each type and size of cables offered.
2.7.3 Following type tests as per IS:1554(Part-I)-1988 including its amendments and additional
type tests shall be carried out on 1.1KV grade PVC insulated cables:
a. Tests on conductor
a. Annealing test (for copper)
b. Tensile test (for aluminium)
c. Wrapping test (for aluminium)
d. Conductor Resistance test.
b. Test for armouring wires/strips
c. Test for thickness of insulation and sheath
d. Physical tests for insulation and outer sheath.
i.
Tensile strength and elongation at break
ii.
Ageing in air oven
iii.
Shrinkage test
iv.
Hot deformation, Loss of mass
v.
Heat shock test
vi.
Thermal stability.
Page 9 of 382
e.
f.
g.
h.
i.
j.
Insulation resistance
High voltage test (water immersion test only a.c. test as per clause No. 16.3.1)
High voltage test at room temperature
Flammability test
Oxygen index and temperature index test on outer sheath
Short time current test on power cables of sizes 240 Sq. mm and above.
i.
On conductor(s)
ii.
On armours.
2.7.4 Following type tests as per IS:7098(Part-2)-1988 including its amendments and additional
type tests shall be carried out on XLPE insulated HT cable up to 33KV earthed system:
a. Tests on conductor
i.
Annealing test (for Copper)
ii.
Tensile test (for aluminium)
iii.
Wrapping test (for aluminium)
iv.
Resistance test.
b. Test for armouring wires/strips
c. Test for thickness of insulation
d. Physical tests for insulation
e. Physical tests for outer sheath
f. Partial discharge test
g. Bending test
h. Dielectric power factor test
i. Heating cycle test
j. Impulse withstand test
k. High voltage test
l. Oxygen index temperature index test on outer sheath
2.7.5
Following type tests as per IS:7098 (part-3)-1993 including its amendments and
additional type tests and additional type tests shall be carried out on XLPE insulated HT cable
from 66KV up to and including 220KV:
a. Tests on conductor
i.
Annealing test(for copper)
ii.
Resistance test
iii.
Tensile test (for aluminim)
iv.
Wrapping test (for aluminium)
b. Physical tests for insulation
i.
Test for thickness and dimensions of insulation
ii.
Tensile strength and elongation at break
iii.
Hot set test
iv.
Shrinkage test
v.
Thermal ageing in air oven
c. Resistivity test for semi-conducting layers
d. Test for concentric metallic screen:
i.
Test for concentric copper wire
ii.
Test for concentric copper tape
e. Thickness of metallic sheath
f. Test for armouring material:
Page 10 of 382
i.
Dimensions.
g. Physical tests for outer sheath:
1.
Measurement of thickness
2.
PVC sheath
i. Tensile strength and elongation at break
ii.
Ageing in air oven
iii.
Loss of mass in air oven only for PVC sheath
iv.
Heat shock test
v.
Hot deformation test
vi.
Shrinkage test
vii.
Thermal stability
3.PE sheath.
h.
i.
j.
k.
l.
m.
n.
o.
i.
Carbon black content
ii.
Tensile strength and elongation at break before and after ageing.
iii.
Hot-deformation.
Flammability test (for PVC outer sheathed cables only)
Water tightness test
1. Thermal ageing on complete cable sample.
2.
Tensile strength and elongation at break for insulation and outer
sheath.
3. Resistivity test for semi-conducting layer
Bending test followed by P.D. test
Dielectric power factor and capacitance measurement at ambient temperature
Dielectric power factor measurement at elevated temperature
Impulse withstand test followed by HV test.
Oxygen index temperature index test on outer sheath.
2.7.6 Contractor shall submit type test reports as per clause No. 9.2 of Technical Specification,
Section: GTR for which test conducted once are acceptance (i.e. The requirement of test
conducted within last five years shall not be applicable) for the following:
2.7.7
1.1KV grade PVC insulated cables
High voltage test (water immersion d.c. test as per clause No. 16.3.2 of IS: 1554 (Part1)-1988)
2.7.8
1.1KV grade XLPE insulated cables
a. Water absorption (gravimetric) test as per IS: 7098 (part-1)-1988
2.7.9
XLPE insulated HT cable from 66KV upto and including 220KV
a. Load cycle test followed by P.D. measurement as per IS:7098 (part-3)
2.7.10 Terminating/jointing accessories as per IEC 60840:1999
a. Partial discharge test at ambient temperature;
b. Heating cycle voltage test
c. Partial discharge tests
-At ambient temperature
-At high temperature
d. Impulse voltage test followed by power frequency test.
e. Test of outer protection for buried joints.
Page 11 of 382
2.7.11 The owner reserves the right to witness any or all the tests, for which at least 30 days
advance notice, shall be given- by the contractor.
2.7.11.1
Ten(10) copies of all routine & type test results shall be submitted for approval
before dispatch of the cables from the works.
2.7.12
Bound copies of complete test reports, ten ( 10 ) in number, shall be furnished along
with the cables. These shall include complete reports & results of the type tests,
acceptance tests routine tests.
2.7.13 The owner reserves the light to get the cable Type tests at his own expense for any
further tests to verify the
compliance with the specifications & to reject the cables in
case they are found not satisfying the qualifying
requirements
as
per
relevant
standards.
Page 12 of 382
SECTION-5.2
TECHNICAL SPECIFICATION
415/240 VOLTS LTAC PANELS
Page 13 of 382
VOLUME - IIA
TECHNICAL SPECIFICATION
Section 5.2.
415/240 Volts LTAC Panels
Clause No.
Particulars
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
25.0
26.0
27.0
28.0
29.0
Scope
Completeness of supply
Tropical Protection
Interchangeability
Technical particulars of LTAC Boards
Ventilation
Void
Buses switching devices and connections
Ground Bus
current transformers
Space headers and lighting outlets
Wiring
Terminal blocks
Cable Entry
Control and Indication
Name and Identity plates
Earthing
Indicating 'instruments
Alarms
Power Interrupting devices
Industrial Circuit Breakers
Over load and earth fault protection of Air
Heavy duty switch and fuse units
Neutral connection
Schedule of equipotent of LTAC switch Board
Panel
Outgoing feeders
Tests
Test witness
Page 14 of 382
Volume - IIA
Section 5.2 (415/240 Volts LTAC Panels)
Technical Specification for 415/240 Volts LTAC Panels
1.0
Scope:
1.1
This specification covers the design manufacture, shop testing and supply of
415/240
volts indoor type L.T.AC panels for control of A.C. supply to various auxiliaries in 220
W stations with all materials and accessories for efficient and trouble free operation.
2.0
Completeness of Supply:
2.1
It is not the intent to specify completely herein all details of the equipment. Nevertheless,
the equipment shall be complete and operative in all
aspects and shall conform to
highest standard of engineering and design and workmanship.
2.2
Any material or accessory which may not have been specifically mentioned but which is
necessary for satisfactory and trouble free operation and maintenance of the equipment
shall be supplied without extra charges.
2.3
The contractor shall supply all brand new equipment and accessories as specified herein
with such modification and alteration as agreed upon in writing, after mutual discussion.
3.0
Tropical Protection:
3.1
All equipments, accessories and wiring shall have fungus, protection involving special
treatment of insulation & material against fungus insects and corrosion, screens of
corrosion resistant material shall be furnishedon all ventilating louvers to prevent
the entrance of insects.
4.0
Interchangeability
4.1
All similar component parts supplied shall be interchangeable with one another physically
and electrically.
5-0
Technical particulars of LTAC Boards:
5.1
The switchboard shall consist of completely enclosed self supporting cubicle - type sheet
steel panels. the switch boards shall consists of the required number of sheet steel
enclosures for mounting the circuit breakers, relays, instruments and other equipments.
5.2
Each panel assembly shall be provided with the back easily removable or shall
be
provided -with hinged doors at the back .to enable, easy access for inspection and
maintenance work.
5.3
Cold Rolled Sheet Steel not less than 3 mm thick and structural steel having light sections
shall be used and also 2 mm thick sheet shall be
used for sides and doors. All
fastening between the structural members shall preferably be bolted and not welded, to
provide flexibility during installation. The base of switch gear frame shall be suitable for
Page 15 of 382
erecting on flush concrete floor by means of evenly spaced grounding bolts projecting
through the base channel members of the frame.
5.4
The depth of the boards shall be of the order of 500 mm to 1000 mm. The height of the
board shall preferably be about 2200 mm and equipment shall be so arranged as to
reduce the length of the boards to the minimum possible. The working height shall be
limited within 400 mm to 1800 mm from floor level.
5.5
The construction of the front of cubicle shall be such that heavy capacity breakers
are
isolated from, the adjacent breakers by means of suitable barriers. The design and
construction shall be such as to allow extension at either end.
5.6
The breakers, fuses, bus bars and associated jumps etc, in the L.T.A.C. panel shall be
capable of withstanding 31.5 KA for one second. The symmetrical breaking capacity of
the breakers should be not less than 31.5 KA.
6.0
Ventilation: -
7.0
Ventilating louvers shall be provided.
7.1
All steel surfaces shall be sand blasted , grounded pickled
as required to produce a smooth, clean surface free of
scale, grease and rust.
7.2
After cleaning, the surface shall be given a phosphate coating followed by two coats of
high quality primer and stored after each coat.
7.3
The finishing coat on the exterior of the panels shall be opaline green corresponding to
shade no. 275 of I.S.5 with two coats- of synthetic enamel paint- and colour to the
interior surface shall be finished stoved enamel white.
8.0
Buses switching devices and connections:
8.1
All buses, switching device and connections shall be of sufficient size to limits
the
temperature rise to 45° C over ambient temperature of 45° C
(peak) inside the enclosure
while carrying full load current
8.2
The main buses and connections shall be of type conductivity electrolyte copper.
All
main bus joints and bus taps shall be silver plated and tightly
clamped with through bolts to
ensure maximum conductivity.
83
All buses wherever possible shall be of rigid type. They shall be liberally spaced and so
mounted that their expansion and contraction do not
subject either the bus bars or the
insulating supports to any stresses and
should withstand the stresses due to maximum short
circuit current.
Wherever required suitable expansion joints shall be provided.
8.4
All bus work and connection shall be accessible for inspection and maintenance purpose
from ends and rear, after first removing the respective enclosing plates.
8.5
Bus bars and connections shall be fully insulated for working voltage with adequate phase
to phase and phase to ground clearances. Insulating sleeves for bus bars and shrouds for joints
Page 16 of 382
shall be provided. Bus
creepage
surface.
insulators shall be flame retardant, track-resistant type with high
8.6
Bus bars shall be colour coded for easy identification and so located that the sequence
R-Y-B , shall be from left to right, top to bottom or front to rear when viewed from the front of
the assembly.
9.0
Ground bus:
9.1
For
ensuring the rigid connection, the minimum section of
the ground bus shall not be less than 160 sq.mm.
9.2
The ground bus is to be earthed
solidly and connected to
the station main earth in system, for which suitable provisions shall be
made.
The
ground bus shall be provided with two bolt drillings with G.I
bolts and nuts at each and
to receive 50 x 6 mm. G I. flat.
9.3
All stationery structures shall be directly connected to the ground bus
for effective grounding. The frame of draw out type breakers shall be
times except when the breaker disconnects are separated by a safe distance.
10.0
grounded at all
Current Transformers:
10.1 The current transformers shall be
of cast resin type. Current transformers
to be
provided shall be mounted in the associated circuit breaker housing
in
a
separate
accessible compartment. The core lamination shall be of high grade low loss, silicon steel and
the
excitation current shall be as low
as possible. The Current transformers shall be
designed to withstand the thermal and electromagnetic stress- resulting from the maximum
expected short circuit current. Suitable arrangements shall be made so
that secondary
of CT shall not be open circuited with primary fully loaded.
All secondary connections
shall be brought out to terminal
blocks where
star or delta connection shall be made. Suitable shorting links shall be provided for
shorting the secondary- links shall be provided for shorting the secondary winding of C.T. if
necessary. The particulars of C.T. i.e burden, accuracy class is detailed in the feeder wise
requirement detailed
else where in the specifications.
11.0
Space headers and lighting outlets:
11.1
Thermostat controlled space heaters shall be provided inside to prevent condensation of
moisture. The cubicle heater shall be provided with individual switch fuse circuits . All
switch boards, cubicles etc., shall be provided with suitably located lighting, outlets. The
lighting switch shall be provided inside each entrance door at the back of the panels.
12.0
Wiring:
12-1 The LTAC panels shall be fully- wired at the factory to ensure proper
control., protection and inter locking schemes.
functioning of
12.2 Fuse and links shall be provided to permit individual circuit isolation from bus
without
disturbing other circuits. All spare contacts of relays, push buttons and other devices shall
be up to terminal blocks.
Page 17 of 382
12. 3 Wiring small done with flexible, 1100 V grade, PVC insulated switch board
super flexible multi-slandered tinned annealed copper conductors of
2.5 sq.
control and current circuits and 1.5 sq. mm , for voltage
circuits.
type
mm. for
12.4
Each wire shall be identified at both ends with permanent markers or ferrules bearing
wires numbers as per contractors wiring diagrams.
12.5
Wire terminations shall be made with crimping type connector with insulating sleeves.
Wires shall not be spliced between terminals.
13.0
Terminal Blocks:
13.1 Terminal blocks shall be 1100 V grade box- clamp type with marking strips
similar
to ELMEX 10 sq. mm or equal. Terminals for C.T. secondary leads
shall have provision
for shirting.
13.2 Not more than two wires shall be connected to any terminal. Spare terminals to extent of
20% should be provided.
13.3 Terminals blocks shall be located to allow easy access. Wiring shall be so arranged
individual wires of an external cable can be connected to consecutive terminals.
14.0
that
Cable entry:
14.1 Sufficient space provision shall be made for entry of the cable at bottom of
cubicle
and sufficient space shall be provided base of termination and
connection. Suitable cable
glands for lead sheathed cables for feeders of
100A and above and PVC cables for feeders
of lower rating shall be
provided.
14.2 All provisions and accessories shall be furnished for termination and
connection of
cables including, removable gland plates, cable supports, crimp type tinned copper lugs, brass
compression glands with tapered
washer (power cables only) and Terminal blocks.
14.3 Gland plates shall be minimum of 4 mm thick. The gland plate and
supporting
arrangement for single core power cables shall be such as to
prevent flow of eddy current
15.0
Control and Indication:
15.1 Push button shall be heavy duty, oil tight, push to activate type with
escutcheon plate marked with its function.
integral
15.2 The circuit breaker shall be wired up for local operation. Each breaker
be equipped with the following:
cubicle
shall
One (1) test-normal-trial selector switch stay put type with pistel grip handle and key interlock
for breaker.
Two (2) heavy duty oil tight push buttons for trip and close. Four (4) indicating lights in front of
compartment
Breaker open
-
Green
Page 18 of 382
Breaker closed
-
Red
Breaker Auto - tripped
-
Amber
Breaker spring charged
-
white
15.3 Lamps shall be low-watt filament type with series resistor and coloured lens. Lans and
lamps shall be replaceable from the front suitable for connection to 220 volts D.C. shall be
used.
15.4 The general scheme of connection for control, 'interlock and protection is shown in the
enclosed drawings. Detailed requirements of individual
circuits will be intimated later to the
successful tenderer who shall develop and furnish the schemes accordingly
16.0
Name and identity plates:
16.1 12 mm wide plastic plates bearing suitable identification marks shall be fix-ed on the
exterior of the switch board in a appropriate place to indicate the function of different electrical
devices, measuring instruments etc., and circuit labels. All equipments shall be numbered
according to ASA code
numbers.
17.0
Earthing:
17.1 Earthing of dead metallic parts or metallic bodies of the equipment on the panel shall be
connected with soft drawn single conductor bare copper, Tail connections shall have minimum
area of 14.5 sq.mm. and the main
earthing connections to the earthing bus bar 65 sq.mm .
Those Wires shall
be connected to suitable terminals and close junction. Soldered
connections shall not bee employed. The number of earthing terminals shall be two for
the whole assembly of panels.
18.0. Indicating Instruments:
All instruments shall be of the square switchboard type, back connected, suitable
for
semi-flush mounting and provided with dust tight cases for tropical use with dull black enamel
finish. The dials shall be made of such material as to ensure freedom from warping, fading and
de colouring. Marking on scales shall be black on white background. All instruments all have
easy laboratory means of adjustment to accuracy. The limits of error shall be those permissible
for switchboard instruments as per relevant standards.
18.2 The instruments - shall be capable of indicating correctly when operated continuously
at any temperatures from O°C to 50°C instruments shall be able to give correct indication at a
temperature of 65 deg C for a period of 16 hours. Necessary test blocks shall be provided.
I8.3 Indicating instruments shall be of 96 x 96 mm, 90° Scale, antiglare glass
class of 2% full scale . Each meter shall have zero adjustment on front.
and
accuracy
18.4 Kilo Watt hour meter class 1.5, accuracy shall be provided with built in test facilities.
Alternatively, they may have test block to facilitate testing of meter without disturbing CT or VT
secondary connections.
19.0
Alarms:
Page 19 of 382
19.1 The main incoming feeder circuits and inter connecting feeder shall have lamp
indication and audible alarms for circuit breaker tripping indication.
20.0
Power Interrupting devices:
20.1 The 800A feeders (incomers) shall be provided with industrial type air circuit breaker.
Circuits of a lower rating may be provided with rotary type Switch fuse units.
20.2 The fuses shall be of the high rupturing capacity type with rupturing capacity of not less
than the maximum expected short circuit levels already indicated in the specifications.
20.3 All such equipments shall be back connected, equipped with completely fabricated buses
and shall be rated as shown in the enclosed drawings for the various switch boards.
20.4 All breakers shall be suitable for operation at a voltage 10 % above and 20% below the
normal rated voltage 220V D. C.
20.5 The blow out or suppression features shall minimize the arc and flame so that no damage
will be done to other portions of the circuits breakers arc blow out or suppression features and
contacts shall be rated to carry full load continuously.
21.0
Industrial Circuit Breakers:
21.1 The industrial type circuit breakers shall be electrically operated and equipped with a trip
free and lock out device which shall prevent the
interrupting device from re-closing after it
has been tripped due to an overload or short circuit until the device has been reset manually.
21.2 Each circuit breaker shall be furnished complete with the necessary operating devices,
alarm contacts and direct operated and direct switches as may be required.
21.3 Operating cubicle shall operate satisfactorily at 20% below normal operating voltage of
220 V D.C. Breakers shall be of robust design, trip free, shunt trip and on electrical closing, the
over load relay coils shall trip all the poles simultaneously.
21.4 They shall be of draw out type having service , test and isolated position. Breaker
housing shall be flush mounted on the panel, operating mechanism shall be arranged for
emergency manual operation. Mechanical on / off indicators of the breakers, on operation
counters and mechanism charge /discharge indicator shall be provided. The OFF and ON position
of the breakers shall also be indicated by means of red and green indicating lamps.
21.5 The closing mechanism of the circuit breakers shall have motor operation, designed for
220V D.C. supply For motor wound mechanism spring changing shall take place automatically
after each breaker closing operation. One open operation of the circuit breakers should be
possible
after failure of power supply to the motor.
21.6 Mechanical safety interlock shall be provided to prevent the circuit breakers from being
racked in or out of the service position when the breaker is closed.
21.7 Automatic safety shutters shall be provided- to fully cover the female
primary
disconnects when the breaker is withdrawn and inter-phase barriers
to
prevent
failures.
Necessary carriages for drawing out the
breakers for servicing should be supplied, As
Page 20 of 382
already indicated in clause 9.06 the breaker should have a symmetrical breaking capacity of
31.5 KA
and making capacity as per relevant standards.
22.0
Over load and earth fault protection of air circuit breakers.
22.1
Under normal conditions, the breaker shall not be affected by, moderate or
momentary over loads like those caused by initial in rush currents in the starting of an
appliance motor. However, when such over loads reach
dangerous values, the circuits shall
be opened by the action of the over current relay with adjustable time delay action. The earth
fault relay shall
be provided for protection against earth faults. The over current relays
shall be provided with instantaneous elements also.
23.0
Heavy duty switch and fuse units:
23.1 Heavy duty switch and fuse units shall be air break type, back of board
mounting type
and shall comprise of a heavy duty switch and high rupturing capacity fuses. The frame of these
shall be suitable for mounting
at the back of sheet steel cubicles.
23.2 Suitable interlocks shall be provided such that the doors can not be open until
the
appropriate switch operating handle is in the
'OFF' position.
Similarly, the door
opens. Each switch shall preferably be actuated by a
powerful mechanism arranged to
secure positive closing and quick break
opening action, provision shall preferably be made
for visibility of either OFF or ON position of operating mechanism.
Thus handle shall
have
provision for pad locking in ON and OFF position. Contacts shall make and
break
with a definite wiping action and have a high pressure line
contact of both heel and toe of the moving contacts. Arc chutes of insulating materials
shall be provided forming an effective barrier between
the poles preventing the arcing from
pole to pole or to the body. High breaking capacity cartridge type fuse links shall be fitted
throughout.
23.3 Feeders of capacity 200A and below shall consist of switch fuse units. The
fuse units shall have the ratings indicated in the clause 26.05.
24.0
Neutral connection:
24.1 All feeders are of three phase four wire type. The switch shall make or
individual phases. All incoming and outgoing feeders shall be
provided
disconnect link for isolation of neutral if necessary.
25.0
switch
break
with
the
bolted
Schedule of equipments of LTAC switch board:
25.1
Refer drawing for 415V LTAC panel (Typical) for 220 K V station
auxiliaries. . There will be two independent incoming feeders feeding the two sections of
the bus bars as indicated in the drawing. There will be a
bus section switch fuse unit of 800 A
capacity connecting these two bus bars. The breakers of the two incoming feeders and the bus
section switch fuse unit shall be interlocked so that no two sources are paralleled on to single
bus section.
25.2 Each incoming feeder will normally be feeding its own Section of the bus bars and in the
event of failure of supply on one of the incoming feeders, the bus section switch fuse unit shall
close manually and ensure continuity
of supply on this section of the bus bar al so.
Page 21 of 382
25.3 In addition one bus section shall be connected to 63 KVA D.G. set as
single line diagram, from which priority load will be fed.
26.0
shown in the
Panel:
26 1 The switch board shall consist of the following equipments. One set of LTAC switch
board panels complete with all the equipments
listed below with 3 panel copper bus bar
system and neutral, cable compartments,
self supporting free standing, all steel doors at front
and rear, mimic
diagram in front of the panel, individual compartments, completely wired
and printed, with power outlets, cubicle heating
fuses, ON/OFF switch, current
transformers, etc., as detailed in the drawing shall be supplied.
2 6. 2 Two Nos. of incoming feeders of 800 Amps 3 Phase each comprising of the following
components:
a)
one - air circuit breaker 800 Amps. 415 V AC equipped with shunt trip
suitable
for
220 V.D.C. auxiliary switches, power drive suitable for
220V.D.C. auxiliary with
self
interrupting device conforming to B.S.S. or equivalent standard, mounted on a carriage which
can be drawn out
horizontally.
b)
Four - Indicating lamps for ON/OFF, AUTO TRIP breakers spring
charge indications.
c)
Two - Push buttons ON/OFF.
d)
Three - current transformer cast resign in type ratio 400-200 /5-5 Amps. Double core,
one core with accuracy class 1for metering
and another core with accuracy class 10P 10 for protection. The
VA burden shall be 15 VA each for metering and protection cores.
e)
Three - Moving from ammeters size 96x96 mm flush mounting industrial grade
conforming to BS 89/ISS 1248 or equivalent standard with suitable
scale range of 0-200
Amps.
f)
One - KW meter suitable for CT ratio 400-200 / 5A, 415 volts AC
(flush mounting, size 96 x 96 mm industrial grade conforming to
BS 89 / ISS 1248 or equivalent standards.
g)
One -3 elements, KWHR meter accuracy class 1 .5 415 v suitable
for CT ratio 400-400/5A conforming to ISS 722 or equivalent
standards.
h)
One - voltmeter, range 0-600 V with selector switch, size 96x96
mm flush mounting, industrial grade conforming to ISS 1248 or
equivalent standards.
i)
Two - single pole over current relay, induction type with inverse
characteristics with three seconds minimum time at 10 times the
Plug setting. The range of adjustments of induction element
should be 50 - 200 of 5 Amps- The relay shall be mounted in a
draw out type case with operational indicators conforming to IS:3231 or equivalent
standards The relay also shall have on instantaneous element
of range 200-800%.
j)
One - Earth fault relay, similar to item (i) above but with
setting range of 20 -80%.
k)
Three - under voltage relay with fixed setting with pick up voltage
at 90 % and drop of voltage at 80% of the 415 7 L.T. supply.
l)
Seven - cable and boxes suitable for 3 ½ x 400 sq. mm. PILC
cables (the size and type of cable will however be conformed at
the time of ordering). Necessary test blocks for the instruments
Page 22 of 382
transformers for testing relays and meters shall be provided.
26.3 ) Bus isolator:
a)
One - 3 phase switch fuse unit, 500V, 800A, conforming to
relevant standards.
b)
The purpose of the Bus isolator switch is to connect the two bus sections when one of the.
incomers fails. Normally the two bus sections will be fed from the respective incomers and the
bus switch fuse unit will be open.
26.4
Incomer from DG set:
c)
Incoming from 63 KVA DG set on one bus section, with following
equipments shall be housed in bus coupler panel.
One - switch fuse unit of reputed make of 300 A at 415 v A.C.
with HRC fuses etc.
One - 4 pole, 100A, 415 V AC change over switch, conforming to
relevent standard.
One - Cables -land, for 75 sq. mm. 3 ½ core PVC cable.
26.0
Outgoing feeders:
1)
a)
Two outgoing feeders 200 A 3 phase each consisting of
One switch fuse unit of reputed make of 200A, at 415 V A-C.,
fitted with HRC fuses, etc.
One cable gland suitable for 150 sq. mm 3 ½ core cable. One
feeder should be of each section of the bus.
a)
b)
b)
2)
a)
b)
Eight out going feeder 100 A, 3 phase each consisting of :
One 100 A 415 Volts AC switch fuse unit of reputed make with
suitable HRC fuses.
One cable gland suitable for 75 sq.mm. 3 1/2 core cable.
NOTE:
3)
a)
b)
Four feeders should be on each section of the bus.
Four-teen outgoing feeders of 63 A, 3 phase, each consisting of
One switch fuse unit 63 A, capacity at 415 V AC, with suitable
HRC fuses etc.,
Cable gland suitable for 50 sq. mrn. 3 ½ core cable.
NOTE: Seven feeders should be on each section of the bus.
4)
a)
b)
Twelve outgoing feeders 32 A, 3 phase each consisting of
One switch fuse unit 32 A, capacity at 415 V AC.
One cable gland suitable for 25 sq. mm. 3 ½ core cable.
NOTE: Six feeders should be on each side of the bus.
NOTE:
1)
Necessary wiring, terminals, contacts, bus bars, foundation bolts, keys, control fuses,
mimic bus, lighting, frame, plates, circuit labels, device identification numbers, carrier for cable
Page 23 of 382
termination and safety earthing shall be provided.
2)
One insulated fuse puller shall be 'included to take out HRC fuses from switch board.
3)
Louvers shall be provided 'in cable chamber deers at the rear for ventilation.
4)
The bus tars and other connection leads shall be of copper.
5)
One No. 15 A. multi pin power plug outlets shall be provided for each switch board.
6)
The fuses shall be of high rupturing capacity of not less than the expected short circuit
levels already indicated 'in the specification.
27.0 The successful bidder shall furnish the following drawings in quanta duplication for
purchaser's approval.
a)
b)
c)
d)
e)
f)
g)
Details of construction of cubicles and the complete dimensions
diagram cross section drawing of the switch board
indicating details of location of switches, indicating instruments
relays, bus bars, cable glands and bus supports.
Detailed floor plan and foundations diagram showing necessary
floor openings.
Complete details of the air circuit breakers showing operating
mechanism, quenching
arrangements, etc
and
other
constructional details.
Consolidated Bill of materials.
Schematic diagram.
Wiring diagram.
Instruction manual of LTAC panel and "individual equipment
The manual shall clearly indicate the installation method, check
up and tests to be carried out before commissioning of the
equipment.
Page 24 of 382
SECTION – 5.3
TECHNICAL SPECIFICATION
A.C.OUTDOOR DISTRIBUTION BOX
Page 25 of 382
VOLUME - IIA
TECHNICAL SPECIFICATION
Section - 5.3
Clause No.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
A. C. OUTDOOR DISTRIBUTION BOX
Particulars
Scope
Standards
General requirements
Terminal Blocks
Small Wiring
Circuit labeling
Rating Plate
Equipment Details
Tests
Page 26 of 382
Volume - IIA
Section 5.3 (A.C.Outdoor Distribution Box)
TECHNICAL SPECIFICATIONS FOR OUTDOOR DISTRIBUTION
BOX (A.C.) FOR POWER & LIGHTING CIRCUITS
1.0
SCOPE:
This specification covers the manufacture, testing at manufacturer' works, Supply &
delivery of outdoor type distribution fuse boards for lighting & power circuits at 220 kV
& 110 kV Receiving stations.
2.0
STANDARDS
2.01
The distribution boards shall generally conform to IS:2675/1966 (with latest
amendments) - specification for enclosed distribution fuse boards & courts for voltages
not exceeding 1000 Volts.
3.0
GENERAL REQUIREMENTS
3.01 Irrespective of anything said or omitted in this specification, the distribution box shall be
suitable for the purpose they are intended be used. Each distribution box shall be complete with
accessories such as bus-bars, fuses, lock & key etc.,
3.02 The distribution fuse boards are required for distribution of 415V±10%, 3Phase, 4 wire
/ 240V ± 10% single phase AC
with phase AC neutral
earthed, required for power
supply to group operating switches, CB,
lighting of - outdoor yard, cable duct fighting &
emergency lighting.
3.03 The A. C. distribution fuse boards shall be 500 V grade. The distribution boxes shall be
double front or single front type, as specified with provision
for incomers & outgoing
feeders in each section of the box as shown in
the drawing The general arrangement of the
AC/DC distribution boxes are
shown in the following drawings
1.
Drawing No.KF-B/TECIVSub-Station/220/168/9.9.92 - detailed
distribution box "Type - A" - Single front type.
arrangement
of
2.
Drawing No. KEB/TECIVSub-Station/220/168/9-9.92 - detailed
distribution box "Type - B" - Double front type.
arrangement
of
3.04
The distribution fuse boards shall be fabricated out of 2.5mm thick- M.S.
sheets of tested quality for body & shutters with 40x4Ox4mm M.S .and iron
The shutters & body shall be suitably ribbed to give light but
strong structure.
frame.
3.05 The A.C. distribution fuse boards shall have hinged double doors at front 7
at back
for double front type. Each door shall have independent
type door lock & shall be capable of being opened & closed
independently.
The
doors shall be so fitted as to provide the interior with
maximum
protection
from
atmospheric condition. The hinges shall be of
such construction that the doors can swing
open by not less than 150ºC and in addition binges shall permit doors being completely
Page 27 of 382
removed when
necessary.
3.06 The distribution boxes shall be provided with suitable aprons/canopy as shown in the
drawing enclosed. The un-drilled sides, bottom & top covers
shall be detachable, The
distribution fuse boards shall be designed in such a way that when closed they are ptrf6ctly water
tight dust & vermin proof. Special arrangement to prevent ingress of moisture into the interior
of the distribution boxes shall be made. All bolts nuts & washers used
shall
be
galvanized mild steel. All the doors of the distribution box shall be fitted with dust proof gaskets.
The louver type ventilators shall be provided
the front as shown in drawing & wire nets
shall be provided on the back of
the ventilator for prevention of entry of dust, insects etc.,
into the boxes.
3.07 The cable entry & exit are the sides through the extended box at the top on both sides
& the design of the box must be such as to facilitate for
housing of 100A, MCCB for
incoming & 100 A HRC fuse link, for outgoing,
The clearance inside the box must be such as
to afford fair working facilities during erection & maintenance.
There shall be provision for easy removal of cable during erection & repairs, by suitably bolting the box coven &preferably sliding the bottom plates. A front hinged door with lock arrangement
shall be provided for each of the side box for operation of MCCB &HRC fuse links. However,
the entry of the cable at the extended box is to be through a 50mm G.I.pipe & projecting.50mm
inside the box through suitable gland. The extended box must be provided with suitable gland &
clamp for fixing the cable rigidly. The box shall be suitably ribbed to give a light but strong
structure.
3.08 The distribution boxes shall. be mounted on, a suitable angle iron mounting structure.2
Nos of rust proof grounding lugs shall be provided on
the angle iron framework of box with
terminals suitable for M.S.flat. The earthing ter1ruinal shall be identified by means of the sign
marked legibly
& indelibly adjacent to the earthing terminals.
3.09
FINISH:
All steel surface shall be sand blasted, grounded, pickled as required to
produce
a
smooth, clean surface free of scale, grease 7 rust. After
cleaning, the surfaces shall be given
a phosphate coating followed by
quality primer & stowed after each coat
The finishing coat on the exterior of the distribution' box shall be fight Grey
corresponding to shade No. 631 of IS-5 with two coats of synthetic enamel
paint &
colour to the interior surface shall be finished stowed enamel
white. A small quantity of
finishing paint shall be supplied with each consignment of distribution box to enable to restore
at site any finish,
which may get damaged during transit.
3-10
The distribution fuse boards shall be provided with high purity electrolytic
aluminum bus bars. The side of aluminium, bus-bars phase to phase
spacing should
be consistent with the currents & voltage rating of the
incoming / outgoing feeders. The bus
bars shall be fixed on the Hylam
sheets 10mm thick & of suitable width using 30mm brass
bolt & nuts. Exposed portion of the bus-bar shall b-. provided with insulated sleeves, red for
top phase, yellow for the mid phase, blue for the bottom phase & black for the neutral. The
overhung portion shall be suitably supported- AD current carrying parts shall be rigidly
supported to withstand short circuit stresses. The fuse carrier shall be easily withdrawable. The
short circuit will be about 20 KA at 400V.
3.11
All the terminals used for 'interconnection shall be made out of solid drawn
copper
Page 28 of 382
tubing having suitable conductivity. The interior & exterior surface
of tubular sockets
shall be tinned by electroplating or by hot dip tinning.
After final connections of the bus
bars, the bus-bars shall be completely
insulated with the approved quality insulation tapes.
.3.12 In the A.C. distribution boxes there will be 2 independent circuits each
with
an
incomer & outgoing is provided with removable HRC fuse links for
positive isolation of
the circuit & also from the point of high fault level on
the
sub-station.
The
general
arrangement of the circuits is shown in the drawing referred earlier.
There should be insulated barrier of hylem sheets between the front & back portion of the
distribution boxes carrying different circuits & it should be possible to work on one side of the
box (say front ) with circuit in another side (back 'in energised condition The moulded case CB &
HRC fuses shall be of stranded make, ISI mark. Suitable cable gland should be provided for the
main incomer/outgoing to the distribution boxes.
3.13 The outgoing feeders should be provide with HRC fuses front connected type, & MCB
of adequate rating. The MCB, MCC13 & the HRC fuse
links shall be rated for rupturing capacity of 25 KV at 400 V & they shall
be of reputed & standard make. The 'OFF& 'ON' position of the MCB
& MCCB shall be clearly visible when the doors is open- MCB &
MCCBs used shall be of ISI approved make. All the outgoing circuits
should be brought to terminal blocks of adequate rating from which
outgoing cables will be taken out . The inter connecting wires shall be of
copper & suitable bimetallic connections for connections with the bus-bars
should be used. table cable glands should provided for the outgoing
feeders of the distribution box.
3. 14 The drawing of distribution box shows the typical arrangement. The
etc., are also specified in the drawings.
current ratings
3.15 All the fuse cutouts & cable terminals shall be so arranged that they shall be not cause
them to come in contact with one-another or with the
enclosure by the movement of the
cable after insulation & the fixed
connections shall be such that the necessary contact
pressure is
maintained under the conditions of service & operation. The terminal shall
be such that they shall not turn or get displaced when the connecting
screws
are
tightened & such that the conductors shall not be displaced, while wiring inside the distribution
fuse boards shall be arranged neatly by
grouping the leads properly.
4.0
TERMINAL BLOCKS:
4.1
Terminal blocks shall be 600V grade box clamp type with marking strips
similar to ENGLISH / ELECTRIC / JOHNSON / ELMEX type, of stud & bolt
type, not more than two wires shall be connected to any terminal
Terminals equal in number to 20% of active terminals shall be finished
as spares. Terminal block shall be located to allow easy access. Wiring
shall be so arranged that individual wires of an external cable can be
connected to consecutive terminals.
5.0
SMALL WIRING:
The AC distribution box shall be labeled wired at the factory to ensure proper
functioning & control of protection scheme. Wiring shall be done, using 660V
Page 29 of 382
Grade PVC insulated with stranded famed annealed copper conductor. The size of the
wire shall be 25 sq mm for 100 Amps circuits & 4sq mm for outgoing 15 Amps circuits.
Each wire shall be identified at both ends with permanent markers bearing Wire numbers
as per contractors wiring diagram. Wire terminals shall be made with crimping type lugs
with insulating sleeves. Wires shall not be spliced between terminals. for each circuit the
neutral wire to be connected from neutral bus to terminal block. The colour of the wires
used shall be Red for phase. Yellow for 'Y' phase, blue for 'B' phase & black for neutral.
6.0
CIRCUIT LABELLING:
6.01 Each outgoing & incoming circuits shall be labeled both near the MCCBS / HRC
fuse, MCB s and also near the terminal blocks, provision shall be made. by means of a
label (which is preferably of the renewable type & protected by transparent material) for
recording the circuit title, cable size etc.
7.0
RATING PLATE:
7.01 The following information shall be clearly &indelibly marked on all the
distribution fuse boards
1.
2.
3.
4.
5.
Rated Voltage.
Total number/current rating of incoming fuse ways. going fuse ways.
Total number/current of out'.
Manufacture's name.
P.O. reference & date.
8.0
EQUIPMENT DETAILS:
8.1
One set of AC distribution box complete with all the equipments listed below with
3 pole electrolyte aluminium bus-bar system & neutral,
completely wired, painted, with MCB, MCCB, HRC fuse units, Circuit
labels as indicated in the drawing shall be supplied.
8.2
Single & double front AC distribution box shall comprise of the following
equipments.
Sl
No.
1
2
ITEM
SINGLE FRONT
DOUBLE FRONT
Free standing sheet steel clad
outdoor type, MS cubicle of
dimension
Two independent circuits
a) incomer -415V, 3pole, 100
A MCCB with rupturing
capacity of 20 KA for 1 sec
with separate neutral line
b) outgoing 100 A, removable
HRC fuse links with fuse
base of rating 100A &
rupturing capacity of 25KA
for 1 sec, with separate
neutral line
750 x 1350 x 300 1200 x 1350 x 600
mm
mm
1 No.
2 Nos.
3 No.
6 Nos.
Page 30 of 382
3
Outgoing feeders :
a) 415V, 15/16A, 3 pole 6 Nos.
MCB
b) 10A, HRC fuse links ( for 18 Nos.
3 phase ) with suitable base
(rupturing capacity 25 KA
for 1 sec)
4
5
6
7
8
a) 240V, 5/15 A, multi pin 1 No.
industries socket & plug
b) 240V, 15A, 2 pole, 1 No.
ON/OFF switch
c) 10A, HRC fuse link with 1 No.
suitable fuse base, of
rupturing capacity 25 KA
for 1 sec with separate
neutral link.
Electrolytic aluminium bus-bars
a) for phases & neutral 20 x 6 mm
10 mm thick 100 grade HYLEM
sheet for bus-bar mounting 7
installation
a) 50/70 sq. mm shrouded
terminals for 100 A
incoming & outgoing
circuits
b) 4 sq. mm shrouded
terminals for 10A outgoing
feeders.
Indication lamp for hive bus
indication
24 Nos.
72 Nos.
2 Nos.
2 Nos.
2 Nos.
As required
As required
As required
As required
If required
If required
As required
As required
4 numbers
---------
9.0 Test:
Tests for rust protection: This shall be mad-, on a representative sample
of the material used for enclosure. The test shall be carried out cither on a
sample cut from a complete enclosure or metal identical in all respects to
the metal used for the enclosure & given an identical protective finish.
The same shall be first cleared with a piece of wadding soaked in
Benzons & then dried. Then it shall be totally immersed in a solution
prepared as detailed below:
Solution for use in test for rust protection (13S 214-1973):
Prepare a solution of 7.5 grams potassium femicyanide (K3PC Cns) & 2.5
grams of ammonium per sulphate (NHS) 2 (S2013) in I liter of water. Add
a quantity of about 1 gram of suitable wetting agent for instance a sodium salt of alkaline
naphthalene sulphuric acid to each-liter of the solution. The solution & the sample being
maintained. at a temperature of 20 ± 1º C. After immersion for 5 minutes, the sample shall be
removed from the solution & left dry in air at room temperature. After the test the sample shall
should, no more than two blue colour red spots in any area of 100 sq mm & no spot shall-have a
dimension larger than 1.5 mm. Traces of rust on sharp edges & screw threads & any yellowish
film removable by rubbing shall be ignored.
Page 31 of 382
9.2
TESTS & TEST CERTIFICATES:
All the other type & routine tests prescribed in IS 2675/1966 shall be conducted on all complete
distribution box assembled & completed in all respects & the copies of the certificates shall be
submitted for approval before dispatch of the material. Copies of the latest Type test certificates
from a cognized test house for having conducted such tests on a distribution box to prove the
conformity of the equipment with the above ISS shall be submitted along with the tender.
Copies of the type & routine test certificates for all components used in manufacture of the box
from a recognized test house (to prove the conformity of the components to the relevant
standards) shall be submitted along with the tender.
Page 32 of 382
SECTION-5.4
TECHNICAL SPECIFICATION
BATTERY
Page 33 of 382
Volume - II
Section 5.4 (Battery)
TECHNICAL SPECIFICATIONS FOR BATTERY FOR 220 KV
RECEIVING STATIONS 220 VOLTS, 300 AH CAPACITY
1.0
SCOPE:
1.1
This specification covers the supply of battery system to feed the protection equipments
and emergency lights in the 220 KV Receiving station.
1.2
This specification covers manufacture, supply,assembly, shop testing at manufacturer‟s
works before despatch & delivery, for destination of lead acid batteries with plante type positive
plates of capacity 220 Volts, 300AH Capacity.
1.3
This specification covers supply, erection & commissioning of the battery sets at the
specified station.
2.0
SPECIFICATION FOR 1X 220 VOLTS, 300 AH BATTERY SETS:
2.1
As detailed in clause 1.0 above, the battery sets are required for 220KV
Receiving station.
2.2
The batteries shall be complete in all respects.
2.3
The battery shall be of lead acid with plante type positive plates heavy
durable, half pasted type negative plates confirming to IS : 1652 latest version. The
positive plates shall resist the foaming action of the current during charge & discharge &
retain its strength, rigidity, shape dimensions over the operating life of the plates. The
Battery shall be suited for a long life under continuous float operation and occasional
discharge.
2.4
TEMPERATURE CONDITION: The batteries are required to operate under the
following temperature conditions.
Maximum temperature
45 degree centigrade
Minimum temperature
5 degree centigrade
Average rainfall
varies from 1000mm to 2000mm
Height above M.S.L.
Below 1000 mtrs.
Relative humidity
95%
2.5
STANDARD: - The batteries shall fully conform to the latest edition of
following standards or any other equivalent international Standard.
A LIST OF RELEVANT STANDARDS IS GIVEN BELOW:
i).
IS-1652-1991
batteries, lead
-
Specification for stationery cells and
Acid type with Plante Positive Plates.
Page 34 of 382
ii).
IS- 266 – 1993
iii).
IS- 6071 – 1986
-
Specification for synthetic separators for lead acid
batteries.
iv)
IS- 1069- 1993
-
v)
IS- 1146 – 1981
-
Specification for quality tolerances water for
storage batteries
Specification for rubber and plastic containers for
lead acid storage batteries.
General requirements and methods of tests for
vi)
IS- 8320- 2000
lead-
-
-
vii)
IS- 1885-Part-8/1996
cells &
-
Specification for Sulphuric Acid
acid storage batteries.
Electro technical vocabulary – stationary
batteries
viii)
IEEE- 485/1983
-
IEEE recommended practice for sizing large lead
storage batteries for generating stations and
ix)
IS- 3116
-
stations.
Specification for sealing compound for lead acid
batteries.
x)
IS- 1248
-
Indicating instruments.
xi)
IEEE – 484
-
Recommended design for installation.
2.6
CONTAINERS: - The Container material shall have Chemical & ElectroChemical compatibility and shall be acid resistant. The material shall meet
all the requirement of Plante type batteries and be consistent with the life of
battery. The container shall be fire retardant and shall have an oxygen
index of at least 28%. The Tensile strength of material of container shall be
such as to handle the internal cell pressure of the cells in worst working
conditions. Cell shall not show any deformity or bulge on the sides under
all working conditions. The Container shall be capable of withstanding the
rigours of transport, storage and handling. The containers shall conform to
IS - 1146.
sub-
The containers shall be mounted on insulator blocks. Routine and
Acceptance tests shall be as per the requirements of IS- 1146 – 1981. The
lable attached to the containers shall be marked with the information as per
requirements of Cl. No. 2.2 of the above standard. The supplier’s
manufacturer’s test certificates shall be submitted by the tenderer for the
scrutiny of the purchaser. In case the battery offered conforms to
Standards other than IS -1652, a copy of the relevant standard should be
enclosed to the tender.
2.7 Cell Covers: The covers shall be made of suitable material compatible with
container
material, permanently fixed with the container & provided with vent plug. It
shall be capable to withstand internal pressure without bulging or cracking.
It shall also be fire retardant.
Page 35 of 382
2.8
Rating: The batteries are intended to supply power at 220V to the
protection equipments in the receiving stations. Each battery set
shall contain 110 cells of normal voltage of 2 volts. The batteries are
required to supply indicating lamps, the coils & control scheme of breakers
and disconnectors of GIS, relays & station emergency lighting etc.,
Batteries shall normally remain under floating condition with the trickle
charger supplying the continuous load.
The following particulars shall be noted:
2.9
a)
Normal voltage
220V
b)
Float charge voltage
198-280
c)
Boost/Equalizing charge voltage
190-300
d)
Amperes hour capacity 10
hours discharge rate
:300 AH
END CELL TAPPING: -
The tenders should clarify as to whether it is preferable to have end cell tapping
arrangement in the battery banks in order to control the voltage of the load side, when the battery
banks are being boost charged or not. If end cell tapping is recommended to regulate the voltage
across load, battery set supplier should agree to supply necessary switch to cut-in /cutout the cells
as also end cells as loose item.
2.10 Terminal Posts: Both the +ve and –ve terminals of the cells shall be of proper termination
and shall ensure its consistency with the life of the battery. The surface of the terminal post
extending above the cell cover including bolt hole shall be coated with an acid resistant and
corrosion retardant material. Terminal posts or any other metal part which is in contact with the
electrolyte shall be made of the same alloy as that of the plates or of a proven material that does
not have any harmful effect on cell performance. Both +ve and –ve posts shall be clearly and
unambiguously identifiable.
2.11 Connectors, Nuts & Bolts, Heat shrinkable sleeves:
Where it is not possible to bolt the cell terminals directly to assemble a battery,
separate non-corroding lead or copper connectors of suitable size shall be
provided to enable connection of the cells. Copper connections shall be suitably
lead coated to withstand corrosion due to sulphuric acid at a very high rate of
charge or discharge.
Nuts & Bolts for connecting the cells shall be made of copper, brass or stainless steel. Copper or
brass nuts & bolts shall be effectively lead coated to prevent corrosion. Stainless steel bolts and
nut can be used without lead coating.
The connectors shall be of suitable cross-section to withstand all the working conditions
including 1 min. discharge rate as well as short circuit condition.
All inter cell connectors shall be protected with heat shrinkable silicon sleeves for reducing the
environmental impact including a corrosive environment.
Page 36 of 382
2.12 SEPARATORS: The separators used in the manufacturing of battery cell, shall be of
glass mat or synthetic material having high acid absorption capability, resistant to sulphuric acid
and good insulating properties. The design of separator shall ensure that there is no misalignment
during normal operation and handling. These shall permit free flow of electrolyte and would not
be affected by chemical reaction inside the cell & shall last for indefinite time. The internal
resistance factor of separators shall assure high discharge characteristics under all operating
conditions.
2.13 HYDROMETERS. - Hydrometers suitable for floating in any Cell in the battery, & with
a reasonably long scale permissible for the depth of the cell & capable of reading specific gravity
1100 to 300 with sub-divisions 0.022 shall be provided. A wall mounting type teak wood holder
for the hydrometer shall also be supplied.
2.14 ELECTROLYTE: - The full quantity of electrolyte required for the first filling with 10%
extra shall be included in the offer. The electrolyte shall be supplied in Non-returnable acid
resisting jars. The electrolyte shall generally confirm to IS - 266 or equivalent international
standards. The electrolyte shall have a specific gravity of 1.2 at 270C. Sufficient quantity of
distilled water conforming to IS – 1069 – 1993 shall be supplied in non-returnable containers to
correct the level of electrolyte during initial testing & commissioning.
2.15 SUPPORTING RACKS OR STILLAGE FOR BATTERY BANK:- All batteries shall be
mounted on a suitable metallic stand/frame. The frame shall be properly painted with the acid
resistant paint. The suitable insulation shall be provided between stand/frame and floor to avoid
the grounding of the frame/stand.
The Battery layout arrangement is required to suit battery room dimensions of 7.4x5.7
mtr/existing battery room.
2.16 Capacity requirement: When the battery is discharged at 10 hour rate, it shall deliver 80%
of C (Where C is rated capacity, corrected at 27 degree Celsius) before any of the cells in the
battery bank reaches 1.85 V/cell.
The battery shall be capable of being recharged from the fully exhausted condition (1.75 V/cell)
within 10 Hrs upto 90% state of charge. All the cells in a battery shall be designed for continuous
float operation at the specified float voltage throughout the life.
The Capacity (corrected at 27 degree Celsius) shall also not be less than C and not more than
120% of C before any cell in the battery bank reaches 1.75 V/cell. The battery voltage shall not
be less than the following values, when a fully charged battery is put to discharge at C/10 rate:
(a) After six minutes of discharge : 1.98 V/cell
(b) After six hours of discharge : 1.92 V/cell
(c) After 8 hours of discharge
: 1.85 V/cell
(d) After 10 hours of discharge : 1.75 V/cell
Loss in capacity during storage at an average ambient temperature of 35 degree Celsius for a
period of 6 months shall not be more than 60% and the cell/battery shall achieve 85% of its rated
capacity within 3 charge/discharge cycles and full rated capacity within 5 cycles, after the storage
period of 6 months. Voltage of each cell in the battery set shall be within 0.05V of the average
voltage throughout the storage period. Ampere hour efficiency shall be better than 90% and watt
hour efficiency shall be better than 80%.
Page 37 of 382
2.17 Expected Battery Life: The battery shall be capable of giving 1200 or more
charge/discharge cycles at 80% depth of discharge (DOD) at an average temperature of 27 degree
Celsius. DOD (Depth of discharge) is defined as the ratio of the quantity of electricity (in
ampere-hour) removed from a cell or battery on discharge to its rated capacity. The battery sets
shall have a minimum expected life of 20 years at float operation.
2.18 ACCESSORIES: - The tenderer shall quote unit prices for the following battery
accessories.
Item
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Quantity
Cell testing Voltmeter (range -3 -0- +3 volts) accuracy class 0.5 or better
Rubber apron
Rubber shoes (Knee height)
Thermometer (mercury/ alcohol type)
(0º to 100 º C) with separate gravity correction chart
Glass funnels
Spanners
Acid resisting jars 2 Ltrs capacity
Rubber Gloves
Rubber Siphon
Special tools required for connecting the terminals of batteries
I No.
2 Nos.
2 pairs
2 Nos.
2 Nos.
1 Set
2 Nos.
2 pairs
2 Nos.
2 Sets
2.19 MAXIMUM SHORT CIRCUIT CURRENT:The Bidder shall state the maximum short circuit current of each battery along with the safe
duration in seconds which it can withstand. Methods, proposed to be adopted for protecting
batteries from the short circuit conditions should also be stated to avoid damage to the battery
and loss to the associated equipment.
2.20 VENTILATION:The bidder shall indicate in his bid the requirements of ventilation in the battery room. The
battery shall operate satisfactorily over the entire range of the temperature and humidity indicated
in this specification without affecting its normal life. If any special ventilation requirements are
necessary the same shall be indicated.
2.21 CHARGING:The bidders shall state whether an equalizing charge is recommended for the battery. If so, the
equalizing charge voltage, current, duration and the interval between the equalizing charging
shall be specified in the Data sheet. Bidder shall also indicate the requirements for boost charging
2.22 PACKING: - All materials shall be securely packed, crated & protected against
mechanical damage in conformity 'With manufacturer's standard practice.
2.-23 INSTRUCTION MANUALS:
Eight sets of instruction manuals for installation, commissioning, charging and maintenance
instruction shall have to be furnished.
2.24 Routine maintenance of Battery system: For routine maintenance of battery system, the
contractor shall supply 1 set of following tools:
(a) Torque wrench
(b) Cell test voltmeter ( -3 - 0 - +3) volts with least count of 0.01 Volt.
Page 38 of 382
2.25 Type Test of Battery:2.25.1 Contractor shall submit type test reports of following tests as per IEC 60896-21 & IEC
60896-22, 2004. Tests having been conducted within last five years as mentioned therein shall
not be applicable.
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Description of test
Gas emission
High current tolerance
Short circuit current and d.c. internal resistance.
Protection against internal ignition from external spark sources
Protection against ground short propensity
Content & durability of required markings
Material identification
Valve operation
Flammability rating of materials
Intercell connector performance.
Discharge Capacity
Charge retention during storage
Float service with daily discharges for reliable mains power.
Recharge behaviour
Service life at an operating temperature of 40 degree Celsius for brief
duration exposure time
Impact of a stress temperature of 60 degree Celsius for brief duration
exposure time with 3 h rate discharge test
Abusive over-discharge
Thermal runaway sensitivity
Low temperature sensitivity
Dimensional sensitivity at elevated internal pressure and temperature
Stability against mechanical abuse of units during installation
Tests shall be conducted in accordance with IEC 60896-21 & IEC 60896-22, 2004.
2.25.2 List of Factory & Site tests for Battery:Sl.No.
Test
Factory
Tests
1.
2.
3.
Physical verification
C/10 Capacity Test on the cell
Yes
8 Hrs charge and 15 minutes discharge
test at full rated load
Site Tests
Yes
Yes
2.26 Installation & Commissioning:
Manufacturer of Battery shall supervise the installation and commissioning and perform
commissioning tests as recommended in O&M manual / or relevant standards. All necessary
instruments, material, tools & tackles required for installation, testing at site and commissioning
are to be arranged by Battery manufacturer/Contractor.
Page 39 of 382
2.27
DRAWINGS AND OTHER DOCUMENTS:-
The tenderer shall submit the following drawings/ documents along with his offer failing which
the offer is liable for rejection.
a). General battery arrangement, proposed size of individual and over all dimensions along with
sectional views showing all connections etc.
b). Pamphlets and technical literature giving detailed information of the batteries offered.
Contractor shall submit following documents for approval:
(a) Data sheet / GTP as per Annexure-I
(b) GA of cell and layout drawing
(c) Discharge data for 10 Hour, 8 Hour, 3 Hour, 2 Hour, 1 Hour, 15 minutes and One
minute indicating capacity factors for end cell voltage of 1.75 V & 1.85 V.
(d) Temperature correction factors.
(e) Installation & Commissioning instructions.
(f) O&M manual.
2.28
GUARANTEED TECHNCAL PARTICULARS:-
The Guaranteed technical particulars, as called for in the „Annexure – I & II shall be
furnished along with the tender. Any tender lacking complete information in this respect is
likely to be rejected.
Page 40 of 382
SECTION – 5.5
TECHNICAL SPECIFICATION
BATTERY CHARGER
Page 41 of 382
VOLUME - IIA
SECTION 5.5 - BATTERY CHARGER
TECHNICAL SPECIFICATIONS FOR BATTERY CHARGERS WITH D.C.
DISTRIBUTION BOARDS FOR VARIOUS SUB-STATIONS OF KSPDCL 220VOLTS, 300AH CAPACITY
1.0
Intent of Specification
This section of the specification covers design, manufacture, testing, supply and
supervision of erection and commissioning of battery charger and DC distribution
panel with all materials and accessories required for various Stations of KSPDCL for
boost, float and trickle charging 220V, 300AH battery set and for distribution of DC
supply with efficient and trouble free operation to various equipments in receiving
stations of the owner
1.1
Scope
1.1.1 The brief requirement for each station is detailed below :
a)
A Charger – 1 panel consisting of a separate boost charger and separate
float charger with trickle charging as detailed else where in the
specification.
b)
A Charger – 2 panel exactly similar to (a) above consisting of a separate
boost charger and separate float charger with trickle charging as detailed
else where in the specification and both should be in service.
1.1.2 Two separate DC sources each with one battery charger together with the battery
bank and DC distribution board shall constitute a 220V DC source for supply to
Page 42 of 382
Main-1 & Main-2 numerical relay for distance scheme of protection and various
equipments in the main receiving stations. In addition to this, the charger shall be
capable of being used for initial charging, trickle charging and equalizing charge
as stipulated by battery manufacturer. The arrangement for end cell tapping, if
required will be provided, so that while boost charging, the battery AC supply
voltage fails or float charger feeding loads develops trouble, at least about 84 cells
(84 x 2.62 Volts = 220V) are connected across the load and part of battery
continue to meet the DC requirement till change over takes place and full battery is
put across the load. The detailed circuit arrangement is explained else where in the
specification.
1.2
CODES & STANDARDS:
All the equipments and materials shall be manufactured and tested in accordance
with the latest applicable standards.
1.3
COMPLETENESS OF SUPPLY:
It is not the intent to specify completely herein all details of equipments/
components. Nevertheless, the equipment shall be complete and operate in all
aspects and shall conform of highest standard of engineering design and
workmanship.
Any materials or accessories which may not have been specifically mentioned, but
which is necessary or used for satisfactory and trouble free operation and
maintenance of the equipment shall be furnished.
1.4
SERVICE CONDITION
The battery charger and its associated accessories shall be designed for operation
in the following climatic condition.
i.
Maximum Temperature of Air in Shade
45°
ii.
Minimum Temperature of Air in Shade
5°
iii.
Average Daily Ambient Air Temperature in Degree C.
65°C
iv.
Maximum Relative Humidity
10-100%
Page 43 of 382
v.
Altitude
Less than 1000mm
vi.
Average rainfall
vii.
No. of rainy days per annum
100 Days (Max.)
viii.
Isoceraunic level days /year
46
ix.
Siesmic Level (Horizontal Acceleration).
0.3
100-3000/5000mm
All the equipments, accessories and wiring shall have tropical protection involving
special treatment of metal and insulation against fungus, insects, and corrosion.
1.5
DESIGN CRITERIA
1.5.1 The Battery charger will constitute the DC power supply source for all stations
loads.
1.5.2 The equipment will be installed indoor in a clean but hot, humid and tropical
atmosphere.
1.5.1 The battery charger combination shall be such as to ensure continuity of DC
supply at load terminals at all times without even momentary interruption.
1.5.2 Further, the voltage at load terminals shall never exceed the limits of 10% and –
15% of nominal, system concept.
1.6
System Concept
1.6.1 The battery charger panels shall consists of the following
a)
A Charger – 1 panel consisting of separate boost and float charger suitable
for charging, equalizing charging and trickle charging of 220V, 300AH
battery sets besides meeting continuous and emergency DC loads as
detailed else where in the specification.
The above modes of charging both automatically and manually shall be
through manually operated Auto / manual selection switch.
b)
The boost charger shall be capable of initially charging of the 220V, 300AH
battery at quick rate after an emergency or after a discharge test or for
Page 44 of 382
giving periodical curative charge once or twice a year as per battery
manufacturer‟s recommendations.
c)
The float charger shall always be connected to the DC load and shall
maintain a steady voltage of 220V, plus or minus 0.5 % using a constant
potential controller.
1.6.2 During normal condition the float charger shall be on and working in parallel with
DC load and battery. The rating of the float charger shall be such as to meet the
float charge current requirement of the battery plus the continuous DC load, the
details of which is given else where in the specification. While boost charging the
battery set shall be across boost charger and float charger shall be across the load.
1.6.3 During the boost charging, if there is an AC supply failure, the battery should
automatically be connected to the load to maintain continuity of DC supply.
1.6.4 Further, to have battery supply across load even during short interval of change
over period and if float charger develops trouble, the 84th cell of the battery should
be capable of being connected through a blocker diode to the load so that under
boost charging condition the float charger, the continuous DC load and battery up
to 84th cell are in parallel. A charger – 2 panel exactly same as charger-1 panel is
required as 100% stand by. There should be an interlock in the circuitry such that
if charger No. 1 panel is in service, it should not be possible to put charger No. 2
panel into service and vice versa.
1.7
RATING :
The ratings for boost charger, trickle charger, float charger and emergency lighting
change over system shall be as detailed below :
Sl. No. Particulars
a.
Boost charger
i) Range of voltage
ii) Continuous current rating
b.
Trickle charger and float charger
i) Range of voltage
ii) Continuous current rating – float
iii) Trickle charger current
1.8
Required value
220V, 300AH
190 to 300V
50 Amps
200 to 280 V
20 Amps
200mA Min
800mA Max
Detailed specification for charger panel.
Page 45 of 382
The battery charger shall be supplied complete with all devices including but not
limited to the following. If any device/components felt is required at the time of
approval of drawings, the same shall be provided without any extra cost.
1.8.1 Each charger panel shall consists of –
a)
A Boost charger operating on AC input voltage of 415 volts
–30 % to +10%, three phase, 50hertz, + 5%, to give a DC output ranging
between 190V to 300V so as to quick charge a bank of 110cells each of 2V
from an end voltage of 1.75V to 2.65 / 2.7 V at a Max, continuous rate of
50 A and shall consist of the following components (boost charge current –
start – 50A, finish 25 Amps).
i)
One No. triple pole and neutral pole ON / OFF AC input switch of
adequate rating.
ii)
Required Nos. of HRC fuses with base, fittings etc. for DC output &
AC input.
iii)
Three Nos. of pilot lamps for indicating availability of 3 phase
supply.
iv)
One No. AC contactor triple pole with one normally open contact for
controlling DC contactor connecting battery to the DC bus with
overload release and one No. ON / OFF switch (for providing
interlock between charger – 1 and charger – 2).
v)
One constant potential controller for error detection, load current
detection, amplification etc., so that the Boost charger output voltage
is maintained automatically to the required value, with input voltage
variation detailed above.
vi)
One 3Ph naturally air cooled transformer liberally rated for the
rectifier rating specified with + 2.5% taps on input side for input
voltage correction by means of selection switch mounted on the
Page 46 of 382
front of the panel which can be operated on load for changing the
taping of the input transformer.
vii)
Three Nos. ballast chokes, if required.
viii)
a)
One set of 3- phase full wave bridge connected silicon
rectifier, with zener type thyristor with simple smoothening circuits,
liberally rated to meet the continuous current rating specified with
stepless voltage control.
b)
One set ripple filtering device to limit the ripple content to
less than 2%
ix)
One double pole moulded case circuit breaker backed by HRC fuses
on DC output side.
x)
A set of indicating lamps for DC on indication & A.C supply
indication
xi)
One DC ammeter moving coil type with shunt etc., for measuring
DC output /charge / discharge current and one ammeter for
measuring load current.
xii)
One moving coil voltmeter with selector switch to read boost charge
voltage, float charge voltage, battery tap and off and one volt meter
for AC input voltage.
b)
A float charger operating on AC input voltage of 415 V –30% to + 10%,
three phase 50Hz + 5% to give a DC output ranging from 200V to 280V
separately controlled to give a continuous variable load max 20 A and to
give a trickle charge current of 200 to 800 mA the load current varying
from 0-100% and consisting of the following components.
i)
One AC input triple pole & neutral pole ON/OFF switch of adequate
rating.
ii)
Three Nos. of HRC fuses with fittings.
Page 47 of 382
iii)
Three Nos. of pilot lamps.
iv)
One No. AC input contactor with over –load releases and coil /ON
/OFF switch.
v)
One constant potential controller for error detection, load current
detection, amplification etc., so that the float charger output is
adjusted automatically such that the battery voltage is around 220
volts with load current and input voltage variation detailed above
(both) occurring simultaneously.
vi)
One auto manual change over switch.
vii)
One raise / lower push button for manual operation.
viii)
One main transformer, 3 phase, natural cooled, liberally rated for the
rectifier
rating
specified
with
+ 2.5% taps on input side for input voltage correction by means of
selection switch mounted on the front of the panel which can be
operated on load for changing the tapping of the input transformer.
ix)
a)
One set of 3 phase full wave bridge connected silicon rectifier
with zener type thyristor with simple smoothening circuit liberally
rated to meet the continuous current rating specified with step less
voltage control.
b)
One set of smoothing choke to limit the ripple content to less
than 2%.
x)
One moulded case circuit breaker to control float charger DC output.
xi)
Required Nos. of HRC fuses with base fittings etc for DC output and
AC input.
xii)
One moving coil ammeter for float charger current.
xiii)
One centrezero milli ammeter to measure trickle charging current to
the battery.
Page 48 of 382
[c)
IMPORTANT NOTE :
1.
For each station two charger panels each consisting of one boost charger
and one float charger detailed above shall be supplied.
2.
a)
Fuses for DC output and AC input shall be brought on the
front of the panel and cutouts provided.
b)
Semi conductors devices, Power failure, relay alarms on Ac failure
and to disconnect all internal charger loads from battery to prevent
unnecessary discharging during power failure.
3.
Printed circuit shall be accommodated in modules, plug in type, and similar
modules shall be interchangeable in standard socket chasis.
1.8.2 FOLLOWING
COMMON
EQUIPMENTS
FOR
CHARGER-1
&
CHARGER-2 ARE REQUIRED.
NOTE:
It may be noted that there are two banks of battery sets operating independently
i.e., 1 bank of 300AH battery set. Normally both the banks (300AH) will be in
service.
i)
2 Sets of single pole two way on and off suitably rated for each battery
charger.
ii)
Two sets of single pole two way on and off, suitably rated change over
switch for selection of Battery Float/ Boost mode (one for each battery
bank).
iii)
2 MCCB (one for each battery bank), triple pole for connection of 110th cell
and 84th cell positive and for first cell negative.
iv)
2 DC Contactors, (One for each battery bank), for connecting the battery
110th cell to bus positive through above MCCB.
v)
Two silicon blocker diodes (one for each battery bank) for connecting 84th
cell positive to positive of DC bus through the above MCCB.
Page 49 of 382
vi)
Suitable no. of earth leakage circuits for annunciation both audible and
visual with push button for reset.
vii)
Two sets of milli-ammeter (one set for each battery bank) to indicate the
leakage current when the mid point of the battery is earthed.
viii)
A set of audible and visual alarm annunciation scheme with all necessary
accessories to acknowledge reset and test scheme as also other necessary
relays, with the following facia window.
i. AC Mains fail
ii. Float Charger DC Fail
iii. Boost Charger DC Fail
iv. DC Earth Fault
v. Rectifier fuse fail
vi. Filter fuse fail
vii. Blocking Diode fail
viii. Load Bus DC fail
ix. Boost charger over load
x. Float charger overload
xi. Under voltage of the battery
xii. Over voltage of the battery
xiii.
xiv.
As required
xv.
NOTE :
All MCCB shall be of breaking capacity of 25 KA with over load and short circuit
protection.
1.8.3 A DC distribution board consisting of :
i)
Electrolytic Copper insulated DC bus bars of adequate rating.
ii)
Ten circuits of 60 Amps with switch fuse unit consisting of suitably rated
HRC fuses.
Page 50 of 382
iii)
Ten circuits of 30 Amps with switch fuse unit consisting of suitably rated
HPC fuses.
ii)
One set of automatic emergency light circuits of 10A rating with AC/DC
contactors etc.
1.8.4 The necessary internal wiring, space heater, terminal blocks, panel to mount the
equipments shall be provided.
1.8.5 The equipments not specifically covered in the above schedules but required for
the satisfactory working of schematic arrangements detailed else where in the
specification shall be provided by the supplier, giving all the details.
1.8.6 The makes of all equipments supplied shall be detailed. The equipments shall be
carefully be selected such that only proven components are used particularly the
diodes, thyristors etc., so as to give trouble free operation.
1.8.7 INTEREFRENCE AGAINST RE-CIRCUITS:
The equipment shall be efficiently screened against interference to radio as also
other communications equipment, which may be installed in the same building.
All the sources of noise shall be fitted with Re-suppressors generally in accordance
with relevant ISS/IEC.
1.9
DETAILS OF CHARGER / DC DISTRIBUTION PANELS :
1.9.1 The components detailed in clause 1.5.1 ie., of one boost charger and one float
charger shall be mounted in separate panel. The components common to two
charger panels detailed in clause. 1.5.2, shall be housed in common panel. The
common, panel shall be accommodated in between two charger panels.
1.9.2 The panels shall have maximum height of 2.5 mtrs. and depth around 1.0mtr. It
shall consist of completely enclosed self supporting cubicle type CRCA sheet steel
enclosures for mounting various equipments. Each panel assembly shall have
easily removable hinged door at the back with easy access for inspection and
maintenance.
The sheet steel shall be of minimum 3mm thickness where
equipments are mounted on them and the side and back door sheets shall be
Page 51 of 382
mounted on structural steel of light but rigid sections. The bottom of the panel and
frame works shall be suitable for mounting on slush concreate floor using evenly
spaced ground bolts projecting through the base channel.
The equipment layout on the panel be such as to give neat appearance ease of
operation of various equipments keeping the over all width to the barest minimum.
1.9.3 The rear, side and front enclosing, steel sheet shall be such as to have good
ventilation particularly for the portion housing transformers etc.,
2.0
COOLING :
Natural air cooling shall be employed in all units. Suitable louvers with fine mesh
or perforations are to be provided in the panels for this purpose. The use of fans
etc., for including accelerated air flow is precluded. Oil cooled components are
not acceptable.
2.1
FINISH :
All unfinished surfaces of the steel panels and frame work shall be rust proofed
after fabrication and prior to painting and before applying the finishing coat, and
an under coat suitable to a serve as base and binder for the finishing coat shall be
given. The first coat on the exterior of panels shall be polished cellulose, enamel
or equivalent and of colour to be indicated by the purchaser at al later date. The
interior surface shall be finished stoved enamel white.
A small quantity of
finishing paint shall be supplied with each consignment of panels to enable the
purchaser to restore at site any finish, which may get damaged during transit. The
exterior colour of the panel shall correspond to shade no. 275 of IS-5. The interior
of the panel shall be white enamel.
2.2
Buses, switching devices and connections :
All buses, switching devices and connections shall be of sufficient size to limit to
the temperature raised to 45° C (Peak) inside the enclosure while carrying full load
current. All main bus joints and bus to taps shall be silver plated and tightly
Page 52 of 382
clamped with through bolts to ensure maximum conductivity. All buses wherever
possible shall be of rigid type. They shall be liberally spaced and so mounted that
their expansion and contraction do not subject either the bars or the insulating
supports to any stresses. Wherever required, suitable expansion joints shall be
provided. All bus work and connections shall be accessibly for inspection and
maintenance purpose from end to end rare, after first removing respective
enclosing plates. All buses, AC & DC switches connections shall be designed to
carry 25 KA for 1 second.
2.3
Ground Bus :
For ensuring the rigid connection the minimum section of the ground bus shall not
be less than 160 Sq. mm. The ground bus shall be earthed solidly and connected to
the purchaser‟s station main earthing system through 50 x 6 mm G.I flat with 2
bolts of M12 size.
2.4
SPACE HEATERS AND LIGHTING OUTLETS :
Space heaters shall be provided inside all cubicles and panels to prevent
condensation of moisture. Wiring connection to the space heaters in the cubicles
shall have suitable insulation over a safe length from the heater terminals. All
lightning outlets with the switches etc., shall be provided inside each entrance door
at the back of the panels.
2.5
WIRING
The internal power and control wiring of the charger shall be of adequate rating as
recommended by cable manufacturers and relevant IS.
The interconnecting cables or bus bars carrying load current from the main
transformers secondary onwards upto and including DC output bus bars shall be
copper. Interconnecting leads in the control circuits and leads of filter capacitors
shall also be of copper. Ends of all load current carrying cables shall be fitted with
copper lugs of adequate rating and shall be soldered or crimped effectively to the
conductor to ensure that the temperatures rise at the joints does not exceed that of
Page 53 of 382
the conductors. All cabling and wiring shall be neatly secured in position and
adequately supported. All cables and wire carrying AC supply shall be kept
separate from other cables. The colour scheme employed for the cabling and
wiring shall be shown in the suppliers instructions manual. The colour scheme
employed shall be as follows :
i.
For AC Circuits
-
Grey
ii.
For DC Circuit
-
“Positive”
-Red
“Negative”
-Black
“Earth”
-Green
All outgoing wiring shall be brought out to terminals on terminal blocks provided
with 10% additional terminals. The terminal end shall be provided with suitable
identification marks. All the terminals shall be of nut and stud type of brass coated
with nickel, not less than 8mm and suitably rated to carrying the respective rated
current.
2.6
SPACE FOR CABLE AND CABLE GLANDS :
Sufficient space for receiving the cables inside the switch board on the bottom,
cable glands and mounting arrangements for the feeders shall be suitable for PVC
insulated cables. The size of the cables shall be intimated at later date.
Necessary cable glands for all cables shall be included in the supply.
2.7
MIMIC DIAGRAM :
The mimic diagram shall be incorporated with red and green lamps for indicating
air circuit breakers position. Switchboard purpose, built in resistor type lamps of
low watt consumption inter changeable and suitable for easy replacement shall be
provided. LED lamps are also acceptable.
2.8
NAME AND IDENTIFY PLATES :
Twelve mm (half inch) wide plastic plates bearing suitable identification marks
shall be fixed on the exterior of the switch board in appropriate places to indicate
Page 54 of 382
the function of different switches, electrical devices, measuring instruments etc.,
and circuit breakers. Also suitable designation plates with details shall be provided
for all equipments inside the panel.
2.9
EARTHING :
Earthing of a dead metallic part of bodies of the equipment on the panels shall be
done with a soft drawn single conductor bare copper. Main connection shall have
minimum area of 14.5 mm and the main earthing connection to the earthing bus
bar, 65 sq. mm these wires shall be connected to suitable terminals and clamp
junctions. Soldered connections shall not be employed. The no. of earthing
terminals shall be two for the whole assembly of panels.
3.0
INDICATING INSTRUMENTS :
All instruments shall be of the square switch board type, of 96 Sqmm. Size back
connected, suitable for semi flush mounting and provided with dust light cases for
tropical use with dull black enamel finish. The accuracy class shall be 1.5. The
dials shall be made of such materials as to ensure freedom from wrapping, fading
and discolouring. Marking on scales shall be black on white background. The
dials of the instruments shall be of 2400 scale.
All instruments shall have
practicable laboratory means of adjustments to accuracy. The limits of error shall
be those permissible for switchboard instruments as per IS-1248 or BSS-87. The
instruments shall be capable of indicating correctly when operated continuously at
any temperature from 00C to 500 C. Instruments shall be able to give correct
indication at a temperature of 65 C a for period of 16 hours. Necessary test blocks
shall be provided.
3.1
Regulation :
The DC output shall be maintained at + 1% for input variation of + 10% from no
load to full load and input frequency variation from 47.5 Hz to 52.5 Hz. The
power factor shall not be less than 0.65.
Page 55 of 382
3.2
TESTS OF FACTORY :
The equipment and panels shall be tested in accordance with relevant ISS or BS or
equivalent standards.
3.2.1 ROUTINE TESTS :
During manufacture and on completion the equipment shall be subjected to routine
tests in accordance with latest relevant standards.
3.2.2 TYPE TESTS :
Type test certificates as per relevant standards shall be furnished by the tenderer.
a)
Type tests of battery charger : Radio Frequency interference test.
b)
Routine tests on Battery charger :i)
Insulation resistance test
ii)
Voltage regulation check from 0 to 100% load with + 10% voltage
variation.
c)
iii)
Ripple content measurement
iv)
Heat run test on current limiting value
Routine tests on component parts and accessories as per relevant IS.
TEST WITNESS
Test shall be performed in the presence of Purchaser‟s representatives.
3.2.3 TEST CERTIFICATES
Certified reports of all the tests carried out at the work shall be furnished in 3
copies for approval of the purchaser. The equipment shall be dispatched from
works only after the receipt of Purchaser‟s written approval of test reports.
3.3
SPECIAL TOOLS & TACKLES:
A set of special tools and tackles which are necessary or convenient for erection,
commissioning, maintenance and overhauling of equipment shall be supplied.
3.4.
SPARES:
Page 56 of 382
The Tenderer shall submit a list of recommended spare parts for three years &
satisfactory and trouble free operation indicating the itemized price item of spares.
3.5
TENDER DRAWINGS:
Duplicate copies of the relevant drawings shall be submitted along with the tender.
3.6
CONTRACT DRAWINGS:
The supplier shall submit four copies of the following drawings for approval.
i)
Details of construction of cubicles and complete drawings of the switch
board indicating full details of the location switches, instruments, relays,
bus bars, cable glands, support etc.
ii)
Wiring and cabling diagram for all the circuits.
All devices shall be
numbered according to the international convention.
iii)
Details of construction of boost and float charger.
3.6.1 SUPPLIER SHALL FORWARD
After the drawings are approved six copies of the drawing printed on 90 GSM
paper shall be supplied for immediate use. The supplier should forward the
drawings and literature as follows :
a)
One set of reproducible originals and 12 sets of blue print copies of all
approved drawings along with 12 sets of literature, commissioning and
maintenance manuals to the office of the Chief Engineer, Electy., Tendering
and Procurement, KSPDCL, Kaveri Bhavan, Bangalore – 560 009.
b)
Four sets of blue print copies of all approved drawings along with four sets
of literature and manual to consignees in respect of each of the stations.
c)
Non-supply or part supply of drawings, literature and manuals will be
deemed as incomplete supply of switchboard.
d)
Foundation drawings indicating the details of foundation bolts cable entries
and trenches, etc.,
Page 57 of 382
e)
Elementary diagrams of all controls, metering, protection, annunciation and
other circuits, panel wise. All devices shall be according to SA CODE.
f)
Schematic diagram‟s of PCB‟s and charger.
g)
Dimensional outline of charger drilling diagram and special mounting
arrangement if any of each type of various devices.
3.7
INSPECTION:
All the tests and inspection shall be made at the place of manufacture unless
otherwise specifically agreed upon by the manufacturer and the purchaser at the
time of purchase.
3.8
PACKING:
The supplier shall provide such packing of goods as is required to prevent damage
or deterioration during transport to their final destination. The packing shall be
sufficient to withstand, without limitation, rough handling during transport and
exposure to extreme temperature and open storage. The packing case, size, rates
shall be taken into consideration, where appropriate, the remoteness of goods final
destination and the absence of mechanized heavy handling facilities, at all points
in transport.
3.9
DEVIATION FROM TECHNICAL SPECIFICATION:
The tenderer shall furnish the details of deviation/modification proposed by him to
improve overall performance of the system. The deviation shall be brought in the
tender clause by clause as per annexure.
4.0
PERFORMANCE GUARANTEE:
The equipments offered shall be guaranteed for satisfactory performance for a
period of 60 months from the date of satisfactory commissioning of equipment.
Page 58 of 382
The equipment found defective / failed within the above guarantee period shall be
replaced or repaired by the supplier free of cost within one month from receipt of
intimation. If the defective / failed components of battery chargers are not replaced
/ repaired as per the above guarantee clause, the KSPDCL shall recover an
equivalent amount plus 15% supervision charges from any of the supplier‟s bills.
4.1
MINIMUM EXPERIENCE FOR QUALIFYING AS TENDERER :
4.1.1 The tenderer shall have a minimum experience of five years in the design,
manufacture, testing and commissioning of Battery charger similar to the type
specified in the present enquiry. At least 50% of the quantity of similar type of
battery charger called for in the present enquiry shall be in successful operation for
a minimum period of two years. The tenderer shall also furnish the details of
similar battery charger supplied by them so far giving order reference, name and
address of the customer etc., also indicating the date of commissioning. The
tenderer shall also furnish performance certificates for a period of minimum two
years of similar battery charger in proof of the satisfactory operation of battery
chargers.
4.1.2 Test reports for the test conducted in accordance with relevant ISS or BS or
equivalent standards shall be supplied. Three copies of test certificates shall be
furnished along with the tender without which offer is liable to be over looked.
Further the test certificates furnished shall pertain to test carried out not older than
five year from the date of notification of bid.
********
Annexure - I
Schedule of guaranteed Technical particulars of 220V,
300AH Battery Chargers.
Sl.
No.
Particulars
Page 59 of 382
1.
Manufacturer‟s type of designation
:
2.
Type of Rectifier and rating as per
:
IS – 3895 – 1966 with latest version.
3.
Input AC supply.
a)
Voltage
:
b)
Current
:
c)
No. of Phases
:
d)
Frequency
:
e)
Power Factor
:
4.
Percentage Tap provided on the
Transformer +/- & Voltage ratio of
5.
6.
7.
8.
Transformer & KVA rating.
:
i.
For Boost Charger
:
ii.
For Float Charger
:
Boost/Quick charge current
Minimum
:
Maximum
:
Float Charge Current
Minimum
:
Maximum
:
Trickle Charge Current
Minimum
:
Maximum
:
Whether Auto/Manual feature is
:
provided.
9.
Whether voltage across load is
constant while boost/quick charging
:
the battery.
10.
Whether Automatic change over from
boost charging mode to float charging is :
provided when AC failure takes place.
11.
a) Allowable limits to voltage variation
Page 60 of 382
on A.C. side for satisfactory charging
:
of DC side.
b) Type of device on AC side
12.
:
Instantaneous forward voltage drop
versus instantaneous current at rated
:
service (a graph to be enclosed)
13.
Type of voltage control for Boost Charger,
Float charger & Trickle Charger
14.
:
Instantaneous reverse current
versus instantaneous reverse volts
:
at rated service (a graph to be enclosed)
15.
Range of variation of DC voltage :
and device used for the same.
16.
17.
Rated DC output for
a) Boost Charger
:
b) Float Charger
:
D.C. output voltage regulation from
no load to full load.
:
18.
Maximum ripple content in %
:
19.
Maximum permissible temperature
rise over an ambient temperature
:
20.
Whether the charger is tropicalised
:
21.
Over load capacity.
:
22.
Duration of overload.
:
23.
Efficiency at
24.
a) 25% Load.
:
b) 50% Load
:
c) 75% Load
:
d) 100% Load
:
Dimensions of the charger width x
:
Height x depth in mm
25.
Weight of the charger in Kgs.
:
Page 61 of 382
26.
Recommended spares
:
27.
List of major accessories provided
:
28.
Other Details, if any
:
29.
Rating & make of Thyristor
:
30.
Meters
Ammeter / ltmeter
31.
i)
Type & Make
ii)
Size
iii)
Scale Range
iv)
Accuracy
Heat Sink for Boost Charger & Float Charger
Whether provided
:
Details of Components & Rating
I
II
DC Distribution Board
i.
Maker‟s Name
:
ii.
Country of Manufacturer
:
ii.
Number of Circuits with rating
:
BUS BARS
i.
Sectional Area
:
ii.
Material
:
iii.
Current Carrying Capacity
:
iv
Maximum Temperature rise over 45oC
ambient with continuous full load
v.
III
IV
condition
:
Type of Supporting Insulator
:
Small Wiring
i.
Type
:
ii.
Size
:
Moulded Case (OR Equivalent)
Air Break Switch & Fuse Units
i.
Type
:
ii.
Make
:
Page 62 of 382
iii.
Normal Voltage
:
iv.
Normal Current
:
v.
Interrupting Capacity
:
vi.
Fusing Factor for fuses
:
vii.
Temperature rise of contact under oC
continuous full load condition over 45o
viii.
V
VI
VII
ambient temperature
:
Material & Type of Contact
:
Dimensions of Battery Charging Panel
(Including DCDB)
:
i.
Width
:
ii.
Depth
:
iii.
Height
:
Dimension of DC Distribution Panel
i.
Width
:
ii.
Depth
:
iii.
Height
:
i.
Number of Crates for Shipment, Shipping
Dimensions of the largest crate
ii.
Whether equipments and the switchboards
are tropicalized or not
iii.
:
How is access provided to the
switchboard interior
iv.
:
:
Mounting Arrangements for cable
glands provided.
:
Date :………………..
Signature :…………………………
Place :………………
Designation:……………………….
Company:………………………….
Annexure - II
Schedule of Tenderer’s Experience
1.
Name of the Manufacturer
:
Page 63 of 382
2.
Standing of the Firm as manufacturer of
Equipment
3.
Testing Facility at manufacturer‟s work.
4.
If the Manufacturer is having collaboration With
:
:
another Firm, details regarding standing of :
parent Firm, Period of collaboration
5.
Description of equipment similar to that quoted,
supplied and installed during the last 5 years
with names of parties to whom the supplies are
made along with PO No., the names of persons
:
Shall be furnished in the
Form indicated below
to whom a reference may be made by purchaser
in case the considers such a reference necessary
Sl.
Description
No.
(a)
(b)
Value
Place
Period of Client Persons to whom
of
Where
Execution
reference can be
Work
installed
& date
made
(c)
(d)
(e)
(g)
(h)
Date :………………..
Signature :…………………………
Place :………………
Designation:……………………….
Company:………………………….
Annexure - III
Page 64 of 382
SCHEDULE
OF
DEVIATIONS FROM SPECIFICATION
All deviation from this specification, shall be set out by the bidder, clause by clause, in
this schedule, unless specifically mentioned in this schedule the bidder shall be deemed to
conform to the owner‟s specification.
Sl.
No.
Specification
No.
Clause Deviation By the Tenderer
Justification
Deviation
Date :………………..
Signature :…………………………
Place :………………
Designation:……………………….
Company:………………………….
Page 65 of 382
for
SECTION-5.4
TECHNICAL SPECIFICATION
LIGHTING SYSTEM
Page 66 of 382
VOLUME - IIA
TECHNICAL SPECIFICATION
Clause No.
Particulars
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
Lighting System
Schedule of quantities
Codes and Standards
Lighting Fixtures and Accessories
Receptacles
Switch and Switchboards
Conduit and Conduit accessories
Junction Boxes
Terminal Blocks
Pull out Boxes
Void
Emergency Portable Lighting Fixtures
Lighting Poles
Ceiling fans and Regulators
Lighting wires
Painting of shop made items
Tests and Test reports
Lighting system installation works
System description
Page 67 of 382
VOLUME-IIA
SECTION 5.4: LIGHTING SYSTEM
1.0
LIGHTING SYSTEM:
1.1
General:
1.2
The scope of work comprises of design, engineering , Supply installation, testing
&commissioning of various lighting fixtures complete with lamps, supports & accessories,
ceiling fans complete with regulators and accessories, lighting poles complete with distribution
boxes, galvanized rigid steel conduits, lighting wires, G.I Earth wire , receptacles, switchboards,
switches, junction boxes , pull out boxes complete with accessories both in control room &
outdoor yard. The bidder has to quote for ceiling quantities for various type of luminaries based
on the area and level of illumination required payment will be made for the ceiling quantity vis-avis the actual quantity vis-à-vis at after the detailed Engineering, whichever is less.
1.3
The minimum lux levels to be maintained in the different areas shall be as per following
Sl No
1
2
3
4
5
6
7
8
9
Area
Control room
PLCC Room
LT Room
Battery Room
Corridor & Landing
DG Set Room
Tool Room
Toilet
Switchyard layout
10
Street / road
Average level
350
300
150
100
150
150
150
50
50
Remark
At floor level
At floor level
At floor level
At floor level
At floor level
At floor level
50 lux on main equipments ( power
Tr., capacitor banks , isolators, circuit
breakers, CT, CVT, VTs, surge
Arrestors etc) at first level (
equipment connection level), 20 lux
on balance areas of switchyard
ground level.
At ground level
Bidder shall submit detailed calculation for reaching the above LUX levels. The contractor shall
confirm the lux levels at different locations by measurement after execution of work . ( 2
locations in 220 KV / 110 KV/66KV switchyard & one in each of above place).
1.4
Scope of Work:
The equipment to be furnished & erected as covered in this volume
shall be designed, engineered, manufactured , type tested ,
supplied received at site, unloaded , stored & erected , tested &
commissioned as per requirement specified here under.
Page 68 of 382
1.6
Supply, Storage & Installation of :
i)
ii)
iii)
Lighting fixtures complete with lamps &
accessories.
Receptacles & switchboards
Galvanized iron conduits for lighting system wiring &
fixture supports, complete with all accessories including junction boxes & pull out boxes
& associated civil works.
iv)
Lighting cables & wires for wiring of all lighting fixtures, ceiling fan points,
receptacles etc, from lighting panels/ switch boards.
v)
Lighting poles including associated civil works.
vi)
Earth wires / rods / falls for all lighting fixtures, ceiling fan points, receptacles & GI
conduit installation.
vii)
Battery operated portable the fluorescent lamps & fixtures.
viii) 1400 mm sweep A.C.230 volts ceiling fan.
1. 7
Supply of aluminum ladders for the maintenance of lighting system.
1.8
The following specific areas are included in the scope of lighting.
i)
ii)
iii)
iv)
v)
220K'V / 1 10KV/& 66KV switchyard Area.
Switchyard Control Room building.
DG Set room.
Street lighting inside substation premises
Any other area like 11KV switchyard, approach road etc
intimated to vendor during detail engineering.
1.9
The detailed drawing showing the lighting layout of these areas shall be prepared
by
the bidder & submitted for approval. The above layout
drawings will include disposition &
location of lighting fixtures, receptacles,
switchboards, ceiling fan points etc-, The conduit
layout for substation buildings, cable schedule for sub-station yard etc., for wiring of these
equipment shall also be prepared by the contractor & shall be submitted for approval
1.10 Associated minor civil works like fixing of anchor bolts, breaking of
floors/walls
for fixing conduits / pipes / earth conductors. Sealing of floor /
wall openings after conduits,
pipes, earth conductors have been put shall be carried out by the contractor. Further, Civil
works associated with
erection of lighting poles. Lighting panels etc, are also 'included in
the
scope of the contractor. Hardware's, in addition to conduit required, for
fixing
arrangement for various lighting fixtures are also included in the contractor's scope.
1.11 The supply & erection of double compression glands & lugs required for termination of
cables in receptacles & junction boxes, lighting , panels,
sub-lighting panels, street lighting,
junction boxes & any other area are in
contractor's scope.
1.12 Power cables shall be laid through the available cable trenches to the
maximum
extent possible. Whether cable trench is not available, the cable
shall be laid buried under
ground. The contractor shall quote the unit price
of cable laying & termination in the RCC
trench & buried cable trench separately.
1.13 Each cable & conduit run shall be tagged With number that appears in the cable
&
conduit schedules. Cables & Conduits shall be tagged at their
entrance and/or exit from any
piece from any piece of equipment, junction or pull box floor opening etc.,
1.14 The tag shall be made-up of aluminum with the number punched on it & securely
attacked to the cable by not less than two turns of G.l. wire. cable tags shall be rectangular in
Page 69 of 382
shape for power cables & circular shape for control cables.
1.15 Location of cables laid directly under ground shall be indicated clearly by cable maker
made of galvanized iron plate embedded in concrete block.
1.16 The location of under ground cable joints if any, shall be indicated clearly with
cable
marker with an additional inscription "Cable joint.
1.17 The marker, which is a concrete block, shall project 150mm. above ground
& shall
be spaced at an interval of 30 meters & at every change of direction . It shall also be located on
both sides of the road or drain
crossing.
1.18 The contractor shall furnish & install all tags & markers stated above. The rates
for
supply & erection of these tags & markers have to be included in the erection rates quoted for
cable laying & termination.
1.19 Any material, wire, conduits, accessories etc., not specially mentioned or specified but
required for Installation of lighting fixtures are included in the
scope of contractor.
1.20 The successful bidder shall furnish a computer print out for illumination levels
at
intervals of every 10 metres in the sub-stations area and also
within the buildings. .also
after the installations the illumination at various
points of switchyard will have to cheeked by
suitable instrument for the illumination levels as per specifications.
2.0
SCHEDULE OF QUANTITIES:
The contractor shall supply & install the following equipment accessories in accordance with the
specification.
2.1
VOID
2.2
VOID
2.3
LIGHTING FIXTURES & RECEPTACLES:
The fighting fixtures shall be of standard make only. The typical types are indicated infra.
Sub
item
Type
FC
SC
F1
IF
SF2
Description
2 x 36 W fluorescent lamp in corrosion proof fixture consisting of a
canopy made of fibre glass reinforced polyester (FRP) with gasket a
gear tray made of sheet steel & a reeded acrylic cover fixed by toggle
clips, similar to Philips Cat. No. TDC-10/240/bajaj Cat No.BJI-240
FG/Crompton Greaves.
150 W SON-T Tubular Sodium – Vapour lamp in street lighting
luminary. A special optical reflector clear acrylic cover, a single piece
die cast aluminum housing made out of LM6 & corrosion resistance
proof similar to Philips Cat No. SRP-51 & bajaj Cat No.
BJMSC/150/Crompton Greaves.
2 x 36W fluorescent lamps in industrial reflector type fixture, complete
with accessories & suitable for pendent Mounting, similar to Philips
Cat TKC 24/240 Bajaj cat No. BJIV – 240/ Crompton Greaves.
100W incandescent GLSD lamp in recessed black/anodized bowl,
reflector with provisions fro lamp replacement from bottom, similar, to
Philips Cat. No. BJDR-100/Crompton Greaves.
2 x 250 W, HP Sodium vapour lamps in high Flood lighting fixture
suitable for outdoor mounting with aluminum enclosure: similar to
Page 70 of 382
SF1
PF
IB
FF
MP
Philiphs Cat. No. SNT001/Bajaj Cat. No. BJEF-22CA/Crompton
Greaves.
Weather Proof integral Floor lighting with housing made of corrosion
resistant die cast aluminum painted black. Grey powder coated outside
suitable for 150 W SON-T lamp for termination with conduits/flexible
Cat. No. SNT 100/Bajaj Cat No.BGEMF-150W/Crompton Greaves.
1x11 CFL lamp emergency light with battery operated portable fixture
with build in battery & battery charger suitable for a lighting period to
six hours similar to alpha Deluxe of M/s.DELTA FLASH
LITE/MICRO LITE of M/s. MICRO.
9W CFL lamp in bulkhead fixtures with cast Aluminum alloy body,
suitable for column, wall & ceiling mounting finished stove enameled
silver gray outside white inside, to be supplied complete (priest, front
glass, wire guard, tropicalised, gasket & E.S. Procelain, lamp holder
taped ¾ E.T. for conduit entry) similar to Philips Cat.No. FXC
101/Bajaj Cat. No. BJBE-19/Crompton Greaves.
2x36 fluorescent lamp with mirror optics in recseed mounting type
decorative fluorescent fitting consisting of whit stove enameled sheet
steel housing with accessories & reflector of aluminum sheet steel duty
of aluminum sheet duty electro-chemically brightened & iodized fitted
with aluminum lamellae white. Similar to Philiphs Cat No. TBS285/236 & Bajaj Cat. No. 240/Crompton Greaves.
125 W MV Lamp, in weather proof post top latern with case aluminum
canopy, mounting piece, opal acrylic cover tripod gasket & all other
accessories for mounting on pole top similar to Philips Cat.No. HRC40/Crompton Greaves.
RECEPTACLES
RO
RI
RP
SWITCH BOARDS
SWD1
SWD2
15 A, 240V, Outdoor Receptacle.
5/15A, 240V, Indoor Receptacle.
63A, 415V, Interlocked switch
Socket , Outdoor Receptacle.
Decorative type switch-board with
Nos.-5A switches & No-5A receptacle.
Decorative type switch-board with
Nos.-5A switches & No-5A receptacle.
CONDUITS & ACCESSORIES
Galvanised Rigid Steel Conduits:
Sub – Item
Description
19 mm
25 mm
32 mm
40 mm
JUNCTION BOXES
Page 71 of 382
Sub – Item
Description
Qty. in Nos.
Junction Box with 5 Nos.
Of terminal blocks
LIGHTING POLES
Sub – Item
Description
Qty. in Nos.
Type A1 poles
Type E1 poles
LIGHTING WIRES
Sub – Item
Description
Qty. in Nos.
2.5 Sq. mm Cu
4.0 Sq. mm Al
6.0 Sq. mm Al
10.0 Sq. mm Al
Sub – Item
Description
Qty in metres
15 SWG GI wire 50x6 thick
M.s. Road 20mm Dia M.S.
Road.
1400 mm Sweep with
Ceiling fans (Nos.)
Electronic regulator
MAINTAINANCE EQUIPMENT (Nos.)
Cart wheel mounted aluminum
Ladder vertical height 7.5 mtrs.
CABLE LAYING IN RCC CABLE
TRENCHES & TERMINATION (Kms)
415V – 4C x 95 Sqmm. Al. PVC
415V – 2C x 25 Sqmm. Al. PVC
415V – 2C x 6 Sqmm. Al. PVC
Armoured cable
415V – 2C x 70 Sqmm. Al. PVC
Power cable
Page 72 of 382
CABLE LAYING IN BURRIED CABLE
TRENCHES & TERMINATION (Kms)
415V – 4C x 70 Sqmm. Al. PVC
415V – 2C x 25 Sqmm. Al. PVC
415V – 2C x 6 Sqmm. Al. PVC
Armoured cable
415V – 2C x 70 Sqmm. Al. PVC
Power cable
3.0
CODES AND STANDARDS
3. 1
The design, manufacture, performance of equipment shall comply with all currently
applicable standards, regulations & safety codes in the locality where the applicable, will be
installed. Nothing in this specification shall be constructed to relieve the Bidder of these
responsibilities.
3
Unless other-wise specified equipment offered shall confirm to latest applicable Indian &
IEC standards. Equipment complying, with any other authoritative standards such as 7-3r-1tish,
U.S.A, VDE etc., will also be considered if it ensures performance equivalent be installed.
Nothing in this application shall be constructed to relieve the bidder of these responsibilities.
LIGHTING FIXTURES & ACCESSORIES
i)
IS: 19 13
General & safety requirements for
electric lighting fittings.
ii)
IS:3528
Waterproof electric lighting fittings.
iii)
IS:4012
Dust proof electric lighting fittings.
iv)
IS:4013
Dust tight proof electric
fittings.
v)
IS: 10322
Industrial' lighting
reflectors.
vi)
IS: 10322
Industrial lighting fittings with metal
reflectors.
vii)
IS:2206
Well glass lighting fittings for use under ground in
mines(non-flame prooftype)
viii)
IS: 10322
Specification for flood lights.
ix)
IS: 10322
Specification for decorative lighting outfits.
x)
IS: 10322
Luminaries for street lighting .
xi)
IS:2418
Tubular fluorescent lamps.
lighting
fittings with metal
Page 73 of 382
xii)
IS:9900
High pressure mercury vapour lamps.
xiii)
IS: 1258
Specification for
fluorescent lamps.
xjv)
IS:3323
Bi-pin lamp holder tubular fluorescent
lamps.
xv)
IS: 1534
(Part-1)
Ballasts for use in fluorescent lighting
lamps.
xvi)
IS: 1569
Capacitors for use in fluorescent
lighting lamps.
xvii)
IS:2215
Starters for fluorescent lamps.
Bayonet
xviii) IS:33324
Holders for starters
fluorescent lamps.
xix)
IS:418
GLS
xx)
IS:3553
Water tight electric fittings.
xxi)
IS:2713
Tubular steel poles.
xxii)
IS:280
MS Wire for general engg. Purposes.
lamp
for tubular
lamps.
3.4 CONDUITS, ACCESSORIES & JUNCTION BOXES
i)
IS:9537
Rigid steel conduits for electric wiring
ii)
IS:3480
Flexble steel conduits for electric
wiring.
iii)
IS:2667
Fittings for rigid steel conduits for
electric wiring.
iv)
IS:3837
Accessories for rigid steel conduits for
electric wiring
v)
IS:4649
Adapters for flexible steel conduits.
vi)
IS:5133
Steel & Cast Iron boxes.
vii)
IS:2629
Hot dip galvanizing of Iron & Steel.
LIGHTING PANELS:
I)
IS:13947
LV Switchgear & Control gear
(Part- I to 5)
ii)
IS: 8828
CB's for over current protection for
Page 74 of 382
house hold & similar installations.
iii)
IS: 5
Ready mix paints
iv)
IS:2551
Danger notice plates.
v)
IS:2705
Current Transformers.
vi)
IS:9224
HRC Catridre fuse links for voltage
vii)
IS:5082
Wrought aluminum & Al. Alloys, bars.
Rods, tubes & sections for electrical purposes.
viii)
IS:8623
Factory built Assemblies of Switchgear & Control gear for
voltages upto, & including 1000V AC & 1200V DC.
ix)
IS: 1248
Direct Acting indicating instruments.
CABLES:
IS: 694 PVC insulated cables for working
voltages upto & excluding 1100 volts.
IS: 1293
3 Pin plug.
IS: Two or three ceiling roses.
IS:3854
Switches for domestic & similar
purposes.
IS:5216
Guide for safety procedures & practices
in electrical work.
IS:732
Code of practice for- electrical vdring
installation
(System
voltage not
exceeding 650v.
IS:3043
Code of practice for earthing
IS:3646
Code of practice of interior alluminum
part 11 & 111.
IS: 1944
Code of practice for lighting of public
through fares. ,
IS:5571
Guide for select-ion 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 uniformly of coating
Page 75 of 382
on zinc coated articles.
IS:6005
Code of practice for phosphate Iron
Steel
INDIAN ELECTRICITY ACT.
INDIAN ELECTRICTY RULES.
LIGHTING FIXTURFS & ACCESSORIES.
4.1
General:
All lighting fixtures & 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,
4.2 Temperature Rise:
All lighting fixtures & 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 degree C.
4.3
Supply Voltage
4.3.1 Lighting fixtures & accessories meant for 24OV A.C. operation shall be suitable for
operation on 240V A.C. 50 Hz, supply With specified voltage & frequency variation between
168 to 264 volts
4.3.2 Lighting fixtures & accessories meant for 220V D.C. operation shall be suitable for
operation on 220V D.C. with variation between 190 to 240 Volts.
4.4
Lighting Fixture
The Lighting fixtures & accessories shall be Phillips or Bajaj or Crompton greaves make
only. The different types of lighting fixtures are as indicated at Annexure-I.
4.4.1
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.
4.4.2
All Lighting fixtures shall be complete with fluorescent tubes/ incandescent
lamps/mercury vapour / sodiumvapour lamps as specified & shall be suitably wired up.
4.4.3
All mercury vapour & sodium vapour lamp fixtures shall be complete with accessories
like ballasts, ignitrons, power factor improvement capacitors etc., These shall be mounted
as far as possible in the fitting assembly only. If these cannot be accommodated inside ,
then a separate metal enclosed box shall be included to accommodate the accessories in
addition with a fuse & terminal block suitable for loop-in , loop-out connections .
Outdoor type fixtures shall be provided with outdoor type weather-proof box. The Bidder
shall indicate starting time of these lamps to attain full light output. Curves for starting,
characteristics with varying supply voltage etc., are to be furnished by the contractor.
Page 76 of 382
4.4.4
All fluorescent lamps fixture shall be complete with all accessories like ballasts. power
factor improvement capacitors, lamps, starters, Holders etc.,
4.4.5
High bay fixtures shall be suitable for pendeng Mounting & the floodlights shall have
suitable base Plate / frame for mixing on structural steel member. Hook mounted High
bay figures are not acceptable.
4.4.6
Each fixture (other than bull head fixtures) shall have Terminal blocks suitable for 2.5 sq
mm stranded copper conductor. The internal wiring should be completed by the
manufacture & terminated on the above terminal blocks. Tae bidder shall specifically
furnish details of internal size of wires, type of installation including other technical
particulars & indigenous availability. In certain cases the fluorescent fixtures, which are
located adjacent to each other, shall require adequate terminals to facilitate loop in - loop
out connections of 2.5sqmm. Stranded copper conductor The above shall be as curtained
by the tendered at the Time of erection. The terminal blocks shall be as specified in clause
no. 9 of this section.
4.4.7
Each lighting, fixture shall be provided with an earthing terminal suitable for connection
to 16 SWG GI earthing conductors.
4.4-8 All metal or metal enclosed parts of the housing shall be suitably constructed so as to
ensure satisfactory earthing continuity throughout the fixture upto the earthing terminal
4.4-9 The mounting facility & conduit knock-outs for the fixtures shall be as specified & shall
be suitable for minimum 20-conduit entry.
4.4-10 On completion of manufacture, all surfaces of the fixtures shall be thoroughly cleaned &
degreased. The fixtures shall be free from scale, rust, sharp edges &
burrs.
4.4-11 All enamel finishing shall have a minimum thickness of 2 mils for outside
surface & 1.5 mils for inside surface. The finish shall be non-porous & free
from blemishes, blisters & fading,
4.4.12 The housing shall be stove -enameled or vitreous enameled or anodized
aluminum as indicated in the specification of the relevant fixture.
4.4.13 The surface shall be scratch resistant & shall show no sign to cracking or flaking
bent through 90 degree. Over 1/2 inch diameter mandrel.
when
4.4 14 the light reflecting surfaces shall have optimum light reflecting, co-efficient
such as to ensure the overall light output as specified by the manufacturer.
4.4.15 The diffusing levels used in the fluorescent fixtures specified (as applicable) shall be
made of height compact.. Polystyrene sheet & shall have no yellowing property over prolonged
use.
4.4.16 For certain areas the fixtures offered shall be suitable for provision of
vibration dampers, if required during installation to enable the lamps to perform the full
lamp life. Bidder shall indicate the cost of such dampers separately.
4.4.17 The different types of lighting, fixtures required are as indicated in clause
Page 77 of 382
2 above.
4.4.18 Accessories
4.5.1
Reflectors
The reflectors shall be manufactured from sheet steel
aluminum as applicable of not less than 22 SWG
thickness. They shall be securely fixed to the captive
type.
4.5.2
Lamp holders & starter holders
4.5.3
a)
Lamp holders &starter holders for florescent tubes shall be of the spring
loaded, low contact resistance, begin rotor type, resistant to wear & suitable for operation at the
specified temperature, I out deterioration in with insulation value, contact resistance or retention
of the lamp/starter. They shall hold the lamp/starter in position under normal shock & variation.
(b)
Lamp holders /starter for incandescent lamps &HPMV/HPSV lamps shall
be of screwed, manufactured in accordance with relevant standard &designed to give long &
satisfactory service.
4.5.4
BALLASTS:
a)
b)
c)
d)
e)
The Ballasts shall be designed, manufactured &
supplied in accordance with relevant standard &
function satisfactorily under site condition specified.
The ballasts shall be designed to have a long service life
& low power loss.
Ballasts shall be mounted using self-locating antivibration during & shall be easy to remove without
dismantling the fixtures. They shall be totally enclosed
units.
The Ballasts shall be of the inductive, heavy duty
filled the thermosetting insulating moisture
polyester compound filled under pressure or vacuuming
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/HAPSV
lamps shall be provided with suitable to set the
voltage within the range specified End connections &
taps shall be brought out in a suitable terminal block,
rigidly fixed to the ballast enclosure.
Separate ballast for each lamp shall be provided in case
of multi-lamp fixtures.
The successful Bidder has to submit G.A. & wiring
diagram with all terminal details for owner's approval.
4.5.4 Starter:
Starters shall have bimetal
electrodes & high mechanical strength.
Starters
Page 78 of 382
shall
be replaceable without disturbing the reflector or lamps & without the use of any tool. Starters
shall have brass contacts & radio
interference suppressing capacitor.
4.5.5
CAPACITORS:
a) The capacitors shall have a constant value of capacitance & shall be
across the supply of individual lamp circuits.
connected
b) The capacitors shall be suitable for operations at supply
voltage as specified & shall have 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.
4.6
Lamps:
4.6.1
General Lighting Services (GLS) lamps shall be provided
with screwed caps
shall be of 'clear' type unless
otherwise specified.
4.6.2
The fluorescent lamps MDS shall be 'Day-light-colour' type
unless otherwise specified & shall also be provided,
features to
avoid blackening of lamp ends. The bidder
should clearly state these, features in the bid.
4.6.3
Mercury vapour lamps, sodium vapour lamps shall be
colour corrected type, with screwed caps.
4.6.4
The lamps shall be suitable for use in any position.
Restrictions, if any, shall be clearly stated in the bid.
4.6.5
The lamps shall be capable of withstanding small
vibrations & the connections at lead-in-wires
filaments / electrodes shall not break under such
circumstances.
&
4.6.6
The constructional features of gas discharge lamps for
special applications shall be included in the bid.
4.6.7
The contractor shall supply and install all the above
type of lamps. The cost of the lamps shall be included in
that of the lighting figures as specified.
4.7
The bidder shall furnish typical wiring diagram for
fluorescent. HPMV HPSV fitting including
all
accessories. The diagram shall include technical details
of accessories the, starters , chokes, capacitors etc.,
Page 79 of 382
4.8
Flexible conduits if required, for any fixture shall be
deemed to be included in the contractor's scope.
5.0
RECEPTACLES
a)
All receptacles shall be of cost steel/aluminum, heavy
duty type, suitable for fixing on wall/column & 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 m2C x 6 sq mm. PVC armored cable &
a metallic cover tied to it with a metallic chain &
suitable for installation in most location indoor/outdoor. The switch
shall be of rotary type. Receptacles shall be housed in an enclosure
made
out of 2mm thick G1 -sheet with hinged door quality
padlocking
arrangements. Door shall be lined with good quality
gasketing and shall
conform to IP-55.
ii)
Type RI - Combination of 5A & 15 A, 240V, 3 pin type with
third pin grounded, suitable for flush mounting.
The switch shall be
of piano key type & shall be flush mounted.
iii)
6.0
Type RP-63A, 415%!, 3 phase, 4 pin interlocked plug &
switch with contacts. Other requirements shall
be same as The receptacle shall be suitable for
3.5Cx.25/3.5x70sqmm. Aluminum conductor cables
entry & shall also be suitable for loop-in & 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 2mrn thick G.I.sheet, with
hinged door with radio arrangement. Door shall be
lined with good quality casketing . They shall conform
to IP-55.
SWITCH & SWITCH BOARDS
a)
All switch boards/boxes~ shall be of bent steel construction,
fabrication of 16 SWG sheet with 6mm thick Bakelite or 3mm thick
Perspex sheet cover.
b)
Switch board/boxes located M* office building areas shall be flush
mounted type or brick wall with only the switch knob projecting
outside.
c)
Switch board/boxes shall have conduit knock outs on all the sides.
Adequate provision shall be made for ventilation of these boxes.
d)
Flush type receptacles provided shall be so located that only the
Page 80 of 382
plug project outside.
e)
Switches shall be of piano key type having quick make & quickbreak mechanism complete with position indicator & shall
conform to relevant standard.
f)
Regulator for fans wherever present shall be mounted
on a separate board.
g)
All the components housed in the switchboard shall be used to an
outgoing terminal block by 2.5sqmm. Stranded copper wire (as
specified in clause 15 of this section). The terminal block shall be of
adequately rated & shall be as specified in Clause No. 9 of this
suitable for termination of sizes up to 2 nos. 10mm
stranded
conductor:- on the outgoing side.
section,
Aluminum
h)
The exact number of switch of the same in the switchboard shall
be to the requirement during installation.
7.0
CONDUITS & CONDUIT ACCESSORIES:
7.1
The contractor shall supply & install] all rigid steel, heavy duty conduits all accessories
required like associated couplers, pull out boxes, elbows, tees, reducers, junction boxes, steel
wire for cable/wire pulling, GI saddles, screws, bolts, nuts required. The size of conduits to be
used shall be as required supply erection of ail accessories excepting GI wire & junction boxes
shall be included in unit rates quoted for erection of conduits.
7.2
All conduits shall be seemed by wedding, shall be of heavy gauge & shall be hot dip
galvanized.
7.3
The conduits shall conform to IS: 9537. The minimum size of conduit shall be 20mm.
7.4
Each of conduits shall be straight, free from blister & other defects & furnished in
standard length of 3.0 Mts. threaded at both ends. The manufacturer's name shall be stamped on
each piece.
7.5
Flellble conduits wherever required shall be made with bright, cold rolled annealed &
electro-galvanized mild steel strips.
7.6
All conduits accessories shall conform to relevant IS & shall be hot dip galvanized.
8.0
JUNCTION BOXES:
8.1
The contractors shall supply & install the junction boxes.
8.2
The junction boxes shall be suitable for mounting on walls, columns, lighting poles,
structures etc., The supply & erection of brackets, bolts, nuts & screws required for the erection
shall be included in the installation rates.
8.3
Junction boxes shall be of square /rectangular type of 1.6mm sheet steel with minimum
6mm thick pressure die cast aluminum material LM-6 & shall have bolted cover with good
quality gasket lining ..Bidder shall quick separate price for both types of junction boxes.
Page 81 of 382
8.4
The junction box & cover shall be hot dip galvanic.
8.5
The junction boxes shall be complete with conduit knockouts/ thread nuts & provided
with terminal strips which shall be as specified under clause No. 9 of this section. The junction
boxes shall be suitable for termination of conduit/glands of dia. 20mm, 25mm, 32mm, and 40mm
on all sides. The junction boxes shall be provided with 4 way terminals suitable for two numbers
10 sq.mm. wire and for street Earthing / switchyard lighting suitable for 2 No. 4Cx16 sq mm
Aluminum cable.
8.6
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
8.7
The junction boxes shall be weather proof type with gaskets conforming to IP-55 as per
IS:13947 (Part-!). The conduit connections shall also be properly, scaled to prevent entry of
water.
9.1
Multi way terminal blocks shall be ESSEN/Tosha make, complete with screws, nuts,
washers & marking strips. Terminals shall be stud types.
9.2
Each terminal shall be suitable for terminating up to 2 Nos. 10 sq. mm stranded
Aluminum conductors without any damage to the conductors or any looseness of connections.
Terminal strips provided in street-lighting poles shall be suitable for terminating up to 2 Nos. 4C
x 16 sq mm aluminum cables.
10.0
PULL OUT BOXES
10.1
The contractor shall supply & install the pull out boxes.
10.2 The pull out boxes shall be suitable for mounting on walls, column, structures etc. The
supply of bolts, nuts screws required for the erection shall be included in the installation.
10.3 The pull out boxes shall be circular of cast n or 16 SWG sheet steel & shall have cover
with good gasket lining.
10.4
The pull out boxes & cover shall be galvanized.
10.5 The pull out boxes shall be completed with conduit knock outs/threaded hubs & provided
at approximately 3 meters intervals in a conduit run.
10.6 The pull out boxes used outdoors shall be weather proof type with gaskets conforming to
IP-55 as per IS:13947(part-l).
10.7
Bidder shall include the cost of pull out boxes in the installation rates of conduits.
11.0
VOID.
Page 82 of 382
12.0
EMERGENCY PORTABLE LIGHTING FIXTURES
12.1
The contractor shall supply, store & install Emergency Lighting Fixtures.
12-2 The portable fixtures shall have a built in battery rated for hours, battery chargers & solid
inverters. These shall be of approved make.
12.3 The portable fixtures shall be of a single unit, completely tropicalised & suitable for
prolonged use with no maintenance.
12.4 The portable fixtures shall be supplied & necessarysupporting brackets of galvanized steel suitable for
wall/column mounting shall also be supplied.
12.5
The portable fixture shall come-up automatically in the event of failure of normal supply.
12.6 The contractor shall submit schematic along with all details & GA drawing for owner‟s
approval.
13.0
LIGHTING POLES
13.1 The contractor shall supply, store & install the following types of steel tubular lighting
poles required for street lighting,
a) Type Al Street Lighting Pole - for one fixture.
b) Type El Post top lantern Pole - for one fixture.
13.2 Street/ flood light poles shall conform to the drawings. The complete civil works for
erection of the lighting poles shall be 'included in the scope of work.
13.3 Lighting poles shall be complete with fixing brackets & junction boxes. Junction boxes
should be mounted one meter above ground level.
13.4 The lighting poles shall be coated with preservation paint on the inside as well as on the
embedded outside surface. Exposed outside surface shall be coated with coats of metal primer
(comprising) of red oxide & zinc chromate in a synthetic medium).
13.5 The galvanized sheet steel junction box for street lighting poles shall be completely
weather proof conforming to IP-55 & provided with a lockable door &
HRC fuse mounted on a fuse carrier & fuse base assembly. The junction box shall be as specified
at Clause No. 8, however, terminals shall be stud type
suitable for 6 Nos. 16sqmm cable.
13.6
Distance of center of pole from street edged should be approximately 1000 to 1200 mm.
13.7 Earthing of poles should be connected to the switchyards and main earth mat wherever it
is available & the same should be earthed though 3M long, 20mm diameter, earth electrode.
14.0
CEILING FANS AND REGULATORS.
14.1
The contractor shall supply & install 1400m sweep ceiling fans complete with electronic
Page 83 of 382
regulator & switch, suspension rod, canopy & accessories.
14.2 The contractor shall supply & install the switch, electronic regulator & board for
mounting switch & electronic regulator.
14.3 Winding of the fans & regulators shall be insulated with class-E insulating material.
Winding shall be of copper.
14.4 Electronic regulator smooth control shall be provided. Precautions shall be taken in
manufacture of fans regulators to ensure reasonable degree of silence at, all speeds.
14.6 Type tests, acceptance tests & routine tests for the fans & regulators shall be carried out
as per latest relevant standard.
14.7
Fans & electronic regulators shal.1 be of Compton Greaves /Bajaj Electrical /Usher
Electrical make.
15.0
LIGHTING WIRES
15. 1
The wiring used for lighting shall be standard products of reputed manufacturers.
15.2
The wires shall be of 1100V grade, PVC insulated product of reputed manufacturers.
15.3 The conductor sizes for wires used for beyond lighting panels shall be single core
4sqmm, 6 sqmm & 10 sq. stranded aluminum wires & 2.5 sqmm,
4 sq.mm, 6 sq.mm & 1.5 sq. mm stranded copper-wire.
15.4 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, I 100V grade flexible PVC insulated cords, unsheathed, conforming to IS: 694 with
nominal conductor cross sectional areas of 2.5 sq. mm.
15.5
The contractor's scope covers the supply & installation of the above wires.
15.6
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 (Negative)
16.0
PAINTING OF SHOP MADE ITEMS:
16.1 All sheet steel work shall be phosphated in accordance with the following procedure &
steel mi accordance with IS:6005 'Code of practice for phosphate Iron & Steel.
16.2
Oil grease & dirt. shall be thoroughly removed by emulsion cleaning.
16.3
Rust & scale shall be removed by pickling with dilute acid followed by washing with
Page 84 of 382
water, rinsing with slightly alkaline hot water & drying.
16.4 After phosphate thorough rinsing shall be carried out with clean water, followed by final
rinsing with diluted dichromate solution & oven drying.
16.5 The phosphate coating shall be sealed by the application of two coats of ready mixed
stoving type metal primer (comprising of red oxide & zinc chromate
in a synthetic medium). The first coat may be flash dried 'while the second coat shall be staved.
16.6 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 external of panels shall
be applied after completion of tests.
16.7 Both outside & inside of lighting panel, sheet metal fabricated junction boxes etc., &
outside of lighting fixtures shall be finished in light Grey (IS-5 shade 631). Inside of lighting
fixtures shall be finished in white.
16.8 Each coat of primer & finishing paint shall be of slightly different shade so as to enable
inspection of the painting.
16.9 The final finished thickness of paint film on steel shall not be less than 100 microns &
shall not be more than 150 microns.
16.10 Finished painted appearance on equipment shall not be present on aesthetically pleasing
appearance, free dents, & uneven surfaces.
17.0
TESTS AND TEST REPORTS
17.1 Type tests, acceptance tests & routine test for the lighting fixtures & accessories covered
by the specification shall be carried out as per the relevant
standard for the respective fixtures & their accessories.
17.2 Manufacturer's type and & routine test certificates shall be submitted for the fixtures &
accessories. The type test certificates shall be furnished shall be furnishied along' the bid.
18.0
LIGHTING SYSTEM INSTALLATION WORKS
18.1
General
18.1.1 In accordance with the specified instructions as shown on manufacturer drawings or as
directed by owner, Contractor shall unload, erect, install, test & 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, plump square & properly aligned & oriented. Tolerances
shall be as established in manufacturer drawings or as stipulated by owner.
18.1.2 Contractor shall furnish all supervision, labor, tools, equipment's, rigging materials &
incidental materials such as bolts, wedges, anchors, concrete inserts etc., required to complete the
'installation test & adjust the equipment.
18.1.3 Manufacturer's
drawings,
instructions & recommendations shall be
correctly followed in handling, setting, testing & commissioning of all
equipment & care shall be exercised in handling to avoid distortion to structures, the marring of
Page 85 of 382
finish or damaging of delicate instruments or other electrical
parts. Adjustment shall be made as necessary to the stationary structures for plumb & level for
the sake of appearances or to avoid twisting of frames, bending of hinged members etc.,
18.1-4 All apparatus, connections -& cabling shall be designed so as to minimize risk of fire or
any damage, which will be caused in the event of fire.
18.2
CONDUIT SYSTEM
18.2.1 Contractor shall supply, store & install conduits required for the lighting installation as
specified. All accessories/ fittings required for making, the
complete, 'including but not limited tom pull out boxes (as specified in Clause No.. 10) ordinary
& tees & elbow, checkouts, male & female bushings (brass
or galvanized steel), caps square headed make plugs, nipples, gland sealing fittings, pull boxes,
conduits terminal boxes, glands, gaskets & box covers, saddle terminal boxes, & all steel
supporting work shall be supplied by the contractor. The conduit fittings shall be of same
maternal as conduits.
18.2.2 All un-armoured cables shall run within the conduits from lighting panels to lighting fix
wires, receptacles. Etc.,
18.2.3 Size of conduit shall be selected as required.
18.2.4 Exposed conduits shall be run in straight lines parallel to building columns, beams &
walls. Unnecessary-y bends crossings shall be avoided to present a neat appearance.
18.2.5 Conduit support shall be provided at an interval of 750mm for horizontal runs & 1000
mm for vertical runs.
18.2.6 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 & to concrete or brickwork by grouting or by nylon raw plugs. Wooden plus,
inserted 'in the masonry or concrete for conduit support is not acceptable.
18.2.7 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.
18.2.8 Spacing of embedded conduits shall be such as to permit flow of concrete beem them &
in no case shall be less than 40mm.
18.2.9 Where conduits are along With cable trays they shall be clamped to supporting steel at an
interval of 600 mm.
18.2.10
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 & to hold it in place.
18.2-11
Conduit shall be installed in. such a way as to insure against trouble from tapped
condensation.
18.2.12
Running threads shall be avoided as far as practicable. Where it is unavoidable,
Page 86 of 382
check nuts shall be used.
18-2.13
Conduits shall be kept, - wherever possible, at least 30-Omm away from hot pipes,
heating devices etc., when it is evident that such property may reduce the service life of cables
18.2.14
Slip joints shall be provided when conduits cross structural expansion joints or
where long run of exposed conduits are 'installed, so that temperature change shall cause no
distortion due- to expansion or
contraction of conduit run.
18.2.15
,wiring.
For long conduit run, plug boxes shall be provided at suitable intervals to facilitate
18.2-16
Conduit shall be secure1v fastened to junction boxes or cabinets, each with a lock
nut inside & outside the box.
18.2.17
cut.
Conduit lengths shall be joined by screwed couplers. Couplers shall be cleanly
18.2.18
Conduit joints &n connections shall be made through watertight & rust proof by
application of a thread compound which insulates the joints. White lead is suitable for application
on embedded conduit & lead for exposed conduit.
18.2.19
Field bends shall have a minimum radius of four (4) times the conduit diameter
shall bends shall be free of kinks, indentations of flattened surfaces. Heat shall not be applied in
melding any conduit bend. Separate bends
ray be used for this purpose.
18.2.20
The entire metallic conduit system, whether embedded or exposed, shall be
electrically continues & thoroughly grounded. Where slip joints are used, suitable bounding shall
be provided around the joint to ensure a continues,
ground circuit.
18-2.21
Conduits & fittings shall be properly protected during construction period against
mechanical injury. Conduit ends shall be plugged or capped to prevent entry of fore material.
18.2-22
After installation, the conduits shall be thoroughly cleaned by compressed air
before pulling, in the Wire.
18.2-23
conduit run.
18.3
Lighting fixtures shall not be suspended directly from the junction box in the main
WIRING:
18.3.1 Wiring shall be generally carried out by PVC wires in conduits. All wires in a conduit
shall be drawn simultaneously. No subsequent drawing of wires is
permissible.
18.3.2 Wires shall not be pulled through more than two equivalent 90-degree bends in a single
conduit run. Where required, suitable junction boxes shall be used.
18.3.3 Wiring shall be spliced only at junction boxes with approved type terminal strip.
Page 87 of 382
18.3.4 For lighting fixtures, connection shall be teed off through suitable round conduit or
junction box, so that the connection can be attended without tiling down the fixture.
18.3.5 For vertical run of wires in conduit, wires shall be suitably supported by means of
wooded/hard rubber plugs at each pull/junction box.
18.3.6 Maximum two wires can be terminated to each way of terminal connections.
18.3.7 Separate neutral wires are to be provided for each circuit.
18.3.8 AC & DC wires should not run through the same conduit.
18.4
LIGHTING FIXTURES & RECEPTACLES:
18.4. 1 Continuous rows of fluorescent tubes shall be mounted on a continuous MS channel for
each row of lights.
18.4.2 Floodlights shall be mounted on steel base facing the tentative direction shown on
drawings. Fixing hole shall be provided with slot to turn the fixture by about 5 degree on both
sides. Bolts shall be finally tightened with spring washer. The contractor shall supply & install
the steel base, channels, angles etc., for the floodlights on the flood light towers. Terminal
connection to the floodlight shall be through flexible conduits, & these flexible conduits shall be
quoted along. with the fixture itself.
18.4.3 The installation rate of lighting fixtures shall include the supply of necessary brackets
except GI conduits for pendant mounted f=res.
18.4.4 The drawings showing the mounting details of each fixture shall be flushed to the owner
& necessary, approval to be obtained prior to installation.
18.4.5 The receptacles shall be installed in the locations shown in the drawing.
18.5
LIGHTING PANELS VOID
18.5.1 VOID
18.5.2 VOID
18.6
STREET LIGHTING / FLOOD LIGHTING POSTS
18.6.1 Street lighting / flood lighting posts shall be installed at a distance not more than 30
meter. In front of control room & other buildings decorative post lantern (Type El) poles shall be
installed.
18.6-2 The steel tubular poles which are specified for the above purpose to be pained with two
coats of aluminum paints after completion of installation. Contractor shall erect the poles
('including foundation works), mount the
assembled fittings & install necessary cabling.
18.7
JUNCTION BOXES
Page 88 of 382
18.7.1 Junction boxes having volume less than 1600 cc shall be installed without any support
other than that resulting from connecting conduits where two or more
rigid metallic conduits enter & accuracy position in box.
18.7.2 Junction boxes with volume equal or greater than 1600 cc & small boxes terminating, on
less Than two rigid metallic conduits or other reasons not rill-.Idly held shall be adequately
supported by auxiliary steel of standard steel shapes or plates to be fabricated & installed.
18.7.3 Necessary holes for conduit / cable entry shall be made during installation depending on
the requirement. The holes shall be drilled / punched neatly & shall be dust vermin proof after
'installation of the conduit.
18.7.4 The welds bolt holes, conduit entry holes etc., made during installation as mentioned
above shall be wire brushed & touched up with metal primer specified
under clause No. 16 of this section.
18.8
FOUNDATION & CIVIL WORKS:
18.8.1 Foundation for street lighting poles / Flood lighting, poles & panel foundation &
transformer shall be done by the contractor. The rates for these civil works shall be included 'in
the erection rates of respective items.
18.8.2 The contractor shall check these foundation before commencement of erection to ensure
their suitability.
18.8.3 All final adjustment of foundation levels, chipping & dressing of foundation surfaces,
setting & grouting of anchor bolts, sills, inserts & fastening devices shall be carried out by the
contractor including minor modification of civil works as may be required for erection.
18.8.4 Any cutting of masonry / concrete work, which is necessary shall be done by the
contractor at his own cost & shall be made good to match the original work. The contractor shall
obtain approval of the site Engineer before proceeding with any cutting of masonry concrete
work.
18.9
EXCAVATION & BACKFILLING
18.9. 1The contractor shall perform all excavation & backfilling as required for ground
connections and for foundations for street lighting poles, panels & transformers.
18.9.2 Excavation shall be performed up to the required depth. Such sheeting & shoring shall be
done as may be necessary for protection of the work.
18-9.3 The contractor shall make his own arrangements for pumping out any water that may be
accumulated in the excavation.
18.10 STEEL FABRICATION:
18.10.1
The steel structures fabricated by the contractor shall be cleaned of rust etc. All
fabrications shall be free of sharp edges.
18.10.2
All steel fabrications shall be painted with two coats of metal primer (comprising
of red oxide & zinc chromate in a synthetic medium) followed by two coats of aluminum paint.
Page 89 of 382
18.11 TESTING & COMMISSIONING
18.11-1
On completion of erection work, the contractor shall request the owner, for
Inspection &.test with minimum of fourteen- (14) days advance notice.
18.11.2
The owner shall arrange for joint inspection of the installation for completeness &
correctness of the work. Any defect pointed out during such inspection shall be promptly by the
contractor.
18.11.3
The installation shall be then tested & commissioned in presence of the engineer.
18.11.4
the tests.
The contractor shall provide all men, materiel & equipment required to carry out
18.11.5
All rectification's, repairs or adjustment work found necessary inspection, testing
& commissioning, shall be carried out by the contractor, without any extra cost.
19.0
SYSTEM DESCRIPTION:
The lighting shall comprise of the following:
19.1
AC NORMAL LIGHTING:
AC lights will be connected to AC lighting panels. All the lights connected to AC lighting system
in different areas woo be connected to the main lighting distribution boards.
19.2
AC EMERGENCY LIGHTING (only for 220KV stations)
This system will be available in control room building, switchyard & D. G. Building 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.
19.3
D.C.EMERGECY LIGHTING:
A few DC emergency lighting fixtures operated in the DC system will be provided in the
strategic locations so that the operating; personal can safely find their way even during
emergency of a total AC failure. These lights will be normally 'OFF& -,will be switched 'ON'
automatically in 220K-V stations when under-voltage occurs in the AC main lighting distribution
board. in 1 10K-V stations the DC emergency lighting will be switched on manually.
19.4
PORTABLE FIXTURES:
At other places, at off sites, like pump houses for extra areas, where it is not possible to have DC
system, portable incandescent fixtures will be provided. These -fixtures will be provided at
important locations in the above mentioned
areas.
Page 90 of 382
SECTION-5.6
TECHNICAL SPECIFICATION
LT TRANSFORMER
Page 91 of 382
VOLUME - II
TECHNICAL SPECIFICATION
Section 5.6 - LT Transformer
Clause No.
Particulars
1.0
Technical Requirements
2.0
Scope
3.0
General Information
4.0
Technical Requirements
5.0
Inspection and Testing
6.0
inspection
7.0
Factor Test
8.0
Fittings
Page 92 of 382
9.0
Spare Parts
10.0
Technical Parameter
1.0
This specification is intended to cover outdoor type oil filled
11/0.433KV, 250KVA/100KVA transformers,
2x250KVA
transformers are intended to be used in 220 KV stations &
1x100KVA Transformer is intended to be used 'in 110 KV
stations.
1.1
Technical Requirements:
1.1.1
Qualifying requirements:
Please refer volume-1, Section - IFB, Clause 11.0
2.0
Scope of work:
2.1
Scope of Supply:
Transformers as listed above, with insulating oil, all
materials & accessories, & complete in all respects.
Gland plates, power cable, lugs, anchor bolts & hardware‟s.
Mediator & optional spares & special maintenance
2.2
a)
b)
c)
d)
e)
Scope of Service:
The scope includes but is not limited to the following items of
work to be performed for all equipment & materials furnished
under this section:
manufacturing, shops testing, packing
dispatch.
Transportation inclusive of insurance & delivery, for site
basis.
Unloading, handling, storming, transportation at site up to
foundations, oil filling & treatment, erection, testing &commissioning.
Civil Works.
Supply of external cables &, termination as required.
Page 93 of 382
3.0
General information
3.1
Bidders may specifying. note that owner propose to insist on
short circuit test as per Clause No.16.11 of IS:2026 (Part1) 1977 & dielectric test as per IS:2026 The type test certificate
for the Similar equipment not older than 5 years as on Bid
opening date shall be furnished, otherwise owner insists
conducting type test at the cost of contractor.
4.0
TECHNICAL REQUIREMENTS:
4.1
CORE:
The core shall be constructed from high grade, non-aging, cold
rolled grain oriented silicon steel laminations. The maximum
flux density in any part of the cores & yoke at normal voltage
& frequency shall be such that the flux density at any tap
position with 10 % -voltage variation from the voltage
corresponding to the tap shall not exceed 1.9 wb/sq-m.
4.2
Windings:
The conductor shall be electrolytic copper, free from scales
and burrs.
4.3
Insulating oil:
The oil supplied with transformer shall be unused & have the
parameters for unused new oil conforming to IS:3335 while
tested at oil contractor's premises, No inhibitor's shall be used
in oil. 10% extra oil shall be supplied for tapping up after
commissioning, in non-returnable containers suitable for
outdoor storage.
4.4
4.5
Terminal Arrangement:
a)
Bushing terminals shall be provided with suitable terminal
connectors of approved type &, size for cable/overhead
conductors termination of HV side & cable termination on LV
side.
b)
The neutral terminals of 433V winding shall be brought out on
a bushing along with the 433V volt phase terminals to form a
4-wire system for the 433V. Additional neutral bushing shall
also be provided for earthing.
c)
The type test certificate for the similar equipment not other
than 5 years as on Bid opening date shall be furnished,
otherwise owner insist conduct nor more rest on the cost of
contractor.
Off Circuit Tap Changing Equipment:
Page 94 of 382
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. There shall be 5 taps with
step voltage of 2.5% of 11 KV with tap range of + 5 %. to -5%.
4.6
Marshalling Box:
A metal enclosed, whet-her, 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: 13947.
4.7
Cable boxes :
Whenever cable connections are required, suitable cable boxes
shall be provided & shall be air insulated. They shall be of
sufficient size to accommodate cables & shall have removable
side/top cover to facilitate cable termination & inspection.
Cable boxes shall be dust & vermin proof.
5.0
Inspection & Testing:
The contractor shall- draw up & carry out a comprehensive
inspection & testing program during manufacture &
commissioning
of the transformer. The programme shall be
duly approved by the owner.
6.0
Inspection:
6.1
Tank & Accessories:
a)
Physical
accessories.
dimensional check of transformer tank &
b)
Crack- detection of major strength weld seams by dye
penetration test.
6.2
Core:
a)
Physical inspection & check of quality of varnish, if used.
b)
Sample testing of core material for checking specific loss,
bend properties, magnetization, characteristics thickness.
c)
Check on completed core measurement of iron loss
check for any hot spot by exciting the core so as to
include the designed value of flux density in the core.
d) HV Test
6.3
Insulating Material:
Page 95 of 382
a) Sample checks for physical properties of the material
b) Check for dielectric strength
c) Check for the reaction of hot oil on insulating material.
6.4
Winding:
a)
Sampling checks on winding conductor for mechanical
properties & electrical conductivity & on insulation
covering.
b)
Sample check on 'insulation paper for pH value, bursting
strength, Electric strength.
6.5
Assembled Transformer:
Check complete transformer against approved outline drawing
provision for all fittings, finish etc.,
6.6
Oil :
All standard tests in accordance with relevant standards shall
be carried out on oil samples taken from the transformer
before & after testing of the transformer.
The contractor shall also prepare a comprehensive inspection
& testing programme for all bought out sub-contracted items
& shall submit the same to the owner for approval- Such
programme shall include the following components:
a)
Bushings
b)
Marshaling Box
c)
Tap changer switch
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
In addition to all type & routine tests, following special tests
shall also be carried out on one transformer of each racing as
per IS: 2026.
a)
Test on oil samples.
7.3
All auxiliary equipment shall be tested as per the relevant IS
Test Certificates shall be submitted for bought out items.
7.4
High voltage withstand test shall be performed on auxiliary
Page 96 of 382
equipment & wiring after complete assembly.
7.5
Tank Tests:
a)
Routine Tests: As per CBIP Manual on Transformers.
b)
Type Tests:
I) Vacuum Tests: As per CBIP Manual on Transformers.
ii) Pressure Tests: As per CBIP Manual on Transformers.
7.6
In addition to the above , the following checks should be
carried out at manufacturer's works before dispatch for all
transformers :
a)
Check for interchangeability of components of similar
transformer & for mounting dimensions.
b)
Check for proper packing & preservation of accessories like
radiators, bushings explosion vent, dehydrating breather,
conservator etc.,
c
Check for proper - provision of to arrest the
movements of core & windding assembly 'inside the transformer
7.7
8.0
The contractor shall submit a detailed inspection & testing
programme for field activities, covering areas -tight from the
receipt of material stage upto commission 1 stage as per IS:
1886 - code of practice for *installation & maintenance of
transformers. The indicative checks & tests are given below
a)
Physical checks on each transformer on receipt at site for any
damage or short suppl3,.
b)
Tests on oil samples.
c)
Oil leakage, test
d)
Physical checks for colour of silica in breather.
e)
Check for oil level in breather housing, conservator tank, etc.,
f)
Check for correct operation of all protections & alarms.
g)
Insulation Resistance Measurement for Main Winding, Control
wiring etc.,
h)
Continuously observe the transformer operation at no load for
24 hours.
Fittings:
Page 97 of 382
The following shall be provided with each transformer
covered under this specification.
a)
Conservator & Radiator with drain plug & oil filling hole with
blanking plate.
ii)
Plain oil Gauge.
iii)
Silicagel Breather
iv)
Pressure Relief Vent
v)
Pocket on tank cover for Thermometer.
vi)
Valves
vii)
Earthing Terminals
viii)
Rating & Terminal Marking Plates
ix)
Lifting., Lugs
x)
Rollers
xi)
Air Release Plug
The Listed above are only indicative & any other fittings
which generally are required for satisfactorily 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 specified in section -l(General)
9.2
In addition, the bidder shall also recommend optional spare
parts & maintenance equipment necessary for 3 years of
successful operation of the equipment. The prices of these
shall be indicated in respective schedules & these shall not be
considered for the purpose of evaluation.
10.j
Technical Parameters:
SI.No.
Description
Parameters
a)
b)
c)
d)
e)
f)
Type
Service
Number of phases
Frequencv
Type of cooling
Rating
Two windirig
Outdoor
Three
150 Hz
ONAN
250K-VA for 220 KV stations
Page 98 of 382
g)
h)
I)
k)
Ratio
Impedance at 750C
with tolerance
Duty
Overload
maximum temperature
rise over 50deg C ambient
i) Oil (Temperature rise
measurement by
thermometer)
ii) Winding (Temperature
rise measurement by
resistance method)
11/0.433 kV
0.05 + / -10%.
As Der IS: 6600
50deg C
55deg C
SECTION-5.7
TECHNICAL SPECIFICATION
FIRE FIGHTING
Page 99 of 382
VOLUME - IIA
TECHNICAL SPECIFICATION
Section 5.7 - Fire Fighting
Clause No.
Particulars
I. 0
Scope
2.0
standard
3.0
General Technical Requirements
4.0
Material, Design and Workmanship
5.0
Test
6.0
Specifications for Nitrogen Injection
Presentation and Extinguishing System
for Transformers
Page 100 of 382
Page 101 of 382
VOLUME IIA
SECTION 5.7 - FIRE FIGHTING
TECHNICAL SPECIFICATION FOR FIRE FIGHTING
EQUIPMENTS:
1.0
SCOPE:
1.1
This specification provides for manufacture, inspection and testing before despatch,
packing and delivery FOR destination of fire fighting equipments required for 220KV, 110 KV
substations.
a) Chemical foam type extinguisher.
1. 45 liters capacity.
2. 9.0 liters capacity.
b)
Water type (gas pressure extinguisher).
1. 9.0 Liters capacity.
c) C02 Type extinguisher.
1. 6.0 liters capacity.
d) GI Buckers1. 9.0 liters capacity.
e) Steel stand for Buckets.
1.2
The fire fighting equipments shall conform in all respects to high standards of
engineering, design, workmanship and latest revisions of relevant standards at the time of offer
and purchaser shall have the power to reject any work or material, which in his judgment, is not
full accordance there with1.3
Technical requirements of fire fighting equipments are as furnished in clause No.3.0
2.0
STANDARD:
2.1
The fire fighting equipments to be supplied shall conform to the latest revisions there of
the following Indian standards (IS).
IS:933-1976
IS:940-1972
Portable chemical fire extinguisher foam
type
Portable chemical fire extinguisher water
type(gas pressure)
Page 102 of 382
IS:2546-1974
IS:2878-1964
IS:5490-1969
Galvanized mild steel fire buckets
Portable chemical fire extinguisher carbondioxide type
Refills for portable fire extinguishers and
chemical fire engines
THE STANDARD MENTIONED ABOVE ARE AVAILABLE FROM:
STANDARD
IS
NAME AND ADDRESS
Bureau of Indian standards, Mank Bhavan,
9 , Bahadur Shah Zafar Marg, New Delhi 110001.
2.2
Fire fighting equipments offered by the supplier if conform to other standards, salient
points of difference between the standards adopted and the specified standard shall clearly be
brought out in the offer. Four (4) copies of the reference standards in English language shall be
furnished along with the offer.
3.0
GENERAL TECHNICAL REQUIREMENTS:
The portable chemical foam type extinguisher shall conform to IS: 933 - 1976. It shall have
capacity of 45.0 liters, 9.0 liters 2.0 liters. The portable chemical &e extinguisher, water type
(gas pressure) shall conform to IS: 940-1972, It shall have capacity of 9.0 liters. The portable fire
extinguisher, carbon dioxide type shall conform to IS: 2546 -1974. It shall have capacity of 6.0
liters. The steel stand for' hanging buckets shall conform relevant IS standards.
4.0
MATERIAL, DESIGN AND WORKMANSHIP:
4.1
The fire fighting equipments shall be suitable for outdoor use.
4.2
The portable fire extinguishers shall be complete with
handle,
bracket,
(wherever necessary and
other connected accessories. The bracket design shall
that the extinguisher can be easily removed during the fire emergency.
trolley
be such
4. 3
Front of the portable fire extinguishers shall be clearly marked with the type of
extinguisher capacity contents and method of operation.
4.4
In case, of GI buckets, suitable stand hooks shall be provided for keeping 4 Nos. at a
place. The buckets shall be secured at a height of 0.9 Mtrs an above
ground level. The buckets shall be enamel painted (RED) with the contents indicated on each
bucket.
4.5
Reputed makes of various fire extinguishers shall be offered which is subject to approval
of the purchaser. All extinguishers shall be approved by the National standards Institution.
50
TEST:
51
All type tests and routine/ acceptance tests shall be conducted as per relevant IS.
TYPE TESTS:
5.2
Bid shall contain the type tests certificates, as per relevant IS not older than 5 years in
Page 103 of 382
respect of fire fighting equipments from the date of bid opening.
5.3
In case the fire fighting equipments offered, has already been type tested. The bidder shall
furnish four sets of type. test report along with the offer. In case these type tests are conducted
earlier than five years, all the type tests as per the relevant standards shall be carried out by the
successful bidder in the presence of owner's representative at free of cost.
The owner reserves the right to demand repetition of some or all the type tests in the presence of
his
representative. For this purpose, the bidder may quote unit rates for carrying out each type
test. The prices quoted by the bidder towards conductance of the type tests and additional tests
shall be taken into consideration for bid evaluation. For any change in the design /type already
type tested and the design/ type offered against this specification, the purchaser reserves the right
to demand repetition of tests without any extra cost.
TECHNICAL SPECIFICATIONS FOR NITROGEN INJECTION FIRE PREVENTION
& EXTINGUISHING SYSTEM FOR TRANSFORMERS.
1.
The power transformers shall be supplied with Nitrogen Injection Fire
Protection System.
2.
GENERAL DESCRIBED.
Nitrogen Injection Fire Protection System designed for oil transformers, shall prevent tank
explosion and the fire during internal faults resulting in an are where tank explosion will
normally take 3-4 seconds after arc generation and also extinguish the external fires on
transformer top cover due to tank explosion and / or external failures like bushing fires, OLTC
fires and fire from surrounding equipments. it should be fully automatic and shall require
minimum maintenance and practically no running cost.
The system shall work on the principle of Drain & stir and on activation,
shall drain a pre-determined quantity of oil from the tank top through
outlet valve to reduce the tank pressure and inject nitrogen gas at high
pressure from the lower side of the tank through inlet stirring action and reduce the temperature
of top oil surface below flash point to extinguish the fire. Conservator tank oil shall be isolated
during tank explosion and oil fire to prevent of fire.
Transformer isolation shall be an essential pre-condition for activating the system. The system
shall consist of following equipments.
1
2.
3.
4.
5.
Fire extinguishing cubicle placed on a plinth at about 5-10 metres
away from the transformer.
Control box placed in the control room
Pre-stressed non-return valve in the conservator pipe / high speed
pneumatically operated ball valves. Backup valve may be provided
to the main valve, if necessary. These backup valves could be
operated on the same principle or by a different principle as the
main valve.
Required number of fire detectors on the tank top cover.
Signal box fitted on the tank top or tank side wall.
Terminating signals from PRV, fire detectors! differential relay.
buchcholtz relay, PNRV Pneumatic valve and for cable
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6.
connecting to control box.
On line testing facility of the
3.
OPERATION CONTROLS
The system shall be provided with automatic controls for fire prevention and fire
extinction and besides remote electrical push button control on control box and local
manual control in the fire extinguishing cubicle shall be provided.
4.
SYSTEM ACTIVATING SIGNALS:
(a)
To avoid transformer explosion two fast trip signals given by circuit
breaker of transformer and Buchholtz relay paralleled with pressure
relief valve / pressure & temperature sensors to initiate.
I.
Explosion prevention by opening quick depressurization valve to release
the internal pressure and to prevent the transformer
explosion.
ii.
Oil cooling - by injecting a large flow of nitrogen at the
transformer base to limit the damages of overheated parts
affected by short circuit and to evacuate the very explosive
hydrogen gas by dielectric oil.
(b)
I.
The fire protection back up system should be initiated by two signals from
one of the high temperature sensors, located on the transformer cover and by the
operation of Buchholtz relay paralleled with pressure relief device / pressure &
temperature sensors. The drain valve should open out within 3 second. The nitrogen
injection shall cause stirring of transformer oil and should immediately drop its surface
point to extinguish fire with a minimum possible time. Nitrogen injection should continue
for sufficient time, which will further cool the transformer and prevent any recombustion
ii.
Fire protection back up system shall be provided to function in case if all
transformer electrical protections leading to breaker
trip or if all pressure sensors have failed during the 'incident, by
the conventional nitrogen fire extinguishing method. in case of fire, even if the circuit
breaker has not tripped the system shall inject nitrogen into the transformer tank even
when the transformer is live but after giving warning signal to the operating personnel to
manually isolate the circuit breaker.
(c)
The system shall be of automatic operation and in addition, remote
push button control through control box and manual local control in
fire extinguishing cubicle are to be provided.
(d)
During The initiation / activation of sensing devices mentioned in 4(a) & (b)
above, for prevention of tank explosion or for fire protection, the
oil from the conservator tank should be isolated, by action of PNRV
POBV.
5.
TECHNICAL PARTICULARS:
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(a)
Power supply, for control box
220V DC
Fire extinguishing cubicle (lighting) 230V AC
(b)
Fire Extinguishing Cubicle Dimension
Weight / capacity
Control Box
dimensions / weights
Suitable for 31.5MVA and 150MVA
Transformer
Suitable for 31.5MVA and 150MVA
Transformer
(d)
Nitrogen Cylinder Capacity
Suitable for 31.5MVA and 150MVA
Transformer with
Approximately 40 to
50 Tonnes of
Transformer oil
(e)
Fire detectors Heat sensing
Temperature
6.
DETAILS OF SUPPLY OF SYSTEM EQUIPMENTS AND OTHER
RELATED ACTIVITIES
A.
SYSTEM EQUIPMENT
(c)
141 deg C
1.
Fire extinguishing cubicle with base frame and containing
Nitrogen gas cylinder of sufficient capacity with pressure
regulator and manometer with sufficient number of
adjustable NO contacts.
-Oil Drain Assembly
-Mechanical release device for oil drain and nitrogen release
-Limit switches for monitoring of the systems
-Panel lighting
Flanges on top of the panel for connecting oil drain and
nitrogen injection pipes for transformer
-Oil drain pipe extension of suitable size for connecting pipes
to oil pit.
-Limit switch for pressure switch / sensor.
2.
Control box to be installed in the control room of the station
for monitoring system operation, automatic control and
remote operation, with alarms, indication light, switches,
push buttons, audio signal, suitable for tripping and
signaling on 220V DC supply.
3.
Pre-stressed non-return valve (PNRV)
high speed
pneumatically operated ball valve (POBV) with sufficient
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number of NC contacts for remote alarm indication and with
visual position indicator.
B.
4.
Required number of fire detectors rated for heat sensing at
141 deg C or suitable temperature recommended by the
manufacturer and each fitted with two numbers PG 13.5 size
cable glands.
5.
Signal box for terminating cable connections from PRV
Pressure Sensor, PNRV / POBV, fire detectors and circuit
breaker tip signal.
Arrangements required on transformer tank
1
Oil drain opening with pipe flange and manual gate valve at
about 120mm below the top cover.
2.
Nitrogen injection openings with suitable size of pipe with
flange and manual gate valve on tank sides at about 5C200mm from the bottom plate.
3.
Flanges on the conservator pipe between buchholz relay
and conservator tank for fixing PNRV / POBV.
4.
Provision for Pressure & Temperature Sensors if required.
5.
Supply and welding of the fire detector brackets on top
cover.
6.
Supply and welding of the brackets for flang signal box at a
suitable location on top cover or tank side wall.
Guidelines be given for transformer manufacturers to make arrangements on new
transformer during tank fabrication.
C.
Pipe connections between transformer, fire extinguishing cubicle
and oil pit.
1.
Oil drainpipe connection between outlet valve provided on
the transformer tank and the flange provided on FE cubicle
top.
2.
Oil drain pipe connection between oil drainpipe bottom
(in FE cubicle) to the oil pit.
3.
Nitrogen injection pipe connection between inlet openings on
transformer tank and flange provided on FE cubicle top.
D.
The scheme of operation of prevention of tank explosion and fire
protection, along with a flow chart, along with time of operation of
various devices shall be furnished.
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E.
CABLING:
I
Connecting fire detectors, PNRV / POBV, buchholz relay and
other signals on transformer top cover and terminals in
signal box, using fire retardant cable of size 4 core, 2.5mm
square.
2.
Connecting signal box mounted on transformer and control
box placed in the control room, as well as control box and FE
cubicle using FRLS cable of size 12 core 1.5mm square.
F
Installation and pre-commissioning test.
Pre commissioning tests shall be carried jointly with the purchaser's representative prior
to handing over the system. Not with standing above technical specifications any
additions be incorporated for correct operating of nitrogen injection fire protection system
without extra cost.
7.
DEVIATION FROM TECHNICAL SPECIFICATION
The tenderer shall furnish the details of deviation modification proposed by him to
improve overall performance of the system. The deviation if any shall be brought 'in the
tender clause by clause.
8.
TESTS:
Type test certificates not later than 5 years as per relevant standards for Nitrogen injection
fire protection system as a whole unit shall be furnished.
9.
PERFORMANCE GUARANTEE:
the equipment offered shall be guaranteed for satisfactory performance for a period of 18
months from the date of satisfactory commissioning of equipment. The equipment found
defective / failed within the above guarantee period shall be replaced or repaired by the
supplier free of cost within one month from the receipt of intimation. If the defective /
failed nitrogen injection fire protection system are not replaced / repaired as per the above
guarantee class, the KSPDCL shall recover an equivalent amount plus 15% supervision
charges from any of the supplier‟s bills.
10.
MINIMUM EXPERIENCE FOR QUALIFYING AS BIDDER:
the bidder shall have a minimum experience of 5 years in design, manufacture, testing
and commissioning oh nitrogen injection fire protection system in the present enquiry. At
least 50% of the quantity called for in the present enquiry shall be in successful operation
for a minimum period of 2 years. The tenderer shall also furnish the details of similar
nitrogen injection fire protection system supplied by them so far, giving order reference
name and address of the customer etc, also indicating the period of commissioning. The
bidder shall also furnish performance certificates for a period of minimum 2 years of
similar nitrogen injection fire protection system in proof of satisfactory operation of the
equipment.
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The purchaser however reserves the right to waive the minimum experience condition stipulated:
i.
in case of firms having collaboration with well experienced firms in manufacture of
similar equipment not less than 10 years. The waiving of minimum experience
condition will be considered by the purchaser only on furnishing the performance
guarantee of the nitrogen injection fire protection system by the collaborating firm.
ii.
In case of new entrant who had supplied to KSPDCL one system free of cost for
watching performance for a period of 1 year and for having worked satisfactorily.
iii.
Furnish type test certificates for the operation of the entire system as a whole instead
of individual components.
iv.
Furnish guarantee for performance for a period of 5 years.
Page 109 of 382
SECTION 5.8
TECHNICAL SPECIFICATION
D.G. SET
Page 110 of 382
VOLUME-IIA
TECHNICAL SPECIFICATION
SECTION 5.8 D.G SET
CLAUSE
PARTICULARS
1.00
SCOPE OF SUPPLY.
2.00
SCOPE OF SERVICE.
3.00
SPARE PARTS.
4.00
TECHNICAL PARAMETERS AND GENERAL
REQUIREMENTS.
5.00
TESTS.
6.00
COMMISSIONING CHECKS.
Page 111 of 382
VOLUME IIA
SECTION 5.8 - D.G.SET
D.G.SET (Only for 220KV Station)
1.0
Scope of Supply
The scope covers supply of Diesel Generator Set of stationary type
having a net electrical output of 63KVA capacity at specified site
conditions of 500C ambient temperature & 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 all accessories.
iii)
Complete starting arrangement, 'including battery & charger.
iv)
Base frame, foundation bolts etc.,
v)
Interconnection piping, cables, cabling & accessories.
vi)
Double compression type brass cable glands & timed copper
lugs for all cables.
vii)
All lubricants consumable, touch up paints etc., for first
filling testing & comrnissioning at site. The fuel oil for first
commissioning will also be provided by the contractor.
viii)
Earthing with Interconnection.
ix)
x)
xi)
xii)
xiii)
xiv)
2.0
Day tank
Automatic voltage Regulator
Exhaust silencer package
AMF panel for control, metering and alarm
Enclosure of silent type DG Set
Set of GI pipes, valves, stainer, unloading host pipe as required for fuel transfer
system from storage tank to fuel tank including motor driven fuel pump
Scope of Service: The contractor shall provide following, services:
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a.
Design, manufacture, shop testing including assembly
test.
b.
Dispatch transportation to Site.
c.
Erection, testing & commissioning with all
equipments / materials required for the purpose.
d.
Drawings, data, design calculations & printed
erection, operation & maintenance manual.
e.
Certificate and compliance for meeting noise level and commission
parameters and other requirements in accordance with latest notification
of MOEF
3.0
Spare parts
3.1
Mandatory spare parts
The list of Mandatory spares, which are considered essential by the owner, is indicated at
Annexure-I of Section-I (GENERAL). Whenever spares have been defined as 'of each type' the
type (rating) of the spares shall also be defined.
3.2
Optional Spares
In addition to the mandatory spares, Bidder shall indicate the recommended optional spares with
unit & total prices for three- (3) years of normal operation of the equipment. The owner reserves
the night to buy any or all-recommended spares.
4.0
Technical Parameters & General Requirements
4.1
The ratings of DG sets are as follows.
1)
D.G.Set net output after considering for engine and alternator separately due to
temperature rise inside the enclosure and on account of power reduction due to auxiliaries shall
be 63 KVA, 1500 RPM, 0.8 p.f., 415 V, 3 phase, 50 Hz. The above ratings are the minimum
requirements. However standard capacity D.G.sets meeting the above mentioned requirement
shall be provided.
4.2
DG sets shall also be rated for I 10% of full load for I hour/day of continuous running,
4.3
The output voltage, frequency & limits of variation from open circuit to full load shall be
as follows
Voltage variation
±5% of the set value provision
shall exist to a4just the set value
between 90% to I 10% of nominal
Generator voltage of 415V.
Frequency
50 Hz ± 5%
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Efficiency
> 90%
4.4
The equipment shall be suitable for continuous full load operation for 140 hours.
4.5
The equipment shall be suitable for site conditions.
4.6
The Diesel generator and other auxiliary motor shall be of H class with temperature rise
limited to class F for temperature rise consideration.
4.7
Noise level and commission parameters shall be as per latest notification of MOEF
4.8
Based on above, the systems envisaged each D.G.Set shall generally comprise of the
following equipments.
4.9
a)
DG set of min. 63 KVA rating complete with all accessories
control & protections.
b)
A control & metering panel automatic voltage regulator
(AVR) & a generator Circuit Breaker (CB).
c)
Starter batteries & battery charger.
d)
Fuel system including day .
e)
Engine Cooling & lubrication system.
f)
Engine air-filtering system.
g)
Exhaust silencer package.
h)
Set of piping, valves, stainers, unloading hose pipes as
required.
Diesel Engine
A : Design Parameters
The engine shall comply with the IS 10002/BS 5514/ ISO 3046 latest edition.
a) The capacity of Day tank is designed to provide at least 24
hours storage of diesel oil when the generator, is running at
full load. The tank- shall be painted with oil resistant paint &
shall be erected in accordance with Indian explosive act of
1932.
b) Facility for manual start of diesel engine
& connection to 415V AC Bus bar shall be provided.
This shall be done locally.
c) A three (3) attempt starting facility using two Hinpulse timers
& summation timer for enome shall be provided & if the
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voltage fails to develop within specified time from receiving
the first impulse, the set shall block.
d) The generator Term Mal box shall be suitable to house
necessary cables & current Transformers for protection
purposes.
B:
System Design
a)
The Diesel Generator units shall be installed indoors. Suction
of air shall be from indoor for ventilation and exhaust fume will be let out to outside atmosphereCondensate traps shall be provided on the exhaust pipe. The exhaust pipe, & silencer shall be
thermally insulated.
b)
The fuel used shall be high Speed Diesel oil(HSD) or Light Diesel Oil(LDO) as per IS:
1466.
c)
The diesel engine shall be directly water cooled. Cooling of water through radiator & fan
is envisaged.
d)
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.
C
PLANT DESIGN
a)
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.
b)
The equipment shall be safe & proper & without undue
vibration or stored for continuous operation at all loads up to
rated output at operating & test conditions.
c)
The equipment shall have proposition for easy maintenance,
overall cleaning & 'inspection & replacement of parts. All
tools for operation & maintenance of equipment shall be supplied.
d)
Diesel engine shall be turbo charged multi-cylinder Vtype in line type with mechanical fuel injection system.
e)
f)
Manual electric starting by DC star-ter motor shall be
provided. Necessary battery with battery charger shall
be provided.
Air suction and Filteration
g)
The filter shall be dry type air filter with replaceable element.
h)
Fuel injection and regulator:
(i)
The engine shall be with electronic governor suitable for class A-1 as per
IS 10000.
(ii)
The engine shall be fitted with a heavy, dynamically balanced fly wheel suitable
for constant speed governor duty.
Page 115 of 382
4.10
Alternator:
(a) The Alternator shall comply with BS 2613/ IS 4722/ IEC 34 latest edition.
(b) The Alternator shall be continuously rated duty suitable for 415V, 3 Phase, 50
Hz power development having brush-less, synchronous, self excited, self
regulating system.
(c) The Alternator shall be drip proof, screen protected as per IP-23 degree of
protection.
(d) The rotor shall be dynamically balanced to minimize vibration
(e) The Alternator shall be fitted with shaft mounted centrifugal fan.
(f) It shall the winding of class H but limited to class F for temperature rise
consideration.
(g) The Alternator regulator shall be directly coupled to the engine and shall be
complete with the excitation system, automatic voltage regulation and of + - %
Voltage adjusting potentiometer and under/over speed protection.
4.11
Terminal Box:
(a) Output terminals shall be provided in Alternator terminal box. Terminals shall be
suitable for 1 no. of single core …… sq.mm. XLPE/PVC cable per phase for 63 KVA
D.G.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 materials.
(b) The Alternator with all accessories shall be enclosed in a enclosure to made it work
silently (within permissible noise level)
4.12
Coupling:
(h) The engine and alternator shall be directly coupled by means of self aligning
flexible flange coupling to avoid misalignment.
(i) The coupling shall be provided with a protecting guard to avoid accidental
contact.
4.13
Mounting arrangement:
(a) The engine and alternator shall be mounted on a common heavy duty, rigid fabricated
steel base frame constructed from ISMC of suitable section.
(b) Adequate no. of antivibration mounting pad 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 common base frame or foundation of DG Set.
4.14
Control & Instrumentation
a)
Each D.G.Set shall be provided with suitable instruments,
interlock & protection arrangernent suitable annunciation's
& indications etc., for proper start up, control, monitoring &
safe operation of the one local AMF control panel along With
each D.G.Set ( D.G.Control Panel ) shall be provided by the
supplier to accommodate these instruments i.e., protective
circuits, relays, lamps etc., The AMF Panel shall have IP52 degree protection as per IS: 2147.
b)
Following instruments shall be provided with Diesel Engine:
Page 116 of 382
i)
Lub oil pressure gauge (en ine panelgin
ii)
Lub oil temperature thermometers (both on engine & at
local panel)
iii)
Water temperature thermometers (both on engine & at
local panel)
iv)
Exhaust gas pyrometer 111krith temp. s%Vitch (at, local panel)
v)
Engine tachometer /HR ( engine panel)
Any other instruments necessary for DG Set operation shall be provided.
vi)
Meters: Ammeter, Voltmeter with selector switch phase, KWHr meter with 5
Amp CT, frequency.
c)
The Diesel Generator & other auxiliary motor shall have epoxy thermosetting type
insulation but limited to class B for temperature rise consideration.
BATTERY AND BATTERY CHARGER
d)
(i)
24V batteries complete with all leads, terminals and stand shall
be provided. Each battery shall have sufficient capacity to give
10nos. successive starting impulse to the diesel engine.
(ii)
The battery charger shall be complete with transformer, suitable
rating (415 V, 3ph., 50Hz./230V, 1Ph., 50Hz) rectifier circuit,
charge rate selector switch for “trickle”/’boost’ charge, D.C.
ammeter & voltmeter, annunciation panel for battery charge
indication/ loading/ failures.
(iii)
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.
(iv)
Manual control for coarse and fine voltage variation shall be
provided. Float charger shall have built-in load limiting features.
(v)
Ripple shall not be more than 1% (r.m.s) to get smooth DC
voltage shall be provided.
(vi)
Charger shall be provided with Out-put Voltmeter & Ammeter.
Page 117 of 382
(vii)
Change over scheme for selecting battery charger by changeover
switch should be provided.
e)
Diesel Generator Shut-down: Interlocking to prevent the
shutdown of DG while the DG circuit breaker is closed shall
be provided.
f)
The diesel generator shall commence a shutdown sequence
whenever any of the following conditions appear in the systern.
Over speed
Overload
High temperature of engine and cooling system
High temperature inside enclosure
Low lub oil pressure
Short circuit protection
Reverse power
Under voltage
Under frequency
Under Voltage
Over voltage
Generator differential protection
Further interlocking of breaker shall ble provided to
prevent parallel operation of DG set With normal
station supply.
g)
Following indication lamps for purposes mentioned as under shall be provided in AMF
panel:
h)
(i)
Pilot indicating lamps for the following:
Mains ON
Alternator ON
Charger ON/OFF
Breaker ON/OFF
Main LT supply ON/OFF
(ii)
Visual annunciation shall be provided for set shut down due to :
Engine overheating
Low oil pressure
Lack of fuel
Set failed to start in 30 secs after receiving the first start impulse
High cooling water temperature
Low level in daily service fuel tank
Overspeed trip
Audio & visual annunciation for alternator fault.
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.
Page 118 of 382
i)
AMF panel shall have facility for adjustment of speed and
voltage including fine adjustments in remote as well as in local
mode.
Following shall also be provided in AMF panel:
(i)
Frequency meter
(ii)
3 Nos. single phase CT’s for metering
(iii) 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.
(iv) One (1) DC Ammeter (0-40A)
(v)
One (1) DC Voltmeter (0-30V)
(vi) One (1) DC Voltmeter Selector switch
(vii) One (1) AC Ammeter
(viii) One (1) AC Voltmeter
(ix) Three (3) Timers (24V DC)
(x)
Two (2) Auto/Manual Selector Switch
(xi) Two (2) Auto/test/Manual Selector Switch
(xii) Eleven (11) Aux. Contractors suitable for 24V DC
(xiii) One (1) Motorised Potentiometer for voltage adjustment
(xiv) Two (2) Set Battery charger as specified in Technical
Specification
(xv) One (1) Set phase & Neutral busbars
(xvi) Any other item required for completion of Control
scheme shall be deemed to be included.
5.0
D.G. Set Enclosure
5.1
General requirements
a) 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 50Degree 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
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suitable viewing glass to view the local parameters on
the engine.
b) 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 finalized
during detailed engineering.
c) 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.
d) Engine and Alternator used inside the Enclosure shall
carry their manufacturer’s Warranty for their respective
Models and this shall not degrade their performance.
e) 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.
5.2 All the Controls for Operation of the DG Set shall be easily
assessable there should be provision for emergency shut down from
outside the enclosure.
5.3 Arrangement shall be made for housing the battery set in a tray
inside the enclosure.
5.4
CONSTRUCTION FEATURES:
a) 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.
b) 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.
Page 120 of 382
c) 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.
d) High quality rock wool of required density and thickness
shall be used with fire retardant thermo-setting resin to
make the enclosure sound proof.
5.5
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.
6.0
Installation Arrangement.
DG Set enclosed in enclosure shall be installed on Concrete Pedestal 300mm
above FGL.
7.0
TESTS:
The diesel generator sets shall be tested as per the relevant IEC
standards. The supplier shall submit test repots as per the
following but not limited to
-Quality test of materials
-Crack detection & ultrasorlic tests of foreign &
castings.
-Hydrostatic tests on pressure parts.
-Static balancing on rotating parts, shafts shall be statically & dynamically
balanced.
-Bench tests on safety control devices
-Performance tests on fuel pump & injectors.
a)
Routine tests
-Measurements of the open circuit & short circuit characteristics
-High voltage test
-Regulation test
-Phase sequence test
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-Noise & vibration test
b)
Type tests:
The alternator & start motor shall be type tested as per the
relevant specifications. Type test shall 'include following tests:
Resistance measurement & air gap measurement.
Measurement of leakage reactance & pottier reactance.
Short circuit characteristics(Alternator)
Efficiency test
Momentary overload test
Over speed test
Installation test ( Before & after HV test)
Determine deviation of voltage wave form
Measurement of polarisation index.
Load characteristics test.
8.0
Commissioning Checks
In addition to the checks & test recommended by the manufacturer,
the contractor shall supervise the following commissioning
checks to be carried out at site.
a)
Load Test :
The engine shall be given test run for a period of at least 6 hours.
The set shall be subjected to the maximum achievable load as
decided by the owner without exceeding the specified DG Set rating:
During the load test, half-hourly records of the following shall be
taken:
i)
Ambient temperature.
ii)
Exhaust temperature if exhaust thermometer is fitted
iii)
Cooling water temperature at a convenient point adjacent to
the water output from the engine jacket.
iv)
Lubricating oil temperature where oil cooler fitted.
v)
Lubricating oil pressure
Page 122 of 382
vi)
Colour of exhaust gas.
vii)
Speed
viii)
Voltage, Wattage & current output.
ix)
Oil Lank level
The necessary load to carryout the test shall be provided by the
owner.
b)
Insulation Resistance Test for Alternator
Insulation resistance in mega-ohms between the coils & the frame
of the alternator when tested with a 500V megger shall not be less
than
IR = 2 x (rated voltage in KV) + 1.
c)
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.
d)
Insulation Resistance of Wiring
Insulation resistance of control panel wiring shall be checked by
500 V megger. The IR shall not be less than one mega ohm
e)
f)
Functional Tests
i)
Functional tests on control panel.
ii)
Funct:ional tests on staruing provision on the engine.
iii)
Functional tests on all field devices.
iv)
Functional tests on AVR and speed governor.
Measurement of vibration :
The vibration shall be measured at load as close to maximum achievable load & shall not
exceed 250 microns.
g)
Noise Level (Sound pressure level) check
Noise level measurement shall be done generally following the include lines given in IS:
12065. The measurement shall be carried out with a calibrated integrating sound level
meter as per IS: 9779.
Sound level shall be measured a1l round the diesel Generator set at a distance of 1 meter
from the nearest surface of the machine & at a helght of 1. 5 meter from the floor level as
Page 123 of 382
illustrated in IS: 12065 for electrical machines.
A minimum of 8 points (5 around diesel engine & 3 around alternator)
shall be covered for measurement. Additional measurement points shall be considered in
case the criteria indicated in Clause of IS: 12065 is not met.
The measurement shall be done with slow response meter on the A-weighing scale. The
average of the A-welghed sound level measurement expressed in decibels to a reference
of 0.0002 microbar shall not generally exceed 93 dbA.
The tests shall be carried out with the D.G.Set operating at rated speed & at maximum
achievable load. DG set shall be located in a room having an approximate dimension of
10m x 8m. Necessary correction for Test environment condition & background noise will
be applied as per IS: 12065.
Page 124 of 382
SECTION 5.9
TECHNICAL SPECIFICATION
11KV UG CABLE
Page 125 of 382
Volume IIA
Technical specification
Section 5.9 11kv UG cable
Clause No.
Particular
1.0
Qualifying requirement
2.0
General
3.0
Technical
4.0
Cable drums
5.0
Tests
6.0
Cable laying
Page 126 of 382
VOLUME IIA
SECTION 5.9 - 11 kV U.G.CABLE
TECHNICAL SPECIFICATIONS FOR 11 KV U.G CABLE
1.0
QUALIFYING REQUIREMENT FOR MANUFACTURER:
Please refer volume- 1 section IFB, clause 11.6.2
2.0
GENERAL
The bidder shall quote for the entire scope of work. The preferred cable size is 3 core, 95 sq. mm
,240 sq. mm,400 sq. mm & 1 core 1000 sq. mm
2.1
Successful bidder shall prepare the entire laying, jointing and termination schedule.
3.0
TECHNICAL
3.1
Standard: The underground cable shall conform to IS: 7098 part (2), 1985 with
amendments. "Specification for cross linked polyethylene insulated PVC insulated cables.
3-2
Technical requirement
a)
Specific requirement:
3 core 6.35/ 11 KV grade, 90 deg C rating, heavy duty power cable with stranded compacted
circular aluminium conductor shielded with extruded semi-conducting compound, cross linked
polyethylene insulated, shielded with extruded semiconducting compound and copper tape,
shielded cores laid up with fillers inner sheath of extruded PVC, Galvanised round steel wire
armored and PVC ST- 2 overall sheath.
b)
Single core cables
Single core, 6.35/11 KV grade, 90 deg. C and rating, heavy duty power cable with stranded
compacted circular aluminium conductor, shielded with extruded semiconducting compound
cross linked polythene insulated, shielded with extruded semiconducting compound, and a
copper tape, inner sheath of extruded PVC, hard drawn alurninium round wire armored and PVC
type ST-2 overall sheath.
3.3
DESIGN CRITERIA:
I)
The cables will be used for connection of the station. Auxiliary 250 KVA, 11/0.433/KV
transformers with the 11 KV switchgear.
ii)
The cable will be laid direct in ground/duct with uncontrolled backfill, with channels of
logging.
iii)
The cable shall be designed to with stand the mechanical electrical and thermal stresses
under steady and transient conditions.
Page 127 of 382
iv)
The conductor insulation shield, XLPE insulation and insulation shield shall be by triple
extrusion process.
v)
Core identification shall be by coloured strips or by numerals.
4.0
CABLE DRUMS:
I)
Cable shall be supplied on non-returnable seasoned, strong wooden drums. The wood preprotective shall be applied on the entire drums.
ii)
seals
The cable ends on the drums shall be sealed with good quality heat shrinkable cable end
4.1
CABLE LENGTH:
The cable length on the drum shall generally the specified so as to avoid unnecessary joint The
normal delivery lengths shall be
I core - 1000 sq mm - 500 Mtr.
3 core - 95 sq. mm - 300 Mtr.
3 core - 240 sq. mm - 250 Mtr.
3 core - 400 sq.mm - 250 Mtr.
5.0
TESTS:
5.1
The cable supplied should have been already type test tested and reports furnished to the
owner.
5.2
The owner reserves the right to witness the acceptance test.
5.3
The routine test reports should be approved by the owner.
6.0
CABLE LAYING:
6.1
The cable shall be laid generally as per the cable installation shall be as per IS: 1255-1983
section 3, clauses 8 to 11 as per IS 1255 - 1967 direct in ground except at the point of
terminations where they shall be in air and at road crossing or drains where they shall be laid in
stoneware pipes or cement concrete Hume or span pipes.
6.2
The excavation shall be open cut and its width shall be that minimum as is necessary for
drawing the cable in the trench
without causing any damage to the cable.
6.3
The minimum depth of laying from ground surface to the top of the cable shall be 0.9 m.
6.4
The excavated earth shall be stacked by the side of the trench itself duly ensuring that the
heaped earth does not cave into the trench.
6.5
Where trenching is done in looses soils which are prone to collapse, the side of the trench
shall be shored with wooden planks or such other strutting so as to prevent the trench sides from
collapsing or caving in.
Page 128 of 382
6.6
The bottom of the trench shall be filled with a sand cushion of not less than 50 mm in
depth and the cable shall be laid over this cushion by being drawn steadily over cable rollers
without any sharp bends and crossings. No surface damages shall be caused during laying to the
cable. The rollers shall preferably be of the wooden sheaved type free hand rollers.
6. 7
The cable on being laid shall again be provided around with another layer of Protective
sand cushion of not less than 75 mm and finally covered with cable tiles. The minimum bending
radii shall not exceed indicated in clause 5.3 of IS 1255-1967. The tiles shall be clay fired
embossed with the words KSPDCL. The trench shall finally be covered with the excavated earth
and consolidated.
TECHNICAL SPECIFICATION FOR JOINTS AND TERMINATIONS SUITABLE FOR
11 kV CLASS XLPE INSULATED UNDER GROUND CABLE
1.0
QUALIFIYING REQUIREMENTS FOR MANUFACTURER:
Please refer volume 1, section IFB, clause 11.6.2
1.1
SCOPE:
This specification covers, in brief, the manufacture, testing,
inspection, packing & supply of heat shrinkable type power cable
accessories, such as, straight through joints, indoor and outdoor
termination's, suitable for the underground cables manufactured
in general conformity to IS: 7098 part (2) - 1985
i) The accessories shall be suitable for 3 core and single core.
6.35/11 kV grade XLPE insulated compacted circular
aluminium conductor ar-moured and overall PVC sheathed
underground cables.
ii) Definition: The term "accessory" shall mean; straight through
joints indoor/outdoor terminations used in cable power
transmission systems.
2.0
SERVICE CONDITIONS:
2-1
The straight through joints shall be suitable for use with cables directly buried in ground.
2.2
The indoor terminations shall be suitable for use indoor/outdoor type switchgear cubicles.
2.3
The outdoor terminations shall be suitable for use in directly
exposed to atmospheric conditions.
3.0
POWER SYSTEM PARTICULARS:
1) System voltage
2) Highest voltage
3) Neutral
4) Frequency
5) Cross sectional area of conductor
11 KV
12 KV
Effectively earthed
50 Hz
Page 129 of 382
3 x 95 sq.mm. Aluminum
3 x 240 sq.nm Aluminiurn
3 x 400 sq.mm Aluminum
I x 1000 sq.mm Aluminium
6) Continuous rated current at 90
deg C of cables (approx)
7) Maximum short circuit capability
of cables KA for one sec.
8) Approx. overall diameter of
cables
4.0
3x240 sq.mm 300 Amps
3x400 sq.mm 400 Amps
1x1000 sq.mm 650 Amps
25 KA
3x95 sq.mm 62 to 64 mm
3x140 sq.mm 80 to 82 mm
3x400 sq.mm 94 to 96 mm
1x1000 sq.mm 64 to 66 mm
STANDARDS:
4.1
The testing of the completed system of accessory, with cable of heat shrinkable joints and
terminations shall be in accordance with the standard, with latest amendments there of and
revisions.
I)
IS 13573 - 1992 : Joints and terminations of polymeric cables for worldng voltages
from 6.6 W up to and including 33 kV, performance requirements and type tests, with latest
amendments
ii)
Accessories tested in accordance with any other recognised national/International
standards are also acceptable.
5.0
DESIGN REQUIREMENTS:
5.1
The heat shrinkable accessory system shall be suitable for
6.35/11 KV grade, cross-linked polyethylene insulated, and aluminium conductor (of specified
area of cross section) underground cables.
The accessories should be compatible with the operating conditions of the cable and suitable for
the service conditions. The accessory shall provide effective stress control, insulation, and
environmental seal and should have non-tracking properties, irnpervious; to moisture and
resistant to ultraviolet radiation.
STRAIGHT THROUGH JOINTS:
The joint shall provide for the following performance functions:
I)
Electric stress control between the cable semiconducting screen and over the ferrule.
ii)
Continuity of armour.
iii)
Reinstatement of cable insulation and screen, similar to cable construction.
iv) Environmental protection and moisture sealing.
Page 130 of 382
v) Mechanical strength and protection.
5.3
TERMINATION:
The termination shall be designed to provide:
I.
Electric stress control for the cable insulation shield terminus.
ii.
Complete external leakage insulation between the cable conductor/ conductors and earth.
iii Sealing the cable against ingress of moisture and other atmospheric agencies.
iv. The entire core length from lug seal to cable breakout shall have voltage, non-tracldng
material.
5.4
The main components of the accessories shall be
I. The internal insulating and external protective tubings.
ii. Stress control tubings.
iii. Anti tracking and weather resistant tubing - indoor/outdoor.
iv. Break- out/Glove made from HV anti-tracking material.
v. Lug sealing sleeve made from HV anti-tracking material.
vi. Rain sheds made from HV non-tracking material.
vii. All other items like, lugs, ferrules connectors, earth continuity
material etc., necessary), for a complete joints/terminal
6.0 TESTS
6.1 ROUTINE TESTS
a) Visual inspection
b) Dimensional check
c) Physical verification of kit contents as per bill of materials
Page 131 of 382
SECTION 6.0
SWITCHYARD ERECTION
Page 132 of 382
VOLUME-IIA
TECHNICAL SPECIFICATION
SECTION 6.0 SWITCHYARD ERECTION
CLAUSE NO.
PARTICULARS
1.0
GENERAL.
2.0
ACSR CONDUCTOR.
3.0
GALVANIZED STEEL EARTH WIRE.
4.0
TUBULAR BUS CONDUCTORS.
5.0
EARTHING CONDUCTORS.
6.0
VOID.
7.0
BUS POST INSULATORS.
8.0
EARTHING.
9.0
MAIN BUS BAR.
10.0
BAY EQUIPMENTS.
11.0
LIGHTING PROTECTION.
12.0
TERMINAL POINTS.
13.0
EQUIPMENT ERECTION NOTES.
14.0
EARTHING MATERIAL
15.0
DIRECTLY BURIED CABLES.
16.0
INSTALLATION OF CABLES.
17.0
JUNCTION BOX
18.0
TESTING AND COMMISSIONING
Page 133 of 382
VOLUME - IIA
SECTION 6.0 - SWITCHYARD ERECTION
TECHNICAL SPECIFICATION FOR SWITCHYARD ERECTION
1.0 GENERAL
220 KV switchyard will consist of either double main bus or single main bus
switching scheme. For exact type of switching scheme the single line diagram
may be referred. The main bus will be of rigid type with Aluminium tube of size
75 mm. The equipment connection will be with a combination of aluminium tube
of 63 - mm size.
The detailed scope of work :includes design, engineering,
manufacture, testing at work, supply on F.O.R destination site basis, insurance,
handling, storage, erection testing and commissioning of various items, (along
with its spares) as detailed herein.
This section covers the description of the following items.
-
String insulators and hardware
ACSR conductor
Galvanised steel Earthwire
Aluminum tubular bus bars
Bus post insulators
Earthing & Earthing materials
Lightning protection
Cabling material, etc.
Bay marshalling kiosk.
1.1 String insulators & Hardwares Power Connectors:
The insulators for suspension and tension strings shall conform to IS: 731 insulator
hardware shall conform to IS: 2486.
1.2 CONSTRUCTION FEATURES:
1.2.1
Suspension and tension insulators shall be of wet process
Porcelain with ball and socket connection. Insulators shall be interchangeable and
shall be suitable for forming either suspension or strain strings. Each insulator shall
have rated strength markings on
porcelain printed and applied before firings.
1.2.2
Porcelain used in insulator manufacture shall be
homogeneous, free from laminations, cavities and other fiaws or imperfections that
might affect the mechanical or dielectric quality and shall be thoroughly vitrified,
Page 134 of 382
tough and impervious to moisture.
1.2. 3
Glazing of the porcelain shall be uniform brown colour,
free from blisters, burrs and other similar defects.
1.2.4
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 substance due to chemical
action. No radio interference shall be caused when operating at normal rated voltage.
1.2.5
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 galvanised 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.
1.2.6
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 insulators, the manner in which mechanical stresses are transmitted
through discs to adjacent parts, provision
for ineetinc, 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.
1.2.7
VOID
1.2.8
Insulator hardware shall be of forged steel. Malleable cast iron shall not be
used 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 localised
pressure. The metal
parts shall not produce any noise-generating- corona under operating conditions.
1.2.9
VOID
1.2.10
The tension string assemblies shall be supplied along with suitable
turnback. Sag compensation springs if required may also be provided.
1.2.11
All hardware shall be bolted type.
The following types of clamps are required:
a) Tension type
b) Suspension type
c) Post insulator clamps d) Spacer clamp
1.2.12
VOID
1.2.13
Tests:
both for single and twin conductor
both for single and twin conductor
both for single and twin conductor
for twin conductor
Page 135 of 382
In accordance with the stipulations under section - 2, the suspension and tension
strings, insulator discs and hardware shall be subjected to the following type tests,
acceptance tests and routine tests:
1.2.13.1
Type tests on insulator strings:
a) Dry and wet power frequency voltages withstand test with corona control rings as
per IS-731.
b) Lightning impulse voltage withstand test (dry) with corona control rings as per IS731.
c) Voltage distribution test (Dry)
The string shall be energised with 100 KV power frequency voltage. The voltage
across each insulator unit shall be measured by using a high impedance voltmeter.
The voltmeter shall be calibrated before and after the measurement. The voltage
across any disc shall not exceed 13% for 220 KV suspension and tension insulator
strings.
d) Corona test (Dry)
As per Annexure-A of Section -2
e) RIV test (Dry)
As per Annexure-A of Section -2
f) Mechanical strength test
The complete insulator string along with its hardware fittings 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 5 minutes & then removed. After removal of the load, the static
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.
1.2.13.2
Type tests on disc insulators
a) Thermal mechanical performance tests as per IEC: 575, clause 3.
1.2.13.3
Acceptance tests for disc insulators:
a) Visual examination.
b) Verification of dimensions as per Cl no. 10.5 of IS: 731.
Page 136 of 382
c) Temperature cycle test as per Cl no. 10.6 of IS: 731.
d) Puncture test as per Cl No. 10.10 of IS 731.
e) Galvanising test as per Cl no. 10.12 of IS: 731.
f) Mechanical performance test as per Cl. 4. of IEC-575.
g) Test on locking device for ball and socket coupling as per
IEC 372(2).
h) Porosity test as per Cl no. 10.11 of IS: 731.
1.2.13.4
Acceptance test on hardware fitting:
a) Visual examination as per Cl. 5.10 of IS :2486 (Part-I)
b) Verification of dimensions as per Cl. 5.8 of IS:2486
(Part - 1)
c) Galvanising/ electroplating tests as per Cl. 5.9 of IS
2486 (par-t-1)
d) Slip strength test as per Cl 5.4 of IS:2486 (par-t-1)
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).
g) The load shall be so applied that the component is stressed "in the
same way as it would be actual service and the procedure as given in 1.2.13.1
above should be followed.
f) Test on lockng devices for ball and socket coupling as per IEC : 372 (2)
1.2-13.5
a)
b)
c)
Routine test disc insulator
Visual inspection as per Cl no. 10. 13 of IS : 731
Mechanical routine test as per C1 No. 10. 14 of I S:703 1
Electrical routine test as per Cl no. 10. 15 of IS:73 1
1.2.13.6
a)
b)
Routine test on hardware fittings:
Visual examination as per Cl 5.10 of IS:2486 (part- 1)
Mechanical strength test as per Cl. 5.11 of IS : 2486
(part - 1)
1.2.13.7
Test during manufacture on all components as
applicable on disc insulator:
a)
Chemical analysis of zinc used for galvanising.
Page 137 of 382
Samples taken from the zinc ingot shall be chemically analysed 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 recognised procedures for these tests. The sampling will be based on
heat number and heat treatment batch. The details regarding tests will be discussed and
mutually agreed to by the contractor and owner in quality assurance programme.
1.2-13.8
Tests during, manufacture on all. components as applicable on hardware fittings:
a)
Chemical analysis of zinc used for galvanizing
Samples taken from the zinc ingot shall be chemically analysed as per IS: 209. The purity
of zinc shall not be less than 99.95%..
b)
Chemical analysis, hardness tests and magnetic particle for forging:
The chemical analysis, hardness tests and magnetic particle inspection. for malleable
casting will be as per the internationally recognised procedures for these tests. The
sampling will be based on heat number and heat treatment batch. The details regarding
tests will be discussed and mutually agreed to by the contractor and owner in quality
assurance programme.
c)
Chemical analysis and mechanical hardness tests and magnetic particle inspection
for fabricator hardware.
The chemical analysis, hardness tests and magnetic particle inspection for fabricated
hardware will be as per the internationally recognised procedures for these tests. The
sampling will be based on heat number and heat treatment batch. The details regarding
test will be discussed mutually and agreed to by contractor and owner in quality assurance
programme.
1.2.14. PARAMETERS
1.2.14.1
1
2
3
4
5
DISC INSULATORS
Type of insulators
Size of insulator units
(mm)
Electromagnetic
strength
220
Fog type
255 x 145
110
Fog type
255 x 145
120 KN for 90 KN
tension
90 KN for
suspension
Creepage distance of 430mm
292mm
individual
insulator
units (minimum and
as required to meet
total
creepage
distance)
Markings
Markings on Markings
porcelain
on
66
Fog type
255 x 145
33
Fog type
255 x 145
90 KN
90 KN
292mm
----
Markings
on
Markings
on
Page 138 of 382
shall
be
printed
applied
before firing
6
Power
puncture
voltage
1.2.14.2
porcelain
shall
be
printed
applied
before
firing
frequency 1.3 times the 1.3 times
withstand actual wet the actual
flashover
wet
voltage
flashover
voltage
porcelain
shall
be
printed
applied
before
firing
1.3 times
the actual
wet
flashover
voltage
porcelain
shall be
printed
applied
before
firing
1.3 times
the actual
wet
flashover
voltage
INSULATOR STRING
Power frequency withstand
voltage of string with
corona control ring(wet)KV rms
Lighting impulse withstand
voltage of string with
corona rings
(dry) KVP
Switching surge withstand
voltage of string with
corona rings (wet) –KVP
Minimum corona extinction
voltage level of string with
corona control rings (dry) –
KV rms
RIV level in micro volts of
string with corona control
control rings at 305
KV(rms) for 400 KV string
and 156 KV for 220KV
string across 300 ohms
resistor at 1 MHz
Total creepage distance of
the insulator string (mm)
Total number of discs per
string
395
230
140
70
+ / - 900
550
325
170
NA
---
---
---
156
---
---
---
1000(MAX) ---
---
---
6125
---
---
---
16
for --tension
14
for
suspension
---
---
Note: For tension purpose double insulator strings and for suspension purpose single
suspension insulator string shall be used.
2.0
ACSR CONDUCTOR:
2.1
Details of conductor:
2.1.1 The conductor shall be Drake & conform to IS : 398 (Part - V) 1982 except where
other wise specified herein.
Page 139 of 382
2.1.2 The details of the conductor are tabulated below
Stranding and wire diameter
Sectional area of aluminium
Total sectional area
Overall diameter
Approximate weight
Calculated DC Resistance at 20 degC
Minimum UTS
Drake
26 / 4.442mm + 7/3.454 mm steel
402.9 sq. mm
468.4 sq.mm
28.14 mm
1624 kg / km
0.0715 ohm / km
141.75 KN
2.2
WORKMANSHIP
2-2.1
The finished conductor shall be smooth, compact, from uniform and
free from all imperfections including spills, 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 accounting of reaction with trapped rain water etc), dirt, grit etc.
1.2.2 All the aluminium. and steel strands shall be smooth, uniform and free from all
imperfections such as spills and splits, diemarks scratches abrasions and kinks
after drawing,
1.2.3 The steel strands shall be hot dip galvanised and shall have minimum zinc coating
of 260 gms / sq mm after stranding of the uncoated wire surface. The zinc coating
shall be smooth, continuous and of uniform thickness, free from
Imperfection and shall withstand minimum three dips after stranding in standard
Preece Test. The Finished strands and the individual wire shall be of uniform
quality and have the same property and the characteristics as prescribed in ASTM
designation : B 498-74 and relevant IS.
2.2.4
The steel strands shall be preformed and postformed in order to prevent the spreading of
the strands in the event of cutting of composite core wire. Care shall be taken to avoid
damage to galvanisation during preforming and postforming operation.
2.3
Joints in wires
2.3.1
Aluminium wires
No joints shall be permitted in the individual wire 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 shall and be
such that no such joints are within 15 mtr of each other in the complete stranded
conductor.
2.3.2
Steel wires
Page 140 of 382
There shall be no Joints of any kind in the finished wire entering into the manufacture of
the strand. There shall also be no strand splices in any length of the completed stranded
steel core of the conductor.
2.4
Tolerances
The manufacturing tolerance to the extent of the following limits off 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
Aluminium
Steel
Standard
maximum
Minimum
3.53 mm
3.53 mm
3.55 mm.
3.51 mm
3.60
mm 3.46 mm
b)Lay ratio of conductor
Steel
7 wire layer
Aluminium 12 wire layer
18 wire layer
26 wire layer
2.5
Materials
2.5.1
Aluminium
Maximum
18
14
13
12
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%.
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
Manizanese
Phosphorous
Sulphur
Silicon
2.5.3
% composition
-
0.50 to 0.8S
0.50 to1.10
not more than 0.035
not more than 0.045
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
Page 141 of 382
2.6.1 The conductor shall be supplied in standard length of 1500/1800 meters 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
be carried out on the conductor.
manufacturing
shall
2.7.2
Type tests
The following type tests shall be conducted on samples of conductor. The testing charges
for the type tests shall be indicated separately in the prescribed schedule of the bid.
a)
UTS test on stranded The number of samples shall be mutually
conductor
agreed between contractor and owner)
b)
Corona extinction voltage
test (dry)
c)
Radio interference voltage
test (dry)
d)
DC resistance test on
on standard conductor
2
Acceptance Tests
As per Annexure-A
2.7.3
a)
Visual check for joints
scratches etc., and
length of conductor
b)
Dimension checks 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
g)
Wrap test on steel
aluminium strands
h)
DC resistance test
As per Annexure - A
-do-
IS:39S (p-T-.i N7) 1982
clauses 1-15.2, 12.7
& 12. 8
Page 142 of 382
aluminium strands
i)
UTS test on welded
joints of aluminium
strands
As per.Amnexure - A
NOTE:
All the above tests except test mentioned at ( i ) shall be carried out on aluminium and steel
strands after stranding oniy.
Routine Tests
a)
b)
c)
check to ensure that the joints are as per specifications.
Check that there are no cuts, fins etc, on the strands.
All acceptance test as mentioned in clause 2.7.3 above to be carried out on each coil.
2.7.5
tests during manufacture :
a) chemical analysis if zinc used for galvanizing
b) chemical analysis of aluminium used for making aluminium strands.
c) Chemical analysis of steel used for making steel strands.
For all these please refer ANNEXURE – A
2.7.6
Sample batch for type testing:
The contractor shall offer material for selection of samples for type testing, only after getting
approval for quality assurance plan from owner.
The samples shall be manufactured strictly in accordance with the quality assurance plan
approved by owner.
3.0
VOID
4.0
TUBULAR BUS CONDUCTORS
4.01
GENERAL: (Supply and erection)
4.02
This specification is in two parts, part-II and part - III in addition to part-I (general
condition)
4.03
Part - II relates to technical specification in regard of manufacture, testing and supply of
Aluminium pipes and accessories like post insulator clamps, corona bells, expansion
joints etc.
4.04
Part - III relates to erection of aluminium bus bars with accessories supplied as per
specification in part - II and includes bending, and welding of aluminiurn pipes, fixing
corona, bells, making expansion joints etc.
4.05
The scope of this specification covers the erection of tubular aluminium bus bars as
detailed below:
Page 143 of 382
i)
Erection of 220KV, 110 KV or 66 KV main bus of 75 mm/ 63 mm, 33KV single main
bus of 50 mm aluminiurn pipe with rigid cross bus connection to disconnects.
The scope of work covered by this specification is indicated in the layout plan drawings
annexed . The main rigid bus is to be connected to the expansion type connectors of the
disconnects through rigid cross bus aluminium pipes. Supply of terminal connectors of
the disconnects, is not in the scope of supply.
4.06
VOID
4.07
The schedule of requirements is indicated in schedule of quantities, Volume II section - I
General.
4.08
STANDARDS:
4.10
The materials offered shall conform to the relevant IS standards
4.11
Qualifying requirement : Refer Section IFB Volume I
4.12
The quantities and arrangement based on the drawing furnished by the purchaser may be
altered by the successful bidder for ensuring better working arrangements with the written
consent of the purchaser. The tenderer shall filrnise reasons in detail for suggesting such
alterations. The purchaser reserves the right to accept or to reject any or all of the
alterations or suggestions made by the bidder without assigning any reason whatsoever.
The following points shall be kept in view while submitting the offer:
a)
The vertical connections from main bus bar to disconnects shall be as follows
i.
Through "inverted Y" tap or 'V' tap of height of 2500 mm with 63 mm. Aluminiurn pipe
in case of 220 KV side bus connections. The Y and 'V' tap shall be connected by bolted
type clamp at top and bottom. Through a straight tap of height 1750mm and 1250 mm
with 63 and 50 mm aluminium pipe in case of 110 KV and 66KV side bus connectors.
The straight tap shall be connected by bolted type clamps both at top and bottom.
ii.
Through a straight tap of height 1200 mm with 38 mm aluminium pipe in case of 33KV
side bus connectors. The straight taps shall be connected by bolted type clamps both at
top and bottom.
b)
The horizontal connector from vertical tap to disconnects shall be of aluminium pipe of
the same size as that of vertical connectors and be rounded off at the end.
c)
Length of the horizontal connector from tap to disconnects is assessed, based upon the
width of isolators of standard make. Hence there may be slight difference in the total
length of horizontal connectors required, depending upon the make of disconnects which
are being procured
4.13 OPERATING CONDITIONS
The materials supplied and the workmanship involved shall be suitable for operating
conditions, which are detailed below
Page 144 of 382
Particulars
220 KV
Normal current As per normal
to base handled rating Al. pipes
indicated
in
annexure
Impulse
1050
withstand
voltage(KV)
Power
460
frequency
withstand
voltage(KV)
66KV
As per normal
rating Al. pipes
indicated
in
annexure
325
110KV
As per normal
rating Al. pipes
indicated
in
annexure
550
33KV
As per normal
rating Al. pipes
indicated
in
annexure
170
140
230
75
4.14 DRAWING FOR APPROVAL:
Detailed layout drawings indicating the various components as detailed below shall be got
approved by the successful tenderer before execution of work.
a)
Aluminium pipes of various size.
b)
Position of post insulator clamps indicating various types i.e., rigid expansion / sliding
type.
c)
Position of welds
d)
Cross - section at vital points like welding points, connection of vertical taps of 220KV, I
IOKV and 33 KV main bus bars, post insulators, clamps points rigid, expansion and
sliding types.
e)
Detailed drawings of various components namely length and cross section of pipes,
straight taps, post insulators clamps, rigid, sliding, expansion clamps, aluminium pipe
connectors 75 mm to 63 mm, 63 mm to 50mm, 50mm to 38mm used for connecting main
bus bars to disconnects.
4.15
ALUMINIUM PIPE: (Supply of aluminium pipes and accessories)
4.16
The purchaser proposes to use the under mentioned nominal size of aluminium pipes
220KV
Main busbars
75mm
Cross
bus 63mm
connecting
main busbars
and disconnects
4.17
110KV
75mm
63mm
66KV
63mm
50mm
33KV
50mm
38mm
Aluminium pipe to be supplied shall conform to BS-1600 schedule 40(EPS) standard pipe
sizes or equivalent standard having mechanical and electrical characteristics as detailed in
annexure-I.
Page 145 of 382
4.18
The aluminium pipe to be supplied should be of aluminium alloy of type 6340 WP as per
IS-5082 of 1981 and shall have the chemical composition and electrical characteristics as
detailed in annexure-I and II respectively.
4.19
The requirement for total lengths of various sizes of aluminium pipe is indicated in
section I of volume II. The tubes shall be supplied in convenient lengths so as to keep
wastages to a minimum without diminishing any of the mechanical and electrical
properties. The length of the pipes indicated is based on the drawings furnished. Any
increase in lengths of pipes owing to any practical reasons, miscalculation will be to the
account of the bidder.
4.20
The material shall be suitable for operating conditions detailed elsewhere of this
specifications.
4.21
The aluminium pipes to- be supplied should withstand high temperature encountered
during welding and no stress should develop in the pipe adjacent to the welding portion.
4.22
CORONA BELLS
4.23
These are required to be fixed at both ends of main buses to reduce corona effect.
4.24
The requirement of corona bells is indicated in the schedule of requirement.
4.25
SOLID CYLINDRICAL POST INSULATOR CLAMPS:
4.26
These are envisaged for holding the 220KV, 110KV, 66KV, and 33KV main bus
supported on cylindrical type solid core post insulators. The clamps to be supplied shall
be suitable for mounting holes on the insulator and size of the pipe which is detailed
below :
Nominal diameter of Cylindrical
solid Pitch
circle
Aluminium
pipe core post insulator
diameter
of
(inches)
mounting holes on
top (mm)
i. 75 mm
As per IS 5350
Part II
a) 220KV main bus
127
b) 110KV main bus
127
ii. 63 mm
As per IS 5350
Part II
a) 66KV main bus
127
iii. 50 mm
As per IS 5350
Number of holes
(numbers)
a) 33 KV main bus
4
Part II
76
4
4
4
4.27
The clamps shall conform to latest edition of IS : 5561
4.28
The clamps required are of three types viz. Rigid, sliding and expansion types
i
RIGID TYPE CLAMPS : Are required to hold the aluminium pipe rigidly allowing for no
lateral movement of pipe. These are required at points marked 'R' in the layout drawings
and shall be suitable for insulator and aluminium pipe details indicated in clause 4.24. At
Page 146 of 382
all rigid clamp locations, there shall be vertical straight tap connections in case of 220KV,
110KV, 66KV and 33KV main buses for connecting disconnects respectively.
ii)
SLIDING TYPE CLAMPS : Are the ones located in between a rigid clamp and expansion
type clamp, which shall allow for movement of pipes. These are marked as 'S' in layout
drawing. These clamps may be bolted type or plain type i.e, without bolts. As in case of
rigid type clamps, vertical straight line tap connections are located on sliding clamps also.
iii)
EXPANSION TYPE CLAMPS : Are the ones located between two rigid clamps and
marked 'E' in the layout drawing. These clamps are meant for allowing for expansion of
aluminium pipes used for main bus. The expansion joints so used in the clamps shall be
complete in all respects with required aluminium straps, filler inserts, etc., and should
allow for proper expansion of the portion of aluminium pipes between two rigid clamps.
4.29
„V‟ OR 'Y' TAPS OR STRAIGHT LINE TAPS:
4.30
As detailed in clause 4.23 and clause 4.12 in part-I, the main bus is to be connected to
equipment of various terminal bays by means of straight taps in case of 'Y' or 'V' taps in
case of 220KV main bus, 110KV, 66KV, and 33KV main buses.
4.31
The vertical taps are to be connected to disconnects by means of horizontal taps
4.32
The tap connections shall be with 63 mm aluminium pipe for 220KV, 110KV system and
with aluminium pipe for 66KV (38mm) aluminium pipe for 33KV system.
4.33
The height of vertical taps shall be 2500mm for 220KV system, 1750 mm for 110KV
system, 1250 mm for 66KV system and 1200mm for 33KV system.
4.34
The joints between the main bus and vertical tap and vertical tap to horizontal tap shall be
made up of suitable clamps, which should conform to the latest edition of IS-5561.
4.35
WELDED JOINTS, INSERTS, ETC:
4.36
The main bus shall consists of standard lengths of aluminium pipe joined at various points
by welded joints or expansion joints as the case may be.
4.37
Welded joints to an extent of 10% of the total quantity for each KV class shall be tested
by radio-graphic test to prove the soundness of the weld joints. Further if desired by the
owner, the tenderer shall arrange for the radio-graphic test of more number of joints for
which the unit rates are to be indicated in price schedule.
4.38
The welded joint or the expansion joint shall be complete in all respects with required
number of pipe filler inserts, proper welding etc.
4.39
The successful tenderer shall submit the quality assurance plan for the work and welder
qualification for approval. The weld should be cut open to see the quality of the welds at
no extra cost to the purchaser .
4.40
DRAWING
Page 147 of 382
4.41
The tenderer should submit drawing in respect of all the components detailed in clause
1.00 to 5.00 and other essential and necessary components required for without which the
tender will be rejected.
4.42
As stated in clause 6.00 of part-1 the tenderer shall submit drawings of various
components for purchaser's approval. The material shall be offered for inspection only
after purchaser's approval is accorded to the drawing.
4.43
The drawings of clamps and connectors should be exhaustive i.e, various views shall be
depicted and current rating (Amp capacity) mentioned.
4.44
MATERIALS:
4.45
The material used for the various pipe joints, connectors shall be of proven tested quality
and workmanship. The composition of alloys used shall be made available to the
purchaser for verification. The bolts and nuts shall conform to IS-1363- 1967 with latest
revisions.
4.46
The clamps offered shall be complete in all respect and shall perfectly suit the required
size of aluminium pipes specified in clause 1.00 of part-II.
4.47
All ferrous metal parts like bolts, nuts of size l2mm and above shall be hot dip galvanised
and bolt sizes below 12mm may be electro galvanised. The threads in nuts shall be cut
after galvanising and shall be lubricated and greased. All other threads shall be cut to take
care of increase in diameter due to galvanising.
4.48
All bolts shall be provided with a lock nut along with fastening nut.
4.49
All casting shall be free from blow holes and other casting defects such as cracks etc.
4.50
The connectors shall have the same electrical characteristics as the associated aluminium
bus bars and, shall be capable of carrying the normal and short time current rating
detailed in clause 5.00 of part-I.
4.51
Special care should be taken in clamp design to account for
(i) Galvanic corrosion,
(ii) cold flow or creep of aluminium,
(iii) thermal cycling.
The clamp body shall be of high conductivity aluminium alloy of high strength and noncorrosive. The aluminium alloy shall be copper free. The bolts and nuts used shall be of
high tensile, non-corrosive galvanic resistant material. Aluminium alloy, phosphorous
bronze or galvanised iron may be used as required by the clamp design.
4.52
Bolting pressure shall be well distributed. The outer surface of the clamp shall be smooth
and free from sharp edges.
4.53
TESTS
4.54
Aluminium pipe, associated clamps and corona bell shall be designed for trouble free
operation in the climatic and atmospheric conditions enumerated in the project data.
Page 148 of 382
Hence, the tests and especially the Corona discharge test, Special features of design to
meet the requirement shall be brought out in the tender.
4-55
TYPE TESTS: Tenderer shall furnish the following type test certificates in respect of the
aluminium pipe and accessories.
Aluminium Pipe
1. Tensile test
2. Resistance test
3. Temp.rise test
4. Short time current test
5. Visual discharge test.
-----------Applicable
Applicable
Applicable
Applicable
Clamps
Corona bells
Applicable
Applicable
Applicable
Applicable
Applicable
-------------Applicable
Applicable
Applicable
Applicable
4.56
Acceptance tests: The following acceptance tests are to be conducted in presence of
owner's representative.
a) Tensile test.
b) Resistance test.
c) Temperature rise test.
d) Visual and dimensional verification
4.57
The visual discharge is specified to know the corona effect. Special care shall be taken to
design and manufacture to minimise corona discharge. Corona discharge shall not be
visible from the clamps when the system consisting of pipe with clamps is energised to
phase ground system.
4.58
For the purpose of temperature rise and other tests, the current carrying capacity of
various clamps may be reckoned as follows clamps or part thereof in contact with IPS
aluminium pipe of nominal diameter.
a) 75 mm
b) 63 mm
c) 50 mm
d) 38 mm
2000 Amps.
1250 Amps.
1250 Amps.
800 Amps,
4.59
The purchaser reserves the right to conduct temperature rise tests at rated current on any
erected portions of the bus works. Total temperature of clamps more than 85 deg C
(temperature rise plus ambient) will not be acceptable. Clamps which are found to show
the usual corona discharge at the rated voltage will not be acceptable
4.60
SAMPLES
4.61
The tenderer shall furnish typical samples of tubular bus bar materials of 500 mm.
Minimum length and one unit of each of components like clamps, corona bell, power
connectors, etc., used in the above works, to enable the purchaser to assess the quality of
workmanship of the products.
4.62
ERECTION AT SITE
4.63
WORKS AND WORKMANSHIP :
To elaborate the work involved at site
Page 149 of 382
i)
ii)
iii)
iv)
v)
vi)
It consists of cutting of tubular bus bars to required sizes.
Making of straight tap.
Welding of aluminium tubes after installation and mounting of tubular bus
bars.
Welding of heater plates
Bending and assembly of aluminium tubes with other accessories and equipments as
shown in the tender drawings.
Radiographic test of all welded Joints.
4.64
The workmanship shall be of highest order. The cutting shall be smooth, even without
any burrs on the cut edges. The welding shall be perfect and the successful tenderer shall
take radiographs and furnish the same to the purchaser to depict the perfectness of
welding,
4.65
WELDING OF JOINTS:
4.66
Surface to be welded shall be cleaned thoroughly so that the same are free from grease,
dust and loose particles. Sleeves shall be used for welded joints under short circuit
conditions.
4.67
Pure argon gas shall be used for welding. In view of argon gas shield around the arc, the
welding operation shall be shielded from wind that could displace the gas envelope.
4.68
The welding process shall be carried out at the rate of 15-30 cms per minute. After
completion of welding, the surface shall be cleaned.
4.69
The ' weld ' shall have an average strength ranging from 120 to 155 KG/cm2.
4.70
TESTING AND COMMISSIONING
4.71
After satisfactory completion of works as detailed in clause 1.05 and 2.01 above, the
tubular bus bars will be energised in the presence of the tenderer or his authorised
representative.
4.72
TESTS
4.73
a)
b)
Radio - graphic tests:
The test is intended for the presence of the cracks, discontinuity in the welds.
A minimum of 10 % of the welded joints are to be subjected to radio- graphic tests. These
welded Joints shall be selected at random by the purchaser.
Further if the purchaser desires for the radiographic test for more number of welded
joints, the contractor shall arrange for the same.
c)
4.74
SL No.
1
2
3
4
5
6
Test to prove the mechanical strength i.e, to withstand 155 KG/ cm2 shall be conducted
on 5% of the welded joints.
Particulars
Nominal size
Outer diameter
Inner diameter
Wall thickness
Area of cross-section
Weight per unit length
Unit
mm
mm
mm
mm
Sq. mm
Kg/mtr
75 mm
75
88.9
77.92
5.449
1439
3.884
63 mm
63
73.03
62.71
5.16
1100
2.97
50 mm
50
60.33
52.51
3.91
693.55
1.878
38 mm
38
48.26
40.89
3.68
516.13
1.4
Page 150 of 382
7
8
9
10
11
12
Section modules
Cubic
cm
Movement of inertia
Cm 4
Radius of gyration
Cm
DC Resistance (max) Micro
at 20 deg C
ohm/mtr
Reactance at 304.8 mm Micro
( 1 foot ) spacing at 50 ohm/mtr
Hz
Current rating at 50 Hz Amps
for outdoor conditions
28.258
17.451
9.186
5.345
125.606
2.957
21.8
63.683
2.406
28.4
27.709
1.999
45.149
12.9
1.581
60.73
123.7
136.2
148.3
162.73
2350
1950
1440
1160
ANNEXURE -II
CHEMICAL PROPERTIES OF ALUMINIUM ALLOY
(Clause 10.03)
1.
I.S specification 5082-1981
6340-wp type or
equivalent of any
international standards.
2.
Chemical composition percentage
Cu - 0.04 Max
Mg - 0.4 to 0.9.
Si - 0.3 to 0-7.
Fe- 0.5 Max.
- 0.03 Min
Al - remaining part
3.
Minimum 0.2% proof stress
16.5 Kg. Per Sq.rrm
4.
Minimum ultimate tensile strength
20.5 Kgs/Sq.mm
5.
Minimum toleration on 50 mm.
10%
6.
Electrical resistivity (max) at 20* C
1133 Micro ohms cm
7.
Minimum electrical conductivity
55% I.A.C.S
8.
Temperature co-efficient of resistance
per centigrade degree
0.00364
Linear temperature co-efficient of
expansion (20 deg C - 200 Q per
centigrade degree
0.000023
Thermal conductivity
(Calories/sec/sq. mm/cm/deg. Q
at 100 deg C
0.43
9.
10.
Page 151 of 382
11.
Modulus of elasticity
5.0
EARTHING CONDUCTORS
5.1
General
6700 Kgs./sq.mm.
All conductors buried in earth and concrete shall be of mild steel. All conductors above
ground level and earthing leads shall be of galvanized steel, except for cable trench
earthing. The minimum sizes of earthing conductor to be used are as indicated in clause
8.4 of this section.
5.2
5.2.1
Constructional features
Galvanised steel
a) Steel conductors above ground level shall be galvanized according to IS : 2629.
b) The minimum width of the zinc coating shall be 618 gms/sq.m and minimum
thickness shall be 85 microns.
c) The galvanized surface 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 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
5.3
Tests
In accordance with stipulations under section - 2 galvanised steel shall be subjected to
four one minute dips in copper sulphate solution as per IS .- 2633.
6.0
VOID
7.0
BUS POST INSULATORS
The post insulators shall conform in general to latest IS 2544, IEC – 168, IEC – 815 and
IS: 5350.
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 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.
Page 152 of 382
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.
1.1.5
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 insulator
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 : 4579. 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)
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 bolts heads/nuts bear upon the levelled surfaces they shall be provided
with square tapered washers of suitable thickness to afford a seating square with the axis
of the bolt.
c)
All bolts and nuts shall be of steel with well formed hexagonal heads forged from
the solid and shall be hot dip galvanised. The nuts shall be good fit on the bolts and two
clear threads shall show through the nut when it has been finally tightened up.
7.1.9
Bidder shall make available data on all the essential features of design including the
method of assembly of shells and metals parts, number of 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 under section - 2 the post insulators shall be subject to
type, acceptance, sample and routine tests as per IS : 2544 and IEC - 168
7.2.1
In addition to acceptance/sample/ routine tests as per IS : 2544 and IEC-168, the
following tests shall also be carried out.
a)
b)
Ultrasonic test as an acceptance test
Soundness test, metallurgical tests and magnetic test on MCI caps and pedestal tests as
acceptance test.
All hot dip galvanised components shall be subject to check for uniformity of thickness
and weight of zinc coating on sample basis.
The bending test shall be carried out at 50% minimum falling loads in four directions as a
routine test and at 100% minimum falling load in four directions as an acceptance test.
c)
d)
Page 153 of 382
e)
Acceptance norms for visual defects allowed at site and also at works shall be agreed in
the quality plan
7.2.2
The following type tests are proposed to be conducted on the post insulators. The test
charge for conducting these tests shall be indicated in the offer
a) Power frequency withstand test (dry & wet) .
b) Lightning impulse test (dry).
c) Measurement of R.I.V. (Dry).
As per Annexure - A. section - 2.
d) Corona extinction voltage test (Dry).
As per Annexure - A, section - 2.
e) Test for deflection under load.
f) Test for mechanical strength
7.3
Technical parameters of Bus post insulators
Sl No.
A
B
C
D
E
F
G
H
I
J
K
Type
Voltage class (KV)
Dry and wet one
minute
power
frequency
withstand voltage
(KV rms)
Dry
lighting
impulse withstand
voltage (KVP)
Solid core
245
460
72.5
140
+ / - 1050
325
Wet
switching
surge
withstand
voltage (KVP)
Max
radio
interference
voltage
(
in
microvolts)
at
voltage 156(rms)
for
220KV
between phase to
ground
Corona extinction
voltage( KV rms)
Total
minimum
cantilever strength
(KN)
Minimum
torsional moment
Total height of
insulator(mm)
PCD
Top (mm)
Bottom (mm)
No. of bolts
-
-
1000
-
245 KV
72.5 KV
6
6
As
per
IEC 273
2300
As per IEC
273
770
127
254
127
127
Page 154 of 382
L
M
N
Top (mm)
Bottom (mm)
Diameter of bolt
holes (mm)
Top (mm)
Bottom (mm)
Pollution level as
per IEC 815
4
4
4
4
M16
18
Heavy(III)
M16
16
Heavy(III)
Minimum
total 6125
creepage distance
for heavy pollution
(mm)
1815
7.3.4
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 in accordance with requirements given here under. The earthmat
design/drawing to be furnished by successful bidder.
8.2
Neutral points of system of different voltages, metallic enclosures and frame works
associated with all current carrying equipments and extraneous metal works associated
with electric system shall be connected to a single earthing system unless stipulated
otherwise.
8.3
Earthing and lightning protection system installation shall be in strict accordance with the
latest editions of Indian electricity rules, relevant Indian electricity rules, relevant 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
8.4
Details of earthing system
Item
a)
Main earthing conductor
to be buried in ground
b)
Conductor above ground
& earthing leads
(for equipment)
c)
Conductor above ground
& earthing leads (for
columns & aux. Structures)
Size
Material
As per approved design &
drawing
Page 155 of 382
d)
Earthing of indoor LT panels
and out door marshalling boxes,
MOM boxes, junction boxes
& lighting panels etc.,
e)
Rod earth electrode
f)
Pipe earth electrode (in treated
earth pit) as per IS.
100mm dia,
2750mm long
C. I pipe
g)
Earthing for motors
25x3mm GS flat
--- do---
h)
Earthing conductor along
outdoor cables trenches
5Ox6mm MS
flat
Mild steel
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
Whenever earthing conductor crosses cable trenches, underground service ducts, pipes,
tunnels, railways tracks etc., it shall be laid minimum 300mm. below them and shall be
re-routed 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 columns, beams, 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
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.
8.5.6
Earthing conductors crossing the road shall be laid 300mm below road or at greater depth
to suit the site conditions.
8.5.7
Earthing conductors embedded 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
Page 156 of 382
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.
Electrically continuity shall be ensured by bonding different sections of handrails 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 A separate earthing conductor shall be provided for earthing lighting fixtures
receptacles, switches, junction boxes, lighting conduits etc.
8.6.6
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.
8.6.7
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.
8.6.8
Railway tracks within switchyard area shall be earthed at a spacing of 30m and also at
both ends.
8.6.9
Earthing conductor shall be buried 1500mm away from the switchyard fence. All the
gates and every alternate post of the fence shall be connected to earthing arid as
specified in earthmat design.
8.6.10 Flexible earthing connectors shall be provided for the moving parts.
8.6.11 All Lighting panels, junction boxes, receptacles fixtures, conduits etc., shall be bonded in
compliance with the provision of I.E. rules
8.6.12 A continuous wound conductor of 16 SWG wire shall be run all along each conduit run
and bonded at every 600mm. by not less than two turns of the same size of wires. The
conductor shall be connected to each panel ground bus. All junction boxes, receptacles,
lighting fixtures etc., shall be connected to this 16 SWG ground conductor.
8.6.13 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
8.7
Jointing
8.7.1
Earthing connections with equipment earthing pads shall be bolted type. Contact surface
shall be free from sales, paint, enamel, grease, rust or dirt. Two bolts shall be provided for
Page 157 of 382
making each connection. Equipment bolted connections, after
tested, shall be painted with and corrosive paint/compound.
being
checked
and
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 lavers 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 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. Ail welded joints shall be
allowed to cool down gradually to atmospheric temperature before putting any load on it.
Artificial cooling shall not be allowed.
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 50x 6 mm 41 flat shall be clamped with the equipment support structures at
1000mm interval.
8.8
Power Cable Earthing
Metallic sheaths and armour of all multicore power cables shall be earthed at both
equipment and switchgear end. Sheath and armour of single core power cables shall be
earthed at switchgear end only.
8.9
Specific Requirement for Earthing Systems
8.9.1
Each earthing Iead from the neutral of the power transformer shall be directly connected
to two pipe electrodes in treated earth pit (as per IS ) which in turn, shall be burred in
cement concrete pit with a cast iron cover hinged to a cast iron frame to have an access to
the joints. All accessories associated with transformer like cooling banks, radiators etc.,
shall be connected to the earthing grid at minimum two points.
8.9.2
Earthing terminal of each lightning arrester & capacitor voltage transformer shall be
directly connected to rod earth electrode which in turn shall be connected to station
earthing grid,
8.9.3
Auxiliary earthing mat comprising of closely spaced (300mm x 300mm)
conductors shall be provided at depth of 300 mm from ground level below the operating
handles of the M.0.M box of the isolators. M.0.M boxes shall be directly connected to the
auxiliary earthing mat.
9.0
Main Bus Bars
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The brief description of the bus switching scheme, bus bar layout and equipment
connection to be adopted are indicated in section-1. The bus bar arrangements are shown
in drawings enclosed with the bid documents.
9.1
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.
9.1.1
Corona bells 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
electromagnetic discharge loss at the end points.
There shall be a small drain hole in
the corona bell.
The material of corona cell shall be aluminium alloy similar to that
of clamps & connectors.
9.1.2
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 electric and mechanical
characteristics shall also be furnished along with the bid. Welding at site shall be done
by adopting a qualify procedure and employing qualified welders as per ASME - section
IX.
10.0
BAY EQUIPMENT:
10.1
The disposition of various bay equipment is shown in single line diagrams and layout
drawings.
10.2
Bay Marshalling Kiosk
One number of bay marshalling kiosk shall be provided for each 220 KV bay. The bay
marshalling kiosk shall be provided in 66 KV bays as per necessity. In addition to the
requirement specified in section 2 (GTR). the bay marshalling kiosk shall have three
distinct compartments for the following purpose:
i)
200 nos. terminal blocks in vertical formation for lnterlocking facilities.
Additional marshalling kiosk shall be provided in case the existing marshalling kiosks 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.
11.2
The lightning protection system shall not be in direct contact with underground metallic
service ducts and cables.
11.3
A 40 mm dia. 2750 mm long earth electrode with test links , CI frame and cover shall be
provided to connect down conductor of lightning masts and towers with peak.
11.4
conductors of lightning protection system shall not be connected with the conductors of
safety earthing system above ground level.
Page 159 of 382
11.5
Down conductors shall be cleated on the structures at 2000 mm interval.
11.6
Connection between each down conductor and rod electrode shall be made via test joint (
pad type compression clamp ) located approx. 1500 mm above ground level.
11.7
Lightning conductors shall not pass through or run inside G.I conduits.
11.8
All metallic structures within a vicinity of 2000 mm in air and 5000 mm below ground
shall be bound to the conductors of lightning protection system.
12.0
TERMINAL POINTS
The terminal points for the scope of work of switchyard are given below
12.1
Line Feeders
12.1.1 The transmission line shall terminate on line side gantry structure. The supply and
erection of tension insulator string for line termination and tension clamps for earth wire
termination are included in the scope of the Bidder.
12.1.2 Lightning protection down conductor at this end, tap offs and jumper connections from
this dead end to all equipment in the switchyard are also in the Bidder's scope.
13.0
EQUIPMENT ERECTION NOTES
13.1
All support insulators, circuit breaker interrupters and other fragile equipment shall
preferably be handled with cranes having suitable booms and handling capacity.
13.1.1 The slings shall be of sufficient length to avoid any damage to insulator due to excessive
swing, scratching by sling ropes etc.
13.1.2 Handling equipment, sling ropes etc., should be tested periodically before erection for
strength.
13.1.3 Bending of 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
13.1.4 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.
13.1.5 Muslin or leather cloth shall be used for cleaning the inside and outside of hollow
insulators.
13.1.6 All the equipment, instruments and auxiliaries required for testing and
commissioning of equipment shall be arranged at site by the contractor.
13.2
STORAGE
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13.2.1 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
EARTHING MATERIAL
Cable tags and Markers
Each cable and conduit run shall be tagged with numbers that appear in the cable and
conduit schedule.
14.2
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.
14.3
Location of cables laid directly underground shall be clearly indicated with cable marker
made of galvanised iron plate.
14.4
Location of underground cable joints shall be indicated with cable marker with an
additional inscription "cable Joints".
14.5
The marker shall project 150 mm above ground and shall be spaced at an interval of 30
meter and at every change in direction. They shall be located on both sides of road and
drain crossings.
14.6
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
every twenty meters ( 20 m ) 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.
14.7
Storage and handling of cable drums
14.7.1 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. In the
absence of any indication the drums may be rolled in the same direction as it was rolled
during taking up the cables.
14.8
Cable Supports and Cable Tray Mounting Arrangements
14.8.1 The contractor shall provide embedded steel inserts on concrete floors/walls to secure
supports by welding to these inserts or available building steel structures, for the purpose
of casting in the control room.
14.8.2 The supports shall be fabricated from standard structural steel members.
14.8.3 Insert Plates and the Cable support angles shall be provided as per the drawings enclosed.
Page 161 of 382
14.9
Cable Termination and Connections
14.9.1 The termination and connection of cables shall be done strictly in accordance with cable
and termination and kit manufacturer's instructions, drawing and / or as directed by the
owner.
14.9.2 The work shall include all clamping fittings, fixing, plumbing, soldering, drilling, cutting
taping heat shrinking ( where applicable), connecting to cable terminal shorting and
grounding as required to complete the job.
14.9.3 Supply of all consumable material shall be in the scope of contractor.
14.9.4 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 9.5 Control cable cores entering control panel, switchgear / MCCB / miscellaneous panels
shall be neatly bunched, clamped and tied with nylon strap or PVC perforated strap to
keep them in position.
14.9.6 The contractor shall tape / ferrule control cable cores at all termination's, 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.
14.9.7 Spare cores shall be similarly tagged with cable numbers and coiled up.
14.9.8 All cable entry points shall be scaled and made vermin and dust proof. Unused openings
shall be effectively closed.
14.9.9 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 termination's.
14.9.10
The cable glands shall be tested as per BS : 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.
14.9.11
The cable glands shall also be tested for dust proof and weather proof termination.
The test procedure has to be discussed and agreed to between owner and cable gland
manufacturer.
14.9. 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.
14.9. 13
Crimping tool used shall be of approved design and make.
Page 162 of 382
14.9.14
Cable lugs shall be of tinned copper solderless crimping type conforming to IS 8309 & 8394 . Cable lugs shall be of approved make.
14.9.15
Solderless crimping of terminals shall be done by using corrosion inhibitory
compound. The cable lugs shall suit the type of terminals provided.
15.0
DIRECTLY BURIED CABLES
15.1
The contractor shall construct the cable trenches required for directly buried
cables. The scope of work shall include excavation, preparation of sand bedding, soil
cover, supply and installation of brick or concrete protective covers, back filling and
ramming, supply and installation of route markers and Joint markers. The bidder shall
ascertain the soil conditions prevailing at site, before, submitting the bid.
15.2
The cable (power and control) between LT station, control room and DG set room 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.
15.3
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 shall be on cable racks, in built-up trenches, vertical shafts, excavated trenches
for direct burial, pulled through pipes and conduits laid in concrete ducts, run bare and
clamped on wall/ceiling/steel structures etc., as shown in the drawings in detailed
Engineering stage. Where specific cable layouts are not shown on drawings, Contractor
shall route these as directed by the owner.
16.2
The contractor shall fabricate and install mounting arrangements for the support and
installation of all the cables on angles in the trenches. These mounting structures/cable
racks shall be fabricated from structural steel members (channels, angles and flats) of the
required size. The fabrication, welding and erection of these structures shall conform to
the relevant clauses of chapter - STRUCTURES in addition to the specification given
herein.
16.3
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
firiishing coats of aluminium paint. The red oxide and zinc chromate shall conform to IS :
2074. All welding works inclusive of the consumables required for fabrication and
installation shall be 'in the scope of the contractor.
16 4
All interpole cables (both power and control) for all equipment, shall be laid in
cable trenches conduit pipes of NTB 50/100 mm diameter, class medium as per IS:
1239/part-I and IS : 4736 which shall be buried in the ground at a depth of 250 mm. The
interpole cabling piping of breakers shall be laid in cable trenches. The scope shall
include all labour, material, equipment, for transporting, laying, burying etc.,
including required bends and end seals.
16.5
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
Page 163 of 382
equipment or in case the distance is small notch / opening on the floor
shall
be
provided. In all these cases necessary bending radius as recommended by the cable
manufacturer shall be maintained. Cabling in the control room shall be done on ladder
type cable trays.
16.6
Cables from the equipment to trench shall run in conduits. Necessary
conduits
of
adequate sizes and length shall be supplied and installed by the contractor. Flexible
conduit should be used between fixed conduit/cable trays (perforated type) and equipment
terminal boxes, where vibrations are anticipated.
The flexible conduit shall be as per
the relevant IS
16.7
Power and control cables 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.
16.8
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.
16.9
Trefoil clamps for single core cables shall be of pressure die cast aluminium (LM- 6),
Nylon - 6 or fibre Pads and shall include necessary fixing GI nuts, bolts, washer etc.,
These are required at every 2 meter of cable runs.
16.10 Power and control cables shall be securely fixed to the trays/supports with self locking
type nylon ties with de-interlocking facility at every 5 meter interval for horizontal run.
Vertical and inclined cable runs shall be secured with 25 mm wide and 2mm thick
aluminiurn strip clamps at every 2m
16.11 Cables shall not be bent below the minimum permissible limit. The permissible limits are
as follows:
Power cable - 12D
Control cable - 10 D
where D is overall diameter of cable
16.12 Where cables cross roads, drains and rails tracks, these shall be laid in reinforced spun
concrete or steel pipes buried at not less than one metre depth,
16. 13 In each 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.
16.14 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.
16.15 Control cable termination's inside equipment enclosure shall have sufficient lengths so
that changing of termination In terminal blocks can be done without requiring any
splicing
Page 164 of 382
16.16 Metal screen and armour of the cable shall be bonded to the earthing system of the
station, wherever required by the owner
16.17 Rollers shall be used at intervals of about two meters while pulling cables.
16.18 All due care shall be taken during unreeling, laying and termination of cable to avoid
damage due to twist, kinks, sham bends, etc,
16.19 Cable ends shall be kept sealed to prevent damage.
16.20 Inspection on receipt, unloading and handling of cables shall generally be in accordance
with IS : 7255 and other Indian Standard Codes of practices
16.21 Wherever cable pass through floor or through wall openings or other partitions, wall
sleeves with bushes having a smooth curved internal surface so as not to damage the
cable should be supplied, installed and properly sealed by the contractor.
16.22 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 rot likely to be taken up for some time.
16.23 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 modification are made.
16.24 Contractor shall paint the tray identification number on each run of trays at an interval on
10 m
16.25 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
of' the owner, i.e. the contractor shall not be paid forinstallation and removal of the
damaged cable.
16.26 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 no, %kith insulating tape, sleeve or paint.
16.27 Tests on Cable Trays
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)
Page 165 of 382
A 2.5 metre straight section of 300 mm, 600 mm wide cable tray shall be simply
supported at two ends. A uniform distributed load of 76 Kg-m shall be applied along with
the length of the tray. The maximum deflection at the mid-span shall not exceed 7mm.
16.28 Conduits, Pipes and Duct Installation
16.28.1
Contractor shall supply and install all grid conduits, mild steel pipe & 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.
16.28.2
Contractor shall have his own facility for bending cutting and trenching the
conduits at site. Cold bending should be used. Ail cuts & threaded ends shall be made smooth
without leaving any sharp edges. Anti-corrosive paint shall be applied at all field threaded
portions.
16.28.3
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.
16.28.4
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.
16.28.5 Conduit installation shall be permanently connected to earth by means of special
approved type of earthing clamps. GI pull of adequate size shall be laid in all conduits before
installation.
16.28.6 Each conduit run shall be painted with its designation as indicated on the drawings such
that it can be identified at each end.
16.28.7
Embedded conduit shall have a minimum concrete cover of 50 mm.
16.28.8
Conduit run sleeves shall be provided with the bushings at each end.
16.28.9
Metallic conduit runs at termination shall have two locknuts and a bushing for
connection. Flexible conduits shall also be suitably clamped at each with the help of bushings.
Bushings shall have rounded edges so as not to damage the cables.
16.28.1
Where embedded conduits turn upwards from a slab or fill, the termination
dimensions shown on the drawings, if any, shall be taken to represent the position of the straight
extension of the conduit external to and immediately following the bend. At least one half of the
arc length of the bend shall be embedded.
16.28.11
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.
16.29.12
For underground runs, contractor shall excavate and back fill as necessary.
Page 166 of 382
16.28.13
Contractor shall supply, unload, store and install conduits required for the lighting
installation as specified. All accessories/fittings required for making the installation complete,
including but not limited to pull out boxes, ordinary and inspection tees and elbow, check-nuts,
male and female bushings (brass or galvanised steel), caps, square headed male plugs, nipples,
gland sealing fittings, pull boxes, conduits terminal boxes, gaskets and box covers, saddle
terminal boxes, and all steel supporting work shall be supplied by the
contractor. The conduit fittings shall be of the same material as conduits.
16.28.14
All unarmoured cables shall run within the conduits from lighting panels to
lighting fixtures, receptacles etc.
16.28.15
Size of conduit for lighting (shall be selected as per the table given in the
drawings enclosed with the bid documents).
16.28.16
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.
16.28. 17
Conduit supports shall be provided at an interval of 750 mm for horizontal runs
and 1000mm for vertical runs.
16.28.18
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 raw plugs. Wooden
plug inserted in the masonry or concrete for conduit support is not acceptable.
16.28.19
Embedded
conduits shall be securely fixed in position to preclude any
movement. In fixing embedded conduit, If welding or brazing is used, extreme care should be
taken to avoid any injury to the inner surface of the conduit.
16.28.20
Spacing of embedded conduits shall be such as to permit flow of concrete between
them and in no case shall be less than 38 mm.
16.28.2 1
Where conduits are along with cable trays, they shall be clamped to supporting
steel at an interval of 600 mm.
16.28.22
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.
16.28.23
Conduit shall be installed in such a way as to ensure against trouble from trapped
condensation
16.28.24
Conduits shall be kept, wherever possible, at least 300 mm away from hot pipes,
heating devices etc., when it is evident that such proximity may reduce the service life of cables.
16.28.25
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.
16.28.26
wiring.
For long conduit run, pull boxes shall be provided at suitable intervals to facilitate
Page 167 of 382
16.28.27
Conduit shall be securely fastened to Junction boxes or cabinets, each with a lock
nut inside and outside the box.
16.28.28
Conduit joints and connections shall be made thoroughly 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.
16.28.29
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.
16.28.30
The entire metallic conduit system, whether embedded or exposed, shall be
electrically continuous and thoroughly grounded. Where slip joints are used, suitable binding
shall be provided around the joint to ensure a continuous ground circuit.
16.28.31
After installation, the conduits shall be thoroughly cleaned by compressed air
before pulling in the wire.
16.28.32
conduit run.
17.0
Lighting fixtures shall not be suspended directly from the junction box in the main
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 are given below. Contractor shall perform an additional test
based on specialties of the items as per the field Q.P/ instruction of the equipment contractor or
owner without any extra cost to the owner. The
contractor shall arrange all instruments required for conducting these tests
alongwith calibration certificate and shall furnish the list of instruments to the
owner for approval.
18.2
GENERAL CHECKS
a)
Check for physical damage.
Page 168 of 382
b)
Visual examination of zinc coating/plating.
c)
Check from name plate that all items are as per order/specification
d)
Check tightness of all bolts, clamps and connecting terminals using torque wrenches.
C)
For oil filled equipment, check for oil leakage, if any. Also check oil level
and top up wherever necessary.
f)
Check around 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 and their drawings and manuals as
well as all tests specified in the relevant code or erection.
i)
Check for surface finish of grading rings (Corona control ring).
j)
Pressure test on all pneumatic lines at 1.5 times the rated pressure shall be conducted .
18.3
STATION EARTHING
a)
Check soil resistivity
b)
Check continuity of grid wires
c)
Check earth resistance of the entire arid as well as various sections of the
same.
d)
Check for weld joint and application of zinc rich paint on galvanised
surfaces.
e)
Dip test on earth conductor prior to use.
18.4
TUBULAR BUS WORK AND POWER CONNECTORS
a)
Physical check for finish
b)
Electrical clearance check
c)
Testing of torque by torque-wrenches on all bus bar power connectors and other
accessories.
d)
Millivolt drop test on all power connectors.
e)
Sag and tension check on conductors
18.5
ALUMINIUM TUBE WELDING
a)
Physical check
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b)
Millivolt drop test on all joints
c)
Dye penetration test & Radiography test on 10% samples basis on weld
joints
d)
Test check on 5% sample joints after cutting the weld piece to observe any voids etc.
18.6
INSULATORS
Visual examination for finish, damage, creepage distance etc.,
19.0
In case of switchyard materials, although the quantities arc indicated in bid proposal
sheets, the successful bidder shall supply the exact quantifies required to commission the
substation as per the scope. The payment will be made for the quantity indicated in the
Bid proposal sheets vis-a-vis the actual quantities (arrived at after the Engineering)
whichever is lower.
Page 170 of 382
ANNEXURE- "A"
(Testing Procedure for ACSR DRAKE 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 141.75 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
VOID
3.0
VOID
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 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 deg C as per clause no. 12.8 of IS :398 (part V) 1982 . The resistance
corrected at 20 deg C shall conform to the requirements of this specification
5.0
Chemical Analysis of Zinc
Sample 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.
Sample taken from the aluminium ingots/strands shall be chemically spectrographically analysed.
The same shall be in conformity to the requirements stated in this specification.
7.0
Visual Checks 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 re-winding.
8.0
Dimensional Checks 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.
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The lay-ratios of various layers shall be checked to ensure that they conform to the requirements
of IS specification and clause no- 9.4 and 9.5 of IS-398 (PartV) 1982.
10.0
Galvanising Test
The test procedure shall be as specified in 1S:4826-1968. The material shall conform to
the requirements of this specification
11.0
Torsion and Elongation Tests on Steel strands
The test procedure shall be as per relevant clause of IS:398 (part V) 1982. In torsion test, the
number of complete twists before fracture shall not be less than 18 on a Length equal to 100
times the standard diameter of the strand before stranding & 16 after stranding. In case test
sample length of less or more than 100 times the standard diameter of the strand, the minimum
number of twist will be proportionate to the length and if number comes in the fraction then it
will be rounded off to next higher whole number. In elongation test, the elongation of the strand
shall not be less than 4% for a gauge length of 200mm
12.0
Breaking load test on welded Aluminium strands .
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 strands guaranteed by the bidder
ANNEXURE B
(Testing Procedure for Galvanised Steel Earthwire)
UTS TEST
Circles perpendicular to the axis of the earth wire shall be marked at two places on sample of
earth wire of minimum 5m length suitably compressed with dead end clamps at either end. The
load shall be increased at steady rate 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 56.98 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 earth wire sample of minimum 5 m 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 deg 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 usually
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.
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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 I00 times the standard diameter of the strand, the minimum number of twists will be
proportionate to the length and if number comes in the fraction then it will be rounded off to next
higher whole number, In elongation test, the elongation of the strand shall not be less than 64 for
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 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.
S.
CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING
Samples taker, from zinc ingots shall be chemically/spectrographically analysed. The same shall
be in conformity to the requirements stated in this specification.
9.
CHEMICAL ANAYSIS OF STEEL
Samples taken from ingots / coils / strands shall be chemically spectrogaphically
analysed. The same shall be in conformity to the requirements stated in this
specification.
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SECTION – 7.0
TECHNICAL SPECIFICATION
STRUCTURES
Page 174 of 382
VOLUME-IIA
TECHNICAL SPECIFICATION
SECTION 7.0 STRUCTURES
CLAUSE
PARTICULARS
1.00
GENERAL.
1.1
SCOPE.
1.2
LIGHTING MASTS.
1.3
DESIGN, DRAWINGS, BILL OF MATERIALS AND
DOCUMENUS.
1.4
FABRICATION OF STEEL.
1.5
ASSEMBLY.
1.6
BOLTING.
1.7
WELDING
1.8
STABILITY OF STRUCTURE.
1.9
GROUTING.
1.10
GALVANIZING.
1.11
INSPECTION BEFORE DISPATCH.
1.12
TEST CERTIFICATES.
1.13
ERECTION.
1.14
SAFETY PRECAUTIONS.
Page 175 of 382
VOLUME - IIA
TECHNICAL SPECIFICATIONS
SECTION 7.0
(STRUCTURE)
1.0
GENERAL
1.1
The scope of specification covers fabrication, protoassembly, supply
& erection of galvanized steel structure of towers, girders, &
equipments structure. Towers, girders, support structure shall be
lattice/tubular type structure fabri6ated from structural steel conforming to
IS:2062 (latest). Single line diagrams are provided for lattice type towers/
girders/lightning mass. Bidder has to develop the structural drawing for the same based
on the single- line diagrams and switchyard diagram. Based on the switchyard
requirements like live- point height, phase to phase dimension and weight, dimensions of
the equipment / post insulators, the supporting structures are to be designed by the
successful bidder, which shall be approved by the owner. Lattice type structures are
proposed for all equipments and tubular type is proposed for post insulators.
The scope shall include all types of bolts, nuts, hangers shackles, clamps step bolts, inserts in
concrete , gusset plates, equipment mounting bolts, structure earthing bolts, foundation bolts,
spring washers, fixing plates angles & bolts for stiucture mounted or ground mounted
marshalling boxes AC/DC Marshalling box & equipment control cabinets) and any other item as
required to complete the job.
The connection of all structures to their foundations shall be by base plates embedded anchor/
foundation bolts. All steel structures & anchor/ foundation bolts shall be fully galvanized. The
weight of the zinc coating shall be atleast 0.610Kg/sq m for anchor/ foundation bolts & for
structural members. One additional nut shall be provided below the base plate, which may be
used for the purpose of leveling.
1.2
Lighting masts
The lighting masts shall be fabricated as per owner's design and fabrication drawings
lighting masts shall be provided with the structural steel ladder. The ladder shall be
provided with protection rings. Platform shall be provided for mounting of lighting
fixtures. The platform shall also have protection railing.
1.3
DESIGN DRAWINGS, BILL OF MATERIALS AND DOCUMENTS
The towers beams and lightning masts shall be fabricated as per the single line diagrams
furnished. In the part 1 of Technical specifications, only the single line diagrams
enclosed.
In respect of support (mounting) structures, the bidder has to quote as per their own designs.
Successful bidder has to furnish the design/ drawings based on the equipments to be supplied,
heights to be maintained which shall be approved by owner. Only after getting the due approval
of the owner the fabrication work shall be taken up.
1.3.2
The fabrication drawing and Bill Of Materials(BOM) in respect of towers and beams
shall be developed by the bidder based on the single-line diagram furnished. In case of
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support structures the bidder has to develop the fabrication drawing and the BOM based
on the inputs from switchyard drawings and parameters of the equipment to be supplied.
1.4
FABRICATION OF STEEL :
1.4.1
the contractor shall bear the expenditure at all stage on account of loading unloading
transportation and other miscellaneous expenses and losses and damages for all materials
up to the fabrication yard shop and there-after to the erection site including all other
expenses till the erection of work has been completed and accepted. The unit rates shall
be deemed to be inclusive of all such incidental expenses and nothing extra shall be
payable on any account in this regard.
1.4.2
The fabrication and erection shall be carried out generally in accordance with IS: 802
(latest). A reference however may be made to IS: 800(latest) in case of non-stipulation of
some particular provision in IS: 802 (latest). All materials shall be completely shop
fabricated furnished with proper connection material & erection marks for ready
assembly in the field.
1.5
ASSEMBLY:
i)
The component parts shall be assembled in such a manner that they are neither
twisted nor otherwise damaged & shall be so prepared that the specified camber, if any, is
provided. In order to minimize distortion in member the component parts shall be
positioned by using the clamps, clips, dogs, jigs & other suitable means & fasteners (bolts
& welds) shall be placed in a balanced pattern. If the individual components are to be
bolted paralleled & tapered, drifts shall be used to align the part so that the bolts can be
accurately positioned.
ii)
Sample towers, beams & lightening masts shall be trial assembled keeping in view
the actual site conditions, before erection, in the fabrication shop & shall be inspected &
approved by owner before mass fabrication. Necessary match marks shall be made on
these components in the shop before disassembly & dispatching,
1.6
BOLTING
i)
Every bolt shall be provided with a spring 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 & washers shall be hot dip galvanized.
iii)
2% extra nuts & bolts shall be supplied for erection-
1.7
WELDING:
The work shall be done as per approved fabrication drawing which clearly indicate
various details of joints to be welded, type of weld, length & size of weld, whether shop
or site weld. Symbols for welding on erection & shop drawings shall be according to IS: 8
13. Efforts shall be made to reduce site welding so as to avoid improper welding due to
constructional difficulties.
1.7
FOUNDATION BOLTS:
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1.7.1
Foundation bolts for the towers & equipment supporting structures & 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.
1.7.2
The contractor shall be responsible for the correct alignment & leveling of all steelwork
on site to ensure that the towers/ structures are plumb.
1.7.3
All foundation bolts for lattice structure, pipe structure are to be supplied by the
contractor.
1.7.4
All foundation bolts shall be fully galvanized so as to achieve 0.61 Kg per.sq m. of zinc
coating as per specifications
1.8
STABILITY OF STRUCTURE:
The supplier shall be responsible for the stability of the structure at all stages of its
erection at site & take all necessary by the additions of temporary bracing's & giving
equipment & their operations.
1.9
GROUTING:
The method of grouting the column basts shall be subject to approval of owner & shall be
such as to ensure a complete uniformly of contact over the whole area of the steel base.
The contractor will be fully responsible for the grouting operations.
1.10
GALVANIZING:
1.10.1 All structural steel works & single pipe supports shall be galvanized after fabrication as
per IS:2629(latest) IS:4759 (latest).
1.10.2 Zinc required for galvanizing shall have to be arranged by the manufacturer. Purity of
zinc to be used shall be 99.5% as per IS:209 (latest revision)
1.10.3 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.
1.11
INSPECTION BEFORE DISPATCH:
Each part of the fabricated steelwork shall be inspected certified by the owner or his
authorized representative as satisfactory before it is dispatched to the erection site. Such
certification shall not relieve the contractor of his responsibility regarding adequately &
completeness of fabrication.
1.12
TEST CERTIFICATE:
Copies of all test certificates relating to materials procured by the contractor for the works
shall be forwarded to the owner.
1.13
ERECTION:
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The contractor should arrange his own erection plant & equipment, welding- set, tools
tackles, scaffolding, trestles equipment's etc-, & any other accessories & ancillaries
required for the work. The erection work shall be started after concrete has acquired its
full strength i.e, 14 days . The members shall not be subjected to any undue stress,
damage to steel or galvanizing during erection.
1.14
SAFETY PRECAUTIONS:
The contractor shall strictly follow at all stages of fabrication, transportation & erection of
steel structures, raw materials & other tools & Tackles, the stipulation contained in Indian
Standard Code for erection for structural steel work as per IS: 7205. (Latest revision).
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VOLUME – IIA
TECHNICAL SPECIFICATION
SECTION – 8
CIVIL WORKS
Page 180 of 382
Page 181 of 382
VOLUME-II
SECTION – 8
TECHNICAL SPECIFICATION FOR CIVIL WORKS
PARTICULARS
1
General conditions and Guide lines
2
3
Site leveling
Foundation to station towers, equipments & other
works
R.C.C. cable ducts, Cable Duct at Road crossings and
4
R.C.C. Hume pipes Sub ducts
5
6
8
9
10
11
12
13
14
15
16
17
Antiweed treatment
Jelly spreading
Road work
Culvert across approach Road
Baffle wall between Transformers
Chain link mesh security fencing and Security
Compound wall
Main gate, Wicket gate and gate pillars
Control room building
Drilling Bore well & Arranging water supply
Construction of Oil storage sump tank
Yard protection works & storm water drainage
Foundation & A.C. sheet shelter for metal clad 11 KV
VCB Switch Gears
Page 182 of 382
VOLUME-II
SECTION - 8
TECHNICAL SPECIFICATION FOR CIVIL WORKS
I. General Conditions and Guide Lines:
The bidder shall go through the following guidelines and conditions
thoroughly before quoting the rates for individual items of work.
1) Design, engineering and construction of all civil works at sub-station shall
satisfy the general technical requirements specified in other sections of the
specification and as detailed below. They shall be designed to the required
service conditions/loads as specified elsewhere in this specification or implied
as per National/International Standards.
2) All civil works shall be carried out as per applicable Indian Laws, standards and
codes. All materials shall be of best quality conforming to relevant Indian standards
and codes.
3) The contractor shall furnish all design (unless otherwise specified), drawings, labour,
tools, equipment, materials, temporary works, constructional plant and machinery,
fuel supply, transportation and all other incidental items not shown or specified but as
may be required for complete performance of the works in accordance with approved
drawings, specifications and direction of owner.
4)
The work shall be carried out according to the design/drawings to
be developed by the contractor and approved by the owner or
supplied to the contractor by the owner. For all buildings, structures,
foundations etc., necessary layout and details shall be developed by the contractor
keeping in view of the functional requirement of the equipments and facilities for
providing enough space & access for operation, use and maintenance in due course by
the owner. Certain minimum requirements are indicated in this specification for
guidance purposes only. However, the bidder shall quote according to the complete
requirements.
5) The site will be handed over as “As it is where it is” condition. The layout and levels
of all structure etc shall be marked by the contractor at his own cost from the general
grid layout drawing and as per the benchmarks given by the Engineer-in-charge for
checking of the layout and levels.
6) Earth work excavation: This includes excavation in all types of soil strata including
hard rock and disposing of excavated surplus stuff after back filling to the places,
shown by the Engineer-in-charge within the station premises or outside the premises
of sub-station, to any notified disposal point of local bodies.
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7) Back filling and consolidation: Back filling shall be done in layers of 250 mms
thick for yard leveling & 150 mms thick for trenches backfilling duly watering and
compacting to the required density. If the excavated earth is not suitable for back
filling, then the approved new earth shall be brought from outside, mixed with 3%
cement (only for casing below foundations / trenches backfilling) and shall be used
for back filling. Back filled earth & the sub-grade for the roads and embankment shall
be compacted to minimum 96% of the standard Proctor‟s Density at OMC.
8) Cement concrete mixing and laying: The cement concrete shall conform to the
requirement mentioned in IS-456 and all the test shall be conducted as per relevant
Indian standard codes. The concrete shall be machine mixed and laid in layers of 150
mms thick and compacted using suitable vibrators to required shape. The bidder shall
arrange for testing of concrete cubes at different stages of work as desired by the
owner at his own cost.
9) Cement: The cement used shall be ordinary port land cement (OPC) of 43/53 grade
and shall conform to relevant IS. The bidder shall produce test certificates for each lot
of cement procured.
10)
Reinforcement steel: Reinforcement shall be TMT bars conforming to IS1786-2008(Fe 500 grade) and in specific areas, mild steel (Grade-I)
conforming to IS: 432 can also be used. Bidders shall produce test certificate
for each lot of reinforcement procured at site. Clear cover as per IS provision
shall be left to the reinforcement from the external concrete surface.
11) Jelly: The jelly used shall be of hard broken granite/basalt/trap metal free from dust
and organic material and shall be well graded. For bed concrete/leveling course (PCC
1:4:8) 40 mm and down size jelly shall be used and for coping, basement, cills, screed
concrete, structural concrete, Design Mix etc (PCC/RCC 1:2:4, 1:3:6 & concrete M20
Grade) 20 mm and down size jelly shall be used.
12) Sand: white river sand free from clay and any other organic materials very well
grained and cleanly sieved shall be used.
13) Bricks: Standard size table molded, well-burnt Bricks having minimum compressive
strength of 45 Kgs per Sq Cms with neat edges shall be used. But in places where
laterite stones are available the same may be used in place of bricks.
14) Centering, formwork: Only steel/plywood/plank centering shall be used for
construction work. The centering material shall be discarded as soon as it losses its
shape. Centering works shall be done to line and plumb with sufficient support to bear
the dead weight of concrete and live loads during execution of work. The centering
shall be water tight to avoid wheezing out of cement slurry during vibrating.
15) Curing: Curing shall be done for a minimum period of 10 days & maximum period
of 28 days until the structures develops the required strength. The bidder shall
construct a water storage tank for storing water and install 1 HP pump with
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distribution line for usage of water for construction & curing, as per the direction of
Engineer-in-charge. The exposed faces of concrete shall be covered with gunny bags
to keep the surface damp. The Max & Min period of curing may be decided with the
Engineer in charge of the work depending upon the importance and type of the
structure& surface to be kept damp.
16) VOID
17) Contractor shall comply with all the applicable statutory rules pertaining to factories
act (as applicable for the state), fire safety rules of Tariff Advisory committee, Water
act for pollution control etc.
18) Foundation system adopted shall ensure that relative settlement shall be as per
provision of IS-1904 and other Indian standards.
19) Interaction: The proper co-ordination and execution of all interfacing civil works
activities like fixing of conduits in roofs/wall floors, fixing of foundation bolts, fixing
of lighting fixtures, fixing of supports/embedment, provision of cutouts etc., shall be
the sole responsibility of the contractor. He shall plan all such activities in advance
and execute in such a manner that interfacing activities do not become bottlenecks and
dismantling, breakage etc. is reduced to minimum.
20) VOID.
21) The excess quantity of earth obtained from site leveling and from foundations and
other works shall be filled in low laying areas of the station premises or transported to
any notified areas of local body outside the station without any extra cost.
22) Bidder shall visit the site and shall obtain all required information regarding the
availability of labour, materials, machineries etc., before submitting their offer. Any
other additional information and details can be obtained from the concerned
transmission offices of KPTCL. Any plea/request for the revision of rates owing to
non-availability of the materials or insufficient quantity of materials will not be
considered/entertained under any circumstances, which may please be noted.
II. SITE LEVELING:
SCOPE: - The scope of Site leveling work includes the following with out any
additional cost.
1) The bidder shall take the block levels of entire station area at an interval of 5 mtrs and
plot the same marking contours at regular intervals. The block level drawing shall be
submitted for approval along with calculations of cutting and filling quantities duly
proposing the economical FGL of the yard.
2) Based on the above block levels,
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3) the owner will decide the FGL to suit the requirement of station yard.
4) Clearing the site area free of bushes, trees including removal of roots, any unsuitable
materials, demolition of any temporary building/structure and removal of
debris/unserviceable materials, stacking within the premises or any disposal point
away from the station area as per the decisions of the Engineer in charge of the work
and stacking of useful/serviceable materials outside the yard within the station
premises in the manner directed.
5) Leveling the station area to the required RL. The work includes cutting/excavating the
areas above FGL in all types of soil and rock including soft rock, hard rock, hard
laterite by blasting or chiseling, transporting the excavated earth to the areas lower
than FGL, removal of roots, vegetation and other organic materials, breaking of clods,
filling the areas lower than FGL in layers of 250mm loose thickness and consolidating
the same using PRR to Proctors density of 96% to the required line, grade and cross
section.
6) The shortage of earth if any shall be made good with the surplus earth from the
foundation and other works. However if the earth is found shortage for leveling even
after usage of all surplus available earth from all excavations, then such excess
quantity of new earth brought from outside and used for site leveling only, will be
paid at such rates provided in the price schedule for associated civil Engineering
works or payment will be regulated as per the terms and conditions stipulated in the
contract.
7) The excess/surplus earth & excavated rock shall be disposed off to the places within
the station premises/stocked at the desired places or outside the premises to any
notified disposal point of the local bodies as per the decisions & directions of the
Engineer in charge of the work.
8) In the areas where the movement of roller is not possible, compaction shall be done
using surface vibrators duly adding water to get the required density. Due care shall
be exercised so as not to damage any foundation, structure, equipments etc during
compaction.
9) If the type of soil encountered is black cotton soil/expansive soil or unsuitable for
acceptance, then new approved earth/murrum brought from outside shall be spread to
the entire switchyard area to a depth of 300mm (compacted thickness) excluding
plinths of the structures, roads, drainage, buildings, cable ducts etc and
consolidated/compacted to proctors density of 96% to the line, grade and cross section
after completion of casting of foundations and other works before Antiweed treatment
and Jelly spreading. Payment for the use of new earth for site leveling will be
regulated as stated under Sl.N0. (6) above.
10) Bidder shall quote rate per CMTR to carryout:
(i)
Site leveling – Cutting in all types of soil and rock and filling with available
earth including compaction, disposal of surplus earth etc
.
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(ii)
Filling the yard with new / borrowed earth including compaction etc.
III. FOUNDATION TO STATION TOWERS, EQUIPMENTS AND OTHER
SUCH WORKS
a) General:
1)
Hard copy of the soil investigation report if available may be obtained from the
concerned transmission office of KPTCL and if the same is not available the
contractor has to carryout the soil investigation and the designs shall be based on
the test report.
2)
Work covered under this clause of the specification comprises the design, supply
and installation of foundation and other RCC/PCC constructions for switchyard
structures, equipment supports, trenches, drains, jacking pad, pulling block,
fencing, control cubicles, bus supports, transformers, marshalling kiosks, auxiliary
equipment and systems, buildings, tanks or for any other equipment or service and
any other foundation required to complete the work. This clause is as well
applicable to the other RCC constructions. Reactor/transformer shall
rest on block foundations only.
3)
Concrete shall confirm to the requirements mentioned in IS: 456 and all the tests
shall be conducted as per relevant Indian Standard Codes. M20 grade(Min)
concrete shall be used for construction.
4)
If the site is slopy, the foundation height will be adjusted to maintain the exact
level at the top of foundation of the structures to compensate such slopes.
5)
The switchyard foundations’ plinths and building plinths shall
be minimum 300mm and 750mm above finished ground level
respectively.
6)
Minimum 75mm thick lean cement concrete 1:4:8 shall be provided below all
underground structures, foundations trenches etc to provide a base for
construction unless otherwise specified..
7)
Concrete works done with Portland slag cement shall be carefully cured and
special importance shall be given during the placing of concrete and removal of
shuttering.
8)
The design and detailing of foundations shall be done based on the approved soil
data and sub-soil conditions as well as for all possible critical loads and the
combinations thereof. The spread footings foundation or pile foundation as may
be required based on soil-sub-soil conditions and superimposed loads shall be
provided.
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9)
If pile foundations are adopted, the same shall be cast-in-situ driven/bored or precast or undreamed type as per relevant IS Code. Only RCC piles shall be
provided. Suitability of the pile foundations adopted shall be justified by way of
full design calculations. Detailed design calculations shall be submitted by the
bidder showing complete details of piles/pile groups proposed to be used.
Necessary initial load test shall also be carried out by the bidder at their cost to
establish the piles design capacity. Only after the design capacities of piles have
been established, the contractor shall take up the job of execution of pile
foundation. All the work (design & testing) shall be planned in such a way that
these shall not cause any delay in project completion.
b) Design:
1)
Foundation shall be of RCC type only. The design and
construction of cement concrete structures shall be
carried out as per IS: 456 and minimum grade of
concrete shall be M-20. Higher grade of concrete than specified
above may be used at the discretion of bidder, which has to be stated at
the time of bidding. If the reinforcement is required the same shall have to
be provided by the bidder with out additional cost.
2) Limit state method of design shall be adopted unless specified otherwise in
the specification. For design and construction of steel concrete composite
beam IS: 11384 shall be followed.
3) For detailing of reinforcement IS: 2502 and SP: 34 shall be followed. TMT
bars conforming to IS-1786-2008(Fe 500 grade) shall be used as
reinforcement. However, in specific areas, mild steel (Grade-I) conforming
to IS: 432 can also be used. Two layers of reinforcement (one inner and
outer face) shall be provided for wall & slab sections having thickness of
150 mm and above. Clear cover to reinforcement towards the earth face
shall be 40mm In case of sidewalls of cable ducts and for tower
foundations & equipment foundation, clear cover shall be 50mm.
4) RCC water retaining structures like storage tanks, cooling water basin etc.
shall be designed as uncracked section in accordance with IS: 3370 (part I
to IV) by working stress method. However, water channels shall be
designed as cracked section with limited steel stresses as per IS: 3370
(part I to IV) by working stress method.
5) The procedure used for the design of the foundations shall be the most
critical loading combination of the steel structure and or equipment and/ or
super structure and other conditions, which produces the maximum
stresses in the foundation or the foundation component, and as per the
relevant IS Codes of foundation design. Detailed design calculations shall
be submitted by the bidder showing complete details of piles / pile groups
proposed to be used.
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6) All foundations shall rest below virgin ground level and the minimum depth
of foundation below the virgin ground level shall be at least 500mm for
equipment foundations and 1000 mm for towers, transformers and
reactors.
7) Design shall consider any sub-soil water pressure that may be
encountered following relevant standard strictly.
8) Necessary protection to the foundation work if required shall be provided to
take care of any special requirements for aggressive alkaline soil, black
cotton soil or any other type of soil, which is detrimental / harmful to the
concrete foundations.
9) RCC columns shall be provided with rigid connection at the base.
10)
All sub-structures shall be checked for sliding and overturning
stability during both construction and operating conditions for various
combinations of loads. Factors of safety for these cases shall be taken as
mentioned in relevant IS codes or as stipulated elsewhere in the
specifications. For checking against over turning, weight of soil vertically
above footing shall be taken and inverted frustum of pyramid of earth on
the foundation should not be considered.
11)
Earth pressure for all underground structures shall be calculated
using coefficient of earth pressure at rest, coefficient of active or possible
earth pressure (whichever is applicable). However, for the design of
substructures of any underground enclosures, earth pressure at rest shall
be considered.
12)
In addition to earth pressure and ground water pressure etc., a
surcharge load of 2T/Sq.m shall also be considered for the design of all
underground structures including channels, sumps, tanks, trenches,
substructure of any underground hollow enclosure etc., for the vehicular
traffic in the vicinity of the structure.
13)
Following conditions shall be considered for the design of water tank
in pump house, channels, sumps, trenches and other underground
structures.
a) Full water pressure from inside and no earth pressure and ground water
pressure & surcharge pressure from outside (application only to structures,
which are liable to be filed up with water or any other liquid).
b) Full earth pressure, surcharge pressure and ground water pressure from
outside and no water pressure from inside.
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c) Design shall also be checked against buoyancy due to the ground water
during construction and maintenance stages. Minimum factor of safety of
1.5 against buoyancy shall be ensued ignoring the superimposed loading.
14)
Base slab of the any underground enclosure shall also be designed
for empty condition during construction and maintenance stages with
maximum ground water table (GWT). Minimum factor of safety of 1.5
against buoyancy shall be ensured ignoring the superimposed loadings.
15)
Base slab of any underground enclosure like water storage tank shall also
be designed for the condition of different combination of pump sumps
being empty during maintenance stages with maximum GWT.
Intermediate dividing piers of such enclosures shall be designed
considering water in one pump sump only and the other pump sump
being empty for maintenance.
16)
The foundations shall be proportioned so that the estimated total and
differential movements of the foundations are not greater than the
movements that the structure or equipment is designed to accommodate.
17)
Machine foundations:
a) All machine foundations shall be designed in accordance with the
provisions of the relevant parts of latest revisions of Indian standards IS:
2974, IS: 456, IS: 2911. The provisions of DIN 4024 (latest) shall also be
followed.
b) All block foundations resting on soil or piles shall be designed using the
elastic half space theory. The mass of the RCC block shall not be less than
three times the mass of the machine. Dynamic analysis shall be carried out
to calculate natural frequencies in all the modes including coupled modes
and to calculate vibration amplitudes. Frequencies and amplitude criteria
as lay down by the relevant IS codes and/or machine manufacturers, shall
be satisfied. Minimum reinforcement shall be governed by IS: 2974 and IS:
456. & M 20 concrete shall be used for construction.
c) For the foundations supporting minor equipments weighing less than one
tone or if the mass of the rotating parts is less than one-hundredth of the
mass of the foundation, no dynamic analysis is necessary. However, if
such minor equipments is to be supported on building structure, floors etc.,
suitable vibration isolation shall be provided by means of springs, neoprene
pads etc. and such vibration isolation system shall be designed suitably.
18)
Other foundations:
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All foundations shall be designed in accordance with the provisions of the
relevant parts of latest revisions of Indian Standards IS: 2911 and IS: 456.
& M20 concrete (Min) shall be used for construction.
i) Type of foundation system i.e., isolated or combined footing or raft or
pilling shall be decided based on the load intensity and soil-strata.
ii) Minimum three piles shall be provided in any pile group, if required.
The tower and equipment foundations shall be designed for a factor
of safety of 2.2 for normal/broken wire condition and 1.65 for short
circuit conditions.
c)
Admixtures & Additives:
1) Only approved admixtures shall be used in the concrete for the works. When
more than one admixture is to be used, each admixture shall be batched in its
own batch and added to the mixing water separately before discharging into
the mixer. Admixtures shall be delivered in suitably labeled containers to
enable identification.
2) Admixtures in concrete shall conform to IS: 9103. The waterproofing cement
additives shall conform to IS: 2645. Concrete admixtures / Additives shall be
approved by Owner.
3) The contractor shall use an approved neutralized vinsol resin air-entraining
agent in all concrete. The air-entraining agent shall be supplied and batched
as a solution with solids content not exceeding 15 percentages by weight with
suitable, stable & consistent pH. Air –entraining requirements shall be in
accordance with CP 100 part I.
4) The contractor may propose and the Owner may approve the use of water
reducing set-retarding admixture in some of the concrete. The use of such an
admixture will not be approved to overcome problems associated with
inadequate concrete plant capacity or improperly planned placing, operating
and shall only be approved as an aid overcoming unusual circumstances and
placing conditions.
5) The water-reducing set-retarding admixture shall be an approved brand of
ignosulphonate type admixture
6) The waterproofing cement additives shall be used as required / advised by the
owner.
d) Hot Weather Requirement:
1)
As per relevant code, during hot weather, precautions shall be taken to
avoid premature stiffening of the fresh mix and to reduce water absorption
and evaporation losses and when the temperature of the surrounding air is
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higher than 30 degree C; the following shall apply unless otherwise
approved by the owner.
a) The formwork shall be continuously sprayed with cold water in advance of
concreting and excess water shall be removed from inside the forms
immediately prior to placement of concrete.
b) The reinforcement and the formwork (if metal forms are used) shall be
protected from the effect of hot winds and direct sunlight.
c) Suitable barriers shall be provided to protect the freshly placed concrete
from wind until the concrete is sufficiently hard.
d) The concrete when placed shall be maintained at a temperature of less
than 30 degree C by the use of chilled water or by spraying the aggregate
with cold water.
e) The concrete shall be mixed, transported, placed and consolidated, as
rapidly as possible and shall then be covered with an impervious
membrane or wet Hessian until moist curing begins.
f) Curing compounds shall not be used as an alternative to the requirements
of (clause 8.10.3) curing.
g) During hot weather (atmospheric temperature above 40 0 C) or cold weather
(atmospheric temperature at & below 50 C) the concreting shall be done as per
the procedure set out in IS: 7861 (part I & II).
IV(a). R.C.C. CABLE DUCTS
1)
Cable ducts shall be constructed by RCC of grade M 20 as per typical drawings
furnished by the owner. RCC pre-cast cover slabs shall be provided for covering
the top portion. At junction and where pre-cast slabs cannot be provided cast-in
situ slabs may be provided.
2)
The trench bed shall have a slope of 1 in 500 along the run and 1 in 250
perpendiculars to the run.
3)
Trench wall shall not foul with the foundation. Suitable clear gap shall be
provided.
4)
Water flow diagram to drain the storm water collected in the drain shall be
prepared and got it approved. If the topography of the area permits the gravity
flow, water collected in the drain shall be effectively discharged to the convenient
point outside the station by providing 300mm dia RCC Hume pipe NP2 class. If
the site does not permit the gravity flow, then necessary RCC sumps shall be
constructed and suitable pumps installed to drain the water effectively through
RCC Hume pipes & GI pipes as required. Cable trenches shall not be used as
storm water drains. No separate rate or extra rate will be paid for providing
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RCC Hume pipes or for construction of Sump, providing pump and pipe
lines for draining of water from the cable ducts.
5)
All metal parts inside the trench shall be connected to the earthing system.
6)
All the construction joints of cable trench i.e., between base slab to base slab &
the junction of vertical wall to base slab as well as from vertical wall to wall and all
the expansion joints shall be provided with approved quality PVC water stops of
approx 230X5mm size for those sections where the ground water table is
expected to rise above the junction of base slab and vertical wall of cable ducts.
7)
Cable ducts shall be blocked at the ends if required with brick masonry in cement
sand mortar 1:6 and plastered with 12mm thick 1:6 cement sand mortar.
8)
Rate per Rmtr of duct shall be quoted. Rate shall include excavation in all types
of soil and rock, backfilling with available earth or new earth, disposal of surplus
soil/rock to the places directed, concrete= PCC 1:4:8 & M20 concrete, structural
steel work- insert plate, cable support angles, cable trays, lugs etc., pre-cast or
cast in situ RCC slabs, reinforcement, brick works, RCC hume pipe, GI pipe,
Sump tank and other items of works not mentioned herein but required for the
completion of work.
9)
In case of black cotton soil/expansive soil, well compacted murrum casing
with 3% cement shall be provided below PCC 1:4:8,
10)
All mild steel parts shall be fabricated and neatly placed in position to plumbs and
levels and welded as per drawing and painted with two coats of approved
synthetic enamel paint over one coat of shop primer.
IV(b).R.C.C. CABLE DUCTS AT ROAD CROSSING:- (M 20 concrete)
The bidder shall quote rate per No. of duct crossing. Rate shall include cost of
excavation, back filling, and disposal of surplus earth R.C.C. M20 grade for side
walls, raft and top slab, PCC 1:4:8, reinforcement, tray supports, cable trays and
allied works including cost of all materials as per technical specification and enclosed
drawing in all respects.
1) The length of the crossing shall be to the full width of the road and
section shall be kept as that of the duct for which the crossing is
required.
2) The scope of work applicable to RCC duct specified under 4(a) is also applicable to
cable duct crossing.
IV(c).RCC HUME PIPE SUB DUCTS
Bidder shall quote Rate per Rmtr of cable duct. Rate shall include cost of excavation
in all types of soil and rock, backfilling and disposal of surplus earth/rock, supplying,
providing and jointing RCC hume pipes of 150mm dia NP2 class/of required dia with
collars, GI/PVC pipes for taking cables from equipments to ducts/chambers, etc as
per detailed specification and directions of the Engineer in charge of work.
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IV (d). INSPECTION CHAMBERS:
Inspection chambers of size 650x450mm / 450X450mm as required shall be
provided wherever required as per layout and directions of Engineer-In-Charge of
work. Rate per number shall be quoted. Work includes excavation, back filling and
disposal of surplus earth / rock, bed concreting, brick masonry / laterite masonry
walls, CI frame and cover, plastering etc., required for the completion of work as per
specifications and directions of the Engineer-In-Charge of the work.
V. VOID
VI. JELLY SPREADING:
Bidder shall quote rate per Smtr of area for Jelly spreading. After the soil sterilization,
material is applied and surface prepared/compacted to the required slope/grade, 100 mm
thick layer of granite/basalt/trap jelly of 20/25mm size shall be spread over the area
marked in drawing for jelly spreading as per drawing and directions of Engineer in charge
of work.
The material required for jelly spreading shall be free from all types of organic materials,
flakes and shall be of standard approved quality and as directed by the owner.
The 20/25mm nominal size shall pass through IS sieve designation 40mm and nothing
through 16mm IS sieve.
The area marked in the drawing (excluding buildings, pathways, roads, drains, cable
ducts, equipment/structure plinths etc) shall be covered with jelly.
The work shall be taken up after completion of all construction activities.
VII . TRANSFORMER FOUNDATION, RAIL TRACK/ROAD CUM RAIL
TRACK:
The Contractor shall provide a permanent transfer track system integrated with
the transformer foundation to enable installation and the replacement of any
failed unit by the spare unit located at the site. The transformer track system
shall be suitable to permit the movement of any failed unit fully assembled
(including OLTC, bushings) with integral radiators and oil, without the
deenergization of any other equipment in the station. This system shall enable
the removal of any failed unit from its foundation to a repair area and the
installation of the spare unit. This system, preferably, shall not interfere with the
normal internal road and trench system. If trench/drain crossings are required,
then suitable RCC culverts shall be provided in accordance with IRC
Code/relevant IS. Rail tracks shall be of RCC, minimum M20 grade. The space
between the tracks shall be suitably filled with local sand and 75 mm thick PCC of
grade 1:4:8 placed over sand filling. The top of PCC shall be up to the formation
level. Suitable drainage system between the tracks shall be provided.
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The rails shall be first quality 52 Kg/m medium manganese steel as per Indian Railway
specification T-12-64 and its subsequent revision, joined together by fish plates as per
Indian Railway specification T-1/57 and their drawing no.090 M and 27mm diameter fish
bolts.
The Contractor shall provide a pylon support system for supporting the fire fighting
system. For Transformer / Reactor foundation, rails shall be provided in both the
directions.
VIII. ROAD WORK:
The approach road and road within the sub-station provided for access to equipments &
building are in the scope of the bidder. The layout of the roads shall be based on general
details and arrangement drawing for the Sub-station. Parking areas shall be provided for
site personnel and visitors at convenient locations. Adequate turning space for vehicles
shall be provided and bend radii shall be set accordingly. Road to the transformer /
reactors shall be as short and straight as possible. All Sub-station and approach roads be
constructed so as to permit transportation of all heavy equipments.
NOTE: When the length of the Road is more than 250 Mtr,
Asphalt/Bitumen Rroad shall be provided and When the length of the
Road is less than 250 Mtr, RCC road shall be provided.
1)
The double lane road shall have minimum 5M black topping/RCC with 1.6M wide
shoulders on either side of the road. The other service roads shall be with 3.75M black
topping/RCC and 1.3M wide shoulder on either side of the road. The finished top
(crest) of roads shall be 200mm (min) above the surrounding grade level (formation
level). Road construction shall be as per IRC standards. Adequate provision shall be
made for road drainage.
2)
Approach road from the nearest P.W.D. main road up to the proposed Substation is also
in the scope of the contract..
3)
All the culverts and its allied structure (required for road/rail, drain trench crossings etc.)
shall be designed for class AA loading and checked for Class A loading as per IRC
standard.
4)
All roads shall be designed for class „E‟ of traffic as per IRC Standards.
8)
Excavation shall be done in all types of soil & rock to the required cross section, line and
grade. Longitudinal gradient and cross slope/camber shall be provided to dispose off the
rain water to the nearby drains.
9)
The excess/surplus earth shall be disposed off to the places directed as per the directions
of the owner.
a)
Asphalt/Bitumen Road
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1)
The bidder shall quote rate per Rmtr of road including cost of forming the approach,
laying 3 layers of graded metal, spreading of murrum, watering, consolidation using road
roller and forming the shoulders on either side, providing and fixing RCC kerb stones and
walk ways if the space is available, providing chip carpet with seal coat including cost of
all materials, labours etc., complete as per technical specification and enclosed drawing
2)
The macadam road shall consist of sub-base (with 90mm size jelly of consolidated
thickness of 200mm including 25 mm thick murrum layer) and base course in two stages
each of consolidated thickness of 75mm with murrum packing (1st stage with 63 – 40
mm size jelly and 2nd stage with 40-25 mm jelly).
3)
Block top shall consist of 50mm thick B.U.S.G. (Built up spray grout) and 25mm thick
pre-mixed chip carpet. The work shall be carried out as per MOST specification
incorporated in the KPWD Schedule of Rates..
4)
For road in expansive/ BC soil, a consolidated/compacted thickness of
murrum/new earth 450mm thickness below sub-grade and 250 mm for shoulders
shall be provided. RCC Kerb stones (M20 Grade) shall be provided on either side
of the road and fixed as per the drawing. The exposed faces of the kerb stone
shall be painted with two coats of approved synthetic enamel paint (Black &
Yellow stripes as per IRC standards shall be provided).
b) RCC ROAD
RCC Road (M20 Grade) shall be provided as per the drawing furnished.
1)
.
2)
3)
The bidder shall quote rate per Rmtr of road including cost of forming the approach,
providing a consolidated/compacted thickness of murrum/new earth 300mm thick with 3
%cement (for expansive soil / black cotton soil ) providing walk ways/shoulders using
available approved earth or approved new earth (in expansive/BC soil), providing PCC
1:4:8 100mm thck, providing RCC M20 Grade 150mm thick, providing required
reinforcement as per drawing, providing RCC Kerbs on both sides, providing two coats of
synthetic enamel paint to the exposed faces of the Kerb (Black and yellow stripes ) etc to
complete the work in all respects
The RCC road shall consist of 100mm thick PCC 1:4:8 plain concrete using 40mm and
down size jelly , 150mm thick RCC (M20 Grade) with required reinforcement as
indicated in the drawing.
For road in expansive/ BC soil, a consolidated/compacted thickness of murrum/new earth
300mm thickness with 3% cement below PCC 1:4::8 and 250 mm for shoulders shall be
provided. RCC Kerb stones (M20 Grade) shall be provided on either side of the road and
fixed as per the drawing. The exposed faces of the kerb stone shall be painted with two
coats of approved synthetic enamel paint (Black & Yellow stripes as per IRC standards
shall be provided).
IX. CULVERT: ACROSS APPROACH ROAD
The bidder shall quote rate per culvert as a whole including cost of
excavation in all kinds of soil and rock, bed concrete, RCC Hume pipes,
RCC wing walls, back filling etc., complete as per enclosed drawing and
technical specification. The culvert shall be provided either inside the
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substation or outside the substation as directed by the Engineer-in-charge
of work.
1)
Earth work excavation shall be done to the required depth in all types of
soil and strata including Hard Rock.
2)
The length of culvert shall be as per site requirements –Hume pipes may
be single or double row as per requirements.
3)
The RCC Hume pipes shall be of NP-3 class of 45/60/90 cms dia as per requirements
with suitable collars laid to required slope to suit site condition and jointed with cement
and hemp.
4)
Side wall (Wing walls) shall be of RCC M 20 grade as per drawing and constructed over
1:4:8 bed concrete.
5)
The exposed faces of RCC side wall shall be plastered with cement mortar (1:4) 12 mm
thick.
6)
Back filling to the foundation and basement shall be done including watering &
consolidation.
7)
Extra excavated earth shall be disposed off to the place shown by the engineer-in-charge
of work after back filling.
X. BAFFLE WALL BETWEEN TRANSFORMER
GENERAL: Fire protection wall shall be provided in accordance with Tariff
Advisory Committee (TAC) recommendations.
APPLICATION CRITERIA: A fire wall shall be erected between the transformers /
reactors it the free distance between the various pieces of equipment is less than
10m. to protect each one from the effects of fire on another.
FIRE RESISTANCE: The fire wall shall have a minimum fire resistance of 3 hours.
The partitions which are made to reduce the noise level of the transformer /
reactor shall have the same fire resistance where the partitions are also used as
fire walls. The walls of the building, which are used as fire walls, shall also have a
minimum fire resistance of 3 hours.
The fire wall shall be designed in order to protect against the effect of radiant heat
and flying debris from an adjacent fire.
MECHANICAL RESISTANCE: The fire wall shall have the mechanical resistance to
with stand local atmospheric conditions. If this wall shall serve as a support for
equipment such as insulators etc., its mechanical rigidity must be increased.
Connecting the walls by steel or other structures, which may produce a reversing
torque, if overheated, shall be avoided.
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DIMENSIONS: The fire wall shall extend at least 1m on each side of the power
transformer / reactors and at least 1 m above the conservator tank or safety vent.
These dimensions might be reduced in special cases, and if TAC permits so,
where there is lack of space. A minimum of 2 meter clearance shall be provided
between the equipments i.e., transformer / reactors and fire walls.
The building walls, which act as fire walls, shall extend at least 1 m above the roof
in order to protect it.
MATERIALS: The fire wall may be made of reinforced concrete framed structure
(M-20 grade) and infilling with table moulded brick masonry with foundation to
suit soil condition, Materials used must confirm to the standards of the National
Fire Prevention Association and TAC norms.
The exposed surface shall be painted with two coats of waterproof cement painting over
one coat of primer.
The bidder shall quote rate per No.
XI (A). CHAIN LINK MESH SECURITY FENCING:
The bidders shall quote rate per "Rmtr" of securing fencing including
supply and
erection / fixing of RCC fencing poles (vertical / bent up and struts), chain
link mesh, barbed wire, GI flat, bolts and nuts, including cost of all
materials labour etc., complete as per technical specification and enclosed
drawings.
1) The security fencing shall be provided as per the layout drawing and to the areas as per the
directions of the Engineer in charge of the work.
2) The security fencing poles shall be of RCC (1:1.5:3 prop) and of size 0.15 mtrs x 0.15 mtrs
and length as per drawing cast at site using 12 mm and down size jelly and approved clean
sieved sand. The reinforcement shall be 4 numbers of 12mm dia TOR steel vertical bars at
corners and 8 mm dia TOR stirrups at 20 cm C/C including cost of making holes wherever
required as per design.
3) Poles shall be erected at a spacing of 2.5 mtrs C/C with strut poles at all corners in both
directions. Two transverse stay poles shall be provided at every 25 mtrs intervals and at
every change in levels.
4) The chain link mesh shall be of galvanized iron in accordance to specification covered under
IS 2721.
a) Size of mesh
:
Inter links of 50 mm x 50mm
b) Size of coated wire
:
8 gauge (4.06 mm thick)
c) Width of chain link mesh
:
2500 mm
d) Class of zinc coating
:
As per IS standards
5) Above chain link mesh, 3 rows of galvanized barbed wire with loops as shown in drawing
shall be provided.
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6) The barbed wire shall consist of two splices per reel. The barbed wire shall be formed by
twisting two line wires, one containing the barbs. The barbed wire shall be of 12 SWG
galvanized steel with its weight 155-136 gm/m length of the wire. Distance between two
barbs shall be 75 mm. The barbs shall carry four points and shall be formed by twisting two
point wires each two turn tightly round one line wire, making altogether over complete turn.
The barbs shall be furnished in such a way that the four points are set and locked at right
angles to each other. The barbs shall have a length of not less than 13mm and not more than
18mm. The points shall be sharp and well pointed. The barbed wire shall have tensile
properties as below;
Breaking load of line wire: Minimum 216 Kg / Maximum 302 Kg.
Minimum breaking load of:
Complete barbed wire: 444 Kg.
On the results of these additional tests, the whole or portion of the barbed wire shall be
accepted or discarded by the owner, as the case may be.
7) Fence fabric shall not be installed until concrete is cured for a minimum period of 7 days.
8) The chain link mesh shall be stretched tightly to line and plumb all along the fencing and
fixed to the security fencing poles using 50x6mm thick galvanized flat and galvanized bolts
and nuts of size 16mm dia 230mm long.
9) The fencing poles shall be painted with 2 coats of waterproof cement paint of approved color
over 1 coat of cement primer.
XI (B): TOE WALL: Size stone masonry toe wall shall be provided for the security fencing as
per the drawing enclosed. Work includes excavation, back filling and disposal in all types of
soil / rock, PCC 1:4:8 bed concreting, providing new earth mixed with 3% cement for back
filling and casing below foundations in expansive / BC soil, size stone masonry in cement mortar
1:6 for foundation and basement, PCC 1:3:6 for copping and embedding the RCC fencing poles,
pointing to the exposed faces of stone masonry etc., complete as per drawing and directions of
Engineer-In-Charge of the work. Rate / Rmtr. of TOE wall shall be quoted.
XI (C) SECURITY COMPOUND WALL:
Security compound wall shall be provided as per the drawing enclosed/furnished to the areas
indicated in the layout drawing OR to the areas shown by the Engineer in charge of the work.
1) Earth work excavation for foundation shall be done in all types of soil and rock,
backfilling with available approved earth /approved new earth, disposal of the surplus
soil/rock to the places directed within the station premises or outside to any notified areas
of the local bodies.
2) Providing PCC 1:4:8 plain cement concrete 100mm thick below masonry foundation.
3) Providing and constructing granite or trap or basalt size Stone Masonry, stones
hammer dressed in courses not less than 20 cms high with bond stones 2m apart in
each course including curing etc., complete as per specifications, in cement mortar
1:6 for foundation
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4) Providing and constructing granite or trap or basalt size Stone Masonry, in
courses not less than 15 cms high with bond stones 2m apart in each course, edges of
stones chistel dressed and all quoins 2 line dressed 5 cmtr wide on each face
including curing etc., complete as per specifications, in cement mortar 1:6 for
Basement
5) Providing Cement Concrete 1:3:6 for basement, coping & for fixing Security
fencing angle iron supports using 20mm and down size jelly, curing etc complete.
6) Providing Solid cement concrete block masonry wall and pillar using solid
concrete blocks with compressive strength of not less than 35Kg/Sq Cms
7) Providing plastering to the exposed faces of concrete block masonry wall and
pillar and the concrete surface with 20 thick cement mortar 1:6.
8) Providing pointing in 1:3 cement mortar to the exposed faces of the size stone masonry.
9) Providing two coats of water proof cement painting to the exposed faces of the masonry
and concrete over one coat of primer.
10) Providing ISA 50X50X6mm support angle duly fixed in concrete for fixing Chain link
mesh and for drawing GI barbed wire. Providing ISA 45X45X6mm horizontal angle
between vertical supports duly welded.
11) Providing GI chain link mesh 50X50mm size of 8 guage stretched between angle iron
supports and fixed at bottom in concrete and to the angle iron vertical and horizontal
supports using GI bolts and washers.
12) Providing GI barbed wire 12X12 guage 3 rows at the bent up portion of the vertical
support and loops as shown in the drawing.
XII. MAIN GATE, WICKET GATE & GATE PILLARS:
1)
The Gate frame shall be made of medium duty MS pipe conforming to relevant IS with
welded joints.
2)
The gates shall be fabricated with welded joints to achieve rigid connections. The gate
shall be painted with one coat of approved steel primer and two coats of synthetic enamel
paint.
3)
Gates shall be fitted with approved quality iron hinges, latch and latch catch. Latch and
latch catch shall be suitable for attachment and operation of pad lock from either side of
gates. Hinges shall permit gates to swing through 180 degree back against fence.
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4)
Gates shall be fitted with galvanized chain hook or gate hold back to hold gates open.
Double gates shall be fitted with center rest and drop bolt to secure gates in closed
position.
5)
Work shall be carried out as per the drawing and directions of the Engineer-In-Charge of
the work.
6)
The bidder shall quote rate for carrying out the entire job.
XIII. CONTROL ROOM BUILDING:
1)
The scope includes Design, Engineering (Unless otherwise stated) &
construction of RCC framed control room building as per detailed technical
specification and enclosed drawing including providing necessary
treatment to sub-soil depending on the soil conditions, internal water
supply, internal & external sanitary arrangements including construction of
septic tank & soak pit, electrification / Illumination (concealed type) and
internal RCC& Hume pipe cable ducts including cost of all materials, labour
etc., complete.
The rate shall be quoted for the entire job as a whole considering the following aspects
and technical specifications. The payment will be made at different stages of building
i.e., 10% at plinth level, 25% at lintel level, 50% at roof level and 100% after completing
the entire job.
2) DESIGN AND GENERAL CONDITIONS:
The buildings shall be designed:
1.
To the requirements of the National Building Code of India, and the standards quoted
therein.
2.
For the specified climatic & loading conditions.
3.
To adequately suit the requirements of the equipment and apparatus contained in the
buildings and in all respects to be compatible with the intended use and occupancy.
4.
With a functional and economical space arrangement.
5.
For a life expectancy of structure, systems and components not less than that of the
equipment, which is contained in the building, provided regular maintenance is carried
out.
6.
To be aesthetically pleasing. Different buildings shall show a uniformity and consistency
in architectural design.
7.
To allow for easy access to equipment and maintenance of the equipment.
8.
With, wherever required, fire retarding materials for walls, ceilings and doors, which
would prevent supporting or spreading of fire.
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9.
With materials preventing dust accumulation.
10.
a)
Individual members of the buildings frame shall be designed for the worst
Combination of forces such as bending moment, axial force, shear force, torsion
etc.
3)
b)
Permissible stresses for different load combinations shall be taken as per relevant
IS Codes.
c)
The building lighting shall be designed in accordance with the requirements of
relevant section.
DESIGN LOADS
Building structures shall be designed for the most critical combinations of dead
loads, super- imposed loads, equipment loads, crane load, wind loads, seismic
loads, and temperature loads. In additions, loads and forces developed due to
differential settlement shall also be considered.
Dead loads shall include the weight of structures complete with finishes, fixtures
and partitions and should be taken as per IS: 1911 (latest revision).
Super-imposed loads in different areas shall include live loads, minor equipment
loads, cable trays, small pipe racks/hangers and erection, operation and
maintenance loads. Equipments loads shall constitute, if applicable, all load of
equipments to be supported on the building frame.
The wind loads shall be computed as per IS 875, Seismic Coefficient method shall
be used for the seismic analysis as per IS: 893 (latest revision).
For temperature loading, the total temperature variation shall be considered as 2/3
of the average maximum annual variation in temperature. The average maximum
annual variation in temperature for the purpose shall be taken as the difference
between the mean of the daily minimum temperature during the coldest month of
the year and mean of daily maximum temperature during the hottest month of the
year. The structure shall be designed to withstand stresses due to 50% of the total
temperature variation.
Wind and Seismic forces shall not be considered to act simultaneously.
For consideration of loads on structures, IS: 875, “Code of practice for structural safety of
building” shall be followed. The following minimum superimposed live loads shall, however, be
considered for the design.
a. Roof slab 1.5 KN/m2
0.75 kg/m2
for accessible roofs
for non-accessible roofs
b.
for offices and minimum
10 KN/m2 for
equipment floors or
Floor slab 5 KN/m2
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actual requirement, if
higher than 10KN/m2.
based on equipment
component weight and
layout plans.
c.
Stairs &
Balconies
5KN/m2
d.
Toilet
Rooms
2KN/m2
e.
Chequeredplate floor
4KN/m2
f.
Walkways
3KN/m2
In case of CRB1 Control Room used for 66 KV & 110 KV stations, the entire building shall be
designed for first floor office loads of 5KN/m2 & in case of 220 KV Control Room building the
portion other than the control room portion shall be designed for first floor office loads of
5KN/m2. Clear height from floor to bottom of slab of first floor for design purpose may be
taken as 4.0Mtr.
4) Submission
The following information shall be submitted for review and approval to the Owner:
1.
Design criteria shall comprise the codes and standards used, applicable
climatic data including wind loads, earthquake factors maximum and
minimum temperatures applicable to the building locations, assumptions
of dead and live loads, including equipment loads impact factors, safety
factors and other relevant information.
2.
Structural
design
calculations
and
drawing
(including
construction/fabrication) for all reinforced concrete and structural steel
structures.
3.
Fully, dimensioned floor plans, cross sections, longitudinal sections and
elevations of each building. These drawings shall be drawn at a scale not
smaller than 1:50 and shall identify the major building components.
4.
Fully dimensioned drawings showing details and sections drawn to scales
of sufficient size to clearly show sizes and configuration of the building
components and the relationship between them.
5.
Product information of building components and materials, including
walls, partitions, flooring, ceiling, roofing, door and windows and building
finishes.
6.
A detailed schedule of building finishes including color schemes.
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7.
A door & window schedule showing door types and locations, door
locksets and latch sets and other door hardware.
8.
Water supply, internal and external drainage works, internal cable ducts.
Approval of the above information shall be obtained before ordering
materials or starting fabrication or construction as applicable.
(5) a) The building shall be RCC framed structure. The top of the Grade Beams shall be
kept 150mm above ground/FGL. New earth mixed with 3% cement shall be used
for back filling and below foundations for foundation in BC/expansive. All walls
shall be non-load bearing walls in table mould bricks/laterite stone. Min. thickness
of external walls and main walls shall be 230 mm in 1:6 cement sand mortar and
partition walls shall be 115mm thickness in table mould brick masonry/laterite
stone in CM 1:4. 50mm thick DPC in CC 1:2:4 shall be provided at plinth level
before starting masonry work. PCC 1:2:4 Cills shall be provided for window &
Ventilator opening. Through & all-round lintels shall be provided. RCC racks &
Loft with/without brick masonry support shall be provided in T&P room and
wherever required as per the requirements and directions of the Engineer in charge
of the work. The inside face of the Brick masonry wall between FGL & plinth
shall be plastered in cement mortar 1:4, 20mm thick using waterproof compound
before earth back filling and taking up the flooring work.
b) Earth work excavation: This includes excavation for foundation in all types of soil and rock including hard rock,
soft rock and hard laterite. The excavated earth shall be used for back filling the
foundation and basement if the same is suitable for backfilling. In case of black cotton
soil/expansive soil, back filling to the foundation and basement and for casing (soil
stabilization) below the foundation shall be with approved borrowed / new earth mixed
with 3% cement without additional cost.
c) Internal finish :
All internal walls shall have minimum 20mm thick 1:6 cement plasters with lime
rendering. The ceiling shall have 12mm thick 1:4 cement sand plaster with lime
rendering.
All internal walls and ceiling (except battery room) shall have plastic emulsion
paint two coats over one coat of primer.
Walls and ceiling of battery room shall have acid proof resistant paint two coats
over one coat of primer.
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Metal and wood surfaces shall be given two coats of synthetic enamel paint of
approved colour and shade over one coat of primer. Colour scheme shall be
prepared and got it approved.
d) External Finish
All external walls shall have 20mm thick plaster in 1:6 cement mortars.
External walls shall have two coats of Apex/ACE or similar other type of fungus
resistant paints over one coat of primer.
e) Roof
Roof of the building shall consist of cast-in-situ R.C.C. slabs.
Waterproofing treatment of roof /floor slab.
Over the pre-cast RCC floor/roof slab, screed concrete of proportion 1:2:4 75mm
thickness average using 12mm and down size jelly shall be laid to provide a
gradient of 1 in 120 to drain the storm water effectively. Over this, pressed clay
tiles shall be laid over a CM bed of 25mm thickness average of proportion 1:6 and
joints shall be pointed with red oxide.
Terrace plan showing ridge points, gradient, direction of water flow, position of
rain water pipes, sizes of rain water pipes etc., shall be prepared and got it
approved by the owner.
Dowel rods of column for future extension shall be encased in lean concrete mix
and plastered in CM: 1:10.
f) Glazing
Minimum thickness of glazing shall be 6 mm.
g) Diesel Engine Generator House:
The diesel engine generators may be installed in DG room inside control room,
engine generators shall be vibration free, suitable foundation shall be provided for
the same. Door openings shall be dimensioned to allow removal of diesel engine
generators. Suitable ventilation exhaust shall be provided.
h) BUILDING STORM WATER DRAINAGE.
The building design shall provide for the collection of storm water from the roofs
and effective disposal of it to the boundary/roadside drain. This water shall be
collected in junction boxes and these boxes shall drain to the main drainage
system of the station.
PVC/HDPE rain water pipes of 150mm dia of 6KSC pressure as per relevant IS of
approved make with bends shoes etc., be provided to drain off the rain water from
the roof. These shall be suitably fixed to the masonry walls with suitable clamps.
The number and size of down comers shall be governed by IS: 1742 and IS: 2547.
All drains inside the buildings shall have minimum 10mm thick grating covers
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and in areas where heavy equipment loads would be coming pre-cast RCC covers
shall be provided in place of steel grating.
For all buildings, suitable arrangement for draining out water collected from
equipment blow down, leakages, floor washings fire fighting etc. shall be
provided for each floor.
.
i) DOORS & WINDOWS:
The type & size of doors, windows and ventilators shall be as per layout /
drawing supplied
Aluminum doors, Windows & Ventilators:
Doors:
The aluminum sections shall conform to IS standards, anodized to 12 to 15
microns & shall be glossy/mat finish.
Door Frame Sections:
Outer frame, Plain section – 101.60mmx44.45mmx3.18mm
Door shutter:
Vertical section
– 47.62mmx44.45mmx3.18mm.
Top section
– 47.62mmx44.45mmx3.04mm.
Centre section
– 25.00mmx44.45mmx3.00mm.
Bottom section
– 114.3mmx44.45mmx3.18mm.
All the door sections should be anodized to 12 to 15 microns and cut to length,
joints, mitered and corners grinded. The bottom rail hinged or pivoted opening
arrangements with heavy duty aluminum alloy automatic door closers, including
providing and fixing standard approved accessories such as aluminum handles,
tower bolts, lock, PVC/rubber gasket with 12 mm thick pre-laminated sheet (Novo
pan – exterior grade) of approved color for bottom panel of max height 0.90m and
6 mm thick plain or pin headed glass for top panel.
Windows:
Double track frame of size
– 61.85mmx31.75mmx1.50mm.
Shutter Section
– 40mmx18mmx1.25mm
Inter lock section
– 40mmx26.70mmx1.10mm
The shutter should be mounted on nylon rollers for easy sliding with approved
quality fixtures such as aluminum handle, tower bolt etc. The shutter should be
provided with 6mm thick plain or pinheaded glass with rubber beading.
All the aluminum sections used for door and windows should be treated for
removal of any rust and prevention of further rust formation and coated with
greasy materials for non-adherence of mortar or any other sticky materials. The
assembled frame should be stiffened with corner angles strips and fixed with
screws, rawl plugs and teak wood guttas to RCC column or masonry on sides,
beams and mosaic flooring at bottom, including cutting, chiseling and making
good with cement mortar to match the surface. All the frames should be thoroughly
cleaned free of rust, scale or dirt. Work should be carried out as per the approved
drawings and directions of the Engineer in charge of the work.
Ventilators: Ventilators shall be provided as per the drawing supplied.
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Wooden Door : i) Mathi / Nandi wood frames:
Providing and fixing mathi or Nandi wood frames of 65xl25mm with or without
ventilators with glass 6mm thick and 2 M.S.Rods of 16mmdia as per design and
drawing fixed in masonry with 40x5mm flat iron hold fasts 40cm long embedded
in CC 1:3:6 with granite metal of size 20mm and down, 15cm thick.
ii) Honne wood fully paneled shutters:
Honne wood fully paneled shutters with styles and rails of 40mm thick and with
25mm thick panels with required door fittings as per drawing & filed requirement
(Aluminum handle, Aluminum Aldrop, hinges, tower bolts, doorstoppers etc) shall
be provided for each door.
iii) Composite polymer laminated sal wood door shutter :
Providing and fixing factory made splendoor of solid core single leaf rigid
composite polymer laminated sal wood, door shutter of 30mm thick, manufactured
out of solid core confirming to IS 2202 (Part-1) 1991, laminated with 0.8mm thick
polymer, termite, water resistant and fire retardant with superior gluing based on
vacume lamination technology and with various pre-moulded design on both faces
confirming to IS 6307 – 1985, using adhesive confirming to IS 4835 – 1979 and
door shutter tested in confirmation to IS 4020-1994. The finish of shutters will be
TEAK / OAK / CEDAR / ROSE WOOD / WAL NUT, plain colours WHITE /
IVORY / BEIGE / LIGHT GREY including providing all fixtures.
j) Flooring:
The entire building (except battery room, lavatory, T&P room & D.G. Room) shall
be provided with granite flooring using 19mm thick pre polished water cut / gang
saw grey granite slabs laid in cement mortar 1:4, 20mm thick (average) over
cement concrete bed (PCC 1:4:8, 100mm thick) / floor slab and pointed with white
/ grey pigment etc.
Skirting 125mm high shall be provided using 19mm thick pre polished water cut /
gang saw grey granite slabs laid in cement mortar 1:4, 20mm thick after chipping
the walls etc., complete.
The battery and lavatory rooms shall have first class ceramic tiles flooring, tiles of
approved make (Spartek/ Johnson/ Naveen) and size 20cms x 20 cms. Dadooing
for battery room walls shall be done up to lintel level (2400mm) using ceramic
tiles of
20cms x 20cms size. The lavatory room walls shall be provided with
ceramic tiles dadoing upto l20cms height and in areas of urinals and washbasin as
per requirements. (Note: All flooring tiles shall be laid on l00 mm thick CC l: 4:8
in ground floor & over cement mortar bed over floor slab).
T&P Room and D.G. Room shall be provided with Ironies flooring over 100mm
thick PCC1:4:8. And skirting 125mm high in cement mortar 1:3 and 15mm
projection shall be provided.
k) Flagging concrete and Path ways. :
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Flagging concrete & pathways in PCC 1:4:8, 100mm thick and 50mm thick PCC
1:2:4. and top finished with 12mm thick 1:4 cement mortar shall be provided for
a width of 900mm all-round the building and 1500mm wide from the main road
to control room building entrance.
l) Internal Water Supply:
Internal water supply shall be done using 20/15mm CPVC pipes confirming to IS 15778
embedded in brick masonry with necessary specials like valves, taps etc., as per drawing and
directions of the Engineer in charge of the work.
m) Sanitary arrangement:
Necessary sanitary arrangements shall be made as per requirement. This
includes providing and fixing approved quality closets in both gents and
ladies toilets, wash basin, Mirror, Toilet paper holder, etc & laying PVC
sanitary pipe line with inspection chambers. For 66 KV Control Room
building, a soak pit of 2.50m x 2.00 mtr internal dimension and required
depth constructed with size stone masonry/Laterite with suitable weep
holes to soak sewage water/liquid waste, RCC cover slab of 15cm thick with
suitable inspection cover etc shall be provided as per the directions of the
owner. For 220 KV Control Room building, Septic tank and soak pit as per
the drawing supplied shall be provided.
n)
RCC & Hume pipe cable duct inside CR Building: Necessary RCC (M20 Grade) &
Hume pipe cable ducts shall be constructed inside the control room building including
providing cable supports, cable trays, M.S.angles, M.S. flats, Chequered plates etc., as per
enclosed drawing and directions of the owner. The open spaces left after the erection of
panels shall be covered with 6mm thick chequered plates with suitable lifting
arrangements.
0)
Collapsible gates/doors:
Collapsible gates/doors shall be double leaf made of 20mmX20mmX2mm channels and
braced with flat iron diagonals 20mmX5mm size with top & bottom rails of section
40mmX6mm fitted with 38mm dia steel rollers (pulleys), brass handles on both sides,
locking device from both sides, two coats of paint over one coat of primer etc complete.
p) Electrification:
The building lighting shall be designed and provided in accordance with the
requirements of relevant section.
q)
r)
Providing air conditioning system for C&R panel Room of 220kV control room
building. The scope includes design, Engineering and providing air
conditioning system in accordance with the requirements of relevant
sections.
False ceiling for C&R panel of 220kV control room building.
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The scope includes providing false ceiling as per design / requirement and
providing 15mm thick densified regular edged eco friendly light weight
calcium silicate false ceiling as per the specifications of KPWD SR.
XIV. DRILLING BORE WELL & ARRANGING WATER SUPPLY:
a) The bidder shall be overall responsible for supply of water within the switchyard for drinking
purpose, fire fighting, earthing and other miscellaneous purpose.
b) A scheme shall be prepared by the bidder indicating the layout and details of water supply
and shall get it approved by the owner before commencement of work.
c) One good yielding bore-well for 66&110kV stations / two bore wells for 220kV stations shall
be drilled. The bore well shall yield sufficient water to meet the required demand. If the
drilled bore well fails or yield is not sufficient to meet the demand before handing over of
sub-station, additional bore well shall be drilled by the bidder without extra cost.
d) Suitable pump set of sufficient capacity shall be installed and serviced with all accessories
like control panel board, UG cable, earthing arrangements etc.
e) Main supply line from borewells to the water tank on the control room building and
distribution line for water supply to buildings shall be with required dia CPVC pipes with
necessary fittings.
f) 2000 ltrs synthetic water storage tank shall be provided over the raised platform over the roof
slab of control room building in case of 66kV & 110kV sub-stations and in case of 220kV
sub-station, the tank may be placed over the first floor roof slab with necessary arrangements,
with suitable electrical water level controller as per the directions of the Engineer in charge of
the work.
g) The distribution system for watering earth pits & for drinking water shall be with required
dia CPVC pipes with necessary fittings, as per directions of the Engineer in charge of the
work and scheme to be approved by the owner.
XV. CONSTRUCTION OF OIL STORAGE SUMP TANK
The bidder shall quote rate per No. Work includes, cost of earth work excavation
for foundation in all types of soil and strata including hard rock, bed concrete,
construction of size stone masonry wall, pointing to the exposed faces of wall,
plastering to the inside faces of the wall with cement mortar using water proof
compound, R.C.C cover slab and connection from transformer to sump tank
using suitable size G.I. pipes with necessary G.I. specials and valves. Work shall
be carried out according to detailed specifications. The rate includes cost and
conveyance of all materials, labour etc., complete.
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1)
Earth work excavation shall be done to the required depth as per design in all strata.
2)
Bed concrete shall be of 1:4:8 proportions
3)
Size stone masonry shall be with granite/trap/basalt size stone built in cement mortar 1:6
proportion.
4)
The coping concrete shall be of 1:2:4 proportions.
5)
The flooring shall be with PCC 1:2:4 and finished with 20mm thick 1:4 cement mortar
using water proof compound.
6)
The walls and the bottom of the slab shall be finished with cement mortar 1:4 proportion
20 mm thick with waterproof compound.
7)
The roof slab shall be of R.C.C (M.20) with necessary reinforcement as per the drawing and
one inspection chamber with frame and cover & locking arrangement as per directions
shall be provided.
8) The pipe connections between transformer and the sump tank shall be provided with required
diameter G.I. pipes with necessary G.I. specials as per directions of the Engineer in
charge of the work.
9) Heavy duty Gate valve shall be provided at suitable location and for easy accessesability &
operation during emergency & kept in the manhole chamber with locking arrangements.
10) GI ladder shall be provided for usage during maintenance as per directions of the
Engineer-In-Charge of the work.
XVI. YARD PROTECTION WORKS AND STORM WATER DRAINAGE
Scope of the work includes for Design, Engineering and Construction of size stone masonry or
RCC retaining wall, Size stone masonry or RCC drain and Size stone masonry or dry pitching
with size stone masonry toe wall.
Items of the work involved in the job and quantities are furnished in the schedule. Bidders shall
develop the designs and drawings to suit the site requirements in consultation with the owner and
shall start commencement of work after approval of the designs and drawings by the owner.
Retaining wall or Pitching as required shall be constructed along the boundaries and in between
the levels to retain earth filling/cutting as per requirements and directions of the owner.
Size stone masonry or RCC drain as required shall be constructed all along the boundaries and
along the approach road. Necessary gradient shall be provided to ensure that silting is minimized
and water flows freely. Final discharge point shall be located in consultation with the Engineer in
charge of the work.
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XVII. FOUNDATION & A.C SHEET SHELTER FOR METAL CLAD 11KV, VCB
SWITCH GEARS:The bidder shall quote rate per No. which includes the cost of earth work excavation for
foundation in all types of soil and in all types of rocks and strata, bed concrete,
construction of size stone masonry, plastering to the exposed faces of walls, flooring,
structural steel which includes I beams, channels, angles for shelter work and cable duct,
A.C. sheets, electrification to shelter etc. complete as per drawing & directions of the
engineer-in-charge- of work.
1. Earthwork excavation shall be done to the required depth & width as per design in all
strata & as per drawing.
2. Bed concrete shall be of 1:4:8 proportion
3. Size stone masonry shall be granite/trap/basalt built in cement mortar 1:6 proportion.
Necessary pouches shall be left in the masonry walls to embed I-beam sections.
4. Working plat form shall be provided with size stone masonry in CM 1:6, bed concrete
in CC 1:4:8, 1:2:4 basement concrete. & Flooring using CC 1:4:8 and CC 1:2:4, top
of the concrete finished with CM 1:3. The flooring of the trench shall be with CC
1:2:4 & plastered with cement mortar 1:3.
5. 6mm thick chequered plates shall be covered to the open portion of ducts after
erecting switchgears. Necessary handles to lift plates shall be provided including two
coats of enamel painting over one coat of primer.
6.
Structural steel work, which includes ISMC, ISMB, and ISA, of, required sizes as per
enclosed drawing should be provided for vertical supports, rafters, purlins, cable duct
tray supports, cable trays etc.
7. A.C. sheet roofing 6mm thick including 10mm dia G.I. ` J‟. Hooks & bitumen Zinc
washers with an end lap of 15 cm shall be provided, including A.C. ridges & hips
sheets. Vertical drop of 1.00m shall be provided all-round the shelter using A.C.
sheet.
8. All structural steel members shall be painted with two coats of synthetic enamel paint
over one coat of primer.
9. The vertical supports shall be embedded in CC 1:2:4 to the required size and depth.
Necessary lugs shall be provided to the vertical supports at bottom.
10. RCC Hume pipe/PVC pipe of required dia shall be provided to lead off the water
collected in duct to the nearest drain or upto the natural gradient to lead off the water.
This includes cost of excavation, providing pipes, etc. Also required dia RCC Hume
pipe/PVC pipe shall be provided for entry and exit of cables.
11. Electrification to the shelter shall be done by providing necessary switch points, U.G.
cables, service connection and providing 6 numbers of industrial type fluorescent
fittings with 2 numbers of 4ftX40 watts tubes.
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Page 212 of 382
SECTION – 9.0
TECHNICAL SPECIFICATION
RELAY & PROTECTION PANELS WITH SUB-STATION
AUTOMATION SYSTEM FOR 220KV SUB-STATIONS
Page 213 of 382
TECHNICAL SPECIFICATION FOR RELAY & PROTECTION PANELS WITH
SUB-STATION AUTOMATION SYSTEM FOR 220KV SUB-STATIONS
SECTION –1
CLAUSE
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
11.00
12.00
13.00
14.00
15.00
16.00
17.00
18.00
19.00
20.00
21.00
22.00
23.00
24.00
25.00
26.00
27.00
28.00
29.00
30.00
31.00
32.00
33.00
34.00
35.00
36.00
RELAY & PROTECTION PANEL
PARTICULARS
SCOPE.
BRIEF DESCRIPTION OF PROJECT.
STANDARDS.
CLIMATIC & GEOGRAPHICAL CONDITONS
SYSTEMS DETAILS.
AUXILLARY SUPPLY.
TYPE OF PANEL.
CONSTRUCTIONAL FEATURES.
MOUNTING.
PAINTING.
WIRING.
TERMINAL BLOCKS AND TERMINAL
CONNECTORS.
SPACE FOR CONTROL CABLE AND CABLE
GLANDS.
VOID.
NAME PLATE AND MARKINGS.
INTERNALLY MOUNTED EQUIPMENTS,
FUSES.
EARTHING.
VOID
TEST TERMINAL BLOCKS.
CONTROL SWITCHES,
VOID
PUSH BUTTON SWITCHES.
SYNCHRONIZING EQUIPMENTS.
VOID.
INDICATING AND INTEGRATING EQUIPMENTS.
RELAYS.
PROTECTION SCHEME.
PROTECTION PHILOSOPHY
CO-ORDINATION OF DRAWINGS OF ASSOCIATED
EQUIPMENTS OF OTHER MANUFACTURES.
DRAWINGS AND LITERATURES
TESTS, TEST CERTIFICATES AND INSPECTION
SPARES
MAINTENANCE TOOLS & EQUIPMENT
QUALITY ASSURANCE PLAN
MINIMUM EXPERIENCE FOR QUALIFYING AS A
TENDER.
Page 214 of 382
37.00
38.00
39.00
PERFORMANCE GUARANTEE
TRAINING TO BOARD ENGINEERS
DESPATCH
40.0
41.00
42.0
43.0
DEVIATON FROM TECHNICAL SPECIFICATION
SCHEDULE OF REQUIREMENTS & DELIVERY
SCHEDULE OF PRICE.
GUARANTEED TECHNICAL PARTICULARS.
ANNEXURE-RPP1-SAS
ANNEXURE- RPP2-SAS
ANNEXURE- RPP3-SAS
ANNEXURE- RPP4-SAS
ANNEXURE- RPP5-SAS
ANNEXURE- RPP6-SAS
ANNEXURE- RPP7-SAS
ANNEXURE - SAS
Page 215 of 382
SECTION-2
SUB-STATION AUTOMATION:
CLAUSE
PARTICULARS
1.0
GENERAL
2.0
SYSTEM DESIGN
3.0
BAY LEVEL FUNCTIONS
4.0
SYSTEM HARDWARE
5.0
SOFTWARE STRUCTURE
6.0
TESTS
7.0
SYSTEM OPERATION
8.0
POWER SUPPLY
9.0
DOCUMENTATION
10.0
TRAINING, SUPPORT SERVICE, MAINTENANCE &
SPARES
11.0
MAINTENANCE RESPONSIBILITY
12.0
RELIABALITY & AVAILABALITY
13.0
SPARES
14.0
LIST OF EQUIPMENTS
ANNEXURE – I (GTP IAS)
ANNEXURE-RRP-TVM
Page 216 of 382
SECTION-1
KARNATAKA SOLAR POWER DEVELOPMENT CORPORATION
LIMITED
TECHNICAL SPECIFICATION FOR RELAY & PROTECTION PANELS
WITH SUB-STATION AUTOMATION SYSTEM FOR 220KV SUBSTATIONS
SECTION – RELAY & PROTECTION PANEL
1.00
SCOPE:
1.01
This Technical specification covers design, manufacture, inspection, testing at works
and supply of relay and protection panels, with sub-station automation system for
220KV Sub-Stations of KSPDCL grid.
1.02
The equipment should conform in all respects to the relating standards and shall be
manufactured to the highest quality of Engineering, design and workmanship. The
equipment manufactured shall ensure satisfactory and reliable performance
throughout the service life.
1.03
The equipments offered shall be complete in all respects. Any material / component /
accessories/software not specifically stated in this specification but which is otherwise
necessary for trouble free operation of the equipment specified in this specification
shall be deemed to be included unless excluded expressly. All such components/
accessories / software shall be supplied at no extra cost.
1.04
The design and manufacturing shall be such that the equipment / components/
accessories/software of the same type and of identical rating shall be interchangeable.
Likewise similar or corresponding parts/ components or accessories thereof shall also
be interchangeable.
1.05
Wherever and whenever a material or article or component is specified or described
by the name of a particular brand or manufacturer or vendor, the specific item
mentioned shall be understood as establishing type, function and quality and not as
limiting competition. However, tenderers are invited to offer other similar
equipments/components/accessories provided they meet with the required standards,
design, duties and performance.
1.06
All equipments offered shall confirm to type tests and shall also be subjected to
acceptance and routine tests in accordance with the requirements stipulated herein.
The purchaser reserves the right for conducting any or all of the type tests in
accordance with the relevant standards. Such type tests shall be done free of cost.
Where type tests have already been conducted the tenderer shall submit copies of the
same along with tender. The type tests certificates should however be not older than
five years as on the date of bid opening. Any extra cost for repeating the type tests
shall be indicated in the relevant price schedules.
Page 217 of 382
2.00
BRIEF DESCRIPTION OF PROJECT:
2.01
The details of the project are as per Annexure enclosed.
2.02
The protection to be provided for various lines, transformers etc., shall be as follows:
i. Main protection i.e. distance scheme and differential scheme shall be of fast acting
numerical type.
ii. Back up protection shall be of numerical type.
2.03
There may be changes in components ordered as per purchase order and as per approved
drawing. However, subsequent inspection and supply of panels shall conform to the
approved drawing.
3.00
STANDARDS:
Unless specified otherwise, equipment covered by this specification shall conform to the
Indian Electricity Rules and to the latest editions of relevant Indian Standards, British or
American IEC or other equivalent standard. In the event of supplies confirming to other
equivalent international standards, the salient features of comparison shall be brought out
in the tender. One copy of such standard specification in English language shall be
enclosed with the tender. A general reference list of standards is furnished as follows:
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Particulars
IS
Application guide for electrical relays for
3842
protection and other relays
Electrical relays for power system
3231
Current transformers
2705
Voltage transformers
3156
Push buttons and control switches (LV
6875
switching devices for control and auxiliary
circuits)
AC electricity meter
722
Static protective relay
8686
Indicating instruments & recorders
---Fuses
2203
AC static watt hour meter for active energy
---Colours for ready mixed paints and enamels
5
Ready mixed paints, brushing, finishing
127
exterior and semi glass for general purpose
white
Paints, finishing interior white
641
Direct acting indicating analog electrical
1258
measuring instruments and their accessories
part : 1-5
7-9
Degree of protection provided by enclosures
2147
for low voltage switch gear and control gear.
BS
IEC
142
50
-------------
50255
----------
------89/90
88
---------
---------66
686
------
-------
-------
----
-----
Page 218 of 382
Sl. No.
16
17
18
19
20
21
4.00
Particulars
Performance tests for protective
scheme used in protection of light
gauge steel against corrosion
Sub-Station Automation System
Communication Protocol
Numerical relays
Environmental testing
Insulation
co-ordination
for
equipment
with
low-voltage
system
IS
4177
BS
----
IEC
----
----------------
----------------
61850
60870-5-104
61000
68
664
CLIMATIC AND GEOGRAPHICAL CONDITIONS:
4.01
Sl.
No.
1.
2.
3.
4.
5.
6.
7.
8.
Particulars
Altitude
a) Max. ambient air temperature
b) Average daily ambient air temperature
Minimum ambient temperature
Relative humidity
Average annual rainfall
Average period of rainfall in a year
Maximum wind pressure in Kg/Sq. mt.
Isoceraunic level
Not exceeding 1000 Mtrs.
50 deg.C
35 deg.C
5 deg. C
10-100%
1000 to 3000mm / 5000mm
5 months
150
46
4.02
The climate is moderately hot, tropical climate conducive to rust and fungus growth.
4.03
The climatic conditions are given to indicate wide range of variation in ambient
conditions.
4.04
All electrical devices shall be tropicalised and given fungicidal treatment. They shall also
be capable of satisfactory operation under the hot and humid climatic conditions that
would prevail at the site.
4.05
All the equipments, contacts, etc., shall be designed to withstand seismic acceleration
equivalent 0.3 g. Air conditioning is not available in the control room.
Page 219 of 382
5.00
SYSTEM DETAILS:
5.01
Following is salient particulars of the system.
Sl.
No.
1
2
3
4
5
Particulars
220 KV
66 KV
Nominal system
voltage (KV)
Highest system
voltage (KV)
No. of phases
Frequency ( Hz)
Method of
grounding
220
66
245
72.5
3
50
Effectively
earthed
3
50
Effectively
earthed
5.02
The relays and meters shall be suitable for operation at 1 Amp Current Transformer
secondary and 110V phase to phase and 63.5 volts phase to neutral, secondary voltage of
the Voltage Transformer.
6.00
AUXILIARY SUPPLY:
6.01
The Purchaser shall make separate arrangement for providing low tension AC & DC
power supply for control and auxiliary use. The tenderer shall give in his tender the
estimate for AC & DC power required for the equipment covered by this specification.
6.02
The auxiliary supply voltage available is as follows:
Sl.
No.
1
2
3
Particulars
Details
Power devices (like
drive motors etc)
AC
control
and
protective devices
DC for alarm, control
and
protection
devices
415V, 3 phase, 4 wire, 50Hz AC supply with one
point grounded
240V, 1 phase, 2 wire, 50 Hz AC supply with one
point grounded
a) 220V for 220KV Stations.
- 2 wire ungrounded DC supply from batteries and
battery charger. The ripple content in the DC supply
from the charger will be less than 2%
The above supply voltage may vary as follows:
6.03
1
AC supply
2
DC supply
Voltage variation +10% to –30%
Frequency variation ± 5%
Both variations may occur simultaneously or
independently
+10% to –20%
Each of the foregoing supplies will be made available by purchaser at one terminal point
for each equipment for operation of accessories and auxiliary equipments. In case of
110V, AC supply is required, the tenderer shall include adequately rated 415/110V
control transformers for each equipment. Bidders scope of supply shall include
Page 220 of 382
distribution beyond the points of supply, including supply of interconnecting cables
between instruments and terminal blocks.
7.00
TYPE OF PANEL:
7.01
VOID
7.02
VOID
7.03
Simplex Panel: Simplex Panel shall consist of vertical front panel with equipments
mounted there on and wiring occurs from rear of the control panel and either from rear or
front of relay panel. In case of panels having width of more than 800 mm, double leaf
doors shall be provided, the door shall have handles with either built in locking facility or
shall be provided with pad lock.
8.00
CONSTRUCTIONAL FEATURES:
8.01
Relay Panel shall be of Simplex type design. It is the responsibility of the bidder to ensure
that the equipments 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 either more number of panels or
panels with larger dimensions. No price increase at a later date on this account shall be
allowed. However the width of the panels that are being offered to be placed in existing
control room should be in conformity with space availability in the control room.
8.02
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.
8.03
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 3mm 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 surfaces, and resistance to
vibration and rigidity during transportation and installation.
The dimensions of the panels shall be as given below:
Height
2312 mm including base channel height of 102mm.
Depth
610mm
Width
800/ 1000 mm.
8.04
All doors, removable covers and panels shall be gasketed all around with Synthetic
gaskets. Neoprene/EPDM generally conforming with provision of IS-11149. However
XLPE gasket 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.
8.05
Design, materials selection and workmanship shall be such as to result in neat
appearance, inside and outside with no welds, rivets or bolt heads appearing from outside,
with all exterior surfaces smooth.
Page 221 of 382
8.06
Panels shall have base frame with smooth bearing surface, which shall be fixed on the
embedded foundation channels/insert plates. Anti-vibration strips made of shock
absorbing materials, which shall be supplied by the bidder, shall be placed between panel
& base frame.
8.07
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.
8.08
Relay panels of modern modular construction would also be acceptable.
8.09
The purchaser reserves the right to order the panels in full or part of the quantity indicated
in the annexure. However, the breakup will be station – wise.
8.10
The offer shall include dummy panels and filler plates wherever necessary to have
continuous formation. However the purchaser reserves the right to order the dummy
panels and filler plates.
9.00
MOUNTING:
9.01
All equipment on and in panels shall be mounted and completely wired to the terminal
blocks ready for external connections. The equipments on front of panel shall be mounted
flush with only their bezels projection.
9.02
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.
9.03
The centre lines of switches, push buttons and indicating lamps shall be not less than
750mm from the bottom of the panel. The center lines of relays, meters and recorders
shall be not less than 450 mm from the bottom of the panel.
9.04
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.
9.05
Final arrangement of control instruments & relays shall be as per the drawing approved
by the purchaser.
9.06
No equipment shall be mounted on the doors.
9.07
At existing station, panels shall be matched with other panels in the control room in
respect of dimensions, colour, appearance and arrangement of equipment (center lines of
switches, push buttons and other equipment) on the front of the panel.
9.08
All the equipment connections and cabling shall be designed and arranged to minimize
the risk of fire and damage which may be caused by fire.
9.09
The contractor shall carry out cut out, mounting & wiring of free issue items supplied by
other which are to be mounted in this panel in accordance with corresponding equipment
manufacturers drawing.
Page 222 of 382
If any cutouts are left blank for mounting of future equipment, it shall be properly
blanked off with metal plates, and wires left shall be properly insulated or terminated to a
terminal block.
10.00 PAINTING:
10.01 All sheet steel work shall be phosphated in accordance with the IS: 6005 "Code of
practice for phosphating iron and steel”.
10.02 Sheet steel shall be sand blasted to remove rust and scale, oil grease, dirt and swarf shall
be thoroughly removed by emulsion cleaning.
10.03 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.
10.04 After phosphating, thorough rinsing shall be carried out with clean water followed by
final rinsing with dilute dichromate solution and oven drying.
10.05 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.
10.06 After application of Primer, the panel exterior shall finally be painted with two coats of
synthetic enamel paint, each coat applied by stoving. The colour of the finishing paint
shall generally be "Siemens grey" corresponding to shade No. RAL 7032of IS-5 for panel
exterior. All cubicle interiors shall be painted white, so as to give a contrasting effect with
cubicle wiring
10.07 Each coat of primer and finished paint shall be of slightly different shade to enable
inspection of painting. The final finished thickness of paint film shall not be less than 60
microns and shall not be more than 100 microns.
10.08 The finished paint appearance shall be aesthetically pleasing and shall be free from
scratches, dents or unevenness. A small quantity of paint shall be supplied free of cost for
minor touching up, if any that may be required at site.
10.09 In case the tenderer proposes to follow any other established painting procedure like
electrostatic painting, the procedure shall be submitted along with offer/bid for
purchaser's review and approval.
11.00 PANEL INTERNAL WIRING:
11.01 All wiring shall be of switch board type super flexible multi-stranded, tinned, annealed
copper wire with suitable PVC insulation of 1.1KV grade conforming to IS-694 which
has proved its utility in tropical regions against hot and moist climate and vermin (mice,
white ants and cockroaches, etc.) and of fire retardant type.
11.02 The size of wiring in different circuits shall not be less than those specified below:
Area of cross-section of
Sl.
Circuits
conductor ( minimum
No.
permissible size of wire)
Page 223 of 382
1
2
3
Metering and relaying circuits connected to CTs
and PTs
Audio visual annunciation, signaling and control
circuits
AC/DC Auxiliary control supply circuits
2.5 sq. mm
1.5sq. mm
1.5sq. mm
11.03 Following colour scheme shall be used for the wiring.
Colour of the
Circuit where used
Colour of the ferrule
wire
Red
Red phase of instrument transformer
Red
circuits
Yellow
Yellow
phase of instrument
Yellow
transformer circuits
Blue
Blue phase of instrument transformer
Blue
circuits
Green
Neutral connections earthed or not
Green
earthed in the instrument transformer
circuits
White
AC control wiring circuits using 415/
Respective phase:
240V auxiliary supply and cubicle
Red, Yellow and blue
lighting
Neutral : green
Grey
DC control wiring circuits
Red : Trip circuit
Blue : indicating circuit
Yellow: alarm circuit
Green : relay, auxiliary
and other interconnections
Lower voltage DC supply (from DC to
-“DC converter)
11.04 All cubicle wiring shall be of the grouped type and laid out in flat formation on the
framework, in the interior of the panel cubicles and secured to it by means of cleats.
Wiring shall be run straight and given right angle bends wherever necessary. Wiring
round the hinges shall be of extra flexible conductors twisted around the axis of the wires.
Longitudinal throughs extending through out the full length of the panel shall be preferred
for inter panel wiring. Interconnection to adjacent panel shall be brought out to a separate
set of terminal blocks located near the slots of holes meant for taking the interconnecting
wires. All potential bus wiring, audible alarm, bus wiring, AC & DC control supply bus
wiring, wiring for cubicle lighting and such other wiring which runs from cubicle to
cubicle within the switchboard shall be laid down in gutters and shall be carefully
screened.
Wiring connected to the space heaters in the cubicle shall have porcelain headed
insulation over a safe length from the heater terminals.
Each wire shall be continuous from end to end and shall not have any joints within itself.
Individual wires shall be connected only at the connection terminal or studs of the
terminal blocks, meters, relays, instruments and other switch board devices.
Page 224 of 382
Terminal ends of the wires shall be provided with numbered self-locking ferrules suitably
coloured for phase identification. At points of intersection where a change of number is
necessary, duplicate ferrule shall be provided with the appropriate numbers on the
changing end.
Wire ends shall be elegantly hooked with Ross - Courtney solder less Terminals. At the
terminal connection, washers shall be interposed between wire terminals and the holding
nuts. All holding nuts shall be secured with locking nuts. The connection stud shall
project at least 3 mm from the lock nut surface,
Wiring shall be so connected at the terminal studs that no wire terminal number ferrule
gets masked due to succeeding connections. All wire shall be suitable for bending and
shall meet the terminal studs at right angles with the stud axis and they shall not be
skewed.
All studs, nuts, bolts, screws etc., shall be threaded according to the IS practice unless
purchaser's approval to any other practice of threading is obtained. Spare quantity of nuts,
lock nuts and washers of all varieties used on the switchboard shall be supplied to the
extent of 10% of the used quantities. The supplier should note that there would be no
mezzanine floor for the control room building for cable spreading and the method of
taking the cables directly into panel from the duct shall be clearly indicated.
Contractor shall be solely responsible for the completeness & correctness of the internal
wiring and for the proper functioning of the connected equipments.
12.00 TERMINAL BLOCKS AND TERMINAL CONNECTORS:
12.01 Terminal blocks shall be of the projecting stud type with check nuts and washers. The
insulation housing of the terminal connector along with barriers shall be moulded from
thermosetting resin dielectric and shall be of AC 1100V grade. The studs shall be fully
threaded and shall be of tin plated brass. The size of the studs shall be suitable for a
continuous rating of not less than 35 Amps and shall accommodate the conductor
terminal with a close fit, check nuts and washers shall also be of tin plated brass. Check
nuts shall be hexagonal and shall be suitable for being tightened with tubular box type
spanners. The end termination facility shall be suitable for tightening with screw driver.
Tin plated brass inserts shall be provided between the terminal connector studs for
effective resistance free, electrical contact between the incoming and outgoing
terminations.
12.02 Terminal connectors shall be preferably of bolt and nut type for being assembled on to
standard mounting channels for multi-way grouping to form terminal blocks. These
terminal blocks shall be mounted vertically in columns inside the panel in a pillar type
formation and shall be so located that the incoming tail ends of the control cables can be
terminated to these terminal blocks easily.
12.03 All terminal blocks shall be provided with removable shrouds made of transparent
dielectric material rated for 1100V grade. Each shroud shall be etched or provided with a
plastic marker strip to identify the circuits that are terminated.
12.04 Each terminal block shall be provided with at least 30% spare terminals on each panel
and these spare terminals shall be uniformly distributed on all terminal blocks.
Page 225 of 382
12.05 All studs, nuts, screws etc., shall be threaded according to IS:7684. Sufficient spare
quantities of all varieties and size of bolts, studs, nuts, washers and screws used in the
cubicle shall be supplied along with cubicle free of cost.
12.06 Where terminal blocks are arranged in different columns or rows then minimum clearance
of 150 mm shall be provided between the terminal block. A minimum clearance of 250
mm shall be kept between Terminal blocks and associated cable gland plates.
12.07 Terminal blocks containing CT secondary leads shall be provided with test, isolating,
short circuiting & earthing facilities / sliding link type and VT‟s secondary leads shall be
provided with isolating features.
12.08 Arrangement of terminal block assemblies & wiring channel within the enclosure shall be
such that a row of terminal blocks is run in parallel & close proximity along each side of
the wiring duct to provide for convenient attachment of internal panel wiring. The side of
terminal block opposite to wiring duct shall be reserved for the owner‟s external cable
connections. All the adjacent terminal blocks shall also share the field wiring corridor.
All wiring shall be provided with adequate support inside the panels to hold them firmly
& to enable free & flexible termination without causing strain on terminals.
13.00 SPACE FOR CONTROL CABLES AND CABLE GLANDS:
All control and supply cable will be conducted at the bottom of the cubicles. The bottom
plates of panels shall be fitted with removable gland plates and fixed with the cable
glands, the size of which shall suit the owner's external cables. Cable glands shall be
screened type and made of brass or nickel plated steel and shall be suitable for PVC
unarmoured cable. Necessary drawing showing the cable entry position and foundation
bolt location shall be supplied by the bidder. The required quantities of cable glands
suitable for the cable sizes as described below shall be provided in each panel.
19 C x 2.5 Sq. mm for Power Transformer.
19 C x 2.5 Sq. mm for Circuit Breaker.
10 C x 2.5 Sq. mm for Circuit Breaker.
4 C x 6.0 Sq. mm for CT Circuits.
2 C x 10 Sq. mm for NCT Circuits.
4 C x 10 Sq. mm for PT Circuits and D.C.
10 C x 2.5 Sq. mm for Isolator.
2 C x 2.5 Sq. mm. for coupling capacitor.
14.00 MIMIC DIAGRAM: VOID
15.00 NAME PLATE & MARKINGS
15.01 Each unit panel shall be provided with a circuit label of size 40mm x 200mm (min)
located prominently at the top on the front and rear face of the panel. Circuit labels shall
be located inside the cubicle also for easy identification on both halves of the panel.
These name plates and labels shall bear the name of the circuit or equipment etc., to
which the panel is associated with. The letter shall have a minimum height of 20mm.
15.02 The name plate shall be 50mm width plates made of brass or black plastic and shall be
etched with 3mm sized letters of the name of the associated circuit / equipment. The
Page 226 of 382
etched letters shall be duly filled in with white enamel paint, if the plate is of black plastic
or with black enamel if the plate is of brass.
15.03 All instruments, relays and such other electrical devices and accessories mounted in the
control panel shall be provided with name plate bearing the name of the manufacturer,
serial number, type and technical rating data. These name plates shall be installed at the
rear of the device inside the cubicle.
15.04 VOID
15.05 Each panel shall be provided with a label located at the bottom corner on the front and
shall contain the following details:
i.
ii.
iii.
iv.
Manufacturer's name.
P.O. No. & date.
Drawings reference No. that pertains to that panel.
Serial No. of the panel.
The letters on name plates shall have minimum height 4 mm and the gap between lines /
words shall be more than 2 mm.
16.00 INTERNALLY MOUNTED EQUIPMENTS:
16.01 SPACE HEATERS:
Each control and relay panel shall be provided with a strip type or coil type tubular
enclosed space heaters to prevent condensation of moisture within the panel. It shall be
installed at the base of the cubicle and operated on 240V AC single phase supply. The
surface temperature shall be well below visible heat. Space heaters shall be provided with
an independent switch control, fuse and an adjustable thermostat to regulate the
temperature.
16.02 PANEL LIGHTING:
The interior of the cubicles shall be illuminated by fluorescent lamps. The illumination
shall be free from hard shadows and shall be planned to avoid any strain or fatigue to a
wire man working inside the cubicle due to any abnormal or non-uniform illumination.
These lamps shall be operated through switches or door push buttons. It shall operate on
240V, AC single phase supply.
16.03 POWER SOCKETS:
At least 3 nos. of 5 Amps three pin multiple plug points and 2 nos. of 15 Amps, 3 pin
power plug outlets shall be provided at convenient points in each set of the 220KV,
110KV, 66KV and 33KV control panels. The plug points shall be provided with electrical
and mechanical cover with chain. For simplex panels, a single phase 5A plug and socket
and a 15 Amp. 3 Pin power plug & socket with switch is to be provided with security
cover
17.0
FUSES:
17.01 H.R.C. fuses of adequate current and voltage rating shall be provided inside the cubicle
for the various protection, control and incoming auxiliary AC & DC supply circuits.
Page 227 of 382
The fuse bases and carriers shall be mounted inside the cubicle in an easily accessible
location. They shall conform to relevant standard and shall be designed to carry HRC
cartridge fuse links. The fuse bases and carriers shall be moulded from the thermosetting
resin dielectric or moulded standard grades phonolic Bakelite or equivalent thereof and
shall be black in colour. The selection of the main and sub-circuit fuse ratings shall be
such as to ensure selective clearance of sub-circuit faults. All accessible live connections
to fuse bases shall be adequately shrouded. Fuses shall have operation indicators for
indicating blown fuse condition. Fuse carriers and bases shall have imprints of the fuse
rating and voltages.
The short time fuse rating of fuses shall be not less than 9KA.
There shall be individual fuse units for each of the following circuits:
i)
ii)
iii)
iv)
v)
vi)
vii)
Signaling and Annunciation circuits.
V.T. secondary instrument circuits.
V.T. secondary, relay circuits.
AC & DC control circuits (shall be separate for CB & Isolators).
AC auxiliary circuits.
AC Power socket, cubicle space heater and lighting.
Others if any.
18.00 EARTHING:
18.01 All panels shall be provided with a bare copper tinned earthing bus extended throughout
the length of the panel. Location of earth bus shall ensure no radiation interference for
earth system under various switching conditions of isolators and breakers. The material
size of the earthing bus shall not be less than 25 mm x 6 mm,perforated copper with
threaded holes at a gap of 50mm with provision of bolts & nuts for connection with cable
armours& mounted equipmentsetc for effective earthing. When several panels are
mounted adjoining each other, the earth bus shall be made continuous and necessary
connection and clamps for this purpose shall be included in the scope of supply. Provision
shall be made for extending the earth bus bars at a future date into new adjacent panels to
be installed if any. Provision shall be made at the end panels for connecting the same to
the system earth ground mat.
18.02 All metallic cases of instruments, relays, accessories installed within the cubicle shall be
connected to the earth bus with 1100V grade standard multicore 2.5 sq. mm PVC
insulated conductor of green colour. The run of the wires shall be continuous without any
joints and shall be crimped at either end with open type solder less lugs.
18.03 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.
18.04 VT & 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.
Page 228 of 382
18.05 An electrostatic discharge arrangement shall be provided in each panel so as to discharge
human body before handles the equipments inside the panels.
19.00 INDICATING LAMPS: VOID
20.00 TEST TERMINAL BLOCKS:
20.01 Each panel where metering is involved shall be installed with instrument test terminal
blocks. These test terminal blocks shall be designed for use on panels with poly-phase
meters to facilitate their in-situ testing. The test terminal blocks shall be mounted at the
bottom end of the front face of the panel. They shall be of the projecting type semi-flush
mounted with wire connected at the back. All wiring to indicating, integrating and
recording instruments shall be done through the Test Terminal Block. The test terminal
block shall be provided with screw type front cover such that the removal of this cover
shall grant access to the terminals in the front for connecting check meters or for injection
of external supply to the panel instruments.
20.02 The test terminal blocks shall facilitate in-situ testing of instruments without interrupting
the primary load circuit. The current terminals shall therefore be provided with shorting
arrangement through links before interrupting the normal circuit for insertion of external
check meters or for injection of an external supply into the panel instruments without
causing an open circuit in the current transformer secondaries. The potential terminal
shall be provided with sliding links for isolation of the normal supply voltage to the panel
instruments from the secondaries of voltage transformer.
20.03 The test terminal block shall have its insulation housing made of a moulded dielectric
materials such as phonolic Bakelite or equivalent thereof with adequate insulation
between current and potential terminals of different phases. The potential testing studs
shall preferably be housed in narrow recesses of the block moulded insulation to prevent
accidental short circuit between potential studs themselves or between potential and
current terminals. The cover studs to be provided shall be suitable for sealing with lead
seals so as to prevent unauthorized access to the test studs.
20.04 The test terminal block rating shall be 1100 volts, 35 Amps, The terminals shall be
nickel-plated brass and their contact resistance shall be less than 1 milli ohm. The test
Terminal Block shall preferably be of IMP make or any other standard link type makes.
21.00 CONTROL SWITCHES:
21.01 Control and instrument switches shall be rotary operated type with escutcheon plates
clearly marked to show operating position and circuit designation plates and suitable for
flush mounting with only switch front plate and operating handle projecting out. Handles
of different shapes and suitable inscriptions on switches shall be provided as an aid to
switch identification.
21.02 The selection of operating handles for the different types of switches shall be as follows;
a) Selector switches
Oval or knob, black
b) Trip transfer switches
Pistol grip, lockable, black
Page 229 of 382
21.03 VOID
21.04 VOID
21.05 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.
21.06 All control switches wires shall be connected at the back. The contact mechanism shall
become operated. The contacts shall be silver plated and designed for liberal rating of the
duty involved. The contacts shall be provided with a dust and vermin proof removable
protection cover. The protection cover shall preferably be of transparent, inflammable
material made of moulded dielectric materials. Springs to be provided in the switch shall
not be used as current carrying parts.
The contacts provided in the switch shall not be used as continuous current carrying parts.
The contact combination and their operation shall be such as to give completeness to the
interlock and function of the scheme. The contact rating of the switches shall be as
follows :
Contact rating in Amps
Description
220V/110V DC
240V AC
a) Make and carry continuously
10
10
b) Make and carry for 0.5 seconds
c) Break:
1. resistive load
2. inductive load with L/R = 40 ms
30
30
3
0.2
7
---
21.07 VOID
22.00 SYNCHRONIZING SWITCHES: VOID
23.00 PUSH BUTTON SWITCHES
a)
Push button switches provided, shall be of the momentary contact type wired back
connected. They shall be semi-flush mounted and where required they shall be
shrouded to prevent inadvertent or undesirable operation. They shall be provided
with integral inscription plates engraved with their functions.
b)
All push buttons shall be with two sets of Normally Open (NO) and Normally
Closed (NC) contacts. The contact faces shall be silver plated and shall be able to
make/break and carry the rated current. The rated current shall be appropriate to
the duty of the desired function, but not less than 5 Amps.
24.00 SYNCHRONIZING EQUIPMENT: (Applicable for 220KV Sub-Station only)
24.01 The model sequence of synchronizing of various voltage classes in the station is as
follows:
Page 230 of 382
a)
b)
c)
Synchronizing outgoing 220 kV lines with any one of the main buses.
Synchronizing 220KV and 110/66 kV breaker of Power transformer.
Synchronizing outgoing 110/66 kV lines with any one of the main buses.
25.00 ANNUNCIATION SYSTEM: VOID
26.0
INDICATING & INTEGRATING INSTRUMENTS:
26.01 VOID
26.02 VOID
26.03 VOID
26.04 VOID
26.05 INTEGRATING METERS:
a) It shall of static type, 3 phase, 4 wire, 2 element trivector meter suitable for 1 Amp,
CT and 110 volts phase to phase VT secondaries. It must be flush mounted type and
tropicalisesd. It shall have separate registers for recording KWh and KVARh
consumption separately and also demands with automatic resetting at the end of the
month and also to record EXPORT AND IMPORTS.
b) The meter should be of 0.2 accuracy class.
c) The meters shall have legible LED/LCD minimum 6 digits auto-cycle display. The
meter shall have non-volatile memory requiring no battery back up.
d) The meters shall conform to the detailed specification enclosed as Annexure.
26.06 VOID
26.07 VOID
27.00 RELAYS:
27.01 GENERAL:
a)
All relays shall conform to the requirements of IS3231/IEC 50255/IEC 61000 or other
applicable standards. Relays shall be suitable for flush or semi flush mounting on the
front with connections from the rear.
b)
All main protective relays shall be numerical type & communication protocol shall be as
per IEC 61850. Further the test levels of EMI as indicated in IEC 61850 shall be
applicable to these.
Page 231 of 382
c)
A detailed note regarding the various quality control procedures adopted by the
manufacturer should be given with special reference to static / numerical relay
components on their quality assurance tests. Information should be furnished regarding
various equipment used for quality assurance tests.
d)
The numerical relays offered must have proven performance. The bidder shall give a
detailed account of the field experience of the relays offered, information regarding
experience in designing etc.
e)
The protection scheme at the other end of the transmission line will be furnished to the
successful bidder if required. The other particulars like distance of the lines, impedance,
CT ratios, PT details will be furnished to the successful bidder and should provide the
protection schemes suitable for parameters furnished.
f)
The relay codes mentioned in the wiring/ schematic diagram, for auxiliary relays etc.,
which are part of a composite relay, shall be marked on the name plate provided. This is
required to facilitate the field staff, to identify the auxiliary relay provided in the
composite unit at the time of trouble shooting.
g)
All relays, other components, wiring etc shall withstand a test voltage of 2.5kV RMS,
AC, 50 Hz.
h)
The tenderer shall give a detailed account of the field experience of the relays offered.
Information regarding experience within the country should be indicated, giving the
approximate quantity of similar relays supplied in India. The bidder should also give an
account of his experience in designing coordinating similar protective gear within the
country.
i)
The tenderer shall indicate what facilities are available with him within the country for
repair / recalibration of the relays offered by him. Whether such facilities are available for
the repair of imported relays included in his offer shall also be stated in the tender.
j)
The tenderer shall indicate what facilities are available with him for commissioning these
Relays. Such facilities shall cover indigenous and imported equipment. The bidder shall
arrange to train at his cost the engineering staff of KSPDCL for trouble- free operation
and maintenance of these relays.
27.02 a)
The protective and auxiliary relays offered shall be of proven design and based
on sound principles and should conform to BS : 142 and IS : 3231 and IEC : 255
wherever applicable. The protection equipment shall be designed and applied to
provide maximum discrimination between faulty and healthy circuits and its
performance shall be in accordance with the BS standard 3950. The equipment
shall remain in operation during transient phenomenon, which may arise during
switching or other disturbances to the system. They shall be in standard cases and
shall be provided with dust and vermin proof cases and covers, The covers shall
be transparent and shall be removable from the front. The relay shall be suitable
for semi-flush mounting only the flanges projecting in the front and with
connection from the rear. The relays shall be rectangular in space and dull black
or egg shell black enamel painted cases.
b)
All protective relays shall be in draw-out or plug-in type / modular cases with
proper testing facilities. The testing facilities provided on the relays shall be
Page 232 of 382
specifically stated in the tender. Necessary test plugs shall be supplied loose and
shall be included in bidder's scope of supply. Test block and switches shall be
located immediately below each relay for testing. As an alternative to test block
and test plug arrangements the bidder shall also quote alternative testing facility of
protective relays by providing a push button which when pressed connects the
testing equipment to the relay coils and injects current in the coil and
automatically disconnects the trip circuits and on operation of relay gives a signal
that the equipment and the circuits are correct. The above tests shall be carried out
without short circuiting the CT secondary connections. The Purchaser reserves the
right for accepting any one of the above two testing facilities. Unless otherwise
specified all auxiliary relays and timers shall be supplied in non-draw out cases/
plug-in type modular cases.
c)
All AC relays shall be suitable for operation at 50 Hz AC Voltage operated relays
shall be suitable for 110 Volts VT secondaries and current operated relays for 1
Amp CT secondaries as specified. DC auxiliary 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.
d)
All relays coils requiring a continuous voltage shall have adequate thermal
capacity for continuous operation. The current and voltage coil shall be rated for
the current and voltage rating specified under system details and auxiliary supply.
e)
The power supply unit shall be fully rated with liberal design in capacity.
f)
The DC supply for solid state relay shall be from DC / DC converters and these
shall be amply and fully rated for all operating conditions in service. Provision of
DC stand by power supply will however not be acceptable.
g)
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. and 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. Relay cases size shall be so
chosen as not to introduce any limitations on the use of available contacts on the
relay due to inadequacy of terminals. Paralleling of contacts, if any shall be done
at the terminals on the casing of the relay.
h)
All protective relays, auxiliary relays and timers except the lock out relays and
interlocking relays specified shall be provided with self-reset type contacts. All
protective relays and timers shall be provided with externally hand reset positive
action operation indicators with inscription subject to purchaser's approval. All
protective relays which do not have built in hand-reset operation indicators shall
have additional auxiliary relays with operating indicators (Flag relays) for this
purpose. Similar separate operating indicator (auxiliary relays) shall also be
Page 233 of 382
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.
i)
There shall be no relay in the protective circuits, which shall cause tripping of the
circuit breaker when the relay is de-energized.
j)
Timers shall be of solid or static type. Pneumatic timers are not acceptable. Time
delay in terms of milliseconds obtained by the external capacitor/resistor
combination is not preferred & shall be avoided.
k)
Provision shall be made for easy isolation of trip circuit of each relay for the
purpose of testing & maintenance.
l)
All protective relays & alarm relays shall be provided with one extra isolated pair
of contracts wired to terminals exclusively for further use.
m)
The setting range of relays offered, if different from ones specified shall also be
acceptable if they meet the functional requirement.
n)
Any alternative/additional protection of relays considered necessary for providing
complete effective & reliable protection shall also be offered separately. The
acceptance of this alternative/additional equipment shall lie with KSPDCL.
o)
Auxiliary seal-in-units provided on the protective relays shall preferably be of
shunt reinforcement type. If series relays are used the following shall be strictly
ensured.
i)
The operating time of the series seal-in-units shall be sufficiently shorter
than that of the trip coil or trip relay in series with which it operates to
ensure definite operation of the flag indicator of the relay.
ii)
Seal-in-units shall obtain adequate current for operation when one or more
relays operate simultaneously.
iii)
Impedance of the seal-in-units shall be small enough to permit satisfactory
operation of the trip coil on trip relays when D.C supply voltage is
minimum.
iv)
Trip-Circuit seal – in is required for all trip outputs irrespective of the
magnitude of the interrupted current. The trip-circuit seal-in logic shall
not only seal –in the trip outputs but also the relevant initiation signals to
other scheme functions (e.g. initiate signals to the circuit breaker failure
function, reclosing function etc.,) and the alarm output signals.
v)
Two methods of seal-in are required, one based on the measurement of
AC current, catering for those circumstances for which the interrupted
current is above a set threshold, and one based on a fixed time duration,
catering for those circumstances for which the interrupted current is small
(below the set threshold).
vi)
For the current seal-in method, the seal-in shall be maintained until the
circuit breaker opens, at which time the seal-in-shall reset and the seal inPage 234 of 382
method shall not now revert to the fixed time duration method. For this
seal-in method, the seal-in shall be maintained for the set time duration.
For the line protection schemes, this time duration shall be independently
settable for single –and three –pole tripping.
vii)
p)
For numerical relays the scope shall include the following:
i)
ii)
27.03 a)
Seal-in by way of current or by way of the fixed duration timer shall occur
irrespective of whether the trip command originates from within the main
protection device itself (from any of the internal protection functions), or
from an external device with its trip output routed through the main
protection device for tripping Trip-circuit seal-in shall not take place under
sub-harmonic conditions.
Necessary software & hardware to up/down load the date to/from the relay
from/to the personal computer provided in the station.
The relay shall have suitable communication facility for connectivity to
sub-station system/SCADA. The relay shall be capable of supporting IEC
870-5-103 and 61850 protocol.
The materials, the components of static/ numerical relays shall be designed to
withstand the most severe tropical climatic conditions such as corrosive
atmosphere, saline, fog, damp, heat and fungus prone environment. These devices
as such shall be tropicalised in such a manner so as to meet with the IEC-68
standard.
b)
The components shall be loaded by less than half of their rated values. The
resistor shall be of carbon composition or metal oxide type and the capacitors
shall be plastic film or tantalum type. Stringent measures including shielding of
long internal wiring should be taken to make relays immune to voltage spikes. As
per IEC, the relays must meet the requirements of IEC-255-4, appendix 'E'. ClassIII regarding HF disturbance tests, IEC-255-4 regarding impulse test at 5kV and
fast transient test as per IEC-801-4. Insulation barriers shall be provided to ensure
that transients present in CT & VT connections due to extraneous source do not
cause damage to static circuits.
c)
The. cases, racks and sub-units shall preferably be of stainless steel. The screws
used in cases, racks and sub-units shall be either of stainless steel or zinc plated
steel.
d)
The material of connector terminal blocks shall be of dielectric moulded type
resin. The connector plugs shall be corrosion resistive and the lugs shall be made
of tinned brass with the contact face silver / gold plated. All connections with the
connector plug shall be by wire wrapping.
e)
The static/ numerical components forming the electronic solid state circuitry shall
be mounted on printed circuit board of adequate thickness and made of stratified
glass epoxid. A protective lacquer shall be applied when all the components are
soldered. Transformers in the circuitry shall also be impregnated with the same
lacquer. All components shall be clearly marked and all wiring colour coded and
tagged. Flat ribbon cable is exempted from being tagged.
Page 235 of 382
f)
The relays shall be modular units assembled in fully tropicalised draw out cases
with the modules or sub-units plugged into racks. They shall be electrically
isolated on the measuring side through intensity or voltage input transformers with
shield bonded (at the over voltage/fixed voltage) and on the operation side through
on/off relays. The layout of measurement inputs, output relays, detection circuits
and visual display such as to eliminate mutual interference of the circuits
involved. Internal test points shall be provided on the printed circuit at typical
points of the relay diagram. These test points, if possible shall be provided on the
front of the relay to enable testing during operation without having to disconnect
the relay.
g)
Insulation barriers shall be provided to ensure that transients present for CT and
VT connections due to extraneous sources do not cause damage to static circuits.
The static relays offered shall be tested to withstand both 5 kV impulse tests and
high frequency disturbance stipulated by IEC. Details of the equipment used for
tests shall be furnished.
h)
The relay shall be designed for designed for shock wave resistance, temperature
resistance, humidity resistance, transportation resistance and storage resistance
and to be insensitive to radio frequency interferences.
i)
The performance of static/numerical relay shall not be affected by transient,
common mode and transient mode electromagnetic interference..
j)
The solid state relays shall be stable and suitably protected against transient/
induced over voltages and noise signals. The bidder shall state clearly in his bid,
special requirements, if any, for DC input arrangement or cabling considered
necessary for satisfactory operation of solid state relays quoted by him.
28.00 PROTECTION SCHEME:
28.01 Protection scheme shall consist of following :
a)
The main protection, distance and differential protection relays are required to protect the
220KV and 66KV lines and 220/66/11KV Power Transformers and clear the fault within
shortest possible time with reliability, selectivity and full sensitivity to all type of faults.
The relay shall be fast acting numerical type.
b)
Back up protection shall be of numerical type.
28.02 Protection Scheme for 220KV lines :
The line protection relays are required to protect the line & clear the faults on line within
shortest possible time with reliability, selectivity & full sensitivity to all types of faults on
the lines.The general concept is to have two main protections having equal performance
requirement specially in respect of time called as Main-I & Main-II for 220kV lines &
cables and to have Main & backup protection for 110/66kV Lines.
The maximum fault current could be as high as 40KA at 220KV and 31.5KA at 110KV &
66KV, but the minimum fault current could be as low as 20% of the rated current of CT
secondary. However for stations in Bangalore city, the maximum fault current could be
Page 236 of 382
40KA at 66KV. The starting & measuring relays characteristic should be satisfactory
under the extremely varying conditions.
For 220KV lines the protection relays shall be suitable for use with capacitor voltage
transformers having non-electronic damping and transient response as per IEC.
Fault Recorder, Distance to fault Locator and Over voltage relay (Stage-I) 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 clause.
Auto reclose relay function if offered as an integral part of line distance protection relay,
shall be acceptable for 220kV lines only provided the auto reclose relay feature meets the
technical requirements as specified in the respective clause.
Following protections shall be provided for each of the transmission lines:
For 220kV Lines:
Main-I : Numerical distance protection scheme.
Main-II : Numerical distance protection scheme of a make different from that of main-I.
For 220kV XLPE Cables:
Main-I : Numerical line differential protection scheme.
Main-II : Numerical line differential protection scheme of make different from that of
Main-I.
A) Numerical Distance Main-I & Main-II Distance Protection scheme for 220 kV
lines:
Numerical distance protection shall be suitable for use with permissive under reach and
over reach required. Relay shall have continuous self-monitoring and diagnostic feature.
The detailed description of protection is given here under:
Numerical Distance Protection scheme shall :
i.
Be suitable for one amp CT secondary and 110/3V AC potential from potential
transformer of 220 KV Bus.
ii.
Be modular in construction.
iii.
Have high speed non-switched distance relay for three phase systems to clear all
type of line faults within the set reach of the relay.
iv.
It should cover at least two line sections completely with 25% additional margin.
v.
Measure all type of faults without the need to switch the measuring elements to
the faulty phase or phases. Zone switching to extend the reach of the measuring
elements is not allowed. The reach of each zone shall be independently and
individually adjustable over vide range in suitable steps, for each of the zone
measuring elements in steps of 1%. The memory circuits with defined
characteristics shall be provided in all three phases to ensure correct operation
during close-up 3 phase faults and other adverse conditions.
Page 237 of 382
vi.
Have a maximum operating time up to trip impulse to circuit breaker, (with CVT
being used on line side) under source to line impedance ratios under all possible
combinations of fault (with all filters included) at 50% of zone-1 reach, as given
below:
For SIR 0.01-4
-
About 30 ms at nearest end and 40 ms at other end
of line.
For SIR 4 –15
AND
About 35 ms at nearest end and 45 ms at other end
of line.
(Carrier transmission time is not included in the operating time indicated above.
The maximum carrier transmission time may be taken as 20ms. However, any
reduction in carrier time should be directly reflected as reduction in maximum
operating time)
vii.
Have stepped time-distance characteristics and shall have at least two directional
and one non-directional independently variable time graded distance protection
zones to cover two adjacent line sections.
viii.
a) Three zones and one reverse zone of operation shall be available. The reach of
the relay for zones 1, 2 & 3 should be able to cover line lengths as per clause
(iv) above. The relay shall have an adjustable characteristics angle setting
range of 30-75 degree.
(b) Be field selectable for various over reaching, under reaching setting and
blocking/ inter tripping communication scheme.
(c) Have quadrilateral or lens characteristics with a facility to set resistance and
reactance independently to cater for arc resistance on short lines and load
discrimination for long lines.
ix.
Ensure that this long coverage is consistent with limitations imposed by heavy
loading and sound phase components of fault current.
x.
The scheme shall not become inoperative even under severe system fault
condition near the location of the relay when the potentials applied to the relay are
very small. If characteristics of starting relays are such that it cannot pick up
because of very low infeed, under-voltage relays may also be used as
supplementary relays.
xi.
Have two independent continuously variable time setting range of 0-3 seconds for
zone-2 and 0-5 seconds for zone-3.
xii.
Have a maximum resetting time of about 35 milli sec.
xiii
Have facilities for offset features with adjustable 10-20% of zone-3 setting.
xiv.
Have residual compensation variable from 30- 150%.
xv.
Operate instantaneously when circuit breaker is closed to zero volt 3-phase fault.
Page 238 of 382
xvi.
Be suitable for single & three phase Auto re-closing and auto tripping at both
ends.
xvii
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.
xviii
Be selective between internal and external faults.
xix.
Include fuse failure protection which shall:
a1)
a2)
a3)
a4)
a5)
Monitor all the three fuses of CVT/IVT circuit, 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.
Be of solid state type.
xx.
Have facility for under voltage & over voltage protection.
xxi.
Have self diagnostics feature.
xxii.
Have facility for current & voltage supervision.
xxiii. The circuit failure protection be provided as a back up protection in case of failure
protection be provided as a backup protection as required by object protection.
xxiv. Suitable number of potential free contacts (if required, multiplied through reed
relays only) be provided, on each distance scheme for carrier aided tripping, auto
re-closing, circuit breaker failure sequence of events recorder and data acquisition
system..
xxv.
Mutual compensation unit shall be provided such that healthy feeder protection
shall not mal-operate for faults in other lines of multi circuit lines.
xxvi. The scheme shall be adaptable for carrier blocking principle for purpose of
simultaneous inter tripping of breakers connected to the fault section and to
prevent tripping of breakers connected to healthy section. The directional
elements at the two ends of the protected line shall be inter locked by the power
line carrier and shall trip the breakers at the two ends of the protected line
breakers at the two ends simultaneously for fault in the protected zone. The
blocking signal shall be transmitted to prevent the circuit breakers from tripping in
the event of fault external to the protected zone. This shall not prevent the
breakers tripping due to the second and third zone elements acting as back-up
protective relays. The direction comparison carrier relaying shall provide
instantaneous back-up protection and the second and third zone elements delayed
back-up.
xxvii. A separate out of step or power swing blocking relay shall be included to prevent
tripping of the breaker during power swings and system disturbances. The breaker
shall however be caused to trip if the disturbance lasts for an interval of time equal
to or greater than the third zone time setting.
Page 239 of 382
Nevertheless the impedance loci of the distance relays shall be such that they have
maximum tendency to operate on power swings caused by system disturbances.
Note: Provision of optional features other than those indicated above may be indicated
separately. Provision may be made in the relay for up-dating these optional
features at a later date whenever required by KSPDCL.
xxviii. The distance relay shall be compatible for use with PLCC equipments and auto reclose scheme existing. Further, the complete scheme shall also be flexible.
xxix. The distance protection scheme shall be suitable for any length (short lengths also)
of transmission line. Any limitations in this regard shall be clearly specified by the
bidder.
xxx.
Include a directional and non-directional backup Inverse Definite Minimum Time
(IDMT) over current & earth fault relay with normal inverse characteristics as per
IEC-60255-3 as a built in feature.
xxxi. The relays shall have following features either built-in or separately:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Fault locator of an accuracy of 3% or better.
Synchronizing check.
Weak end in feed.
Power swing blocking.
Broken conductor detection.
Compatibility with carrier protection scheme.
Compatibility with Single pole/three pole auto re-closer.
Disturbance Records.
Compatibility with sub-station automation even logger..
Auto Re-Closer.
Direction & Non-directional OCR & EFR
xxxii) All trip relays used in transmission line protection scheme shall be of self/electrical reset
type depending on application requirement.
B)
Auto Re-Closing:
Auto re-closing relay shall
i)
Be provided only for 220 kV line protection scheme. It shall be preferably built in
feature of the Main-I/Main-II distance relaying scheme. The bidder shall coordinate the auto re-close relaying scheme with that of the circuit breaker so as to
ensure satisfactory and reliable operation of the auto re-closing scheme.
ii)
Have single-phase or/ and three phase re-closing facilities.
iii)
Have a continuously variable single phase dead time range of 0.1 – 2 secs.
iv)
Have a continuously variable three phase dead time range of 0.1-2 secs.
v)
Have a continuously variable reclaim time range of 5-25 seconds.
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vi)
Incorporate a four-position selector switch from which single phase/three
phase/single and three phase auto re-closer and non-auto re-closure mode can be
selected.
vii)
Have facilities for selecting check synchronizing or dead line charging features. It
shall be possible at any time to change the required feature by reconnection of
links.
viii)
Be of single shot type.
ix)
Include check synchronizing relay which shall:
a)
Have a time setting continuously variable between 0.5-5 seconds with
facility of additional 10 secs.
b)
Have a response time within 200milli seconds with the timer disconnected.
c)
Have a phase angle setting not exceeding 35 degree.
d)
Have a voltage difference setting not exceeding 10%.
x)
Include dead line charging relay which shall:
a)
b)
c)
d)
C)
Have two sets of relays and each set shall be able to monitor the three
phase voltage.
Have one set connected to the line CVTs with a fixed setting of 20% of
rated voltage.
Have one set connected to the bus IVTs with a fixed setting of 80% of
rated voltage.
Incorporate necessary auxiliary relays and timers to give comprehensive
scheme.
xi)
Also be possible to lockout the auto re-closing transformer scheme relays when
the carrier protection associated with main distance protection schemes are out of
service/ faulty.
xii)
Have separate “Auto re-close operation” and “circuit breaker lock out”
annunciation shall be provided.
Fault Locators function:
The fault locator shall be based on the impedance measurement of the line and shall be
static, microprocessor based only. It shall be capable of measuring the location of the
fault from the relaying point with an accuracy of 3% or better, for all types of faults
including broken conductor detection. It shall be ON LINE type. The fault locator shall
measure the measuring signals prior to the fault, during fault, before tripping of the
breaker and store them in the memory and process them at later stages. The accuracy of
the measurement shall not be affected / influenced by line loading prior to the fault,
remote in feed, magnitude of the fault resistance or mutual effect of parallel line(s), CVT
transients, DC component in fault current, heavy load conditions, temperature variations,
frequency divisions. The fault locator shall have built in display unit for showing fault
location, faulty phase(s), current and voltage magnitudes and their phase relationships.
The fault locator shall be capable of being combined with the respective distance
protection for phase selection information. The calculation of line protection shall take
place when any of the line protections operate on fault. The calculation by the fault
locator shall be based on measuring values prior to and during the fault. These data shall
be stored in the memory of fault locator and calculation shall be made after tripping of the
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line breakers. The distance to fault shall be shown as % of line length or actual fault
location in KM. The fault locator shall be suitable for its application with three (3) cycle
circuit breaker.
D)
DISTURBANCE RECORDER FUNCTION
Disturbance recorder (DR) 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 and neutral current, open or closed position of relay contacts and breakers during
the system disturbances.
Necessary auxiliary VTs to generate open delta voltage, shall be supplied by the bidder.
The bidder shall furnish along with the offer a typical printout for simulated conditions on
original paper.
The disturbance recorder system shall be capable of accommodating eight analog and
sixteen event channels for each feeder. DR shall acquire the fault data and store them in
non-volatile memory.
Necessary software and hardware for down loading the data captured by disturbance
recorder to the personal computer available in the sub-station shall be included in the
scope
The disturbance recorder shall incorporate the features as described below:
i. Simplicity of maintenance and repair:
The number and type of modules employed shall be minimized.
The modules shall be of plug-in type and shall be easily accessible for maintenance and
repair wherever required.
ii.
Immunity from the effects of hostile environment:
The equipment shall be designed to operate satisfactorily even when subject to the effects
of severely hostile electrical environment -such as interference signals arising out of
switching transients.
iii.
Interface with PC
The DR should have an interface arrangement for transfer / storage of data to a PC.
Necessary PC software, special cables etc., shall be part of DR and should be included in
the offer.
PC based user friendly, disturbance recorder evaluation software shall be provided for the
analysis and evaluation of the, record data made available in the PC. The software
features shall include repositioning of analog and digital signals, selection and
amplification of time and amplitude scales of each analog and digital channel, calculation
of MAX / MIN frequency, phase difference values, recording of MAX / MIN values etc.,
of analog channel, group 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.
iv.
Scan Rate
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The frequency response shall be 5 Hz on lower side and 250 Hz or better on upper side.
The DR shall have a scan rate of 1000 Hz/channel or better.
v
Starting Sensors
The, equipment shall have inherent to it starting sensors based on over voltage, rate of
change of current, and rate of change of frequency. The starting sensors, on pick up, shall
preserve the fault data acquired during the period of system disturbance, including prefault and post fault time in solid state memory. Preserved fault data shall not get erased
unless operator erases.
vi.
Pre-fault and Post-fault Time:
Pre-fault shall not be less than 160 ms and the post-fault time adjustable at a minimum of
2 seconds and a maximum of not less than 5 seconds. If another system disturbance
occurs during one post-fault run time the recorder shall also be able to record the same.
vii
Amplitude and event Resolution
Amplitude resolution shall not be less than 8 bit. Event resolution shall be 2 ms or better.
viii
Print out
The print out shall contain the following:
a.
Feeder identity.
b.
Date & time (1 hour, minute & second up to 100th of a second)
c.
Identity of trigger source.
d.
Graphic form of analog and event signals of all the channels.
ix.
Time generator
Each disturbance recorder shall have its own time generator. Facility shall exist of
synchronize the time generator from station time synchronization equipment having
output of following types at 30 min interval.
a.
b.
c.
d.
Voltage signal:
(0-5V continuously settable with 50m sec. Min. pulse duration).
Potential Free Contact(Minimum pulse duration of 50m second)
IRIG - B.
RS232C/RS 485.
Sub-stations where station time synchronization equipment is not available, time
generator of any one of the disturbance recorders can be taken as master and facility shall
exist to synchronize the time generators of other disturbance recorders and event loggers
in that station with respect to it. The recorder shall give annunciation in case of absence
of synchronization pulse within a specified time. The clock of the time generator shall be
such that, the drift is limited to ±0.5 seconds / day, if allowed to run without
synchronization. Facility shall exist to display the time in hour, minute and seconds on the
front of panel.
28.02.A Protection Scheme for 220kV cables:
The cable protection relays are required to protect the cable and clear the faults on cable
within shortest possible time with reliability, selectivity and full sensitivity to all type of
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faults on lines. In case of 220kV XLPE cables, the general concept is to have two fast
operating protection scheme. The current differential protection will be used as Main-I &
Main-II protection.
I.
Numerical Main-I & Main-II Current Differential Protection Scheme:

The line Differential Protection IED (Intelligent Electronic Device) protection
relay should be Numerical with full compliance to IEC 61850 standards in every
respect and Interoperability with other manufacturers IEDs and tools should be
verified.

The IED shall be suitable for Protection, control and monitoring of overhead lines
and cables for all Voltage levels in solidly grounded or impedance grounded
networks.

The protection unit should be based on Phase segregated Line differential
Principle and use.

Advanced and proven algorithms shall support user friendly Engineering tool and
Disturbance handling tool.

It should be possible to integrate Protection and control functionality for several
objects in the IED. The IED shall have complete functionality for single and multi
breaker arrangements with single or three phase tripping.

At least Four/Five independent parameter setting groups shall be included.

IED shall have extensive self supervision including analogue channels.

At new installations or at extensions and replacements in existing installations it
shall be possible to integrate the IED into a substation automation or monitoring
system or use the IED as a stand-alone multifunction unit.

It shall be possible to equip the IED with a HMI for local access of all
information.
A Restrained dual Bias operate characteristic shall be used and the highest phase
current in any line shall be utilized as bias current.
Charging current compensation for increased sensitivity for long lines and cables
shall be included.
The IED should be suitable for multiplexed, route switched or dedicated fibre
networks.
Two time synchronization methods shall be available, the echo-method when
channels with stable and equal delays in both directions are used and GPS to be
used in switched networks with unequal channel delays in both directions.





The communication channel shall be continuously monitored and an automatic
switchover to a redundant channel shall be possible.

IED shall be provided with programmable logic for tripping and indications as
well as a high number of logic blocks and timers for user adaptation.

For Line differential communication it shall be possible to select between a
master-master system or master slave system depending on the functional or
economical requirements. An automatic changeover to Master-slave
communication should take place if an interruption occurs in communication
channel in master-master communication system.
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
A backup high speed full scheme distance protection with at least three zones
should be possible to include in order to get fault clearance in case of
communication failure.It shall be possible to have the distance protection
continuously in operation or only released for operation at communication failure.
The distance Protection shall have characteristics that will give load encroachment
discrimination and load current compensation of the reactance line in the first
zone to avoid over reach. It should be possible to set the distance Protection zone
in forward, reverse or non directional mode. Each zone should have individual
resistive and reactive reach settings. Separate phase selection logic and automatic
switch onto fault logic should be included.

Disturbance recording, event recording shall be built in features and included in
the IED.

IED shall be provided with a front mounted HMI and front port for connection to
a Personal Computer.

The IED shall be provided with communication interface for connection to
Substation Automation system and substation monitoring system. IEC 61850-8-1
& IEC 60870-5-103 communication protocol shall be available. The IED shall
meet the IED 61850 standard in every respect and interoperability with other
manufactures IEDs and tools should be verified.

Power supply modules from 48V to 250V AC/DC shall be available.

It shall be possible to select different mounting alternatives such as rack, flush or
wall mounting. Depending of the required numbers of I/O modules in the IED 1/1
x 19”, ¾ x 19” and ½ x 19” cases shall be available.

GPS time synchronization module with GPS receiver used for time
synchronization shall be available.
28.03 Protection Scheme for 66kV lines
1. Numerical Distance protection scheme for 66KV Lines:
Numerical distance protection shall be suitable for use with permissive under reach and
over reach required. Relay shall have continuous self monitoring and diagnostic feature.
The detailed description of protection is given here under.
The numerical distance protection shall:
i.
Be suitable for one amp CT secondary and 110/√3V AC Potential from potential
transformer of 66 KV Bus.
ii.
Be static and modular in construction.
iii.
Have high speed switched distance relay for three phase systems to clear all type of line
faults within the set reach of the relay, under all operating conditions.
iv.
It should cover at least two line sections completely with 25% additional margin.
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v.
Measure all type of faults by switching over to the measuring elements. The reach of each
zone shall be independently and individually adjustable over wide range in suitable steps
of 1%. Memory circuits with defined characteristics shall be provided in all three phases
to ensure correct operation during close-up 3 phase faults and other adverse conditions.
vi.
The protection scheme shall be fast and first zone shall energize the circuit breaker trip
coil in about one and half cycle. The tripping time of the second and third zone should be
adjustable to any desired value through a separate timing unit.
vii.
Have stepped time distance characteristics and shall have at least two directional and one
non-directional independently variable time graded distance protection zones to cover two
adjacent line sections.
viii.
(a)
Three zones and one reverse zone of operation shall be available. The reach of the
relay for zones 1, 2 & 3 should be able to cover line lengths as per clause (iv)
above. The relay shall have an adjustable characteristics angle setting range of 3075 degree.
(b)
Be field selectable for various over reaching, under reaching setting and blocking/
inter tripping communication scheme.
(c)
Have mho/rectangular/polygonal/circular/oval/lens/quadrilateral characteristics
with a facility to set resistance and reactance independently to cater for arc
resistance on short lines and load discrimination for long lines.
ix.
Ensure that this long coverage is consistent with limitations imposed by heavy loading
and sound phase component of fault current.
x.
The scheme shall not become inoperative even under severe system fault condition near
the location of the relay when the potentials applied to the relay are very small. If
characteristics of starting relays are such that it cannot pick-up because of very low
infeed, under voltage relays may also be used as supplementary relays.
xi
Have facilities for offset features with adjustable 10-20% of zone -3 setting.
xii.
Have residual compensation variable up to 150%.
xiii.
Operate instantaneously when circuit breaker is closed to zero volt 3 phase fault.
xiv
Have a continuous current rating of two times the 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.
xv
Be selective between internal and external faults.
xvi
Include fuse failure protection which shall:
al) Monitor all the three fuses of VT circuit, and associated cable against open circuit.
a2) Inhibit trip circuits on operation and initiate annunciation.
a3) Have an operating time less than 7 milliseconds.
a4) Remain inoperative for system earth faults.
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a5) Be of solid state type.
xvii.
Have facility for under voltage and over voltage protection.
xviii. Have self-diagnostic feature.
xix.
Have facility for current & voltage circuit supervision.
xx.
Suitable number of potential free contacts (if required, multiplied through reed relays
only) be provided, on each distance scheme.
xxi.
Mutual compensation unit shall be provided such that healthy feeder protection shall not
mal-operate for faults in other lines of multi circuit lines. (This clause applicable for line
protection of 66KV lines of 220KV sub-stations only).
xxii.
A separate out of step or power swing blocking relay shall be included to prevent tripping
of the breaker during power swings and system disturbances. The breaker shall however
be caused to trip if the disturbance lasts for an interval of time equal to or greater than the
third zone time setting.
Nevertheless the impedance loci of the distance relays shall be such that they have
minimum tendency to operate on power swings caused by system disturbance.
xxiii. The relay shall have the following features either built-in or separately.
a) Weakend in feed.
b) Power swing blocking.
c) Broken conductor detection.
xxiv. All trip relays used in transmission lines protection scheme shall be of self/electrical reset
type depending on application requirement.
NOTE: Provision of optional features other than those indicated above may be indicated
separately. Provision may be made in the relay for updating these optional features at a
later date whenever required by KSPDCL.
2. Protection Scheme for 66kV Cables:
The Cable protection relays are required to protect the cable and clear the faults on cable
within shortest possible time with reliability, selectivity and full sensitivity to all type of
faults on lines. In case of 110kV & 66kV XLPE cables the current differential protection
will be used as Main protection.
Numerical Current Differential Protection Scheme:

The line Differential Protection IED (Intelligent Electronic Device) protection
relay should be Numerical with full compliance to IEC 61850 standards in every
respect and Interoperability with other manufacturers IEDs and tools should be
verified.

The IED shall be suitable for Protection, control and monitoring of overhead lines
and cables for all Voltage levels in solidly grounded or impedance grounded
networks.
Page 247 of 382

The protection unit should be based on Phase segregated Line differential
Principle and use.

Advanced and proven algorithms shall support user friendly Engineering tool and
Disturbance handling tool.

It should be possible to integrate Protection and control functionality for several
objects in the IED. The IED shall have complete functionality for single and multi
breaker arrangements with single or three phase tripping.

At least Four/Five independent parameter setting groups shall be included.

IED shall have extensive self supervision including analogue channels.

At new installations or at extensions and replacements in existing installations it
shall be possible to integrate the IED into a substation automation or monitoring
system or use the IED as a stand-alone multifunction unit.

It shall be possible to equip the IED with a HMI for local access of all
information.
A Restrained dual Bias operate characteristic shall be used and the highest phase
current in any line shall be utilized as bias current.
Charging current compensation for increased sensitivity for long lines and cables
shall be included.
The IED should be suitable for multiplexed, route switched or dedicated fibre
networks.
Two time synchronization methods shall be available, the echo-method when
channels with stable and equal delays in both directions are used and GPS to be
used in switched networks with unequal channel delays in both directions.





The communication channel shall be continuously monitored and an automatic
switchover to a redundant channel shall be possible.

IED shall be provided with programmable logic for tripping and indications as
well as a high number of logic blocks and timers for user adaptation.

For Line differential communication it shall be possible to select between a
master-master system or master slave system depending on the functional or
economical requirements. An automatic changeover to Master-slave
communication should take place if an interruption occurs in communication
channel in master-master communication system.

A backup high speed full scheme distance protection with at least three zones
should be possible to include in order to get fault clearance in case of
communication failure, it shall be possible to have the distance protection
continuously in operation or only released for operation at communication failure.
The distance Protection shall have characteristics that will give load encroachment
discrimination and load current compensation of the reactance line in the first
zone to avoid over reach. It should be possible to set the distance Protection zone
in forward, reverse or non directional mode. Each zone should have individual
resistive and reactive reach settings. Separate phase selection logic and automatic
switch onto fault logic should be included.

Disturbance recording, event recording shall be built in features and included in
the IED.
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
IED shall be provided with a front mounted HMI and front port for connection to
a Personal Computer.

The IED shall be provided with communication interface for connection to
Substation Automation system and substation monitoring system. IEC 61850-8-1
& IEC 60870-5-103 communication protocol shall be available. The IED shall
meet the IED 61850 standard in every respect and interoperability with other
manufactures IEDs and tools should be verified.

Power supply modules from 48V to 250V AC/DC shall be available.

It shall be possible to select different mounting alternatives such as rack, flush or
wall mounting. Depending of the required numbers of I/O modules in the IED 1/1
x 19”, ¾ x 19” and ½ x 19” cases shall be available.

GPS time synchronization module with GPS receiver used for time
synchronization shall be available.
28.04. Protection scheme for 220/66/11KV Power Transformer Numerical Differential
Protection.
A) Numerical Differential Relay
a)
It shall consist of fully numerical/digital type, variable percentage, biased type
differential relay. It shall be triple pole type, with faulty phase identification/
indication.
b)
The percentage bias shall be low near rated current, sufficient to allow for OLTC
tap variation and CT errors, but shall increase automatically for severe through
faults to ensure stability even under CT saturation errors. It shall offer low burden
to CTs.
c)
The relays shall be suitable for rated current of 1 Amp and have three
instantaneous high set over current units.
d)
The relay shall remain stable under initial magnetizing inrush current, sympathetic
inrush when adjacent transformers are charged, through fault stability and over
fluxing conditions. The relay shall have second harmonic restraint feature.
e)
The relay shall be very fast in operation with an operating time not greater than 30
milli seconds at 5 times setting.
f)
The relay shall be accompanied by interposing auxiliary current transformers for
angle and ratio correction or have internal features in the relay to take care of
angle and ratio corrections.
g)
The bias setting of the relay shall be adjustable with range of 20 – 50 %.
h)
The relay shall have a disturbance feature to record graphic form of instantaneous
values of current in all two/three winding transformer in 6 analog channels, during
faults and disturbances for pre fault and post fault period. The disturbance
recorder shall have the facility to record the following external digital channel
signals apart from the digital signals pertaining to differential relay.
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i)
ii)
iii)
iv)
REF Protection operated.
HV & LV breaker status.
Bucholtz/OLTC surge relay alarm / trip.
WTI/OTI/PRD alarm/trip of transformer necessary hardware and
software for down loading the data captured by disturbance
recorder to personal computer available in the sub-station
automation system shall be included in the scope.
Note: Disturbance recorder shall be provided only for 100MVA/150MVA-220/66/11KV
Transformer/100MVA 220/110/11KV Transformer.
B)
Restricted Earth fault Protection:
The restricted earth fault protection shall
C)
D)
a)
Be single pole static/Numerical type.
b)
Be of high speed, instantaneous current operated and high impedance type.
c)
Have a current setting range of 10-40% of 1 Amp.
d)
Be tuned to the system frequency. It shall have high rejection of DC component of
fault current.
e)
Have suitable non-linear resistor to limit the peak voltage to 1000 volts.
Over fluxing protection:
a)
Over flux protection relays shall be provided for HV side of 220/110/11KV
transformer / 220/110/66KV transformer and shall be of static type.
b)
The relay shall monitor the voltage (volts)/frequency (Hertz) and shall have a
continuous adjustable setting between 100 to 130% of nominal volts/ hertz ratio.
c)
Relay shall have inverse time characteristic compatible with transformer over
fluxing.
d)
The relay shall be energized by two separate time delay relays to work in two
stages for a time delayed alarm and time delayed trip. The variable time setting of
alarm shall be in the range of 2-5 secs and that for trip in the range of 5-30 secs.
Relay shall have a high resetting ration of 98% or better.
Transformer overload relay:
Transformer overload relay shall be provided with two stages. One stage as non-trip
alarm & the second stage is to extend trip command to breakers to have required load
relief.
E)
Auxiliary relay:
The transformer protection panel shall be wired for buchholz alarm and trip, oil
temperature alarm and low oil level. The auxiliary flag relays shall be provided for
contact multiplication wherever they are needed for buchholz alarm/trip, winding
temperature alarm/trip, oil temperature alarm/trip, pressure relief device trip, oil surge
relay trip. Current operated relays shall be preferred to voltage operated relays.
Page 250 of 382
Note: REFT, Over flux relay & auxiliary relays shall be separately provided externally and shall
not be inbuilt features of differential relay.
28.05 BACK UP PROTECTION:
28.05A) Back-up Directional Over Current & Earth fault protection scheme for 66kV Lines &
UG Cable :
a) Shall have three over current and one earth fault element (s) which shall be either
independent or composite unit (s).
b)
Shall be of Numerical type.
c)
Shall include necessary VT fuse failure relays for alarm purposes.
d)
Shall (for over current protection)

have IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times
setting

have a variable setting range of 50-200% of rated current.

have a characteristic angle of 30/45 degree lead.

include hand reset flag indicators or LEDs.
e) Shall (for earth fault protection)

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 lead.

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.
i.
The operating coil of the DEFR shall be connected in the residual circuit of the star
connection of the line CT's. The polarizing voltage for DEFR shall be obtained from the
open delta connection of the VT secondary circuit.
ii.
The backup protection as aforesaid shall operate independently of the main protection
distance relay, to provide protection for the line section, in the event of failure of the
distance relays, to clear the faulty section or failure of the main protection scheme relay.
iii.
It should be possible to convert the directional relays to non-directional type by suitable
means.
28.05-B Numerical Back-up Over Current & Earth fault protection scheme with high set feature
for Power Transformer:
b)
Shall have three over current and one earth fault element (s) which shall be either
independent or composite unit (s).
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c)
The scheme shall include necessary VT fuse failure relays for alarm purposes.
d)
Over current relay shall




e)
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 each high set instantaneous unit of continuously variable
setting range of 500-2000% of rated current.
have a characteristic angle of 30/45 degree lead.
include hand reset flag indicators or LEDs.
Earth fault relay shall





have directional IDMT characteristic with a definite minimum time of 3.0 seconds
at 10 times setting and have a variable setting range of 20-80% of rated current.
have low transient, over each high set instantaneous unit of continuously variable
setting range 200-800% of rated current.
have a characteristic angle of 45/60 degree lead.
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.
i.
The backup protection as aforesaid shall operate independently of the main protection
differential relay, to provide protection for the transformer section, in the event of failure
of the differential relays, to clear the faulty section or failure of the main protection
scheme relay.
ii.
It should be possible to convert the directional relays to non-directional type by suitable
means.
28.06 Local Breaker Back up protection:
a)
Each breaker shall be provided with breaker fail protection to overcome failure of breaker
mechanism. In such a case adjacent circuit breaker and/or remote end breaker are required
to be tripped.
b)
The relay shall be based on current principle and be set to operate after main protection
operates and CB has not opened out, with some safety margin.
c)
It shall have the following features:
i)
It shall be triple pole type and suitable for station DC supply. It shall have three
over current elements. Each element shall be arranged to get individual initiation
from the corresponding phase of line/transformer protection.
ii)
Static measuring element with short consistent pick up time of approximately 4 to
5 ms and short setting time.
iii)
It shall have an operating time of less than 15 milliseconds and a resetting time of
less than 15 milliseconds.
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iv)
It shall have a setting range of 5 - 80% of rated current and have a continuous
thermal withstand of two times rated current irrespective of the setting.
v)
It shall have a timer with continuously adjustable setting range of 0.1 - 1 seconds.
vi)
No power consumption from DC auxiliary circuit during normal service.
vii)
It shall trip through bus bar protection scheme and lock out all the local breakers.
Simultaneously a direct trip signal shall be sent to remote end circuit breaker and
lock out its auto re-closing features.
It shall be provided with necessary auxiliary relays to make comprehensive schemes.
Note: LBB relay as inbuilt function of Main-I/Main-II distance relay is also acceptable.
28.07 Bus Coupler Panel:
a)
Bus coupler is used for transferring circuits or feeder or transformer from one bus to
another. In case of outage of circuit breaker in respect of the line/transformer circuits, the
bus coupler breaker is used for the same.
b)
It is proposed to provide transfer trip protection scheme to all the line / transformers, to
facilitate transfer of open and close commands from line/ transformer panels to the bus
coupler panel, when one of the lines/transformers CB is faulty.
c)
The control panel wiring of all feeders and transformers shall include the above facility.
d)
Bus coupler shall be suitable for bi-directional power flow.
e)
Two numbers of non-directional over current relays and one number non-directional earth
fault relay shall be provided when the breaker is used as bus coupler.
28.08 Tripping Relay:
Each panel shall be provided with instantaneous DC operated tripping relay. The relay
shall have adequate number of normally open and normally close contacts to meet the
requirement of scheme, other functions like auto re-closing relay, LBB relay, fault locator
disturbance recorder, event logger wherever applicable. The maximum operating time of
the relay shall not exceed ten milliseconds and reset within 20 milliseconds. Relay shall
be provided with operation indicator for each element coil.
28.09 Tripping Circuit Supervision Relay.
a)
Each trip coil of circuit breaker shall be provided with an independent trip circuit
supervision relay. These relays shall be mounted in the control panel associated with the
circuit breakers. Two trip coils will be provided in each pole of 220 KV CB. However, in
respect of 66KV CB there will be only 2 nos. of trip coils for all the three poles of CB.
b)
These relays shall monitor the healthiness of each phase of the trip circuit while the
breaker is in open or closed position and give an alarm for the loss of DC supply or for
faults in the trip coil or for faults in the trip circuit such as leads, auxiliary contacts. The
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relay shall have a time delay on drop off of not less than 200 milliseconds and be
provided with operation indication.
c)
Trip supervision relay shall be located in the panel.
d)
The relay shall have adequate contacts for providing connection to alarm and event
logger.
28.10 DC Supply monitoring relay:
The relay shall be capable of monitoring the failure of DC supply to which it is
connected. Separate DC supply monitoring relay shall be provided for DC main circuit,
control circuit of tripping relay and protection circuit of each panel. It shall have adequate
potential free contact to meet the scheme requirement. The relay shall have a time delay
on drop off of not less than 100msecs and be provided with operation indicator/flag.
Indicating lamp and separate alarm for DC fail shall be provided and shall be operated by
230V AC single phase supply. Push buttons for test and accept shall be provided.
28.11 Voltage Selection Relay:
The relay shall operate from auxiliary DC supply voltage and it shall have sufficient
number of contacts for extending bus VT supply voltage to relays and meters depending
on the bus to which that particular line is connected.
Under no circumstances there shall be either paralleling of two VT supplies through
voltage selection relay or reserve charging of VT secondaries. The relay design shall be
such that operation of the selector relay used will open the operating circuit of the other
relay.
28.12 INTERLOCKING:
The control circuits for operation of the disconnecting switches in the line shall be so
designed that the following interlocking features are provided for usual conditions of
operation and all the necessary devices, auxiliary relays shall be included in the supply of
control panels.
The other interlocks required are (a) it should not be possible to operate either of the bus
selector isolators unless the other bus selector isolator, bypass isolator and line breaker is
in de-energized condition. (b) it should not be possible to operate the by-pass isolator
when the main breaker and the breaker disconnect isolators (on either side of the breaker)
all are in closed position. (c) during change over from the line breaker to bus coupler
control, both breakers will be closed and it will be necessary to close both the bus selector
isolators for making the change over. The interlock required is that it should not be
possible to operate either of the bus selector isolators when the line is in service, unless
the bus coupler is also closed. (d) If the earth switch of the line isolator is connected to
ground, it shall not be possible to close the bus isolator, by-pass isolator or the line
isolator or the breaker.
28.13 220KV BUS BAR PROTECTION:
a)
The bus bar protection shall be of numerical and modular construction.
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b)
The bus bar protection scheme offered shall be very fast acting and have
maximum operating time up to trip impulse to trip relay, for all types of faults of
15 millisecond at 5 times setting value.
c)
The scheme shall be based on the percentage-biased differential and low
impedance, circulating current principle with a slope varying from 50 to 85%. In
order to guard against mal-operations due to any spurious operation of the basic
differential relay, a check feature shall also be incorporated. This check feature
shall be built in feature of the relay. The check feature may be high speed over
current starting relay normally set to coincide with the largest line CT primary
current rating and high speed 3 phase under voltage relay connected to the bus
VTs.
d)
The bus bar protection scheme shall not give rise to false operation during normal
load flow in bus bar. The bus bars protection shall be stable for heavy through
faults condition upto maximum 40KA fault level for 220KV and shall operate
correctly positively for all faults within the protected zone(s) even under
conditions of CT saturation. For every severe internal faults the relay shall operate
and seal-in within the above time i.e. the relays decision shall be made before CT
saturation takes place.
e)
The bus bar protection scheme offered shall be adaptable to different CT ratios in
different bays in any particular substation. The scheme shall allow the use of
multi-tap interposing CTs for ratio matching purposes. It should be possible to
extend the scheme for any limits on the number of additional bays or on the
increasing fault level of the bus. The scheme offered shall include the cost of
ICT‟s required for this purpose.
f)
i)
The scheme shall be single zone protection. The entire bus consisting of
two sections shall be treated as single zone.
ii)
The scheme shall be provided with independent zones of protection for
each bus of double bus with zone indication. (two zone protection) This
scheme shall be provided wherever called for. However, during bypassing
of line transformer breaker through bus coupler, two zone protection will
be converted to single zone protection.
g)
The protection scheme shall provide continuous supervision for the various CT
secondary pilot wires. In case of any open circuiting of CT secondary the relevant
zone of protection shall be shorted and an appropriate alarm initiated.
h)
The bus bar protection scheme shall include continuous DC supply supervision.
i)
It shall include high speed tripping relays conforming to clause 28.08 for each
feeder / transformer circuits including future ones.
j)
As an optional feature the scheme shall provide facilities for built-in automatic
testing at regular intervals. The automatic testing feature shall incorporate
injection of currents through each input circuit of the relay and shall check for
basic operation as well as stability against external faults. The total time taken for
automatic testing shall be less than 30 milliseconds, during which time the
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tripping shall be blocked. In case of failure of any zone the relevant zone shall be
blocked and an alarm initiated.
k)
In case of sub-stations where the C&R Panels are located in the switchyard AC
Kiosk, distributed type bus bar protection shall be provided.
l)
Shall include trip relays, CT switching relays(if applicable), auxiliary CTs (if
applicable) as well as additional power supply module, input modules etc as may
be required to provide a bus bar protection scheme for the complete bus
arrangement ie., for all the bays or breakers including future bays as per the single
line diagram and also for additional 1 No. transformer of the same rating and also
4 numbers of 220kV future lines. In case of distributed bus bar protection, the bay
units for future bays may be installed in a separate panel & same shall be located
where bus bar protection panel is installed.
m)
It shall have 'CT' selection incomplete alarm wherever CT switching is involved.
o)
If CT switching relays are provided then the switching relays shall be provided
only after an ICT. Switching of main CT secondaries shall not be carried out.
p)
Include protection “IN/OUT” switch for each zone.
28.14 Time Synchronization Equipment:
a) The Time synchronization equipment shall receive the co-ordinated universal Time
(UTC) transmitted through Geo positioning satellite system (GPS) and synchronize
equipments to the Indian standard time in a sub-station.
b) Time synchronization equipment shall include antenna, all special cables and
processing equipment etc.
c) It shall be compatible for synchronization of Event Loggers, Disturbance recorders
and SCADA at a sub-station through individual port or through Ethernet realized
through optic fibre bus.
d) Equipment shall operate up to the ambient temperature of 50 degree centigrade and
100% humidity.
e) The synchronization equipment shall have 2 micro second accuracy, Equipment shall
give real time corresponding to IST (taking into consideration all factors like voltage,
& temperature variations, propagation & processing delays etc).
f) Equipment shall meet the requirement of IEC 60255 for storage & operation.
g) The system shall be able to track the satellites to ensure no interruption of
synchronization signal.
h) The output signal from each port shall be programmable at site for either one hour,
half hour, minute or second pulse, as per requirement.
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i) The equipment offered shall have six (6) output ports. Various combinations of
output ports shall be selected by the customer, during detailed engineering, from the
following.

Voltage signal: Normally 0-5V with 50milli seconds minimum pulse duration. In
case any other voltage signal required, it shall be decided during detailed
engineering.

Potential free contact (minimum pulse duration of 50 milli seconds).

IRIG-B

RS232C/RS 485
j) The equipment shall have a periodic time correction facility of one second periodicity
k) Time synchronization equipment shall be suitable to operate from 220V DC or 110V
DC as available at sub-station.
l) 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.
28.15 Rely Test Kit
One relay test kit shall comprise of the following equipment as detailed here under:
3 sets Relay tools kits
2 Nos. Test plugs
1 No. Special type test plugs for using with modular type cases (if applicable).
28.16 VOID
29.00 PROTECTION PHILOSOPHY:
220kV substations are provided with dual DC source. The Main-1 & Main- II distance
protection are to be connected to different DC sources ie source -1 and source -2. The trip
coils TC1 & TC2 of circuit breakers are also to be energized by different DC sources ie
source -1 & source-2.
A)
220 KV Line protection
Carrier aided, high speed, numerical distance scheme (with fault locator, auto re-close,
disturbance records and event recorder) as Main-I & Main-II protection. The MainIIprotection shall operate independent of Main-I protection. In addition to this if cable is
used for lines, line differential protection is used as Main- I and Main-II–protection.
The voltage source from three nos. of C.V.T. provided for each line shall be used for line
charged indication, auto re-close and synchronization etc., The voltage source for
protection and meter circuits of the line feeder will be from the selected bus/line CVT.
Provision can be made in the panel with change over switch to transfer potential to bus
VTs, in case of failure of CVT.
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B)
66 KV LINE PROTECTION
Numerical distance scheme as principal protection and directional over current /
directional earth fault numerical relays as back-up protection. The back-up protection
shall operate independent of primary protection. In addition to this, if cable is used for
lines, line differential protection is used as Main protection and directional over
current/directional earth fault relays as back up protection.
The voltage source for protection and meter circuits of the line feeder will be from the bus
VTs.
a)
For 220KV sub-stations.
The voltage source from line CVTshall be used for line charged indication and
synchronization etc.The voltage source for line feeder for protection circuits shall
be from selected line CVT/Bus VT and for metering circuits will be from the bus
V.T‟s.
b)
For 66 KV sub-stations:
The voltage source for protection and metering circuits of the line feeder will be
from Bus V.T‟s
C)
Power Transformer Protection:
The protection scheme should trip the circuit breaker on HV and MV/ LV side of
transformer for any fault in the transformer.
D)
a)
The differential protection scheme and REF as principle protection.
b)
The directional numerical OCR / EFR provided on HV side and DOCR/DEFR
provided on MV/LV side shall act as back up protection.
c)
Three number of circulating current relay for protection of 11kV Tertiary winding
in case of 220/66/11KV, 150MVA Transformer provided.
d)
The trip impulses received from Buchholz relay, winding temperature relay,
pressure relief device, oil surge relay etc., provided by the transformer
manufacturer, shall trip the breaker through an auxiliary relay.
e)
The necessary matching transformers required for the protection scheme shall be
supplied by the bidder and is deemed to be part of differential protection.
f)
The back up protection shall operate independent of primary protection.
Bus Bar Protection:
a)
The 220KV bus bars shall be protected by a high speed circulating current /
differential protection.
b)
The relays shall be of numerical design and the scheme shall cover all the 220KV
Bus and feeder circuits.
30.00 Co-ordination of Drawings of associated equipments of other manufacturers:
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1.
The purchaser intends to procure all outdoor equipments associated with these
panels from other manufacturers. The supplier is therefore required to co-ordinate
the control and wiring schematics of these panels with control and wiring
schematic of the outdoor equipment manufacturer.
2.
The purchaser will intimate the supplier the details of the outdoor equipments
manufacturers on whom purchaser orders have been placed for the supply of these
equipments along with such relevant details such as P.O. No. and date, delivery
period, and all other technical details such as rating data, wiring diagrams etc. The
supplier shall co-ordinate these diagrams with that of the associated relay and
protection panels, and shall also seek such clarifications as are necessary from
these manufacturers under intimation to the purchaser.
3.
The purchaser will assist and or furnish the supplier with all relevant data as are
necessary for completeness of co-ordination of the wiring diagrams and
interlocking of equipment circuits.
31.00 DRAWINGS AND LITERATURES:
31.01 Tender drawings and literatures:
The following drawings and literatures shall be submitted along with tender documents.
a)
Principal layout drawings of the SIMPLEX Relay and protection with disposition
of meters and control switches, relays. These layout drawings shall be for the
following views:
i.
ii.
Front face of panel.
Inside view of panel.
b)
Illustrated literature with photographs of similar panels supplied by the
manufacturer.
c)
Pictorial and sectional views of control switches, test terminal blocks, indicating
instruments, exploded views of draw out type instruments etc.,
d)
Printed copies of illustrated, literature, general technical data, performance
application, and specifications of relays, fault locators, etc.,
e)
Elementary schematic wiring diagrams of the various metering and protective
schemes.
31.02 Contract Drawing:
In the event of an order, the supplier shall submit drawings, GTP and type test reports in
triplicate for approval of the purchaser, prior to manufacture. After the drawings are
approved six copies of each of the drawings printed on 90 GSM paper shall be supplied
for immediate use.
The successful bidder should forward the drawings as follows.
Page 259 of 382
a)
One set of reproducible, originals and 12 sets of copies of all approved drawings
along with 12 sets of literature commissioning and maintenance manuals to the
Chief Engineer, Electy., Tendering & Procurement, KSPDCL, Kaveri Bhavan,
Bangalore -560 009.
b)
Three sets of copies of all approved drawings along with three sets of literature
and manuals to each of the consignee.
c)
Non supply or part supply of drawings, literature and manual will be deemed as
incomplete supply of equipment.
The contract drawings shall cover the following
a)
Principal layout drawing as per clause No. 31.01 (a).
b)
Details of construction and dimensions of the cubicle and complete switch board.
c)
Foundation drawings indicating the cable entries and trenches etc.
d)
Elementary diagrams of all controls, metering, protection, annunciation and other
circuits. All devices shall be numbered according to ASA code.
e)
Cabling and wiring diagram of the front and rear cubicles and interconnections
between them. Ferrule numbers device members, grouping for cable take offs etc.,
shall be distinctly shown.
f)
Inter-connection diagram between switch board and switchgear equipment, power
transformers, instrument transformers and other associated equipment.
g)
Dimensional outline, drilling diagram and special mounting arrangement, if any,
of each type of the various devices on the switch board.
h)
Individual internal wiring diagram of all devices and elementary wiring diagrams
or relays for internal wiring.
i)
Construction details of the switches, terminal blocks and test blocks etc.
31.03 LITERATURE:
In the event of an order, seven copies of each set of the following literatures shall be
supplied.
a)
Literature describing construction, operation, testing, calibration, adjustment,
rating, specifications, setting details of all the protective and auxiliary relays and
control switches.
b)
Literature giving rated data, details of adjustments for calibration for the
indicating instruments and integrating instruments.
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c)
List of spare parts, identification number from removable parts of relays,
instruments and switches etc., with the help of which the purchaser will be able to
procure spare parts from the supplier at any subsequent time.
d)
Performance application of relays.
e)
Detailed internal drawings of all units / schematic diagrams of all, PCB's of the
relays, reference voltages at convenient test points, functional description,
operational details. This is essential for trouble shooting of the relays.
f)
The literature shall contain wave forms / voltages etc at selected points for easy
identification of faulty units with in the modular unit.
32.00 TESTS, TEST CERTIFICATES AND INSPECTION:
32.01 The following routine tests shall be carried out on the panels at the factory:
a)
Checking of overall dimensions, thickness of panel sheet and paint film.
b)
Checking wiring and continuity of circuits.
c)
One minute HV withstand test – All equipment on panel and internal wiring shall
be tested to withstand a voltage of 2KV to earth for one minute.
d)
Insulation resistance of the complete wiring, circuit by circuit with all equipment
mounted on the panel.
e)
Verification of degree of protection as per IS –2147
32.02 All relays shall be subject to type tests and routine tests as per relevant standards, that is
IS - 3231 or IEC - 60255.
32.03 All other components including indicating instruments and accessories installed within
the panel shall be subject to type tests, routine tests and acceptance tests according to the
standards to which they conform.
32.04 All routine and acceptance tests shall be conducted in the presence of the purchaser‟s
representatives. No material shall be dispatched unless the purchaser communicates his
written approval to these test certificates.
32.05 Type Tests Reports:
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 III (not
applicable for electromechanical relays)
c)
Fast transient test as per IEC 1000-4 level III (not applicable for
electromechanical relays).
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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 disturbance recorder and event logger only performance tests are intended
under this item.
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).
32.06 Steady state & dynamic characteristics test reports on the distance protection relays as
type test, shall be based on general guidelines specified CIGRE Committee 34 report on
evaluation of characteristics and performance of power system protection relays and
protective system A on simulator/network analyzer /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.
33.00 Spares
33.01 The tenderer shall recommend in his offer a set of spares as are required for a period of 5
(five) years in respect of relays and instruments quoted. All like spare parts shall be
interchangeable with respect to each other and shall therefore be suitable for the
parts/components that they would replace.
33.02. The tenderer shall indicate the life expectancy or shelf life of all such spares and their
recommended method of storage.
33.03 Itemized unit price rate for each component shall be furnished in the schedule of prices in
tender proposal sheets. The purchaser reserves the right to order for the spares which in
his assessment are actually required.
34.00 MAINTENANCE TOOLS AND EQUIPMENT:
34.01 a)
b)
34.02 a)
The tenderer shall offer in his tender a set of special tools as are necessary for
routine maintenance and testing of the equipment. These shall include amongst
others relay test jacks, patch cords, etc.
The tenderer is required to supply these tools arranged neatly in wooden boxes.
The tenderer shall offer in his tender, instruments and equipment‟s for conducting
tests on relays and instruments. The relay testing kits shall be suitable for
conducting dynamic tests on the relays to ascertain their characteristics as also to
conduct periodical calibration and maintenance tests.
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b)
The testing kits, shall be self contained compact portable units with built in power
supply units and timers. If the test equipment contains more than one unit then
no extensive inter unit wiring shall be involved at site. The kits shall be capable
of being operated off the auxiliary AC & DC power supplies specified in this
tender document.
34.03 Itemized unit price rate of each such tool/equipment shall be furnished in the schedule of
prices in tender proposal sheets.
35.00 QUALITY ASSURANCE PLAN:
The tenderer shall invariably furnish the following information along with his offer
failing which his offer shall be liable for rejection.
a)
b)
c)
d)
e)
Names of sub-suppliers of individual accessories.
Information and copies of test certificates in respect of bought out accessories.
List of manufacturing facilities available.
List of areas in manufacturing process where stage inspections are carried out for
quality assurance and details of such tests and inspection.
Type test certificates not older than three years as on the previous date of tender
opening.
35.01 The supplier shall within 30 days of placement of order, submit following information to the
purchaser.
i)
ii)
iii)
List of bought out accessories and the names of sub-suppliers selected from those
furnished along with offer.
Type test certificates of the bought out accessories.
Quality assurance plan (QAP) with hold points for purchaser‟s inspection. The quality
assurance plan and hold points shall be discussed between the purchaser and supplier
before the QAP is finalised.
35.02 The supplier shall submit the routine test certificates of bought out items, at the time of routine
testing of the fully assembled panel.
36.00 MINIMUM EXPERIENCE FOR QUALIFYING AS A TENDERER :
i.
Tenderers shall have a minimum experience of five years in the design, manufacture,
testing and commissioning of Control and Relay panels, similar to the type specified in
the present enquiry. At least 50% of the quantity of similar type of main protection relays
i.e., distance and differential, over fluxing, REF relays and Bus bar protection relays
called for in the present enquiry shall be in successful operation for a minimum period of
two years. The tenderer shall furnish performance certificate for satisfactory operation of
similar main protection relays for a minimum period of two years. The tenderer shall
furnish the type test certificates for tests conducted on a similar relay not later than three
years from the previous date of bid opening.
ii.
The tenderer should be the original manufacturer of at least 50% of the total relay types
mentioned, viz., distance relays, auto re-close relays, differential relays and back up
protection relays, High speed trip relays, LBB, Bus bar protection relays, over-fluxing
and REF relays.
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iii.
The purchaser however reserves the right to waive the minimum experience condition
stipulated in clause 36.00 (i) in case of Firm having collaboration with well experienced
Firms. The experience of the collaborating Firms in the manufacture of similar type of
main protection relays shall be not less than five years. The waiving of minimum
experience condition will be considered by the purchaser only on furnishing the
performance guarantee for the main protection relays manufactured by the collaborating
Firms.
37.00 PERFORMANCE GUARANTEE :
The control and relay panels along with the main protection relays offered shall be guaranteed for
satisfactory performance for a period of 24 months from the date of satisfactory commissioning
of C & R Panels. The equipment/relays if found defective/failed within the above guarantee
period shall be replaced or repaired by the supplier free of cost within one month from receipt of
intimation. If the defective/failed equipments/relays are not replaced/repaired as per the above
guarantee clause, the corporation shall recover an equivalent amount plus 15% supervision
charges from any of the supplier‟s bills.
38.0
TRAINING TO BOARD ENGINEERS :
38.01 The purchaser requires that training be imparted to eight Engineers of the Purchaser‟s
organization in the testing, commissioning, calibration, adjustment, trouble shooting and
attending to routing defects, mal-operations in the relays and instruments supplied. Such training
shall be imparted at the supplier‟s works for a period of not less than 2 (two) weeks and shall be
imparted free of cost. The to and fro travel expenses of these Engineers will be borne by the
purchaser. However boarding, lodging and other incidental expenses related there to shall be
borne by the supplier.
38.02 In case training is to be imparted at the works of the supplier‟s collaborators. Then the same shall
be arranged for by the supplier.
38.03 The training shall be imparted before dispatch of the equipment.
39.0
DESPATCH :
39.01 The control and relay panels shall be dispatched in suitable crates with all instruments, relays,
switches and other devices mounted in position and wired. Instruments which cannot be sent in
this manner may be separately dispatched.
39.02 The detailed dispatch schedule for each control & relay panel board shall be supplied well in
advance. In the schedule, items accompanying the control panel items separately despatched in
crates and items for which only drilling and wiring is provided shall be separately listed.
39.03 The packing list for each shipment shall indicate complete details of equipment being shipped to
enable to consignee to identify the parts and to ensure that no equipment stated to have been
shipped has either lost in transit or if damaged, to initiate replacement proceedings and also to
enable the insurance claims to be preferred. If the invoice does not contain full details, if any part
not specifically mentioned in the packing list is missing in transit the supplier shall be
responsible for supply of such parts to the purchaser without any extra cost.
40.0
DEVIATION FROM TECHNICAL SPECIFICATIONS :
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40.01 The tender can suggest modification in the protective scheme detailed in the specification if it
improves the discrimination selectivity and overall performance of the protection scheme, clearly
giving all the details.
41.0
SCHEDULE OF REQUIREMENTS AND DELIVERY :
41.01 The schedule of requirement of components is detailed in annexure. The tenderer should
furnish the breakup prices for various relays and meters for future addition and deletion.
41.02 Station wise schedule of requirement along with the desired delivery is detailed in Annexure. In
case of new stations the basis of comparison will be on package basis i.e. on the complete
requirement of a station.
41.03 The purchaser may ask for addition or deletion of some items during the time of verification of
drawings. The Firm shall agree to supply any additions(at extra cost, if any).
41.04 In case of new 220KV stations space constraints may result in the layout being modified into
single bus both on 220 KV & 110/66 KV sides. In this event the bus coupler panel will be deleted
from requirement.
41.05 In view of 41.04 and also due to other reasons, there may be change in the components of the
panels which will be decided at the time of approval of drawings. In the event of difference of
components between purchase order and approved drawing, payment will be made as per
approved drawing.
42.00 SCHEDULE OF PRICE:
42.01 The tenderer should furnish the schedule of prices for each type of panel station wise. The
supplies should be complete in all respects as stipulated in annexure and preference will be given
to tenederers who confirm that this delivery can be met. The tenderer should indicate in this offer
the breakup of time required for (1) collecting design parameters from purchaser, (2) Designing
of panels and preparation of detailed drawings, (3) Approval of drawing, (4) fabrication of panels
and testing and (5) transportation to site. This information will be used for the purpose of
calculating penalty etc.
42.02 The tenderer shall furnish the breakup price for each of the component of panels. Decision in
regard to adding or deleting any of the component rests with the purchaser.
43.0
GUARANTEED TECHNICAL PARTICULARS:
43.01 The tenderer should furnish the guaranteed technical particulars as called for in Annexure, failing
which the offer is liable to be overlooked.
43.02 Guaranteed technical particulars for panels for different voltage class shall be
furnished separately.
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SECTION -2 - SUBSTATION AUTOMATION SYSTEM
1.0
GENERAL:
1.1
The substation automation system shall be offered from a manufacturer who must have
designed, manufactured, tested, installed and commissioned Substation Automation
System which must be in satisfactory operation on 220 KV system or higher for at least 2
(two) years as on the date of bid opening.
1.2
The Substation Automation System (SAS) shall be installed to control and monitor all the
substation equipments from Remote Control Centre (RCC) as well as from local control
centre.
The SAS shall contain the following main functional parts:

Bay control Intelligence Electronic Devices (IEDs) for control & monitoring.

Station Human Machine Interface (HMI)

Redundant managed switched Ethernet Local Area Network communication
infrastructure with hot standby.

Gateway for remote control via industrial grade hardware (to RCC) through IEC
60870-5-104 protocol.

Gateway for remote supervisory control (to RSCC), the gateway should be able to
communicate with RSCC on IEC 60870-5-104 protocol. The specific protocol to
be implemented shall be handed over to successful bidder. It shall be bidders
responsibility to integrate his offered system with existing RSCC system for
exchange of desired data. The exact IO point shall be decided during detailed
engineering.

Remote HMI.

Peripheral equipment like printers, display units, key boards, Mouse etc.
1.3
It shall enable local station control via a PC by means of human machine interface (HMI)
and control software package, which shall contain an extensive range of Supervisory
Control And Data Acquisition (SCADA) functions.
1.4
It shall include communication gateway, intelligent electronic devices (IED) for bay
control and inter IED communication infrastructure. An architecture drawing for SAS is
enclosed.
1.5
The communication gateway shall facilitate the information flow with remote control
centers. The bay level intelligent electronic devices (IED) for protection and control shall
provide the direct connection to the switchgear without the need of interposing
components and perform control, protection and monitoring functions.
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2.0
SYSTEM DESIGN:
2.1
General system design.
The Substation Automation System (SAS) shall be suitable for operation and monitoring
of the complete substation including future extensions as given in Section-Project.
The system shall be of the state-of-the art suitable for operation under electrical
environment present in Extra high voltage substations follow the latest engineering
practice, ensure long-term compatibility requirements and continuity of equipment supply
and the safety of the operating staff.
The offered SAS shall support remote control and monitoring from Remote Control
centers via gateways.
The system shall be designed such that personnel without any background knowledge in
Microprocessor-based technology are able to operate the system. The operator interface
shall be intuitive such that operating personnel shall be able to operate the system easily
after having received some basic training.
The system shall incorporate the control, monitoring and protection functions specified,
self-monitoring, signaling and testing facilities, measuring as well as memory functions,
event recording and evaluation of disturbance records.
Maintenance, modification or extension of components may not cause a shutdown of the
whole substation automation system. Self-monitoring of components, modules and
communication shall be incorporated to increase the availability and the reliability of the
equipment and minimize maintenance.
Bidder shall provide the Bay control IED (a bay comprises of one circuit breaker and
associated disconnect or, earth switches and instrument transformer in the simplex relay
and protection panels itself (described in other sections of technical specifications)
located in control room. Station HMI is also located in Control Room for overall
optimization in respect of cabling.
2.2
System Architecture.
The SAS shall be based on a decentralized architecture and on a concept of bay-oriented,
distributed intelligence.
Functions shall be decentralized, object-oriented and located as close as possible to the
process.
The main process information of the station shall be stored in distributed databases. The
typical SAS architecture shall be structured in two levels, i.e., in a station and a bay level.
At bay level, the IEDs shall provide all bay level functions regarding control, monitoring
and protection, inputs for status indication and outputs for commands. The IEDs should
be directly connected to the switchgear without any need for additional interposition or
transducers.
Each bay control IED shall be independent from each other and its functioning shall not
be affected by any fault occurring in any of the other bay control units of the station.
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The data exchange between the electronic devices on bay and station level shall take
place via the communication infrastructure. This shall be realized using fibre-optic
cables, thereby guaranteeing disturbance free communication. The fibre optic cables
shall be run in G.I. conduit pipes. Data exchange is to be realised using IEC-61850
protocol with a redundant managed switched Ethernet communication infrastructure.
The communication shall be made in 1+1 mode, excluding the links between individual
bay IEDs to switch, such that failure of one set of fibre shall not affect the normal
operation of the SAS. However, it shall be alarmed in SAS. Each fibre optic cable shall
have four (4) spare fibres.
At station level, the entire station shall be controlled and supervised from the station
HMI. It shall also be possible to control and monitor the bay from the bay level
equipment at all times. Clear control priorities shall prevent operation of a single switch
at the same time from more than one of the various control levels, i.e., RCC, station HMI,
bay level or apparatus level. The priority shall always be on the lowest enabled control
level.
The station level contains the station-oriented functions, which cannot be realised at bay
level, e.g. alarm list or event list related to the entire substation, gateway for the
communication with remote control centres.
The GPS time synchronising signal (as specified in the section relay & protection) for the
synchronization of the entire system shall be provided.
The SAS shall contain the functional parts as described in para 1.2 above.
2.3
Functional Requirements:
The high-voltage apparatus within the station shall be operated from different places:
 Remote control centres.
 Station HMI.
 LocalBay controller IED
Operation shall be possible by only one operator at a time.
The operation shall depend on the conditions of other functions, such as interlocking,
synchrocheck, etc. (see description in “Bay level control functions”).
2.3.1
Select-before-execute:
For security reasons the command is always to be given in two stages: selection of the
object and command for operation under all mode of operation except emergency
operation. Final execution shall take place only when selection and command are
actuated.
2.3.2
Command supervision:
Bay/station Interlocking and blocking.
Software Interlocking is to be provided to ensure that inadvertent incorrect operation of
switchgear causing damage and accident in case of false operation does not take place. In
addition to software interlocking hardwired interlocking are to be provided for:
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a) Bus Earth Switch Interlocking.
b) Transfer Bus Interlocking (if applicable).
It shall be a simple layout, easy to test and simple to handle when upgrading the station
with future bays. For software interlocking the bidder shall describe the scenario while
an IED of another bay is switched off or fails.
A software interlock override function shall be provided which can be enabled to bypass
the interlocking function.
2.3.3
Run Time Command cancellation.
Command execution timer (configurable) must be available for each control level
connection. If the control action is not completed within a specified time, the command
should get cancelled.
2.3.4
Self-supervision.
Continuous self-supervision function with self-diagnostic feature shall be included.
2.3.5
User configuration.
The monitoring, controlling and configuration of all input and output logical signals and
binary inputs and relay outputs for all built-in functions and signals shall be possible both
locally and remotely.
It shall also be possible to interconnect and derive input and output signals, logic
functions, using built-in functions, complex voltage and currents, additional logics (ANDgates, OR gates and timers). (Multi-activation of these additional functions should be
possible).
The functional requirement shall be divided into following levels:
a) Bay (a bay comprises of one circuit breaker and associated disconnector, earth
switches and instrument transformer) Level Functions.
b) System Level Functions.
3.0
BAY LEVEL FUNCTIONS:
3.1
In a decentralized architecture the functionality shall be as close to the process as
possible. In this respect, the following functions can be allocated at bay level:

Bay control functions including data collection functionality.

Bay protection functions.
Separate IEDs shall be provided for bay control function and bay protection function.
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3.1.1
Bay Control functions.
3.1.1.1 Overview.
Functions.

Control mode selection

Select-before-execute principle.

Command supervision:
 Interlocking and blocking
 Double command.

Synchrocheck, voltage selection.

Run Time Command cancellation

Transformer tap changer control (for power transformer bays)

Operation counters for circuit breakers and pumps

Hydraulic pump/Air compressor control and runtime supervision /spring mechanism
supervision

Operating pressure supervision.

Display of interlocking and blocking.

Breaker position indication per phase

Isolator Position Indication

Alarm annunciation

Measurement display

Local HMI (local guided, emergency mode)

Interface to the station HMI.

Data storage for at least 200 events.

Extension possibilities with additional I/O‟s inside the unit or via fiber-optic
communication and process bus.
3.1.1.2
Control mode selection.
Bay level operation:
As soon as the operator receives the operation access at bay level the operation is
normally performed via bay control IED. During normal operation bay control unit
allows the safe operation of all switching devices via the bay control IED.
Emergency operation:
It shall be possible to close or open the selected Circuit Breaker with ON or OFF push
buttons even during the outage of bay IED.
REMOTE mode
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Control authority in this mode is given to a higher level (Remote Control Centre) and the
installation can be controlled only remotely. Control operation from lower levels shall
not be possible in this operating mode.
3.1.1.3
Synchronism and energizing check.
The synchronism and energizing check functions shall be bay-oriented and distributed to
the bay control and/or protection devices. These features are:
 Settable voltage, phase angle, and frequency difference.
 Energizing for dead line – live bus, live line – dead bus or dead line – dead bus with
no synchro-check function.
 Synchronizing between live line and live bus with synchro-check function.
Voltage selection.
The voltages relevant for the Synchro-check functions are dependent on the station
topology, i.e., on the positions of the circuit brakers and/or the isolators. The correct
voltage for synchronizing and energizing is derived from the auxiliary switches of the
circuit breakers, the isolator, and earthing switch and shall be selected automatically by
the bay control and protection IEDs.
3.1.1.4
Transformer tap changer control.
Raise and lower operation of OLTC taps of transformer shall be facilitated through Bay
controller IED.
3.1.2
Bay protection functions:
3.1.2.1
General.
The protection functions are independent of bay control function. The protection shall be
provided by separate protection IEDs (numerical relays) and other protection devices as
detailed in Section-Relay & Protection panels.
IEDs, shall be connected to the communication infrastructure for data sharing and meet
the real-time communication requirements for automatic functions. The data presentation
and the configuration of the various IEDs shall be compatible with the overall system
communication and data exchange requirements.
Event and disturbance recording function:
Each IED should contain an event recorder capable of storing at least 200 time-tagged
events. This shall give alarm if 70% memory is full. The disturbance recorder function
shall be as per detailed in section –Relay & Protection panles.
3.2
System level functions:
3.2.1
Status supervision:
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The position of each switchgear, e.g., circuit breaker, isolator, earthing switch,
transformer tap changer etc., shall be supervised continuously. Every detected change of
position shall be immediately displayed in the single-line diagram on the station HMI
screen, recorded in the event list, and a hard copy printout shall be produced. Alarms
shall be initiated in the case of spontaneous position changes.
The switchgear positions shall be indicated by two auxiliary switches, normally closed
(NC) and normally open (NO), which shall give ambivalent signals. An alarm shall be
initiated if these position indications are inconsistent or if the time required for operating
mechanism to change position exceeds a predefined limit.
The SAS shall also monitor the status of substation auxiliaries. The status and control of
auxiliaries shall be done through separate one or more IED and all alarm and analog
values shall be monitored and recorded through this IED.
3.2.2
Measurements.
a) Analog inputs for voltage and current measurements shall be connected directly
to the voltage transformers (VT) and the current transformers (CT) without intermediate
transducers. The values of active power (W), reactive power (VAR), frequency (Hz) and
the rms values for voltage (U) and current (I) shall be calculated. The measured values
shall be displayed locally on the Station HMI and in the Control Centre. The abnormal
values must be discarded. The analog values shall be updated every 2 seconds.
Threshold limit values shall be selectable for alarm indications.
3.2.3
Event and alarm handling:
Events and alarms are generated either by the switchgear, by the control IEDs or by the
station level unit. They shall be recorded in an event list in the station HMI. Alarms shall
be recorded in a separate alarm list and appear on the screen. All, or a freely selectable
group of events and alarms shall also be printed out on an event printer. The alarms and
events shall be time-tagged with a time resolution of 1 ms.
3.2.4
Station HMI.
3.2.4.1
Substation HMI Operation:
On the HMI the object has to be selected first. In case blocking or interlocking conditions
are not met, the selection shall not be possible and an appropriate alarm annunciation
shall occur. If a selection is valid the position indication will show the possible direction
and the appropriate control execution button shall be pressed in order to close or open the
corresponding object.
Control operation from other places (e.g. REMOTE) shall not be possible in this
operating mode.
3.2.4.2
Presentation and dialogues.
General:
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The operator station HMI shall be redundant with hot standby and shall provide basic
functions for supervision and control of the substation. The operator shall give
commands to the switchgear on the screen via mouse clicks or keyboard commands.
The HMI shall give the operator access to alarms and events displayed on the screen.
Aside from these lists on the screen, there shall be a printout of alarms or events in an
event log.
An acoustic alarm shall indicate abnormalities and all unacknowledged alarms shall be
accessible from any screen selected by the operator.
The following standard pictures shall be available from the HMI.
 Single-line diagram showing the switchgear status and measured values.
 Control dialogues with interlocking and blocking details. This control dialogue shall
tell the operator whether the device operation is permitted or blocked.
 Measurement dialogues.
 Alarm list, station / bay-oriented.
 Event list, station / bay-oriented.
 System status.
3.2.4.3
HMI design principles:
Consistent design principles shall be adopted with the HMI concerning labels, colours,
dialogues and fonts. Non-valid selections shall be dimmed out.
The object status shall be indicated using different status colours for:
 Selected object under command
 Selected on the screen
 Not updated, obsolete values, not in use or not sampled
 Alarm or faulty state
 Warning or blocked
 Update blocked or manually updated
 Control blocked
 Normal state
3.2.4.4
Process status displays and command procedures:
The process status of the substation in terms of actual values of currents, voltages,
frequency, active and reactive powers as well as the positions of circuit breakers, isolators
and transformer tap-changers shall be displayed in the station single-line diagram.
In order to ensure a high degree of security against undesired operation, a “select-beforeexecute” command procedure shall be provided. After the “selection” of a switch, the
operator shall be able to recognize the selected device on the screen and all other
switchgear shall be blocked. As communication between control centre and device to be
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controlled is established, the operator shall be prompted to confirm the control action and
only then final execute command shall be accepted. After the “execution” of the
command the operated switching symbol shall flash until the switch has reached its new
position.
The operator shall be in a position to execute a command only, if the switch is not
blocked and if no interlocking condition is going to be violated. The interlocking
statements shall be checked by the interlocking scheme implemented at bay and station
level.
After command execution the operator shall receive a confirmation that the new
switching position has been reached or an indication that the switching procedure was
unsuccessful with the indication of the reason for non-functioning.
3.2.4.5
System supervision & display.
The SAS system shall be comprehensively self-monitored such that faults are
immediately indicated to the operator, possibly before they develop into serious
situations. Such faults are recorded as a faulty status in a system supervision display.
This display shall cover the status of the entire substation including all switchgear, IEDs,
communication infrastructure and remote communication links and printers at the station
level etc.
3.2.4.6
Event list.
The event list shall contain events that are important for the control and monitoring of the
substation.
The event and associated time (with 1 ms resolution) of its occurrence has to be displayed
for each event.
The operator shall be able to call up the chronological event list on the monitor at any
time for the whole substation or sections of it.
A printout of each display shall be possible on the hard copy printer.
The events shall be registered in a chronological event list in which the type of event and
its time of occurrence are specified. It shall be possible to store all events in the computer
for at least one month. The information shall be obtainable also from a printed event log.
The chronological event list shall contain:
 Position changes of circuit breakers, isolator and earthing devices.
 Indication of protective relay operations.
 Fault signals from the switchgear.
 Indication when analog measured values exceed upper and lower limits. Suitable
provision shall be made in the system to define two level of alarm on either side of the
value or which shall be user defined for each measured.
 Loss of communication.
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 Filters for selection of a certain type or group of events shall be available. The filters
shall be designed to enable viewing of events grouped per:
 Date and time.
 Bay
 Device
 Function e.g., trips, protection operations etc.
 Alarm class.
3.2.4.7
Alarm list:
Faults and errors occurring in the substation shall be listed in an alarm list and shall be
immediately transmitted to the control centre. The alarm list shall substitute a
conventional alarm tableau and shall constitute an evaluation of all station alarms. It shall
contain unacknowledged alarms and persisting faults. The date and time of occurrence
shall be indicated.
The alarm list shall consist of a summary display of the present alarm situation. Each
alarm shall be reported on one line that contains:




The date and time of the alarm.
The name of the alarming object.
A descriptive text.
The acknowledgement state.
Whenever an alarm condition occurs, the alarm condition must be shown on the alarm list
and must be displayed in a flashing state along with an audible alarm. After
acknowledgment of the alarm, it should appear in a steady (i.e., not flashing) state and the
audible alarm shall stop. The alarm should disappear only if the alarm condition is
physically cleared and the operator has reset the alarm with a reset command. The state
of the alarms shall be shown in the alarm list (Unacknowledged and persistent,
Unacknowledged and cleared, Acknowledged and persistent).
Filters for selection of a certain type or group of alarms shall be available as for events.
3.2.4.8
Object picture:
When selecting an object such as a circuit breaker or isolator in the single-line diagram,
the associated bay picture shall be presented first. In the selected object picture, all
attributes like
 Type of blocking
 Authority
 Local / remote control
 RSCC / SAS control
 Errors etc.,
shall be displayed.
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3.2.4.9
Control dialogues:
The operator shall give commands to the system by means of mouse click located on the
single-line diagram. It shall also be possible to use the keyboard for command activation.
Data entry is performed with the keyboard. Dedicated control dialogues for controlling at
least the following devices shall be available:
 Breaker and disconnector
 Transformer tap-changer.
3.2.5
User-authority levels:
It shall be possible to restrict activation of the process pictures of each object (bays,
apparatus...) within a certain user authorisation group. Each user shall then be given
access rights to each group of objects e.g.:
 Display only.
 Normal operation (e.g. open/close of switchgear)
 Restricted operation (e.g. by-passed interlocking)
 System administrator
 For maintenance and engineering purposes of the station HMI, the following
authorisation levels shall be available:
 No engineering allowed.
 Engineering/configuration allowed.
 Entire system management allowed.
The access rights shall be defined by passwords assigned during the log-in procedure.
Only the system administrator shall be able to add / remove users and change access
rights.
3.2.6
Reports:
The reports shall provide time-related follow-ups of measured and calculated values. The
data displayed shall comprise:
 Trend reports:

Day (mean, peak)

Month (mean, peak)

Semi-annual (mean, peak)

Year (mean, peak)
 Historical reports of selected analog values:

Day (at 15 minutes interval)

Week
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
Month

Year
It shall be possible to select displayed values from the database in the process display
on-line. Scrolling between e.g. days shall be possible. Unsure values shall be
indicated. It shall be possible to select the time period for which the specific data are
kept in the memory.
Following printouts shall be available from the printer and shall be printed on
demand:
3.2.7
i.
Daily voltage and frequency curves depicting time on X-axis and the appropriate
parameters on the Y-axis. The time duration of the curve is 24 hours.
ii.
Weekly trend curves for real and derived analog values.
iii.
Printouts of the maximum and minimum values and frequency of occurrence and
duration of maximum and minimum values for each analog parameter for each
circuit in 24 hours period.
iv.
Provision shall be made for logging information about breaker status like number
of operation with date and time indications.
v.
Equipment operation details shift wise and during 24 hours.
vi.
Printout on adjustable time period as well as on demand for MW, MVAR,
Current, Voltage on each feeder and transformer as well as Tap positions,
temperature and status of pumps and fans for transformers.
vii.
Printout on adjustable time period as well as on demand system frequency and
average frequency.
viii.
Reports in specified formats, which shall be handed over to successful bidder.
Trend display (historical data):
It shall be possible to illustrate all types of process data as trends – input and output data,
binary and analog data. The trends shall be displayed in graphical form as column or
curve diagrams with a maximum of 10 trends per screen. Adjustable time span and
scaling ranges must be provided.
It shall be possible to change the type of value logging (direct, mean, sum or difference)
on-line in the window. It shall also be possible to change the update intervals on-line in
the picture as well as the selection of threshold values for alarming purposes.
3.2.8
Automatic disturbance file transfer:
All recorded data from the IEDs with integrated disturbance recorder as well as dedicated
disturbance recording systems shall be automatically uploaded (event triggered or once
per day) to a dedicated computer and be stored on the hard disc.
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3.2.9
Disturbance analysis:
The PC-based work station shall have necessary software to evaluate all the required
information for proper fault analysis.
3.2.10 IED parameter setting:
It shall be possible to access all protection and control IEDs for reading the parameters
(settings) from the station HMI or from a dedicated monitoring computer. The setting of
parameters or the activation of parameter sets shall only be allowed after entering a
password.
3.2.11 Automatic sequences:
The available automatic sequences in the system should be listed and described (e.g.,
sequences related to the trip transfer). It must be possible to initiate pre-defined automatic
sequences by the operator and also define new automatic sequences.
3.2.12 A set of following ETVM reading display and reports (ETVM Provided in Relay &
Protection Panel) are required in the Station HMI.
i)
To present data read from meters.
ii)
To schedule meter reading and to select individual meters for manual
reading.
iii)
To remotely program the electronic meters.
iv)
To manage the billing data and prepare it for exporting to other systems.
Other than the above parameters, those specified in the Annexure CRP-TVM shall
also be provided.
The contents and format of meter reading displays shall be subject to approval by
the purchaser
3.3
3.3.1
Gateway:
Communication Interface:
The Substation Automation System shall have the capability to support simultaneous
communications with multiple independent remote master stations.
The Substation Automation System shall have communication ports as follows:
a) Two ports for Remote Control Centre.
b) Two ports for Regional System Coordination Centre (RSCC).
The communication interface to the SAS shall allow scanning and control of defined
points within the substation automation system independently for each control centre.
The substation automation system shall simultaneously respond to independent scans and
commands from employer‟s control centres (RCC & RSCC). The substation automation
system shall support the use of a different communication data exchange rate (bits per
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second), scanning cycle, and/or communication protocol to each remote control centre.
Also, each control centres data scan and control commands may be different for different
data points within the substation automation systems database.
3.3.2
Remote Control Centre Communication Interface:
Employer will supply communication channels between the Substation Automation
System and the remote control centre. The communication channels provided by
Employer will consist either of power line carrier, microwave, optical fibre, VSAT or
leased line, the details of which shall be provided during detailed Engineering.
3.3.3
Interface equipment:
The Contractor shall provide interface equipment for communicating between Substation
Automation System and Remote control centre and between Substation Automation
System and Regional System Coordination Centre (RSCC).
However, the
communication channels available for this purpose are specified in the section project.
In case of PLCC communication any modem supplied shall not require manual
equalization and shall include self-test features such as manual mark/space keying, analog
loop-back, and digital loop-back. The modems shall provide for convenient adjustment
of output level and receive sensitivity. The modem should be stand alone complete in all
respects including power supply to interface the SAS with communication channel. The
configuration of tones and speed shall be programmable and maintained in non-volatile
memory in the modem. All necessary hardware and software shall also be in the scope of
bidder except the communication link along with communication equipment between
substation control room and Remote Control Centre.
3.3.4
Communication Protocol:
The communication protocol for gateway to control centre must be open protocol and
shall support IEC 60870-5-104 and IEC 61850 for all levels of communication for
substation automation such as Bay to station HMI, gateway to remote station etc.
4.0
SYSTEM HARDWARE:
4.1
Redundant Station HMI, HMI View Node, Remote HMI and Disturbance Recorder
Work Station:
The contractor shall provide redundant station HMI in hot standby mode.
It shall be capable to perform all functions for entire substation including future
requirements as indicated in the SLD. It shall use industrial grade components.
Processor and RAM shall be selected in such a manner that during normal operation not
more than 30% capacity of processing and memory are used. Supplier shall demonstrate
these features.
The capacity of hard disk shall be selected such that the following requirement should
occupy less than 50% of disk space.
1. Storage of all analog data (at 15 minutes interval) and digital data including alarm,
event and trend data for thirty (30) days.
2. Storage of all necessary software.
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3. 20 GB space for OWNER‟s use.
Supplier shall demonstrate that the capacity of hard disk is sufficient to meet the above
requirement.
4.1.1
HMI (Human Machine Interface):
The VDU shall show overview diagrams (Single Line Diagrams) and complete details of
the switchgear with a colour display. All event and alarm annunciation shall be selectable
in the form of lists. Operation shall be by a user friendly function keyboard and a cursor
positioning device. The user interface shall be based on WINDOWS concepts with
graphics & facility for panning, scrolling, zooming, decluttering etc.
4.1.2
Visual Display Units/TFT’s (Thin Film Technology):
The contractor shall provide three display units, one for station HMI, one for redundant
HMI and one for DR work station. These shall have high resolution and reflection
protected picture screen. High stability of the picture geometry shall be ensured. The
screen shall be at least 21” diagonally in size and capable of colour graphic displays.
The display shall accommodate resolution of 1280 x 1024 pixels. The HMI shall be able
to switch the key board and cursor positioning device, as unit among all the monitors at a
consol vis push button or other controls.
4.1.3
Printer:
It shall be robust & suitable for operation with a minimum of 132 characters per line. The
printing operation shall be quiet with a noise level of less than 45 dB suitable for location
in the control room. Printer shall accept and print all ASCII characters via master control
computer unit interface.
The printer shall have in built testing facility. Failure of the printer shall be indicated in
the Station HMI. The printer shall have an off line mode selector switch to enable safe
maintenance. The maintenance should be simple with provisions for ease of change of
print head, ribbon changing, paper insertion etc.
All printers mounted in the control room shall be provided with a separate printer
enclosure each. The enclosure shall be designed to permit full enclosure of the printers at
a convenient level. Plexiglas windows shall be used to provide visual inspection of the
printers and ease of reading. The printer enclosures shall be designed to protect the
printers from accidental external contact and each should be removable from hinges at the
back and shall be provided with lock at the front.
All reports and graphics prints shall be printed on laser printer. One dot matrix printer
shall be exclusively used for hourly log printing.
All printers shall be continuously online.
4.1.4
Mass Storage Unit:
The mass storage unit shall be built-in to the Station HMI. All operational measured
values and indications shall be stored in a mass-storage unit of CD-ROM / DVD-ROM
with 700 MB or more capacity. The unit should support at least read (48X), Write (24X)
and Re-write (10X) operations with Multi-Session capability. It should support ISO9660,
Rockridge and Joliet Filesystems. It should support formatting and use under the
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operating system provided for Station HMI. The monthly back up of data shall be taken
on disc. The facility of back up of data shall be inherent in the software.
4.1.6
Interconnection Cables & Wiring:
The contractor shall provide all interconnecting wires, cables, connectors, terminations,
local area network (LAN) cables and other wiring required by field devices and IED‟s
including cabling required for interfacing with Marshalling Box.
4.1.5
Switched Ethernet Communication Infrastructure:
The bidder shall provide the redundant switched optical Ethernet communication
infrastructure for SAS. The bidder shall keep provision of 50-100% spare capacity for
employer use. One switch shall be provided to connect all IEDs bays of 220 KV, 66 KV
yard to communication infrastucture.
4.2
Bay level unit:
The bay unit shall use industrial grade components. The bay level unit, based on
microprocessor technology shall use numerical techniques for the calculation and
evaluation of external input analog signals. They shall incorporate select-before-operate
control principles as safety measures for operation via the HMI. They shall perform all
bay related functions, such as control commands, bay interlocking, data acquisition, data
storage, event recording and shall provide inputs for status indication and outputs for
commands. They shall be directly connected to the switchgear. The bay unit shall acquire
and process all data for the bay (Equipment status, fault indications, measured values,
alarms etc) and transmit these to the other devices in substation automation system. In
addition, this shall receive the operation commands from station HMI and control centre.
The bay unit shall have the capability to store all the data for at least 24 hours.
One no. bay level unit shall be provided for supervision and control of each 220 KV. , &
66 KV bays (a bay comprises of one circuit breaker and associated disconnector, earth
switches and instrument transformer). The bay level unit shall be equipped with analog
and binary inputs / outputs for handling the control, status monitoring and analog
measurement functions. All bay level interlocks are to be incorporated in the bay level
unit so as to permit control from the bay level unit local bay mimic panel with all bay
interlocks in place, during maintenance and commissioning or in case of contingencies
when the Station HMI is out of service.
The bay level unit shall meet the requirements for withstanding electromagnetic
interference according to relevant parts of IEC 61850. Failure of any single component
within the equipment shall neither cause unwanted operation nor lead to a complete
system breakdown.
4.2.1
Input / Output (I/O) modules:
The I/O module shall form a part of the bay level unit and shall provide coupling to the
substation equipment. The I/O modules shall acquire all switchgear information (i.e.,
data coming directly from the switchgear or from switchgear interlocking devices) and
transmit commands for operation of the switchgear. The measured values of voltage and
current shall be from the secondaries of instrument transformers. The digital inputs shall
be reported by exception with 1 ms resolution. Contact bouncing in digital inputs shall
not be assumed as change of state.
Page 281 of 382
4.3
Extendibility in future:
Offered substation automation system shall be suitable for extension in future for
additional bays indicated in SLD & additional 4 bays for each KV reference. During such
requirement all the drawings and configurations, alarm/event list etc., displayed shall be
designed in such a manner that its extension shall be easily performed by the employer.
During such event, normal operation of the existing substation shall be unaffected and
system shall not require a shutdown. The contractor shall provide all necessary software
tools along with source codes to perform addition of bays in future and complete
integration with SAS by the user. These software tools shall be able to configure IED,
add additional analog variable, alarm list, event list, modify interlocking logics etc., for
additional bays / equipment which shall be added in future. There shall be provision for
change of designation of bay as and when necessity arises.
5.0
Software structure:
The software package shall be structured according to the SAS architecture and strictly
divided in various levels. Necessary firewall shall be provided at suitable points in
software to protect the system. An extension of the station shall be possible with lowest
possible efforts. Maintenance, modification or an extension of components of any feeder
may not force a shut-down of the parts of the system which are not affected by the system
adaptation.
5.1.1
Station level software
5.1.1.1 Human-machine interface (HMI)
The base HMI software package for the operator station shall include the main SAS
functions. The base HMI software package for the operator station shall include the main
SAS functions and it shall be independent of project specific hardware version and
operating system. It shall further include tools for picture editing, engineering and system
configuration. The system shall be easy to use, to maintain and to adapt according to
specific user requirements Systems shall contain a library with standard functions and
applications.
5.1.2
Bay level software: System software:
5.1.2.1 The system software shall be structured in various levels. This software shall be placed in
a non-volatile memory The lowest level shall assure system performance and contain
basic functions, which shall not be accessible by the application and maintenance
engineer for modifications The system shall support the generation of typical control
macros and a process database for user specific data storage. In case of restoration of
links after failure, the software along with hardware shall be capable of automatically
synchronising with the remaining system Without any manual interface. This shall be
demonstrated by contractor during integrated system test
5.1.2.2 Application Software:
In order to ensure robust quality and reliable software functions, the main part of the
application software shall consist of standard software modules built as functional block
elements. The functional blocks shall be documented and thoroughly tested. They form
part of library. The application software within the control/protection devices shall be
programmed in a functional block language.
Page 282 of 382
5.1.2.3 Network Management System:
The contractor shall provide a network management system software for
following management functions:
a. Configuration Management.
b. Fault management.
c. Performance Monitoring.
This system shall be used for management of communication devices and other IEDs in the
system. This NMS can be loaded in DR workstation and shall be easy
to use. user friendly and menu based. The NMS shall monitor all the devices in the SAS and
report if there is any fault in the monitored devices. The NMS shall
a) Maintain performance. resource usage and error statistics for all managed
links and devices and present this information via displays, periodic reports
and on demand reports.
b) Maintain a graphical display of SAS connectivity and device status.
c) Issue alarms when error conditions occurs.
d) Provide facility to add and delete addresses and links.
5.1.2.4
The contractor shall provide each software in two copies in CD to load into the
system in case of any problem related with Hardware communication etc.
6.0
T EST S:
The substation automation system offered by the bidder shall be subjected to
following tests to establish compliance with IEC 61850 for EHV substation
equipment installed in the control room and specified ambient conditions:
6.1
6.1.1
Type Tests:
Control IEDs and Communication Equipment:
1) Power Input:
1.
Auxiliary Voltage.
ii. Current Circuits.
iii. Voltage Circuits.
iv. Indications.
Page 283 of 382
2) Accuracy Tests:
1.
Operational
II.
Currents.
111.
Voltages.
IV.
Time resolution.
3) Insulation
Measured
Values.
Tests:
1.
Dielectric Tests.
11.
Impulse Voltage withstand Test.
4) Influencing Quantities.
1.
II.
111
.
Limits of operation.
Permissible ripples
Interruption of input voltage.
5) Electromagnetic Compatibility Test:
1.
1 MHZ burst disturbance test
11.
Electrostatic Discharge Test.
111
.
IV.
Radiated Electromagnetic Field Disturbance Test.
V.
Conducted Disturbances Tests induced by Radio Frequency Field.
VI.
VI1.
Vlll.
Electrical Fast Transient Disturbance Test.
Magnetic Field Test.
Emission (Radio Interference level]) Test.
Conducted Interference Test.
6) Function Tests:
1.
11.
Indication
Commands
111
.
Measured Value Acquisition
IV.
Display Indications
7) Environmental tests:
1.
n.
Cold
Temperature.
Dry Heat
Page 284 of 382
iii.
Wet heat
lV.
Humidity (Damp Heat Cycle)
v.
Vibration
VI.
Bump.
Vl1.
Shock.
Factory Acceptance Tests:
6.2
The supplier shall submit a test specification for factory acceptance test (FAT)
and commissioning tests of the station automation system for approval. For the individual
bay level IED's applicable type test certificates shall be submitted. The manufacturing phase
of the SAS shall be concluded by the factory acceptance
test (FAT).
The purpose is to ensure that the Contractor has interpreted the
specified requirements correctly and that the FAT includes checking to the degree required
by the user. The general philosophy shall be to deliver a system to site only after it has been
thoroughly tested and its specified performance has been verified, as far as site conditions
can be simulated in a test lab. If the FAT comprises only a certain portion of the system for
practical reason, it has to be assured that this test configuration contains at least one unit of
each and every type of equipment incorporated in the delivered system.
If the complete system consists of parts from various suppliers or some pans arc
already installed on site, the F AT shall be limited to sub-system tests. In such a case,
the complete system test shall be performed on site together with the site acceptance test
.
(SAT)
6.3
Integrated Testing:
The integrated system tests shall be performed as detailed in subsequent clauses
as per the following configuration:
.
Redundant Station HMI, DR workstation with all IEDs & printers.
All other switches for complete substation as detailed in section project shall be simulated as
needed:-
Page 285 of 382
"
6.3.1
Hardware Integration Tests:
The hardware integration test shall be performed on the specified systems, to be
used for Factory tests when the hardware has been installed in the Factory. The
operation of each item shall be verified as an integral part of system. Applicable
hardware diagnostics shall be used to verify that each hardware component is
completely operational and assembled into a configuration capable of supporting
software integration and factory testing of the system. The equipment expansion
capability shall also be verified during the hardware integration tests.
6.3.2
Integrated System Tests:
Integrated System Tests shall verify the stability of the hardware and the software.
During the tests all functions shall run concurrently and all equipment shall operate
a continuous 100 Hours period. The integrated system test shall ensure the SAS is
free of improper interactions between software and hardware while the system is
operating as a whole
6.4
Field tests:
The field tests shall completely verify all the features of SAS hardware and software
7.0
SYSTEM OPERATION:
7.1
Substation Operation:
7.1.1
Normal Operation:
Operation of the system by the operator from the remote RCC or at the substation
shall take place via industry standard HMI (Human Machine Interface) subsystem
consisting of graphic colour VDU, a standard keyboard and a cursor positioning
device (mouse).
The coloured screen shall be divided into 3 fields:
1.
Message field with display of present time and date.
ii. Display field for single line diagrams.
iii. Navigation bar with alarm/condition indication.
Page 286 of 382
,
For display of alarm annunciation, lists of events etc., a separate HMI view mode
shall be provided.
All operations shall be performed with mouse and/or a minimum number of function
keys and cursor keys. The function keys shall have different meanings depending on
the operation. The operator shall see the relevant meanings as function tests displayed
in the command field (i.e., operator prompting) For control actions, the switchgear
(i.e., circuit breaker etc.) requested shall be selectable on the display by means of the
cursor keys. The switching element
selected shall then appear on the background that shall be t1ashing in a different
color. The operator prompting shall distinguish between:
Prompting of indications e.g., fault indications in the switchgear. and Prompting of
operational sequences e.g., execution of switching operations.
,
The summary information displayed in the message field shall give a rapid
display of alarm/message of the system in which a fault has occurred and alarm
annunciation lists in which the fault is described more fully.
Each operational sequence shall be divided into single operation steps, which are
initiated by means of the function keys WINDOW command by mouse. Operator
prompting shall be designed in such a manner that only the permissible keys are
available in the command field related to the specific operation step. Only those
switching elements shall be accessed for which control actions are possible. If the
operation step is rejected by the system, the operator prompting shall be supported
by additional comments in the message field. The operation status shall be reset
to the corresponding preceding step in the operation sequence by pressing one of the
function keys. All operations shall be verified. Incorrect operations shall be
indicated by comments in the message field and must not be executed.
The offer shall include a comprehensive description of the system. The above
operation shall also be possible via Windows based system by mouse.
Page 287 of 382
';'
,
f
.
8.0
POWER SUPPLY:
Power for the substation automation system shall be derived from substation 220 V
DC system.
Inverter of suitable capacity shall be provided for station HMI and its peripheral
devices e.g., printer etc.
In the event of Power failure. necessary safeguard
software shall be built for proper shutdown and restart.
9.0
DOCUMENTATION:
The following documents shall be submitted for employer's approval during detailed
engineering:
a) System Architecture Drawing.
b) Hardware Specification.
c) Sizing Calculations of various components.
d) Response Time Calculation.
e) Functional Design Document.
Following documentation to be provided for the system in the course of the
project shall be consistent, CAD supported and of similar look/feel. All CAD
.
drawings to be provided in “dfx” format.
"
.
.
.
.
List of drawings.
Substation Automation System architecture.
Block Diagram.
Guaranteed Technical Parameters, Functional Design Specification and
Guaranteed availability and reliability.
Calculation for power supply dimensioning.
I/O Signal lists.
Schematic diagrams
~
.
.
List of Apparatus.
List of Labels.
Logic Diagram (hardware & software). -Panel
. Panel layout drawing.
Page 288 of 382
.:,
'r
..
~I,:
~
4" ,~.c..~,""-,,~~,,- '.
.
.
.
.
.
.
.
.
.
GA of and GTP.
Control Room Layout.
Test Specification for Factory Acceptance Test (FAT).
Product Manuals.
Assembly Drawing.
Operators Manual.
Complete documentation of implemented protocols between various elements.
Listing of software and loadable in CD ROM.
Other documents as may be required during detailed engineering.
Two sets of hard copy and Four sets of CD ROM containing all the as-built
documents/drawings shall be provided to CEE (T&P) and to each of the consignee.
10.0
10.1
TRAINING, SUPPORT SERVICES. MAINTENANCE AND SPARES:
Training:
Contractor personnel who are ,experienced instructors and who speak understandable
English shall conduct training. The contractor shall arrange on his
Own cost all hardware training platform required for successful training and
understanding in India.
The Contractor shall provide all necessary training
material. Each trainee shall receive individual copies of all technical manuals and all
other documents used to training. These materials shall be sent to Employer
at least two months before the scheduled commencement of the particular training
course. Class materials, including the documents sent before the training courses
as well as class handouts, shall become the property of Employer. Employer reserves
the right to copy such materials, but for in-house training and use only.
Hands-on training shall utilize equipment identical to that being supplied to Employer.
For all training courses, the travel (e.g., airfare) and per-diem expenses will be borne by the
participants.
The Contractor shall quote training prices individually for each of the courses as. indicated in
Price Schedule.
Page 289 of 382
'
,
"'
,
,
"
~
Employer will have the option to cancel any or all-training courses. In the case of
cancellation, the rate quoted against the respective course will not be paid to the Contractor.
The schedule. location and detailed contents of each course will be finalized
during Employer and Contractor discussions.
10.2
Computer System Hardware Course:
A computer system hardware course shall be offered, but at the system level only.
The training course shall be designed to give Employer hardware personnel
sufficient knowledge of the overall design and operation of the system so that
they can correct obvious problems, configure the hardware, perform preventive
maintenance,
run
diagnostic
pro grams and communicate
with
contract
maintenance personnel. The following subjects shall be covered:
a) System Hardware Overview: Configuration of the system hardware.
b) Equipment Maintenance: Basic theory of operation. maintenance techniques
and diagnostic procedures for each element of the computer system. e.g..
processors, auxiliary memories, LAN's routers and printers. configuration of
all the hardware equipment's.
c) System Expansion: Techniques and procedures to expand and add equipment
such as loggers, monitors and communication channels.
d) System Maintenance: Theory of operation and maintenance of the redundant
hardware configuration, tail over hardware, configuration control panels and failover
switches. Maintenance of protective devices and power supplies.
e) Subsystem Maintenance: Theory of design and operation. maintenance
techniques and practices, diagnostic procedures and (where applicable)
expansion techniques and procedures. Classes shall include hands-on training for the
specific subsystems that are part of Employer's equipment or part of similarly designed
.and configured subsystems. Computing Al1 interfaces to the computing equipment shall
be taught in details
f) Operational Training:: Practical training on preventive and corrective
maintenance of all equipment, including use of special tools and instruments.
,.
.
~.
Page 290 of 382
This training shall be provided on Employer equipment or on similarly
configured systems.
10.3
~
Computer System Software Course:
The Contractor shall provide a computer system software course that covers the
following subjects:
a) System Programming: Including all applicable programming languages and
all stand-alone service and utility packages provided with the system. An introduction to
software architecture. effect of tuning parameters (OS software, Network software,
.database software etc.) on the performance of the system
b) Operating System: Including the user aspects of the operating system, such as
program loading and integrating procedures, scheduling, management, service
and utility functions and system expansion techniques and procedures.
c) System Initialization and Failover: Including design, theory of operation and
practice.
d) Diagnostics: Including the execution of diagnostic procedures and the
interpretation of diagnostic outputs.
e) Software Documentation: Orientation in the organization and use of system
software documentation.
f) Hands-on Training: One week with allocated computer time for trainee
performance of unstructured exercises and with the course instructor available
for assistance as necessary.
10.4
Application Software Course:
The Contractor shall provide comprehensive application software courses
covering all applications including the database and display building course. The
training shall include:
a) Overview: Block diagrams of the application software and data flows.
Programming standards and programme interface conventions.
b) Application Functions: Functional capabilities, design and major algorithms.
Associated maintenance and expansion techniques.
Page 291 of 382
~
c) Software Development: Techniques and conventions to be used for the
preparation and integration of new software functions.
d) Software Generation: Generation of application software from source code
and associated software configuration control procedures.
e) software Documentation: Orientation in the organization and use of
functional and detailed design documentation and of programmer and user
manuals.
f) Hands-on Training: One week, with allocated computer time for trainee
performance of unstructured exercises and with the course instructor available
for assistance as necessary.
10.5
Requirement of training:
The contractor shall provide training for two batches for two-weeks each for following
courses:
11.0
Sl. No.
Name of the Course
1.
2.
3.
4.
Computer System Hardware
Computer System Software
Application Software
MAINTENANCE RESPONSIBILITY:
11.1
Maintenance Responsibility during theGuaranteed Availability Period. During
Guaranteed availability period, the contractor shall take continual actions
to ensure the guaranteed availability and shall make available all the necessary
resources such as specialist personnel spare parts, tools, test devices etc., for
replacement or repair of all defective parts and shall have prime responsibility for
keeping the system operational.
12.0
RELIABILITY AND AVAILABILITY:
The SAS shall be designed so that the failure of any single component, processor or
device shall not render the system unavailable. The SAS shall be designed to
satisfy the very high demands for reliability and availability concerning:
Page 292 of 382
.
..
.
.
.
.
.
.
Mechanical and electrical design.
Security against electrical interference (EMI)
High quality components and boards.
Modular, well-tested hardware.
Thoroughly developed and tested modular software.
Easy-to-understand programming language for application programming.
Detailed graphical documentation and application software.
Built-in supervision and diagnostic functions.
Security
Experience of security requirements
Process know--how
'
Select before execute at operation
.
.
.
.
.
Process status representation as double indications
Distributed solution.
Independent units connected to the local area network Backup functions
Panel design appropriate to the harsh electrical environment and ambient conditions.
Panel grounding immune against transient ground potential rise.
Outage
terms:
1) Outage:
The state in which substation automation system or a unit of SAS is unavailable
for Normal Operation as defined in the clause 7.1 due to an event
directly related to the SAS or unit of SAS. In the event, the owner has taken any
equipment/system other than Substation Automation System for schedule-forced
maintenance, the consequent outage to SAS shall not be considered as outage for
.the purpose of availability.
.
Page 293 of 382
2) Actual outage duration (AOD):
The time elapsed. in hours between the start and the end of an outage. The time
shall be counted to the nearest 1I4th of an hour; Time less than 1/4th of an hour
shall be counted as having duration of 1/4th of an hour.
3) Period Hours (PH):
The number of hours in the reporting period. In a full year the period hour are
8760h (8784h for a leap year).
4) Actual Outage hours (AOH):
The sum of actual outage duration within the reporting period
AOH=AOD
5) Availability:
Each SAS shall have a total availability of 99.98% i.e., the ratio of total time
duration minus the actual outage duration to total time duration.
12.1
Guarantees Required:
The availability for the complete SAS shall be guaranteed by the Contractor. Bidder
shall include in their offer the detailed calculation for the availability .. The
contractor shall demonstrate their availability guaranteed by conducting the availability test
on the total substation automation system as a Whole after commissioning of total
substation automation system. The test shall verify the reliability and integrity of all
sub-systems. Under these conditions the test shall establish an overall availability of
99.98%. After the lapse of 1000 Hours of cumulative test time, test records shall be
examined to determine the conformance with availability criterion. In case of any
outage during the availability test. the contractor shall rectify the problem and after
rectification, the 1000 Hours period start after such rectification. If test object has
.not been met the test shall continue until the specified availability is achieved
The contractor has to establish the availability in a maximum period of three months from
the date of commencement of the availability test.
After the satisfactory conclusion of test both contractor and employer shall
mutually agree to the test results and if these results satisfy the availability
Page 294 of 382
criterion, the test is considered to be completed successfully. After that the system shall be
taken over by the employer and then the guarantee period shall start.
13.0
SPA RES:
13.1
Consumables:
All consumables such as paper, cartridges shall be supplied by the contractor till
the SAS is taken over by the Owner.
13.2
Availability Spares:
The bidder is required to furnish the list of spares, which 'may be required for
ensuring the guaranteed availability during the guaranteed availability period. The final list
of spares shall form part of scope of supply and accordingly the price thereof shall be
quoted by the bidder and shall be considered in the evaluation of the bids. During the
'
guaranteed availability period. the spare parts supplied by the Contractor shall be
made available to the contractor for usage subject to replenishment at the earliest.
Thus, at the end of availability period the inventory of spares with the Employer
shall be fully replenished by the Contractor. However, any additional spares required
to meet the availability of the system (which are not a part of the above spares
.supplied by the contractor) would have to be supplied immediately by the Contractor
free of cost to the Employer.
14.0
LIST OF EQUIPMETNS:
Quantity of equipments shall be decided by bidder in order to achieve guaranteed
"
reliability and availability as declared by bidder.
i, Station HMI.
ii. Redundant Station HMI (in Hot stand by mode).
iii. Bay level units along with bay mimic.
IV. Disturbance Recorder Work Station (Maintenance HMI).
v. Colour Laser Printer - 1 No. (For Reports & Disturbance Records).
vi. Dot Matrix Printer - (one each for Alarms and log sheets).
vii. All interface equipment for gateway to RCC and RSCC.
Page 295 of 382
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viii. Communication infrastructure between Bay level units, Station HML Printers,
gateways, redundant LAN etc.. as required.
ix. Remote workstation including HMI and along with one printer.
x.
Any other equipment as necessary.
Page 296 of 382
TYPICAL ARCHITECTURAL DRAWING OF SUB-STATION
AUTOMATION SYSTEM
DR/
ENGINEERING
HMI
VIEW
NOTE
STATION
HMI
WORK
STATION
GATEWAY
GPS CLOCK
CONTROLCENTER
PRINTER
ROUTER
STATION BUS
EARTHNET RING WITH SWITCHES
BAY
CONTROLLER
RELAY
SWITCHGEAR, CT/VT‟s
ETV
M
BAY
CONTROLLER
RELAY
ETV
M
SWITCHGEAR, CT/VT‟s
NOTES:
1. STATION BUS SHALL BE REALIZED BY HIGH SPPED OPTICAL BUS USING INDUSTRIAL
GRADE COMPONENTS AND SHALL BE AS PER IEC 61850.
2. IEDS FOR TWO BAYS MAY BE HOUSED IN ONE PANEL ALONG WITH ITS SWITCH.
3. INSIDE THE SUB STATION, ALL CONNECTIONS SHALL BE REALIZED AS PER IEC 61850
PROTOCOL.
4. FOR GATEWAY, IT SHALL COMMUNICATE WITH REMOTE SUPERVISORY CONTROL
CENTRE(RSCC), REMOTE CONTROL CENTRE (RCC) ON IEC 60870-5-104 PROTOCOL
5. THE ROUTER SHALL COMMUNICATE ON IEC 60870-5-104 PROTOCOL
6. THE PRINTER AS REQUIRED SHALL BE CONNECTED AT STATION BUS DIRECTLY & CAN BE
MANAGED EITHER FROM STATION HMI, HMI VIEW NODE OR DISTURBANCE RECORDER
WORK STATION.
297 of 382
ANNEXURE – I
(GTP IAS)
Basic Monitoring requirements are:
-
Switchgear status indication
-
Measurements (U, I, P, Q, f)
-
Event
-
Alarm
-
Winding temperature of transformers
-
Ambient temperature
-
Status and display of 415 V LT system, 220V & 48 VDC system.
-
Status of display of Nitrogen injection Fire protection system and Air conditioning system.
-
Acquisition of all counters in PLCC panels through potential free contacts from PLCC or
independently by counting the receive/send commands, for 220 KV lines.
-
Acquisition of alarm and fault record from protection relays
-
Disturbance records for 220 KV lines.
-
Monitoring the state of batteries by displaying DC voltage, charging current and load current
etc.
-
Tap-position of transformer
List of Inputs:
The list of input for typical bays is as below:
Analog inputs:
i)
For line
Current R-phase
Y-phase
B-phase
Voltage R-Y phase
Y-B phase
B-R phase
ii)
For transformer
Current R-phase
Y-phase
298 of 382
B-phase
WTI (for transformer)
OTI (for transformer)
Tap position (for transformer only)
iii)
For bus coupler
Current R-phase
Y-phase
B-phase
iv)
Common
a) Voltage for Bus-I & Bus-II
Voltage
R-Y phase
Y-B phase
B-R phase
b) Frequency for Bus-I & Bus-II.
c) Ambient temperature (switchyard).
d) LT system
i.
Voltage R-Y, Y-B, B-R of Main Switchboard Section-I.
ii.
Voltage R-Y, Y-B, B-R of Main Switchboard Section-II.
iii.
Voltage R-Y, Y-B, B-R of Diesel Generator.
iv.
Current from LT transformer-I.
v.
Current from LT transformer-II.
vi.
Current from Diesel Generator.
vii.
Voltage of 220 V DCDB-I.
viii.
Voltage of 220 V DCDB-II.
ix.
Current from 220 V Battery Set-I.
x.
Current from 220 V Battery Set-II.
xi.
Current from 220 V Battery charger-I.
xii.
Current from 220 V Battery charge-II.
xiii.
Voltage of 48 V DCDB-I.
xiv.
Voltage of 48 V DCDB-II.
xv.
Current from 48 V Battery set-I.
xvi.
Current from 48 V Battery set-II.
xvii.
Current from 48 V Battery charger-I.
299 of 382
xviii. Current from 48 V Battery charger-II.
Digital Inputs:
The list of input for various bays/SYSTEM is as follows:
Sl.
No.
1.
Particulars
220 KV
66 KV
BC
Line bays:
i)
Status of each pole of CB, Isolator, Earth switch
ii)
CB trouble
iii)
CB operation/closing lockout
iv)
Pole discrepancy optd.
v)
Trip coil faulty TC1/TC2
vi)
LBB optd
vii)
Bus bar protection trip relay optd.
viii)
Main bkr auto recloser operated
ix)
A/R lockout
x)
Direct trip sent
xi)
Direct trip received
xii)
Main-I/Backup blocking
xiii)
Main-I/Backup Inter trip send
xiv)
Main-I/Backup Inter trip received
xv)
Fault Locator Faulty
xvi)
Main VT Fuse fail
xvii)
Main Protn trip
xviii)
Back up protn trip
xix)
Main PSB Alrm
xx)
Main softrip
xxi)
Main R-Phase trip
xxii)
Main Y-Phase trip
xxiii)
Main B-phase trip
xxiv)
Main Start
xxv)
Main Carrier aided trip
xxvi)
Main fault in reverse direction
xxvii)
Main Zone-2 trip
xxviii)
Main Zone-3 trip
xxix)
Main weak ends infeed
xxx)
Main fault in reverse direction
xxxi)
Back-up o/c optd
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xxxii)
Back-up e/f optd
xxxiii)
220 V DC-I/II source fail
xxxiv)
Speech channel fail
xxxv)
PLCC protection channel fail
xxxvi)
PLCC protection channel fail
xxxvii)
SF6 Gas Pressure Low
Sl.
No.
Particulars
220 KV
66 KV
BC
xxxviii)Spares – 4 Nos
2.
Transformer bays: 100/150MVA Transformer
i)
Status of each pole of CB, Isolator, Earth switch
ii)
CB trouble
iii)
CB operation/closing lockout
iv)
Pole discrepancy optd.
v)
Trip coil faulty
vi)
LBB optd.
vii)
Bus bar protn. trip relay optd
viii)
REF optd
ix)
DIF optd
x)
Over flux alarm (V)
xi)
Over flux trip (V)
xii)
HV Bus VT fuse (A)
xiii)
MV Bus VT Fuse (A)
xiv)
OTI Alarm/Trip
xv)
PRD optd
xvi)
Overload alarm
xvii)
Bucholz trip
xviii) Bucholz Alarm
xix)
OLTC oil surge relay alarm
xx)
OLTC oil surge relay trip
xxi)
Oil low alarm
xxii)
Back-up o/c (HV) optd.
xxiii) Back-up e/f (HV) optd
xxiv) 220 V DC-I/II source fail
xxv)
Tap mismatch
xxvi) Back-up o/c (MV) optd
xxvii) Back-up e/f (MV) optd
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xxviii) WTI Alaram/Trip
xxix) SF6 Gas Pressure low
xxx)
Spares 4 Nos.
3.
Transformer bays – for others:
i)
Status of each pole of CB, Isolator, Earth switch
ii)
CB trouble
iii)
CB operation / closing lockout
iv)
Pole discrepancy optd.
v)
Trip coil faulty
Sl.
No.
Particulars
vi)
LBB optd.
vii)
Bus bar protn. trip relay optd
viii)
REF optd
ix)
DIF optd
x)
HV Bus VT fuse fail
xi)
OTI Alarm / trip
xii)
PRD optd
xiii)
Bucholz trip
xiv)
Bucholz alarm
xv)
Oil low alarm
xvi)
Back-up o/c HV optd
xvii)
Back-up E/F HV optd
220 KV
66 KV
BC
xviii) 220 V DC-I/II source fail
xix)
Back up o/c LV operated
xx)
Back up E/F LV operated
xxi)
SF6 Gas Pressure low
xxii)
Spares 4 Nos.
4.
Bus-bar Protection:
i)
Bus bar main-I trip
ii)
Bus bar main-II trip
iii)
Bus-bar zone-I CT open
iv)
Bus-bar zone-II CT open
v)
Bus protection relay fail
5.
Auxiliary system:
i)
Incomer-I On/Off
ii)
Incomer-II On/Off
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iii)
415 V Bus-I/II U/V
iv)
415 V Bus coupler breaker on/off
v)
DG set bkr on/off
vi)
Alarm/trip signals as listed in Section: DG Set
vii)
PLCC exchange fail
viii)
Time sync. Signal absent
Alarm/trip signals as listed in Section: Battery &
Battery charger
220 V DC-I earth fault
ix)
x)
xi)
xii)
220 V DC-II earth fault
Alarm/ Nitrogen trip signals as listed in Section:
Fire protection system
The exact number and description of digital inputs shall be as per detailed engineering requirement
apart from the above mentioned digital inputs, minimum of 200 inputs shall be kept for KSPDCL
use in future.
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ANNEXURE – RPP –TVM
TECHNICAL SPECIFICATION FOR RELAY & PROTECTION PANEL FOR 1 & 5
AMPS STATIC ELECTRONIC TRIVECTOR METERS OF ACCURACY CLASS FOR 0.5
/ 0.2 S
1.
The specification covers design, Manufacturing, Testing, Supply & Delivery of HT and/or
LT, Static 3 Vector Energy meter, capable of measuring Electrical energy & demand in
balanced and/or unbalanced loads. The accuracy class and Current rating are stated along
with the requirements.
2
STANDARD:
While drafting this specification, reference has been made to the following Indian and
International standard specifications. In case certain details are not covered in 1hese
specifications any other Indian/ International standard shall be applicable.
1.
2.
3.
4.
5.
6.
7
8
3
IEC 60687 for Class 0.2 S
IEC 1268 for Class 1.0 Reactive Energy
IEC 1000-4-2, for Electrostatic discharge
IEC 1000-4-3, for Electromagnetic high frequency discharge
IEC1000-4-4, for Electrical fast transient/burst
IEC/CISPR 14, for Radio lnterference
Technical report of specification for AC Static Electrical Energy
Meters CBIP, New Delhi
IEC 62056: 1997for communication protocol.
QUALIFYING REQUIREMENT :
The meter manufacturer should have supplied at least 5000 meters of similar type either in
India or internationally.
4
a) CLIMATIC CONDITIONS
The meters shall be suitable to work satisfactory under the following climatic conditions.
i.
ii.
iii.
iv.
v.
Minimum ambient temperature
Maximum ambient temperature
Minimum relative Humidity
Maximum relative Humidity
Altitude
0 deg C
50 deg C
26%
100%
up to 1000 m above sea level.
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b)
SUPPLY SYSTEM ENVIRONMENT
a)
Meters shall be suitable for both balanced and/or unbalanced loads at all power factors in
all the four quadrants meter shall display direct reading without built-in multiplying factor.
The meters shall be suitable for working satisfactorily with following supply system
variations.
(i) Operating voltage range of the meter
:
Vbasic + 20 % to -- 40 %
(ii) OperatingCurrentRange
:
Two times Ibasic
(iii) Frequency
:
50 Hz ± 5 %
(iv) Power-factorRange
:
±1%
b)
Meter should work accurately irrespective of phase sequence of supply
c)
d)
Meters shall be of Universal type i.e, the meter shall be configurable for either 3 Phase 4
wire or 3 phase 3 wire configuration depending on the external power supply arrangement.
Meter shall not get damaged if phase and neutral is interchanged
5
QUANTITIES TO BE MEASURED AND MONITORED
The meters shall be capable of measuring and displaying the following electrical quantities
within accuracy requirements as stipulated in clause 4.6 of IEC 1036 for polyphase
balanced and/or unbalanced loads. The meters shall be capable of measuring 5OHz and
Harmonic Power up to 29th Harmonics.
i)
Phase wise Voltage and Currents
:
V, I
ii)
Active Energy, Reactive Energy,
:
Apparent energy
KWH,KVAH,
KVARH
iii)
iv)
v)
Maximum demand
Power factor
Frequency
:
:
:
KVA, KW, KVAR
P.F
F
The Data shall not be lost in the case of Power Failure
Measuring principles are as per the Appendix - II
6
DESIGN REQUIREMENT
i)
Voltage dips and short interruptions shall not produce a change in the register for more than
0.001 KWH, KVAH when the voltage is restored. The meter shall not have suffered
degradation of its metering characteristics.
ii)
The voltage circuit of the meter should withstand the impulse voltage test as per IS: 13010.
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iii)
The following disturbances shall be considered in the design of the meter to over come the
effect of errors due to:






Harmonics
voltage dips, interruptions and Voltage fluctuations
Conducted Transients
DC and AC Magnetic fields
Electro-magnetic fields
Electro-static discharges
The meter shall be designed in such a way that the above disturbances do not damage the
meter. The meter shall not generate electromagnetic, eletrostatic disturbances which could
interfere with other equipment. The limits of error variation for the above abnormal
'conditions shall be as per relevant standards.
iv)
The meter shall be based on digital measuring principle.
v)
The meters shall provide real time information and display loading conditions and antitamper diagnostic conditions.
vi)
The meter shall have built in Modem for remote communication purpose. Alternatively
meter shall have provision for upgrading on a future date.
vii)
The meter should work even if any one phase supply i.e., either phase to ground or phase to
phase is available. It shall record and store all parameters under these conditions.
viii)
The meter shall be suitable for direct connection without using External Transducers or
devices
ix)
The meter shall be able to operate and sense the input supply from 70 to 415 volts phase to
phase, 3 or 4 wire system
x)
The meter shall have AC voltage withstanding capacity of 4 KV at 50 Hz per minute.
xi)
The Meter Impulse voltage resistance shall be not less than 10 KV / 50 micro sec.
xii)
Drift in real time clock should be within 2 sec per month.
xiii)
Design data shall also be furnished
xiv)
The meter shall have the special feature to defect common ways to tamper and fraud as
indicated in Appendix - IV
7.
DISPLAY
i)
The meter shall have legible Alpha-Numeric LCD displays, along with legend preferably of
minimum of' 3 digits for parameter identification. Minimum dimension of each display
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character shall be of size 8-mm height and 5 mm width. Display with Electronic Back-Lit
display arrangement for better visibility can also be offered
ii)
Nomenclatures used in Display:
This shall be with universally accepted like KWH, KVA, KVARH and the abbreviations
made for items like cumulative billing, TOD etc shall be clearly printed and narrated on the
main cover of the meter itself.
iii)
The details of requirement of scrolling parameters in automatic and manual modes shall be
dynamically selectable at site without opening main cover, are furnished in Appendix - I.
iv)
The meter shall have facility for indication of healthiness of battery and in the event of low
battery condition the battery symbol shall be displayed,
v)
The meter shall indicate the quadrant of operation
8.
COMMUNICATION CAPABILITY:
i)
The meter should be preferably provided with both RS232 and RS485 port to enable
cascading meters in cluster and allow metering data of all the grouped meters to transfer
through one communication channel
ii)
All the meters shall have RS232 port for transfer of data from the meter to remote location
iii)
In addition to the above the meter shall have optical interfacing for local reading or
programming
iv)
The data transfer from the meter either through optical I/F or through RS232/485 port shall
be of open communication protocol. The protocol adopted shall confirm to ANSI Standards
/ European standards.
v)
The bidder should clearly state the adopted protocol. It is deemed as part of the tender that
the bidder will supply the required software for analysis of downloaded data on either
Oracle platform or any other platform mutually agreed
The bidder shall part with protocol details for development of any other programs required
for analyzing the data through third party for the following:
a)
b)
c)
d)
e)
vi)
Load profile memory
Blackout Register
Demand Violation
Exceptional reports
Diversity and Load Factor
The meter shall be compatible to external communication equipment using any one the
following technologies which can be designed by third party.
a.
PSTN
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b.
c.
d.
e.
GSM
VSAT
RADIO
PLCC
9.
ADDITIONAL FEATURES REQUIRED
a)
The meter shall have provision for TOD tariff with the following features
i)
Programmable upto 6 Energy and Demand registers.
ii)
Programmable upto 4 seasons per year
iii)
Provisions for assigning any particular day of the week to one or more registers.
b)
In case if the bidder guarantees life of the battery for 10 years and if average life of the
battery is found to be less and if the same cannot be replaced without opening main cover ,
then the bidder is liable for entire cost of replacements.
c)
The Integration time for load survey parameters shall be selectable at site using Password
without opening Factory seals. The Integration period shall be selectable between 1 min to
60 min in suitable steps.
d)
The meter shall have provision to store maximum demand occurred during the integration
period selected for KW, KVA and KVAR parameters during a month. The meter shall
monitor the demand during the period set and record for each of the TOD zones the
maximum registered values during the particular month.
e)
The meter shall have provision for maximum demand resetting automatically at the end of
Zero hours on the first day of every calendar month and also through an external push
button. The meter shall keep track of such resets and display cumulative value of such
resets. As an added feature History of few number of resets can also be offered
f)
The meter should register energy even when the load is not terminated back to the meter
though a neutral.
g)
The meter shall be capable of recording occurrences of missing potential in any of the
phases and its restoration with date and time and occurrences. The details of cumulative
accounts of such occurrences and cumulative period shall also be available as part of
external data output.
h)
The Load Survey Parameters to be stored in memory shall be cumulative consumption of
KWH, KVAH and KVARH during the integration period. In addition the meter shall have
provision to store average value of voltages, Currents and Frequency . The minimum
memory set shall be sufficient to store half an hour values of at least 8 parameters for 35
days on FIFO basis.
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i)
The meters shall identify and store in memory all occurrences and 'reset of unbalanced
voltages / currents in line / phase current. The trigger value shall be furnished to the
successful bidder.
j)
The meter shall have self diagnostic facility. It shall check periodically its performance of
its electronic circuits and software. The meter shall give error message on display in case of
detection of any mal-functioning within the meter and also as part of external data. The self
diagnostic features shall cover the following:
i)
ii)
iii)
iv)
Performance of electronic circuits and software
Missing Potential
Low battery condition
Attempt to communicate with the meter without proper Password
k)
Meter shall have Provision for setting R T C of the meter periodically within ± 1 minute at
the time of taking readings. The drift of the R T C and new setting shall be given in the
printout.
l)
The meters Preferably shall have facility for storing daily midnight value of cumulative
KWH, KVARH and KVAH for 35 days on FIFO
m)
The meter shall have minimum of five security levels
(i)
For downloading data
(ii)
for changing display Parameter of auto-scrolling
(iii)
For changing Parameters of load survey.
(iv)
For changing TOD register, time etc.
(v)
Measuring principle, computation, self diagnostic features.
The security shared with user shall be without opening main cover. However, it is the
responsibility of the meter manufacturer for the safe keeping of Password for the Security
level which gives access to meter measuring principle, computation, self diagnostic feature
etc.. Any losses incurred to the corporation in view of the leakage of the security level will
be charged to the manufacturer.
10
ACCURACY and GUARANTEE:
The accuracy shall be corresponding to the accuracy class stipulated in the relevant
standards for 0.2 / 0.5 S.
Each meter shall be guaranteed for its design, performance and accuracy for a period of ten
years. If the meter goes faulty during the period of guaranteed performance and accuracy, it
shall be replaced within 30 days failing which the firm will be blacklisted for further
orders. If replacements are not made within stipulated period, corporation reserves the right
to procure meters from outside sources for replacements and recover the cost of the same.
309 of 382
11
CONSTRUCTION OF METER :
a)
The meter shall be made of high quality bakelite or other improved insulating
material totally unaffected by radio frequencies, higher reliability and longer life
shall be ensured. The casing and terminal cover should be sturdy enough to prevent
damage during transport and installation. The meter shall be reliable in design and
should be of surface mount technology, easy to transport and immune to vibration
and shock. The case shall be so constructed such that any non-permanent
deformation does not prevent the satisfactory operation of the meter.
All the insulation materials used in the construction of the meter shall be nonhygroscopic, non-ageing, and of tested quality. Construction of the meter should be
such that it can be sealed independently and secured in such a way that the internal
part of the meter shall be accessible only after breaking the seals and ensure
prevention of tampering. The cover shall not be removable without the use of the
tool. For degree of protection against dust and moisture the meter shall conform to
IP 53 as per IS 12063/ IEC 529.
i)
ii)
iii)
b)
12
The base of the meter should have terminal block to facilitate front
connection. The terminal block should satisfy all conditions specified in IEC
1036 and IS 13779. the terminal cover should have separate sealing facility.
The various displays on the meter should have facility for cycled through up
and down push button.
The resetting of MD shall be achieved through a push button provided in
front of the meter with sealing provision or automatic at 00: 00 Hours of the
beginning of the month.
Every meter
shall be indelibly marked with a connection diagram and
abbreviations used. If the meter terminals are marked, this marking shall appear on
the diagram. Tie diagram shall be either on the meter or inside of the terminal
cover.
MARKING AND NAME PLATE:
Every meter shall be marked with the following Information and the marking shall be
indelible, distinct and clearly visible from outside the meter:
a)
Manufacturer‟s name or trade mark and the place of manufacture.
b)
Design of type which should not be same for any two of designs of meters.
c)
Principal unit in which the meter records. (for KWH , KVARH)
d)
Base voltage, Current and Frequency
e)
Purchase order and Date.
f)
The month and year in which the Guarantee period Expires.
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g)
13
Identification Number
ACCESSORIES OF THE METEREach meter should be accompanied by its Test certificate, present configuration, Software
for down loading, Detailed literature, Suitable lugs for current and voltage circuits.
i)
Necessary hardware for reading the meter through optical interfacing unit, and
RS232 / RS485 port.
One set of such kit shall be supplied for every 50 meters ordered.
ii)
The Bidder shall also supply suitable calibrator and Test Equipment for Testing the
accuracy of the meter, communication capability etc. The calibrators offered shall
have Memory to store at least 100 Nos previous calibrations test results and facility
for taking a print with a portable external printer. The Accuracy class of reference
meter shall be as recommended in relevant Standards for that class of meter. The
necessary scanner having suitable optical head is deemed as part of the
specifications. One set of Test equipments shall be supplied with every 500 meters
or part thereof.
In case the calibrator does not have memory to store all the information downloaded
from the meter, then one Laptop PC shall also be supplied per Calibrator for
collecting the information from the meter memory.
The Bidder shall also supply necessary equipments to check the external
communication outputs.
14
TESTS: TYPE TEST, ACCEPTANCE AND ROUTINE TESTS
Latest type test certificate issued only for the tender sample model has to be submitted in
full and the copies shall be legible / valid.
The hard copies of the output that can be obtained through base computer from the data
downloaded shall be submitted along with the bid
Recommended Type tests., Acceptance and Routine Tests are as per the table at Appendix
V
Sampling plan while conducting Type/ Routine tests shall be as per IS :4905
15
APPENDIX:
APPENDIX - I
APPENDIX - II
APPENDIX - III
APPENDIX - IV
APPENDIX - V
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APPENDIX - I
List of display parameters required:
Scrolling Parameters
A)
B)
BILLING PARAMETERS
1.
Meter Serial number.
2.
Time, Date, Month, Year
3.
Billing KWH - (Universal TOD Register)
4.
Billing KVA, KW MD in TOD Register (Universal TOD Register)
5.
Billing P.F - (Universal TOD Register)
6.
MD Reset count MD last reset date
7.
Self diagnostic display
INSTANTANEOUS PARAMETERS
1.
2.
3.
4.
5.
6.
C)
CUMULATIVE PARAMETERS OF UNIVERSAL (00-24 Hours)
REGISTER.
1.
2.
3.
4.
D)
KWH
KVAH
KVARH Lag & Lead
KVA MD, KW MD, RKVA MD
HIGH RESOLUTION MODE
1.
2.
3.
4.
E)
Phase wise Currents
Phase wise voltages
Instantaneous average P.F
Demand with elapsed time
Running period MD, P.F
Frequency
KWH
KVAH
RKVAH
Phase wise angles between Voltages and Currents
TODZone and time slabs
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Note: The parameters for Automatic scrolling display shall be dynamically selectable through
user's password and without opening of main cover
APPENDIX - II
Measuring principle to be adopted for KVAH and PF
KVAH = √ ( KWH 2 + KVARH 2 ) for lagging PF
KVAH = KWH
for leading PF ( RKVAH = 0 )
(only for consumer meter or single quadrant meters)
PF = (KWH) / (KVAH)
Note : In case of single quadrant meter, the energy transfer during current reversal condition shall
be added to the main register. However, it is preferred in addition to the above, if energy transfer in
this quadrant is available in an independent register.
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APPENDIX - III
Software requirement
1.
Dynamic selection of scrolling parameters, demand sub-intervals (Except universal
register), TOD registers time interval configuration, shall be possible with users password
and without opening main cover.
2.
Along with Monthly bill Records, the following information shall be downloaded to MRI
or PC.
a) Meter ID, Time, Report date as HEADER in all pages
b) Meter configuration consisting of the following Meter data i.e. Serial No., Software
version, Hardware version, Base current and Voltage accuracy class, Pulse output,
anomaly indication etc.
c) All parameter values identified for scrolling display (i.e., auto scrolling and manual
Scrolling)
d) Cumulative counts and duration of all Tamper information
e) Billing data of TOD Registers selected
f) Status of all parameters that can be changed with user's password
g) RTC time before taking monthly reading and after taking monthly reading.
3.
4.
5.
On Demand
a)
Load Survey Data of all parameters, suitable software for obtaining Graphical and
Tabular outputs of all the parameters over a selected period
b)
Detailed data of abnormal conditions occurred.
c)
Historical data of all cumulative parameters for previous 12 months.
d)
Historical data of software changes made.
e)
Historical data of cumulative parameter for previous 30 days (optional)
Remote Meter Reading
a)
Instantaneous Parameters
b)
All Parameters stated in para 2 & 3
Software required on base computer
a)
b)
Software for adding and sub-tracking load survey parameters of selected group of
meters over a period of time..
Selection of Instantaneous/tamper details during defined/selected Time Zones
c)
Protocol information for analyzing all data read from the meters.
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d)
For generation of bills with the existing billing software.
315 of 382
APPENDIX - IV
Abnormal conditions to be identified on FIFO basis ( First In First Out)
The meter shall be capable of recording the following conditions and restoration with duration and
also the account of cumulative total number of such occurrences and cumulative duration. The
number of events stored in the memory shall be minimum of 250Nos. One event means one set of
occurrence and restoration of that disturbance.
1. Potential missing to the meter. (single phase or all phases)
2. Current reversal.
3. Unbalanced voltages and current.
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APPENDIX - V
Test reports to be furnished:
SL
No.
1
1.1
1.2
1.3
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3
3.1
3.2
3.3
3.4
3.5
4
4.1
4.2
4.3
4.4
5
5.1
5.2
5.3
6
6.1
6.2
6.3
7
7.1
7.2
Tests
Laboratory
name
Date of
test
Test
conforms to
Remarks
IS/IEC/CBIP
specification
Test of insulation properties
Impulse voltage test
AC voltage test
Insulation resistance test
Test of accuracy requirements
Test on limits of errors
Test of meter constant
Test of starting condition
Test of no-load condition
Repeatability of error test
Test of ambient temperature
influence
Test of influence quantities
Measurement of phase current
Test of electrical requirements
Test of power consumption
Test of influence of supply
voltage
Test of influence of short time
over currents
Test of influence of self heating
Test of influence of heating
Test
of
electromagnet
compatibility (EMC)
Radio interference measurement
Fast transient burst test
Test
of
immunity
to
electromagnetic HF field
Test of electrostatic discharge
Test of climatic influence
Dry heat test
Cold test
Damp heat, cyclic test
Test
of
mechanical
requirements
Vibration test
Test of protection against
penetration of dust and water
Test of resistance to heat and fire
Software
Protacol
Levels of security provided
317 of 382
7.3
Levels of security provided to
the users
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ANNEXURE – RPP1 – SAS
RELAY & PROTECTION PANEL FOR 220 KV FEEDERS AND BUS COUPLER FOR
STATIONS WITH SUBSTATION AUTOMATION SYSTEM.
(TYPE-2L – FOR 220 KV FEEDERS)
(TYPE-2BC – FOR 220 KV BUS COUPLER)
The SIMPLEX panel shall generally consist of following items:
QUANTITIES
Sl. No.
PARTICULARS
2L
2BC
A
MEASUREMENT & CONTROL:
Bay Control Intelligent Electronic Device
1 No.
1No.
1
As per Cl. No.
3.1.1.1 – Over view
3.1.1.2 – Control & Selection.
3.1.1.3 – Synchronisation & energizing check.
3.2
- System level function
3.2.1 - Status supervision.
3.2.2 - Measurements.
3.2.3 - event & alarm handling.
AC 3 Phase, 2 element, Electronic Tri-Vector meter
1 No.
1No.
2 (a)
(TVM), Accuracy 0.2 with ABT & TOD features
and shall conform to detailed specification
furnished.
1 No.
1No.
(b) Test Terminal block for TVM
Selector switch for control of 220KV CB & 220KV
1 No.
1No.
3.
isolator from local, RemoteBay control unit and
remote – SCADA
Selector Switch with indication
1 No.
4
a) For bus coupler off – FDR1-FDR2…../TR1, TR2
b) For double bus arrangement, for selection of trip
1 No.
1No.
transfer scheme between Feeder/ Transformer and
bus coupler with locking facility.
c) For selection line CVT & bus VT
1 No.
Indication & alarm
1 No.
1 No.
5
As described in Annexure of specification
319 of 382
ANNEXURE – RPP1 – SAS
RELAY & PROTECTION PANEL FOR 220 KV FEEDERS AND BUS COUPLER FOR STATIONS
WITH SUBSTATION AUTOMATION SYSTEM.
Sl. No.
B
1
2
3
PARTICULARS
RELAYS
Main Protection Relay:
a) Numerical / digital distance scheme with fault locator,
disturbance recorder, event recorder suitable for 3-ph /
single phase tripping with other features as described in the
detailed specifications, with test switch- Main-I protection
b) Numerical / digital distance scheme with fault locator,
disturbance recorder, event recorder suitable for 3-ph /
single phase tripping with other features as described in the
detailed specifications, with test switch- Main-II protection.
1 Set
-
Note: Main-II numerical distance protection relay shall be of make
different from that of Main-I.
1 Set
-
-
--
-
--
--
2 Nos.
--
1 No.
Lot
Lot
6 Sets
6 Sets
1 Set
1 Set
1 Set
-
2 Sets
As
require
d
1 No.
2 Sets
As required
1 Set
--
Back-up protection:
a) Numerical directional over current potentially polarized
IDMT relays without instantaneous elements.
b) Numerical directional earth fault potentially polarized
IDMT relays without instantaneous elements
c) Numerical non-directional over current IDMT relay with
instantaneous element.
d) Numerical non-directional earth fault IDMT relay with
instantaneous element.
e) Carrier receive relays, auxiliary relays, timers etc as per
scheme requirements.
Breaker Auxiliary Relays:
a) Trip circuit supervision relay
b) 3 Phase Tripping relay (1 for main-I, 1 for mainII/backup protection & 1 for bus-bar protection)
c) Single phase tripping relay 3 for Main-I & 3 for Main-II
d) DC supply monitoring relay
e) Flag relays, auxiliary relays, timers etc., as per scheme
requirement (breaker failure protection)
f) Local breaker back up relays
g) Auto reclose scheme with check synchronizing and dead
4
QUANTITIES
2L
2BC
line charging relay
Other devices:
a) Test terminal block
b) PVC circuit labels
c) One label indicating manufacturers name, P.O. details,
drawing reference number etc.
d) Internally mounted equipments
1 No.
If required see note
2 Nos.
2 Nos.
1 No.
1 No.
1 Set
1 Set
320 of 382
ANNEXURE – RPP1 – SAS
RELAY & PROTECTION PANEL FOR 220 KV FEEDERS AND BUS COUPLER FOR
STATIONS WITH SUBSTATION AUTOMATION SYSTEM.
NOTE:
1. Other accessories required for operation of the protective scheme including interconnections
shall be included.
2. Numerical distance scheme shall be suitable for all line lengths. Any limitation shall be clearly
specified.
3. The static devices in addition to name plate, shall have labels indicating the function that are
part of that particular relays and their codes in the drawings.
4. Suitable interlock arrangements shall be provided for selection of PT voltages, so that there
should not be paralleling of PT secondaries or energisation of PT secondary of a PT, which is
not charged.
5. Suitable interlock arrangement shall also be provided to prevent local / remote electrical
operation of bus selection isolator when the corresponding breakers are closed.
6. TTB for protection circuit to be provided if the relays are of non-draw out type.
321 of 382
ANNEXURE – RPP1 –Cable – SAS
RELAY & PROTECTION PANEL FOR 220 KV CABLE FEEDERS FOR STATIONS WITH
SUBSTATION AUTOMATION SYSTEM.
(TYPE-2L – FOR 220 KV CABLE FEEDERS)
The SIMPLEX panel shall generally consist of following items:
QUANTITIES
Sl. No.
PARTICULARS
2L
A
MEASUREMENT & CONTROL:
Bay Control Intelligent Electronic Device
1 No.
1
As per Cl. No.
3.1.1.1 – Over view
3.1.1.2 – Control & Selection.
3.1.1.3 – Synchronisation & energizing check.
3.2
- System level function
3.2.1 - Status supervision.
3.2.2 - Measurements.
3.2.3 - event & alarm handling.
AC 3 Phase, 2 element, Electronic Tri-Vector meter
1 No.
2 (a)
(TVM), Accuracy 0.2 with ABT & TOD features
and shall conform to detailed specification
furnished.
1 No.
(b) Test Terminal block for TVM
Selector switch for control of 220KV CB & 220KV
1 No.
3.
isolator from local, RemoteBay control unit and
remote – SCADA
Selector Switch with indication
4
a) For bus coupler off – FDR1-FDR2…../TR1, TR2
b) For double bus arrangement, for selection of trip
1 No.
transfer scheme between Feeder/ Transformer and
bus coupler with locking facility.
c) For selection line CVT & bus VT
1 No.
Indication & alarm
1 No.
5
As described in Annexure of specification
ANNEXURE – RPP1 – Cable - SAS
RELAY & PROTECTION PANEL FOR 220 KV CABLE FEEDERS FOR STATIONS WITH
SUBSTATION AUTOMATION SYSTEM.
QUANTITIES
Sl. No.
PARTICULARS
322 of 382
2L
RELAYS
1
Main Protection Relay:
Main I - Numerical current differential
protection unit based on phase segregated
principle and restrained dual bias operating
detailed in the specification.
Main II – Numerical current differential
protection unit based on phase segregated
principle and restrained dual bias operating
detailed in the specification.
2
4
protection with
line differential
characteristic as
protection with
line differential
characteristic as
1 Set
1 Set
Note:
a)Main-II numerical current differential protection relay shall
be of a make different from that of Main-I
b) Optic fibre is used for communication for tripping the other
end relays. Communication protocol of IEC 61850 & IEC
60870-5-103 shall be used in case the other end relays are with
SAS. Communication protocol of IEC 60870-5-104 shall be
used in case other end relays are with SCADA system (only
RTU)
Breaker Auxiliary Relays:
h) Trip circuit supervision relay
6 Sets
i) Tripping relay (1 for main-I, 1 for Mai-II& 1 for bus-bar
1 Set
protection)
j) DC supply monitoring relay
1 Set
k) Flag relays, auxiliary relays, timers etc., as per scheme
As required
requirement (breaker failure protection)
l) Local breaker back up relays
1 No.
m) Auto reclose scheme with check synchronizing and dead
1 Set
line charging relay
Other devices:
e) Test terminal block
If required see
note
f) PVC circuit labels
2 Nos.
g) One label indicating manufacturers name, P.O. details,
1 No.
drawing reference number etc.
h) Internally mounted equipments
1 Set
323 of 382
ANNEXURE – RPP1 – CABLE-SAS
RELAY & PROTECTION PANEL FOR 220 KV CABLE FEEDERS FOR STATIONS
WITH SUBSTATION AUTOMATION SYSTEM.
NOTE:
1. Refer Note of Annexure CRP-1 SAS wherever applicable.
324 of 382
ANNEXURE – RPP2 – SAS
RELAY & PROTECTION PANEL FOR 100 MVA, 220/66/11 KV
STAR-STAR-DELTA, THREE WINDING POWER TRANSFORMER
OR
220/110/11 KV STAR-STAR-DELTA, AUTO-TRANSFORMERS FOR STATIONS WITH
SUBSTATION AUTOMATION SYSTEM.
(TYPE-2T6 & 2T1)
2T6 FOR 220/66/11 KV TRANSFORMERS
The SIMPLEX C & R panel shall generally consist of the following items:
Sl. No.
A
1
2 (a)
(b)
3.
4 (a)
5
PARTICULARS
QUANTITIES
2T6
MEASUREMENT & CONTROL:
Bay Control Intelligent Electronic Device for both
HV & MV side
As per Cl. No.
3.1.1.1 – Over view
3.1.1.2 – Control & Selection.
3.1.1.3 – Synchronisation & energizing check.
3.1.1.4 – Transformer Tap changer control
3.2
- System level function
3.2.1 - Status supervision.
3.2.2 - Measurements.
3.2.3 - event & alarm handling.
AC 3 Phase, 2 element, Electronic Tri-Vector meter
(TVM), Accuracy 0.2 with ABT & TOD features
and shall conform to detailed specification
furnished on both HV side &LV side.
Test Terminal block for TVM
Selector switch for control of 220KV and
110/66KV CB & 220KV and 110KV/66KV
isolator from local, Remote Bay control unit and
remote- SCADA
For double bus arrangement, for selection of trip
transfer scheme between Feeder/ Transformer and
bus coupler with locking facility.
Indication & alarm
As described in Annexure of specification
1 Set.
2 Nos.
2 Nos.
2 Nos.
1 No.
1 No.
ANNEXURE – RPP2 – SAS
325 of 382
RELAY & PROTECTION PANEL FOR 150MVA, 220/66/11 KV
STAR-STAR-DELTA, THREE WINDING POWER TRANSFORMER
FOR STATIONS WITH SUBSTATION AUTOMATION SYSTEM. (SCADA)
Sl. No.
B
1
PARTICULARS
QUANTITIES
2T6
PROTECTION RELAYS:
Main Protection Relay:
a) Numerical triple pole high speed percentage bias
differential relay with high set instantaneous
element suitable for three winding transformers
with fixed ratio ICT‟s.
b) Over Flux relay.
1 No.
c) Restricted earth fault relay
d) Over load relay
2 Nos.
1 No.
1 Set
326 of 382
ANNEXURE – RPP2 – SAS
RELAY & PROTECTION PANEL FOR 150MVA, 220/66/11 KV
STAR-STAR-DELTA, THREE WINDING POWER TRANSFORMER
FOR STATIONS WITH SUBSTATION AUTOMATION SYSTEM. (SCADA)
Sl. No.
QUANTITIES
PARTICULARS
2 Back-up protection:
2T6
a) Numerical directional over current potentially
polarized IDMT relays with high set
3 Nos.
instantaneous elements (on HV side).
b) Numerical directional over current potentially
polarized IDMT relays with high set
3 Nos.
instantaneous elements (on MV side)
c) Numerical directional earth fault IDMT relay
with potentially polarized IDMT relays with
1 No.
high set instantaneous elements (on HV side).
d) Numerical directional earth fault potentially
polarized IDMT relays with high set
1 No.
instantaneous elements (on MV side)
e) Numerical non-directional over current IDMT
relay with high set instantaneous elements
(suitable for 1000/1 Amps) for protection of
3 Nos.
tertiary winding due to circulating current in
delta winding.
f) Flag relays, auxiliary relays, timers etc., as per
scheme requirement
3 Breaker Auxiliary Relays:
a) Trip circuit supervision relay (HV side)
6 Sets
b) Trip circuit supervision relay (MV side)
2 Sets
c) i. Inter tripping relay (to trip both HV & MV
side
1 Set
of the transformer
1 Set
ii. Tripping relay MV side
1 Set
iii. Tripping relay for Bus-bar
d) DC supply monitoring relay
1 Set
e) Auxiliary relays for Bucholtz trip/alarm,
winding temperature high trip/alarm, oil
As required
temperature high trip/alarm, oil surge relay trip,
pressure relief device trip
f) Flag relays, auxiliary relays, timers etc., as per
As required
scheme requirement
g) Local breaker back up relays (breaker failure
1 No.
protection)
327 of 382
ANNEXURE – RPP2 – SAS
RELAY & PROTECTION FOR 150MVA, 220/66/11 KV
STAR-STAR-DELTA, THREE WINDING POWER TRANSFORMER
FOR STATIONS WITH SUBSTATION AUTOMATION SYSTEM. (SCADA)
Sl. No.
PARTICULARS
4 Other devices:
a) Test terminal block
b) PVC circuit labels
c) One label indicating manufacturers name, P.O.
details, drawing reference number etc.
d) Internally mounted equipments
QUANTITIES
2T6
If required see note
2 Nos.
1 No.
1 Set
NOTE:
2. Refer Note of Annexure CRP-1 SAS wherever applicable.
328 of 382
ANNEXURE – RPP-3 SAS
SIMPLEX TYPE PANEL FOR 220 KV BUS-BAR PROTECTION
TYPE-2 BBA
FOR SUBSTATION WITH SUBSTATION AUTOMATION SYSTEM (SCADA)
Sl. No.
PARTICULARS
1 PVC Circuit labels
2 Internal equipment and small wiring like cubicle
3 Triple pole high speed percentage biased static /
numerical relays
4 Bus barCT secondary wiring supervision and shorting
relays
5 DC Controlling Voltage supervision relays
6 High speed tripping relay for tripping of breakers
7 CT selection / switching relays with adequate number
of NO/NC contacts
8 Bus Zone Indication relays
9 Terminal blocks suitable for testing of the above relay
10 DC fail indication.
QUANTITIES
2 Sets
1 Set
1 Set
As required
1 Set
As required
As required
As required
As required
The offer should include if necessary marshalling
kiosks for CT wring etc., that are needed for
satisfactory working and other internal equipments.
The scheme shall be suitable for adding additional line
/ transformer in each station and all necessary
accessories are to be provided.
329 of 382
ANNEXURE – RPP -4 – SAS
RELAY & PROTECTION PANEL FOR 110/66 KV FEEDERS
(TYPE 6L – FOR 66 KV FEEDER)
FOR STATION WITH SUBSTATION AUTOMATION
(SCADA)
The SIMPLEX panel shall generally consist of the following items:
Sl. No.
A
1
2 (a)
(b)
3.
4
PARTICULARS
MEASUREMENT & CONTROL:
Bay Control Intelligent Electronic Device
As per Cl. No.
3.1.1.1 – Over view
3.1.1.2 – Control & Selection.
3.1.1.3 – Synchronisation & energizing check.
3.2
- System level function
3.2.1 - Status supervision.
3.2.2 - Measurements.
3.2.3 - event & alarm handling.
AC 3 Phase, 2 element, Electronic Tri-Vector meter
(TVM), Accuracy 0.2 with ABT & TOD features
and shall conform to detailed specification
furnished.
Test Terminal block for TVM
Selector switch for control of 110/66KV CB &
110/66KV isolator from local, RemoteBay control
unit and remote – SCADA
Selector Switch with indication
a) For bus coupler off – FDR1-FDR2…../TR1, TR2
b) For double bus arrangement, for selection of trip
transfer scheme between Feeder/ Transformer and
bus coupler with locking facility.
c) For selection line CVT & bus VT
QUANTITIES
6L
1No.
1No.
1No.
1No.
1 No.
1No.
-
330 of 382
ANNEXURE – RPP -4 – SAS
RELAY &PROTECTION PANEL FOR 66 KV FEEDERS
Sl. No.
B
1
2
3
4
PARTICULARS
QUANTITIES
6L
RELAYS:
Main Protection Relay:
Numerical distance scheme suitable for 3 phase
tripping with other features as described in the
detailed specification with test switch.
Back-up protection:
a)
Numerical
directional
over
current
potentially polarized IDMT relays without
instantaneous elements.
b)
Numerical directional earth fault potentially
polarized IDMT relays without instantaneous
elements
c)
Flag relays, auxiliary relays, timers etc., as
per scheme requirement.
Breaker Auxiliary Relays:
a) Trip circuit supervision relay
b) Tripping relay (1 for main 1 for backup
protection)
c) DC supply monitoring relay
d) Flag relays, auxiliary relays, timers, etc., as per
scheme requirement
Other devices:
a)
Test terminal block
b)
PVC circuit labels
c)
Label indicating manufacturers name, P.O.
details, drawing reference number etc.
d)
Internally mounted equipments
1 Set
2 Nos.
1 No.
As required
2 Sets
1 Set
1 Set
As required
2 Nos.
1 No.
1 Set
NOTE: Refer Note of Annexure CRP-1, wherever applicable.
331 of 382
ANNEXURE – RPP -4 - CABLES – SAS
RELAY &PROTECTION PANEL FOR 66 KV FEEDERS
(TYPE 6L – FOR 66 KV CABLE FEEDER)
FOR STATION WITH SUBSTATION AUTOMATION
(SCADA)
The SIMPLEX panel shall generally consist of the following items:
Sl. No.
A
1
2 (a)
(b)
3.
4
PARTICULARS
MEASUREMENT & CONTROL:
Bay Control Intelligent Electronic Device
As per Cl. No.
3.1.1.1 – Over view
3.1.1.2 – Control & Selection.
3.1.1.3 – Synchronisation & energizing check.
3.2
- System level function
3.2.1 - Status supervision.
3.2.2 - Measurements.
3.2.3 - event & alarm handling.
AC 3 Phase, 2 element, Electronic Tri-Vector meter
(TVM), Accuracy 0.2 with ABT & TOD features
and shall conform to detailed specification
furnished.
Test Terminal block for TVM
Selector switch for control of 110/66KV CB &
110/66KV isolator from local, RemoteBay control
unit and remote – SCADA
Selector Switch with indication
a) For bus coupler off – FDR1-FDR2…../TR1, TR2
b) For double bus arrangement, for selection of trip
transfer scheme between Feeder/ Transformer and
bus coupler with locking facility.
c) For selection line CVT & bus VT
QUANTITIES
6L
1No.
1No.
1No.
1No.
1 No.
1No.
-
332 of 382
ANNEXURE – RPP -4 - CABLES– SAS
RELAY &PROTECTION PANEL FOR 66 KV CABLE FEEDERS
Sl. No.
B
1
2
3
4
PARTICULARS
QUANTITIES
6L
RELAYS:
Main Protection Relay:
Numerical current differential protection with protection unit
based on phase segregated line differential principle and
restrained dual bias operating characteristic as detailed in the
specification.
1 Set
Note: Optic fibre is used for communication for tripping the
other end relays. Communication protocol of IEC 61850 & IEC
60870-5-103 shall be used in case the other end relays are with
SAS. Communication protocol of IEC 60870-5-104 shall be
used in case other end relays are with SCADA system (only
RTU)
Back-up protection:
d) Numerical directional over current potentially polarized
IDMT relays without instantaneous elements.
2 Nos.
e) Numerical directional earth fault potentially polarized
IDMT relays without instantaneous elements
1 No.
f) Flag relays, auxiliary relays, timers etc., as per scheme
requirement.
As required
Breaker Auxiliary Relays:
e) Trip circuit supervision relay
2 Sets
f) Tripping relay (1 for main 1 for backup protection)
g) DC supply monitoring relay
h) Flag relays, auxiliary relays, timers, etc., as per scheme
requirement
Other devices:
e) Test terminal block
f)PVC circuit labels
g)Label indicating manufacturers name, P.O. details, drawing
reference number etc.
1 Set
1 Set
h)Internally mounted equipments
As required
2 Nos.
1 No.
1 Set
NOTE:
1. Refer Note of Annexure CRP-1 SAS wherever applicable.
333 of 382
ANNEXURE – RPP -6 – SAS
RELAY & PROTECTION PANEL FOR 66 KV BUS COUPLER
(TYPE-6BC FOR 66 KV BUS COUPLER)
FOR STATION WITH SUBSTATION AUTOMATION SYSTEM
The SIMPLEX panel shall generally consist of the following items:
Sl. No.
A
1
2 (a)
(b)
3.
4
PARTICULARS
MEASUREMENT & CONTROL:
Bay Control Intelligent Electronic Device
As per Cl. No.
3.1.1.1 – Over view
3.1.1.2 – Control & Selection.
3.1.1.3 – Synchronisation & energizing check.
3.2
- System level function
3.2.1 - Status supervision.
3.2.2 - Measurements.
3.2.3 - event & alarm handling.
AC 3 Phase, 2 element, Electronic Tri-Vector meter
(TVM), Accuracy 0.2 with ABT & TOD features and
shall conform to detailed specification furnished.
Test Terminal block for TVM
Selector switch for control of 110/66KV CB &
110/66KV isolator from local, RemoteBay control unit
and remote – SCADA
Selector Switch with indication
a) For bus coupler off – FDR1-FDR2…../TR1, TR2
b) For double bus arrangement, for selection of trip
transfer scheme between Feeder/ Transformer and bus
coupler with locking facility.
QUANTITIES
6BC
1No.
1No.
1No.
1No.
1 No.
1No.
334 of 382
ANNEXURE – RPP -6 – SAS
RELAY & PROTECTION PANEL FOR 66 KV BUS COUPLER
Sl. No.
B
1
2
3
PARTICULARS
QUANTITIES
6BC
PROTECTION RELAYS:
Back-up protection:
a) Numerical non-directional over current IDMT
relay with instantaneous element.
b) Numerical non-directional earth fault IDMT
relays with instantaneous elements
c) Flag relays, auxiliary relay, timers etc., as per
scheme requirement.
Auxiliary Relays:
a) Trip circuit supervision relay
b) Tripping relay (1 for main & 1 for backup
protection)
c) DC supply monitoring relay
d) Local breaker back up relays (breaker failure
protection)
e) Flag relays, auxiliary relay, timers etc., as per
scheme requirement
Other devices:
a) Test terminal block
b) PVC circuit labels
c) One label indicating manufacturers name, P.O.
details, drawing reference number etc
d) Internally mounted equipments
2 Nos.
1 No.
Lot
2 Sets
1 Set
1 Set
1 No.
Lot
If required see
note
2 Nos.
1 No.
1 Set
NOTE: Refer Note of Annexure CRP-1, wherever applicable.
335 of 382
ANNEXURE –SAS
SCHEDULE OF REQUIREMENT FOR SUB-STATION AUTOMATION SYSTEM IN
220KV SYATIONS
Particulars
1)
2)
3)
4)
5)
6)
7)
Station Human Machine Interface
Hot Stand by Station HMI.
Redundant managed switched Earth net Local area Network communication infrastructure
including optic fibre cable etc., with hot stand by ( to RCC & RSCC)
Gate way for remote control via industrial grade hardware through IEC 60870-5-104
protocal.
Peripheral equipment line printer display unit key Board mouse etc.,
system software and Hardware for reliable operation of SAS in conformity with Technical
specification.
Other accessories required for reliable operation of SAS as per Technical specification.
336 of 382
ANNEXURE –RP –GTP
SECTION – RELAY AND PROTECTION PANEL
SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS OF CONTROL
EQUIPMENT AND RELAYS
Bidder's Name
Sl. No.
Description
A.
PANELS :
I
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description, Construction & formation details :
Make and Type reference of manufacturer
Type
i) type of construction or simplex
ii) type of scheme
a) for line
b) for power transformer
Thickness of sheet steel (mm):
i. Door, Top and Bottom of panel
ii. Other
Tentative overall dimensions (L*B *H) (mm) of each
panel
Dead weight of each panel (Kgs)
Approximate weight of each panel with all components
(Kgs)
Details of packing for transport
Overall dimensions of transport package (L*B*H) (mm)
Approximate gross weight of transport package (Kgs)
Exterior paint film thickness (microns) and paint colour
Interior paint film thickness (microns) and paint colour
Cubicle Lighting : Volts, wattage, Type of holder and
fitting whether provided with door control switch or not.
Safety earthing :
a. Material of conductor
b. Size (W*T) (mm)
c. Surface treatment and finish of conductor.
d. Type of end connection
Panel front/rear component identity board
a.
b.
c.
d.
Sl. No.
15
Material
Size
Size of lettering and colour
Method of fixing
Description
Panel wiring :
337 of 382
16
II.
1
2
3
4
5
6
7
III.
1
2
3
4
IV
a. Type and material of wire conductors, insulation and
voltage grade.
b. Conductor cross sectional area or strands/gauge of
wire and colour scheme adopted for :
i. VT secondary circuits and annunciation circuit.
ii. Other Circuits.
c. Type of wire termination
Mimic bus details :
a. Type painted / strip fixed
b. Width (mm)
c. Whether colour scheme specified will be followed
d. If not specify deviations.
TERMINAL BLOCKS AND CONNECTORS (USED
FOR PANEL WIRING)
Make and Type reference of manufacturer
Insulation and voltage grade
Constructional details
Current rating of studs, size and material
Whether shrouding provided or not
Whether space terminals provided or not
Literature enclosed.
INDICATING LAMPS :
Wattage and voltage of lamp
Size of lens and material thereof
Type of lamp holder
Whether provided with series resistor? If yes, specify
Ohmic value power loss
FUSE HOLDERS AND FUSES :
1
Make and Type reference of manufacturer
2
3
4
5
6
Insulation and voltage grade
Type of Insulation material
Type of fuses
Rating of fuses provided for different circuits
Literature enclosed.
338 of 382
Sl. No.
VI.
1
2
3
4
5
6
7
8
9
VII.
1
2
3
4
5
6
7
VIII
1
2
Description
SELECTOR SWITCHES :
Make and Type reference of manufacturer
Type of handle / Switch
Mounting details
Number of positions
Number of contracts available in each position.
a. Open
b. Close
Making capacity of contacts
Breaking capacity of contacts
Whether locking arrangement is available.
Whether detailed literature and drawings enclosed.
(YES/NO)
PUSH BUTTONS :
Make and Type reference of manufacturer
Mounting details
Type of contact
Current and voltage rating
No. of contacts
a. NO
b. NC
Whether shrouding provided to prevent inadvertent
operation (YES/NO)
Whether provided with integral engraved inscription
plates (YES/NO)
AUXILIARY CT's VT'S :
Make and Type reference of manufacture
a. Type
b. Ratios available
c. Burden V A
d. Standard to which it conforms
e. Accuracy class
f. Short time current / voltage rating
g. Temperature rise
h. One minute power frequency withstand voltage
j. Mounting dimensional details
j. Weight
Sl. No.
Description
k. Panel in which to be provided with quantity thereof
and connected ratio
339 of 382
3
4
IX.
1
2
3
4
II
1
2
3
4
5
6
C
I
1
2
3
For CT's only
a. Knee point voltage (KPV) (Volts)
b. Excitation current at KPV and 50% KPV (ma)
c.
Internal impedance of primary and secondary
windings in ohms
Literature enclosed.
SPACE HEATERS :
Make and Type reference of manufacture
Type of space heater (Tubular / strip type)
Rating Wattage
Whether thermostat provided (YES/NO)
INSTRUMENT TEST TERMINAL BLOCKS :
Make and Type reference of manufacturer
Insulation class and rating
Size and mounting details
Type of CT terminal shorting mechanism (LINK /
SCREW)
Type of VT terminal Isolating Mechanism
Whether detailed literatures enclosed. (YES/NO)
GENERAL PROTECTION RELAYS :
The tenderer shall furnish guaranteed Technical
particulars for all types of relay offered, in the following
proforma (separate sheet shall be enclosed for each type
of relay :)
Manufacturer's name or trade marks
Type designation
Size and mounting details (whether in draw out case)
340 of 382
Sl. No.
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
II
1
2
3
A
Description
Rated Values of both input and auxiliary energizing
quantities
Values of the limits of the operative range(s) of the
auxiliary energising quantity (ies)
Contacts data, Number and rating of main and auxiliary
contacts
Rated value or setting range of the characteristic
quantities and or angle
Limiting short-time thermal withstand values
Limiting dynamic values.
i. Burden data ( in case of poly input relays - data shall
be furnished for appropriate set of input terminals).
a. At highest tap - AC current / voltage coil
b. At lowest tap - AC current / voltage (coil)
ii. DC power consumption.
Impulse and dielectric test voltage(s)
Details of accessories (If essential to the relay
performance)
Details of accessories (Optional items)
Whether provided with seal in trip contacts
a. Type of operating characteristics
b. Accuracy of operating characteristics, operating time
with details
H.F. disturbance test voltage (s)
Whether literature enclosed
Type of relay flag indicator and rating of target coil
In addition to the above details, the following details
shall also be furnished for relays specified below :
DOCR / DEFR :
a. Directional sensitivity
b.Minimum voltage at which the directional units operate
c. Characteristic angle
OVER FLUXING RELAY :
a. Whether provided with timer if so time setting
available for Alarm and delayed trip.
Distance Protection Scheme for 220KV / 110KV /
66KV Lines:
Type of distance measuring element
a. Starting unit
i. Type of scheme
b, No. of measuring element or comparator with details
341 of 382
Sl. No.
Description
c. Setting range of the distance measurement
d. No. of zones
i. Overall range for all zones.
ii. Reach setting range at rated current.
Zone - 1 (forward) - ohms
Zone - 2 (forward) - ohms
Zone - 3 (forward) - ohms
Off set zone 3 reverse - ohms
Zone extension (if any)
e. Characteristic of each zone
Zone - 1
Phase fault unit
Earth fault unit
Zone - 2
Phase fault unit
Earth fault unit
Zone - 3
Phase fault unit
Earth fault unit
Zone - 3 off set
Zone -1 in ohms
1. Reach of the relay along with characteristic angle at
rated current and voltage
2. Reach of the relay in resistive direction at rated
current & voltage
3. Reach in reactive direction at rated current & voltage
Zone - 2 in ohms
1. Reach of the relay along with characteristic angle at
rated current and voltage
2. Reach of the relay in resistive direction at rated
current & voltage
3. Reach in reactive direction at rated current & voltage
Zone - 3 in ohms
1. Reach of the relay along with characteristic angle at
rated current and voltage
2. Reach of the relay in resistive direction at rated
current & voltage
3. Reach in reactive direction at rated current & voltage
342 of 382
Sl. No.
B.
C.
Description
Zone - 3 in Reverse ohms
1. Reach of the relay along with characteristic angle at rated
current and voltage
2. Reach of the relay in resistive direction at rated current &
voltage
3. Reach in reactive direction at rated current & voltage
f. Power swing blocking characteristic setting
i. Forward reach
ii. Reverse reach
g. Setting range of residual compensation
h. Setting range of mutual compensation
i. (i) Operating time
Zone - 1
(ii) Time setting range
Zone -2
Zone -3
Power swing blocking
j. Accuracy
Zone - 1 (reach)
Zone - 2 (reach)
Zone - 3 (forward reach)
K. Polarising scheme
Zone - 1
Zone - 2
Zone - 3
Additional featues provided :
a. Fault locator
b. Carrier aided tripping scheme
c. Power swing blocking
d. Broken conductor detection
e. Synchronous check
f. Weakend infeed
g. Switch on to fault
h. Fuse failure supervision
Facilities available for Fault Locator
a. Name and type reference of manufacturer
b. Rating and setting available
c. Rated V A burden
d. Power consumption voltage and current element
343 of 382
Sl.
No.
D
E
F
4
5
Description
e. Memory capacity with details
f. Triggering method
g. Accuracy
h. Method of accuracy
Auto Recloser:
a) Reclosing facilities available
b) Single phase/three phase dead time range.
c) Reclaim time range
d) No. of modes selectable by selection switch
e) Provision of Check synchronizing features and its time setting,
range phase angle setting, voltage difference setting.
f) Provision of deadline charging set range of voltage.
g) Lock out facility.
Disturbance Recorder:
a) No. of event channels
b) No. of analog signals.
c) Sampling rate
d) Recording Band width
e) Over current triggering – range.
f) Under current triggering – range.
g) Over voltage triggering – range.
h) Pre fault time – range.
i) Post fault time – range.
j) Limit time – range.
k) No. of recorded disturbances.
l) Total recording time with 8 Analog and 16 event channels
recorder.
m) Voltage channels – details.
n) Period of built in calendar.
o) Current channels – details,
EVENT RECORDER
a) Time tagging resolution.
b) Events capacity
i) Max. NO. of events per disturbance report.
ii) Max. No. of disturbance reports
c) Time tagging error with synchronization.
i) Once in One second
ii) Once in ten seconds.
iii) Once in sixty seconds
d) Timer tagging error without synchronization.
Restricted Earth fault Relay.
a) Manufacturer Type P designation
b) Operating time 2 x setting
Differential protection scheme :
a. No. of restraining coils and operating coils.
b. Harmonic restraints provided with details
344 of 382
6
7
8
9
III
c. Rated VA Burden and power consumption of
i. Restraining coil
ii. Operating coil
d. Type of slope setting :
If variable, range of slope setting through fault current stability.
Maximum & minimum range of HV / MV / LV current ratio over which
the relay can be used.
e. Whether provided with switching inrush current restraint, if so type.
Trip circuit supervision relay:
a) Name of manufacturer.
b) Type & Designation.
c) Whether preclosing & post closing supervision provided.
d) Time delay
High speed trip relay
a) Name of manufacturer.
b) Type & Designation.
c) Contact rating.
Current ratingi) Continuous rating
ii) Rating for 5 secs.
d) Break Resistive load inductive load (with L/R = 40 msec.
e) Operating time at rated voltage (max).
f) Resetting time.
g) Whether supervisory relay included.
Local breaker back up protection.
a) Name of manufacturer.
b) Type & Designation.
c) Operating time
d) Resetting time
e) Setting range
i) current
ii) time
Bus bar protection
a) Name of manufacturer.
b) Type & Designation.
c) Type of relay (numerical)
d) Principle of operation (biased/low impedance)
e) Operating time
f) Resetting time
g) Setting range.
i) Current
ii) time.
h) Whether will it cause tripping for the differential current below
the load current of heavily loaded feeder (Bidder shall submit
application check for the same).
The tenderer shall confirm whether the following details will be
furnished at the time of approval of drawings:
a. Identification and location of removable parts.
345 of 382
b. Data of permit suitable connection of the relay (including the
polarity)
c. Data concerning the earthing of metallic part
d. To indicate parts of modules which should not be replaced without
observing precaution prescribed by the manufacturer.
346 of 382
GUARANTEED TECHNICAL PARTICULARS FOR ELECTRONIC TRIVECTOR
METERS
Sl. No. PARTICULARS
1
Type of Meter
2
Class of Accuracy
3
Standard to which the meter conforms
4
Current rating for which accuracy is guaranteed for
a. Basic Current (ib)
b. Continuous Current overloading capability
5
c. Short time over current
d. Minimum Starting Current
a)Voltage rating for which accuracy is guaranteed for
6
b)Over voltage withstand capacity - continuous
c)VoltageRange
Other Parameters for which accuracy is guaranteed
a. Reference Temperature
b. Standard Reference Frequency (Hz)
c. Accuracy Guaranteed for
d. FrequencyRange
e, For single Phase Loads / In- put
f. For two Phase Loads / In - put
g. For In-put / Loads without neutral in -puts unbalanced Voltages
7
8
h. TemperatureRange
i. P F range
j. Time
Insulation Resistance
Sampling Plan for measurement of Voltage, Current and Frequency
9
Power Loss in each Current circuit at Basic Current in VA & WATT
10
Power Loss in each Voltage circuit at reference in VA & WATT
11
Display device (Hardware details)
a. Type of Display i.e. LCD
b. Character size of display digits
c. No. of Display digits used
1. For data
2. For parameter identification
347 of 382
d. Life of display unit (Guaranteed)
12
13
e. Method adopted for digit over flow
Display details (Software)
a. Non-volatile memory retention time in absence of power
b. Non - volatile memory capacity in KB.
14
c. RAM Capacity
d. Maximum number of Parameters which can be stored in nonvolatile Memory at each half an hour intervals for Six Months.
Maximum demand
a. Parameters that can be dynamically selected
b. IntegrationPeriodRange
c. Provision for Automatic Rest
d. Type of MD Computation
348 of 382
Sl. No.
15
16
17
18
19
20
21
22
NOTE
23
24
25
26
Sl. No.
27
Description
Communication Inter-phase available
- for calibration
- for data transfer
Electro magnetic interference / Electro magnetic
comparativity level
Mounting arrangement
Meter sealing arrangement
a. Meter body
b. Meter terminal block
c. MD reset bush button
d. Battery unit
Degree of protection against moisture etc.,
a. Provision for real time clock
b. Real time clock accuracy
c. Life of real time clock (Guaranteed)
Power Supply backup
Measuring principle employed for
a. KWH
b. KVAH
c. RKVAH
d. Maximum demand parameters
e. PF
1. Measuring principle adopted for each of the items above
should be specified.
2. Measurement logic employed in case of Harmonics and
contents up to which meter recognizes for measurement
shall be furnished.
Abnormal conditions that will be identified with limiting
values
Guarantee period offered for
a. Performance and accuracy
b. Components not covered under guarantee
Micro processor
a. Address in bits
b. Sampling rate
Compatibility of the software for the following
a. For generation of consumer bill directly with the
existing KSPDCL billing software
b. Compatibility of software provided for MRI, down
loading from earlier version already supplied to KSPDCL
c. Compatibility of software for generation of report for
earlier versions
Description
Additional features available
349 of 382
28
Agreement to furnish protocol details for development of
required software through third party
29
30
Platform on which the meter communicates
Levels of security
a. For changing real time
b. Fir changing display parameters
c. For changing Load survey parameters
d. For changing TOD Registers, clock setting
e. Measuring principle, computation
31
32
33
34
Specification of reference standard offered
Specification of Lapatop Computer offered
Specification of MRI kit offered
Specification of equipment offered for checking
communication capability through RS232/RS485 port
350 of 382
SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS OF SUB-STATION
AUTOMATION
GUARANTEED TECHNICAL PARTICULARS
Sl.
Particulars
No.
A
SUBSTATION AUTOMATION SYSTEM MASTER
CONTROL UNIT OF HMI
a) Name and Country of Manufacture.
b) Manufactures type and designation
c) Memory capacity
i) Hard Disk
ii) RAM
Operating system software type
d) Type of drives provided
i) 3.5” Floppy & MG drive.
ii) Magnetic optical drive (rewritable)
e) Update time of
i) digital input
ii) Analog Input
f) Response time for
i) Alarm Function
ii) Control Function
g) Response time for
i) Alarm function
ii) Control function
h) Whether semi of fully colour graphic type
i) Total number of bay units which can be connected
without effecting the response/update time of the
system
j) Whether facility and hardware for transfer of data to
remote sub-station motorized.
k) Communication protocol adopted for
i) Bay unit
ii) RSCC/LDC
l) Applicable standard
m) Type of auxiliary supply required
n) Speed of data processing in instruction per sec.
o) List of manufacture whose bay units can be
connected to master unit without additional.
p) Whether equipment offered is of industrial grade
q) All necessary software provided for proper
functioning of the system as a whole.
r) List of all software provided
s) Max. Possible distance return bay unit & master.
t) Weight
Sl.
Particulars
No.
u) Dimensions
351 of 382
v) Power Consumption
aa) CPU
ab) Processor speed
ac) Hard disk
a) Type
b) Capacity
ad) Cache Memory
a) On Chip
b) On Board
ae) CommunicationPort
af) VDU
a) Screen size
b) Resolution
B
BAY CONTROL UNIT
a) Name of Country of Manufacture
b) Manufacturers type and designation
c) Type of Mounting
d) No. of bay control units offered
e) Memory capacity
f) Data Storage capacity
g) Standard applicable
h) Rated auxiliary voltage
i) Rated frequency
j) No. of binary inputs
k) No. of outputs
l) Language
m) Type of Communication protocol
n) No. & type of communication port
o) Operation temperature range
p) System response time
q) (i) Exchange of display
ii) Presentation of binary change
iii) Presentation of analog change
iv) Order to process output
v) Order to update display
vi) Report generation
vii) Max. temperature
Max. Humidity
r) Whether data is received on failure of unit.
indicate the duration
If yes,
352 of 382
Sl.
Particulars
No.
s) Speed of transmission between bay and Master control
unit
t) No. of inputs it can accommodate (specify voltage &
current separately)
a) Digital
b) Analog
u) Resolution for digital inputs
v) Update time of
a) analog inputs
b) digital inputs
w) Whether data processing is done in bay unit or master
control unit.
x) Power concentration
y) Humidity
z) Dimensions
C) KEYBOARD
i) Name &county of Manufacture
ii) Manufactures type & designation
a) Operation
b) Engineers.
iii) Whether standard or the numerical keyboard
included in the programming terminal.
D) Local Area Network LAN
1) Standard
2) Protocol
3) Communication Medium
4) Speed
5) Maximum distance
E) Network Operating system
F) SCADA Software
1) Supplies
2) Operating system
3) Facilities Provided (Full details to be enclosed in
separate sheet)
353 of 382
Sl.
No.
G)
Particulars
Printer
1) Colour Printer
2) Manufacturer name
3) Country of Manufacture
4) Model type
5) A3 and A4 size paper supplied
6) Throughput rate
7) Resolution
8) Available data interface
9) Print colour
10) Max. Temperature
11) Max. Humidity.
G(b) Alarm/Event Printer
1)
Manufacturer name
2)
Country of Manufacture
3)
Model type
4)
Paper Size
5)
Paper Loading Facility
6)
Print head
7)
Throughput
8)
Resolution
9)
Available Data Interface
10)
Print Colour
11)
Max. temperature
12)
Max. Humidity (Rh.)
354 of 382
Sl.
Particulars
No.
G(c) SCANNER
1)
Manufacturer name
2)
Country of Manufacture
3)
Model type
4)
Paper Size
5)
Resolution
6)
Available Data interface
H Following information is attached separately with the bid
a) Type, Make and Model No. for each item/sub-item with
relevant catalogues / descriptive information
b) List of installation of similar Equipment now in service
with contact
Persons name and address
Detailed drawing with dimensions of each equipment panel
and interfaces
Full functional description specific to project along with
proposed Architecture/scheme enclosed
I
SYSTEM SOFTWARE
1) Multitasking operating system
2) Background executive
3) File handling utility
4) Magnetic tape/disk data transfer utility
5) Online debugger
6) Object Module library utility
7) Report generator utility for display & Print
8) Communication utility
9) Graphic display generation utility
10) Online system backup capability
11) Test and Maintenance Programs (Diagnostic
software)
12) System generation at site
13) Data base utility
14) Data
acquisition,
processing
and
alarm
monitoring/reporting
15) Communication
16) Operator interface (MMI)
17) Network Operating system
18) Utilities like debugging and software downloading
19) Mathematical and logic function
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
355 of 382
Sl.
No.
II
Particulars
PROCESS SOFTWARE
1) Plant data base
2) Control software
3) Graphic display with points assignment
4) Logs or reports with points assignment
5) Software for communication with external computer
system
6) Relay setting software
7) Any other software.
Note: Bidder shall supplement information in this Data Sheet
with a write up on each topic
CPU
Processing capacity
World Length
Programmable real time clock
Watch dog timer
Auto Restart
Time synchronization
PROCESS INPUT SYSTEM
No. of high resolution inputs
Yes/No.
Yes/No.
Yes/No
Yes/No
356 of 382
SECTION –10.0
TECHNICAL SPECIFICATION
PLCC EQUIPMENTS
PLEASE FIND UPLOADED THE SPECIFICATIONS OF PLCC EQUIPMENTS AS A
SEPARATE FILE WHICH SHALL BE READ UNDER THIS SECTION
357 of 382
SECTION –11.0
TECHNICAL SPECIFICATION
FURNITURE
358 of 382
VOLUME-IIA
TECHNICAL SPECIFICATION
SECTION 11.0 FURNITURE
CLAUSE
NO.
PARTICAULARS
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
GENERAL
QUALIFIYING REQUIREMENTS
STANDARDS
STEEL ALMIRAH(61/2)
OFFICIER‟S TABLE.
STEEL SLOTTED ANGLE RACK (BIG)
STEEL SLOTTED ANGLE RACK (SMALL)
STEEL DUST BIN
EXECUTIVE REVOLVING CAHIR WITH FULL HIGH BACK WITH
HEAD REST.
“S” TYPE CONTINUOUS ARM CHAIR WITH CUSHION SEAT AND
BACK.
STEEL FOLDING CHAIR Wt 3.7 Kb (91.45)
ESTABLISHING TYPE OF BRANDS.
10.0
11.0
359 of 382
VOLUME IIA
SECTION 11. 0 - FURNITURE
1.0
GENERAL:
This specification covers design, engineering, manufacturing, testing and delivery at site of
furniture required for 220 k, 110 kV & 66 kV stations.
2.0
QUALIFIYING REQUIREMENTS:
Please refer volume - 1, section - IFB, clause No. 11.0
3.0
STANDARDS:
Equipments offered shall confirm to relevant Indian standards equivalent or Higher International
standards
4.0
STEEL ALMIRAH (6 1/2):
Size H 1.83 m x W 0.915 m x D 0.48 m (excluding leg of 15.24 cm) fitted, with four fixed shelves
making five compartments double door with three way locking device and duplicate keys, all joints
outside and inside should be spot or arc welded and neatly finished by grinding. The edges of
doors and shelves should be properly bent to U-shape of 25 mm width to ensure good strength and
the cuter edge of U-bent of the door lengthwise should be double folded and neatly finished, the
shelves front side should be bent to U-shape neatly and finished to avoid any possible cuts to
fingers and hand when handled. Longitudinal ) of 15-24 cm Wide including bent to required shape
should be provided and fixed to each door at the centre. The breath of the shelf in the Almirah
should be to the entire width leaving about 12mm up from the shutter when it is closed.
4.1
LOCKING DEVICE:
Three way locking device with 10 guage M.S. sheet for lockine and level olate and with locking
rod of 10 mm dia with strong bracket at top and bottom to hold the locking rodWith six lever lock
should be provided. 65 mm size lever strong locks to be fixed. Handle should be made out of brass
cast alloy with ru'ck-Je chrome plated Lock should be fixed. Handle should be made out of brass
cast alloy with nickle chrome plated, Lock should be similar to Godrej type.
4.02 STEEL ALMIRAH WITH GLASS PANE DOORS:
Size H 1.83 m x W 0.915 m x D 0.48 m (excluding leg of 15.24 cm) fitted with four fixed shelves
making five compartments doubled door with three way locking device and duplicate keys, all
joints outside and inside should be spot or arc welded and neatly finished by grinding. The outside
comer should be rounded off to give good appearance. The edges of doors and shelves should
properly bent to U-shape of 25mm width to ensure good strength and outer edge of U-bent of the
door length wise should be double folded and neatly finished. The shelves front side should be
bent to U-shape neatly and finished to avoid any possible cuts to fingers and hand when handled.
Longitudinal rilb of 15.24 cm wide including bent to required shape should be provided and fixed
to each door at the centre.
360 of 382
The breath of the shelf in the Almirah should be to the entire width leaving about 12mrn gap from
the shutter when it is closed. But with glass door fitted with four fixed shelves nuking five
compartments. Two-way locking systems with 100 x 37-min brass six ]ever locks to be provided.
The glass panels for doors shall be 4mm thick clear glass should be provided. The glass panels
should be fixed with fully covered plate around both inside and outside. Handle should be made
out of brass cast alloy. Locks should be similar to Godrej type with suitable locking device.
5.0
OFFICER'S TABLE:
Have overall size 1.93 m W x 0.786 m H With laminated top. There shall be three drawers with
automatic locking device on the night side and a cupboard with a shelf on the left side with square
legs of section 25 mm x 25 mm 16 G. The top shall be of 20-m thick laminated block board with
32mm thick V-shape teakwood internal beading nicely polished with two coats of colourless
polish- The table shall be confirmed to Godrej T - 102/D. The table shall be derusted. Premier
coated and painted With enamel paint as per indentors choice. All components shall be made out
of NIS sheet of 20G.
6.0
STEEL SLOTTED ANGLE RACK (BIG):
Size 1.80 m x 00.9m x 0.375 m overall with four upright and five panels, the uprights shall be
slotted angle of section 40x40x.2 mm and the panels of size 900 m x 375 m x 20. The panels
should be fixed to the upright by naeans; of-GI. Bolts of size 8mm-x 16 nun by providing 16 nos.
Standard gussets at
The rack shall be painted as per indentors choice.
7.0
STEEL SLOTTED ANGLE RACK (SIMALL):
Size 0.90 m x 0.9m x 0.375 m overall with four upnights and 3 panels. The uprights shall be
slotted angles of section 40 x 40 x 2 nun and the panels of size 900mm x 375 mm x 20 G. The
panel should be fixed to the uprights by means of GI bolts of size 0.079 mm x 0. 158 mm, by
providing 16 nos, standard gussets at comers. The rack shall be painted as per indentors choice.
8.0
STEEL DUST BIN:
Made out of 22G MS sheet. The size of the dust-bin shall be 27.94 cm square at the top and 20.32
cm square at the bottom with a height of 30.48 cm. A sheet leg shall be provided for a height of
5cm. The dust bin shall derusted primer, coated
and painted with synthetic enamel paint as peridentors choice.
9.0
EXECUTIVE REVOLVING CHAIR WITH FULL HIGH BACK WITH
HEAD REST:
Executive revolving chair with tilting and revolving arrangement of standard size 12.7 cm thick
foam for the seat and 10.2 cm thick foam for the back covered with feather touch Bohr Rexin. The
chair shall be with full high back with head rest and to be fitted on the M.S.(tubular ) revolving
base with 5 frongs fitted with ball casters. The colour and shade of rexin cloth as per the indentors
choice.
361 of 382
10.0 'S' TYPE CONTINUOUS ARM CHAIR WITH CUSHION SEAT & BACK:
The name shall be made from MS tubular pipe of 16 gauge and with 25-mm outer dia- The head of
the chair frame shall be 89-cm height 51 cm depth 53 cm width properly bent to its required shape
and neatly ruickled chrome plated or powder coated of approved colour. The seat and back shall be
50-mm thick foam
cushioned on teak-wood frame and neatly upholstered with Bohr Rexin. The arm
rest also shall be cushioned and upholstered. Tour rubber shoes shall be provided at the bottom of
the chair frame.
11.0 STEEL FOLDING CRAIR Wt 3.7 kg (91.45):
Tubular frame sizes helaht 94 cm when folded seat sizes 39.3 cm deep and 45.7 cm Hip-h from the
floor. Rack rest about 20.3 cm wide. The tabular frame should be 22mm OD (18 gauage) ERW or
gas welded steel tube and cross pipe of 16mm OD (20 gauge) steel tubes. The cross pipes are fixed
to the leg pipes by strong rivets. 22 G CRCA steel should be used for the seat and back plate is
neatly pressed to the required contour with rounded comers and fixed on the tabular frame by self
tapping screws in such a way that the chair could be folded and opened easily. Connecting 4 lever
plates 89 mm x 20 trim 10 gauge thick to be fixed at the top Junction of the front and rear legs and
top end of rear legs. Hard plastic shoes should be provided at the bottom of the front and rear legs
and top end of rear le s. The chairs are finished by spray or stove enamel in standard 9 colours.
12.0 Establishing type of brands
Godrej / Chandan / Featherlite.
362 of 382
SECTION –12.0
TECHNICAL SPECIFICATION
EARTHMAT
363 of 382
VOLUME-IIA
TECHNICAL SPECIFICATION
SECTION 12.0- Earthmat
Caluse No.
Particulars
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
Scope
Design of Earthmat
Laying Earth Mat
Earth Connections
Power Cables
Outgoing 11KV Feeders
Sub-Station Fencing
Crushed Rock Surface Layer
Separation Between Cast iron Pipe Electrodes
Power Cables & Control Cables
Labeling of Pipe Electrodes
MS Flat
Execution Payment.
364 of 382
SECTION - 12
EARTHMAT
TECHNICAL SPECIFICATIONS FOR DESIGN AND LAYING OF EARTHMAT
1.0
Scope
1.1
This specification calls for measurement of soil resistivity,
Design of earthmat, laying of earthmat and connecting
equipments to the earthmat, in accordance with IS 3043 &
IEEE-80.
2.0
Design of earthmat
2.1
Various factors that are to be considered for the design of
earthmat are as follows:
i)
The fault levels at the 220 KV sub-station.
220 KV sub-station
Voltage
class
switchyard
220 KV
66 KV
of 3 phase to ground
(MVA)
Single phase to ground
(MVA)
Please refer uploaded
EARTHMAT drawing
scanned
copy
of
ii)
Oil resistivity of sub-station area shall be less than one Ohm metre after laying of
earthmat.
ii)
The touch potential and step potential shall be within permissible limits.
iii)
In case of non uniformity of soil resistivity, or to achieve permissible step and touch
potentials, it may be necessary, to embed the normal electrodes or deep Bore electrodes at
the peripheral of the earthmat.
iv)
In case of hard soil/dry fissured rock/hard rock, treatment with Bentomite clay, may be
necessary.
2.2
The design calculations and drawings are to be got approved by the owner before taking up
the work for execution.
3.0
LAYING OF EARTHMAT:
3.1
I.
While installing the earthmat, the rows and columns shall be interleaved like a
woven mat to obtain better mechanical strength and electrical continuity.
MS Flat of the designed cross section shall be laid at the designed depth of (around 0.9 Mtr.) and
spacing duly straightening and removing any bends.
365 of 382
3.2
As the standard length of flats available in the market is
around 6 meter in length for continuous running of
earthmat, straight through joints are required. When such traight
joints are made, a minimum overlap equal to the width of the
flat shall be maintained.
3.3
The overlap portion shall be welded on all four sides by
continuous welding. To facilitate welding on all four sides,
welding work shall be done on the natural ground surface
and then laid in the trench.
3.4
A thick coat of Anti-corrosive bituminous paint shall be
applied at the welded joints duly removing the deposited
weld flux and any burrs.
3.5
After laying the flats in the trench and. interleaving, all the
perpendicular crossings of flats shall be welded and applied
a thick coat of ACB paint as above. The ACB paint shall be
applied only to the welded portion.
3.6
Projections of flat at the periphery of the earthmat should be
avoided and the overlap shall be in flush with the edge of the
peripheral flat of earthmat. At these joints the welding shall
be continues on all the three sides.
3.7
The peripheral MS round rods of length 1050 mm 25mm dia
shall be driven into the ground at locations shown in the
earthmat drawing. Before driving these rods the top 50mm
portion of the rod shall be flattened and bent and then
welded properly to the MS flat of earthmat firmly. The other
end of the rod shall be sharpened for easy driving.
3.8
When hard soils such as fissured rock/ gravel, laterite etc.,
are encountered at the sub-station site during excavation for
laying the earth mat, Bentonite clay or soft soil or tank clay
shall be used for back filling in trenches of earth mat to a
height of 0.3 mtr.
4.0
EARTH CONNECTIONS
4.1
All earth connections from equipment/cast iron pipe
electrode to the earthmat shall be made using Galvanised
iron flats of cross section equal to the MS flat of earthmat.
All earth connections are to be made only by welding.
Suitable laps and bends shall be formed while making earth
connections from equipment to the earthmat.
4.2
POWER TRANSFORMER NETURAL
366 of 382
Two distinct continuous earth conductors (GI flats without any joints) shall be run in opposite
directions from the power transformer neutral to the cast iron pipe electrodes provided for the
purpose by welding. Further, these cast iron pipe electrodes shall be connected to the earth mat by
welding using GI flats.
4.3
LIGHTNING ARRESTERS:
Each phase of the lightning arrester base shall be connected to the cast iron pipe electrodes
provided for the phase by running GI flat from the base terminal. The cast iron pipe in turn shall be
connected to the earthmat by welding using GI flats. A flexible braided earth bond shall be made
firmly between the base terminal and the GI flat. The length of the earth connection shall be as
minimum as practicable.
4.4
OUTDOOR SWITCHGEAR AND CONTROL ROOM
A minimum of three-cast iron pipe electrodes are to be provided around both the outdoor
switchgear and the control room. The opposite ends and mid points of the earth bus of these panels
are to be connected to the earthmat through these cast iron pipe electrodes using GI flats.
If the earth bus provided in the panels are not continuous, a separate earth bus of GI flats shall be
connected to this bus which in turn should be connected to the earthmat through the cast iron pipe
electrodes.
.4.5
NON CURRENT CARRYING METAL PARTS
All non current carrying metal parts such as transformer body, circuit breaker body, instrument
transformer body, outdoor structures and isolator structure are to be directly connected to the
earthmat using GI flats with two distinct connections run in opposite directions.
The operating handles of isolators are to be connected to the earth conductor (GI flat) using
braided flexible earth bonds.
5.0
POWER CABLES
5.1
THREE CORE CABLES:
The sheath of the cables are to be directly earthed at their terminations and joints, i.e., at the both
switchgear and terminating pot heads (cable sealing end).
5.2
Sheath on single core cable shall be earthed at only one end.
6.0
OUTGOING 11 KV FEEDERS
6.1
When the feeders are erected within the substation fence
The cable end leads sheath is to be earthed and connected to the earthmat through independent cast
iron pipe electrode by running 50 x 6 mm GI flat along the structure from the cable end to CI
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electrodes. In turn these C I electrodes are to be connected to the earth mat. All these connections
shall be made by welding.
6.2
When the feeders are erected out side the sub-station fence.
The lead sheath of the cable end shall be connected to CI pipe electrode of the feeders as
mentioned in clause 4.1. further MS Flat of 50 x 6 mm shall be run at a depth of 0.5 mtr and all the
CI pipe electrodes of 11 KV feeders shall be connected to this buried MS flats by welding using GI
Flats. This system shall be not be connected to the station earthmat and should a1ways be isolated
from the station earth.
7.0
7.1
SUB-STATION FENCING:
Fence earthing shall be isolated from the main earthing of
the sub-station.
7.2 The sub-station earthmat i.e, the last conductor of the earthmat shall be at a distance of 1.5
meter away from the sub-station fence.
7.3
A separate earthing conductor of size 50 x 6 mm MS Flat
should be run along the perimeter of the fence at a depth of
0.9 mtr below the ground surface.
7.4
The perimeter of the fence is to be connected to this MS Flat
through independent vertical electrodes (C I pipe electrodes)
using GI Flat of 50 x 6 mm. The connections are to be made
by welding.
7.5
The C1 pipe electrode shall be provided at comers and mid
points of the fence if the perimeter is more than 200mtr,
otherwise CI pipe electrodes may be provided only at the
comers or midpoints.
7.6
The fence earth and station earthmat shall not have any
electrical tie.
8.0
CRUSHED ROCK SURFACE LAYER:
20mm metal (baby granite jelly) to a height of 100mm shall be provided over the total area of the
sub-station as mentioned in the SECTION 8- CIVIL WORKS
9.0
9.1
SEPARATION BETWEEN CAST IRON PIPE ELECTRODES:
The separation between any two C I pipe electrodes in the
sub-station yard has to be maintained equal to twice the
length of the C I pipe electrode. This is very important due to
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the fact that any lesser electrode intervals will increase the earth resistance
due to mutual interference
9.2
The location of cast iron pipe electrodes shall be planned
earlier keeping in view the following
1.
The C I pipe electrode for lightning arrester and power
transformer neutral shall be as near as practicable to
the respective equipment.
2.
The distance between any two C I pipe electrodes
should not less than twice the length of the C I pipe
electrode.
3.
The lightning arrester earth connection should not be
run over the ground surface. They should be buried at the mat depth and
connected to the earthmat at the nearest point.
10.0
POWER CABLES & CONTROL CABLES
The power cables and control cables shall be laid in a separate concrete duct. A clearance of
minimum of 0.6 mtr shall be maintained between any earthmat conductor and the power/control
cables. Parallelism of power/control cables with earthmat conductor should be avoided.
11.0
LABELING OF PIPE ELECTRODES:
The individual pipe electrodes shall be labeled for proper identification.
12.0
The transformer plinth, control room & out door switchgear shall be surrounded by MS
Flat of designed cross section at the designed depth and the earthmat conductor shall be
terminated on this surrounding MS Flat by welding.
12.1
The earthmat shall be run below the concrete cable duct whenever the mat encounter path
of the cable ducts.
12.2
When structures come in the way of earthmat conductor, one or two conductors may be
slightly shifted. However, the designed spacing must be maintained for other earthmat
conductors.
13.0
Execution
13.1 The soil resistivity and other parameters after the installation of the earthmat will be
measured by KSPDCL (Research wing) to check the values arrived in the approved designs. In
case
of non achieving of values, the contractor will have to execute the measures suggested by
KSPDCL (Research wing).
14.0
Payment
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The bidder has to asses the quantities of earthmat materials and indicate in the bid proposal sheets.
Payment will be made for the quantities indicated by the bidder OR actual quantities arrived
consequent to finalization of designs and actually executed, WHICHEVER is LOWER.
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SECTION –16.0
TECHNICAL SPECIFICATION
TESTING & COMISSIONING
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VOLUME - IIA
TECHNICAL SPECIFICATION
Section 16.0 - Testing and Commissioning
Clause No.
Particulars
1.0
2.0
3.0
4.0
5.0
6.0
General
Other checks
PowerTransformers
Circuit Breakers-Pre commissioning checks
Disconnects- Pre commissioning checks
Current Transformer Pre Commissioning Checks
Voltage Transformers - Pre Commissioning Checks
Station Earthing
Drake ACSR Stringing Work, Tubular Bus Work and
Power Connectors:
Aluminium Tube Welding
Insulators
Cables
Motor
Commissioning Check List for Control & Relay Panels
Commissioning Check List for Relays
Commissioning Check List for Meters
Other Equipments: Battery & Battery Charger, 415V, L.T.
A.C. Panels, Diesel Generator, Distribution Transformers
Commissioning Check List for Electrical Installation
General
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
ITO
18.0
19.0
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VOLUME IIA
SECTION 16.0 - TESTING & COMMISSIONING
TESTING AND COMMISSIONING PROCEDURES
1.0
GENERAL:
1.1
The contractor shall submit a field quality plan consisting of following:
a)
Receipt, storage, pre-erection inspection of all materials in the scope of contractor
b)
Structural work erection
c)
Civil works
d)
Welding procedure for aluminium pipe bus and earth mat system.
e)
Cabling
f)
Pre-commissioning tests.
g)
Commissioning.
1.2
An indicative list of pre-commissioning and commissioning is given below. Contractor
shall perform any additional test based on specialties of the items as
per the field Q.P. /instructions of the equipment supplier or owner without any extra cost to the
owner. The contractor shall arrange all instruments required
for -conducting these tests along with calibration certificates and shall furnish the list of
instruments to the owner for approval.
2.0
GENERAL CHECKS:
2.1
Check for physical damage.
2.2
Visual examination of zinc coatings/ plating
2.3
Check from nameplate that ail items are as per order/ specification
2.4
Check tightness of all bolts, clamps and connecting terminals using torque wrenches.
2.5
For oil filled equipment check for oil leakage, if any.
Also check oil level and top up wherever necessary.
2.6
Check ground connections for quality of weld and application of zinc rich paint over weld
joint of galvanised suxfaces.
2.7 Check cleanliness of insulator and bushings.
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2.8 All checks and tests specified by the manufacturer in the drawings and manuals as well as all
tests specified
2.9 Check for surface finish of grading rings (corona. control rings).
2.10 Pressure tests on all pneumatic lines at 1.5 times the rated pressure shall be conducted.
2.11 Proper lubrication of all moving parts.
2.12 Check space heaters.
3.0 POWER TRANSFORMER
3.1.0 PRE-COMMISSIONING TESTS:
3.1.1 Drying out by using streamline oil filter, vacuum pump, centrifuge and heater set.
3.1.2 Dielectric strength of oil both main and OLTC chamber.
3.1.3 Insulation resistance of windings.
3.1.4 Checking of phase sequence test.
3.1.5 Continuity test.
3.1.6 No load voltage ratio, at all tap positions.
3.1.7 Checking of vector group, polarity and miter phase connections.
3.1.8 Tap changer operation check (Mechanical & Electrical local, remote, group and solo)
including indication and alarm circuits.
3. 1. 9 Magnetizing current check at 415V, 3-Phase, 50 cycles supply for all the three phases.
3.1.10 Measurement of winding resistance.
3.1.11 Breather (check, for silica gel)
3.1.12 Buchholtz's relay operation.
3.1.13 Low oil level for main tank/OLTC chamber.
3.1.14 Physical line connections as per phasing diagram.
3.1.15 Natural connection to earth effectivity.
3.1-15.1
Calibration of different temperature indicators, relays, switches.
3.1.16 Cooler control operational check both from local and remote.
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3.1.17 Check all fans and oil pumps.
3.1.18 COMMISSIONING:
After obtaining approval from the purchaser and supplier the contractor shall proceed to
commission the transformer.
3.2.0 GENERAL CHECKS TO BE DONE BEFOPE/AFTER
COMMISSIONING
3.2.1 All off valves are in correct positions, closed or opened as required.
3.2.2 All air pockets are filled with oil.
3.2.3 Thermometer pockets are filled with oil.
3.2.4 Oil is at correct levels in the bushings, conservator, diverter switch tank; etc.
3.2.5 Earthing connects are done.
3.2.6 The condition of silica gel in the breathers.
3.2.7 Arcing horn gaps on bushings are properly adjusted.
3.2.8 Heaters in cubicles, conservator etc., where provided should be checked.
3.2.9 Any other alarm / trip contacts of flow meters differential pressure gauges etc.
3.3.0 If all t1ie above tests/checks are found satisfactory, a time of at least 24 hours for setting of
oil shall be allowed and air released from all points. The
transformer shall be energized after setting the
protective relays to the minimum extent
possible. Wherever possible the voltage shall be built up in steps. Any abnormality during
commissioning such as vibration of radiator parts, hum etc., should be observed. After a few hours
of energisation at no load, the transformer shall be switched off. The Buchholtz relay should be
checked for collection of air/ clyas. Abnormalities noticed shall be corrected.
All protective
relavs should be reset to normal values. Transformer shall be reenergised and loaded gradually.
After commission the contractor shall fu the test results and all relevant details, drawings of
erection testing and commissioning of the Purchaser all properly bound With plastic jackets.
4.0
CIRCUIT BREAKER - PRE COMMISSIONING CHECKS:
4.1
Insulation resistance of each pole.
4.2
Check adjustments, if any, suggested by manufacturer.
4.3
Breaker closing and tripping time, pole discrepancy etc.
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4.4
Slow and power closing operation and opening.
4.5
Minimum pick up voltages of trip and close coils.
4.6
Contact resistance.
4.7
Functional checking of compressed air plant and all accessories including adequacy of the
air receiving for design set of operations.
4.8
Functional checking of control circuits, interlocks, tripping through protective relays
and
reclose operation.
4.9
Insulation resistances of control circuits, motor,
4.10
Resisting of closing and tripping coils.
4.11
Check on simultaneous closing of all three poles, three- phase/single phase auto reclosures.
4.12
Blocking of operation at low pressure.
4.13
Checking of electrical & mechanical interlocks.
5.0
DISCONNSECTS - PRE COMMISSIONING CHECKS:
5.1
Insulation resistance of each pole.
5.2
Manual and electrical operation and interlocks.
5.3
Insulation resistance of control circuits and motors.
5.4
Ground connections of structures & operating handle.
5.5
Contact resistance 'of each pole per gap between male and female contacts.
5.6
Proper alignment so as to minimise to the extend possible the vibration during operation.
5.7
Measurement of operating Torque for Isolator and Earth switch.
5.8
Resistance of operating and interlocking coils.
5.9
Manual and Electrical -interlocks.
5.10
Clearances in op.-In & closed operations.
6.0
CURRENT TRANSFORMER - PRE COMMISSIONING CHECKS:
6.1
Insulating Resistance test.
6.2
Polarity test.
etc.
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6.3
Ratio identification test - checkng of all ratios on all cores by primary injection of current.
6.4
Dielectric test of oil (wherever applicable).
6.5
Magnetising characteristics test.
6.6
Checkng of earth connection at only one point.
6.7
Shorting of spare C.T. cores.
6.8
Dielectric tests (wherever applicable).
6.9
Checking gas pressure wherever required.
7.0
VOIAPAGE TRANSFORMERS - PRE COMMISSIONING CHECKS
7.1
Insulation Resistance Test
7.2
Polarity test oil all windings
7.3
Patio test of all windings
7.4
Dielectric test of oil (wherever applicable)
7.5
Open delta test with low voltage (wherever applicable)
7.6
Capacitance and tan delta measurement.
7.7
Checking gas pressure measurement where required.
8.0
LIGHTNING ARRESTOR.
8.1
Grading leak-age current
8.2
Resistance of ground connection.
9.0
STATION EARTHING:
9-1
Check oil resistivity
9.2
Check continuity of
9.13
Check earth resistance of the entire grid as well as various sections of the same.
9.4
Check for weld joint and application of zinc rich paint on galvanised surfaces.
9.5
Dip test on earth conductor prior to use.
grid wires
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10.0
DRAKE ACSR STRINGING WORK TUBULAR BUS
WORK AND POWER CONNECTORS:
10.1
Physical check for finish
10.2
Electrical clearance check
10.3
Testing of torque wrenches on all bus bar power
connectors and other accessories.
10.4
Millivolt drop test on all power connectors.
10. 0 Sag and tension check on conductors.
11.0
ALUMINIUM TUBE WELDING:
11.1
Physical check
11.2
Millivolt drop test on all joints.
11.3
Die penetration test/Radiography test on 10% sample
basis on weld joints.
11.4
Test check on 5% sample Joints after cutting the weld piece to observe any voids, etc.
12.0
INSULATORS:
12.1
Visual examination for finish damage, creepage distance etc.
13.0
CABLES:
13.1.0 PRELIMINARY CHECKS:
13.1.1 Check details as per specification13.1.2 Check for physical damage.
13.2.0 COMMISSIONING CHECKS:
13.2.1 Megger test between each core & armour/sheath.
13.2.2 Continuity check.
13.2.3 Connections.
13.2.4 And all other checks as specified by equipment manufacturers/ Engineer.
14.0
MOTOR
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14.1.0 PRELIMINARY CHECKS:
14.1.1 Check name plate details according to specification.
14.1.2 Check tightness of all bolts, clamps and connecting terminals.
14.1.3 Check ground connections.
14.1.4 Bearing lubrication.
14.1.5 Check clearance inside terminal box.
14.2.0 COMMISSIONING CHECKS:
14.2.1 Megger testing of motor vymidings and cables.
14.2.2 Motor Widings, control and power cables continuity check.
14.2.3 Resistance of motor windings in case of large motors.
14.2.4 Control and interlocks.
14.2.5 Overload and short circuit relay tests and settings.
14.2.6 Phase sequence and rotation.
14.2.7 Operating of timer in case of star-delta starting.
14.2.8 Starting and no load current.
14.2.9 No. of load operation (observe vibrations, temperatures of bearings and body of the motor)
14.2.10
On load operation, starting and running currents (observe vibrations, temperatures
of bearings and body).
14.2.11
In case of close loop arrangement for cooling the windings of the motor, inlet and
outlet temperature of the cooling air.
14.2.12
15.0
And all other checks as specified by equipment manufacturers/ Engineer.
COMMISSIONING CHECK LIST FOR CONTROLS:
RELAY PANELS:
15.1.0 PRELIMINARY CHECKS:
15.1.1 Check name plate details of every associated equipment according to specifications
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15.1.2 Check for physical. dam age of various meter and relays.
15.1-3 Check tightness of all bolts and nuts and wiring terminals.
15.1.4 Check earthing
15.2.0 COMMISSIONING CHECKS:
15.2.1 Switch developments.
15.2.2 Each vaire shall be traced by continuity tests and it should be made sure that the wiring is
as per relevant drawings. All inter connections between panels/ equipment shall be similarly
checked.
15.2.3 All the wining shall be meggered.
15.2.4 Checks on relays.
15.2.5 Checks on meters.
15.2.6 Settings of relays, other alarm, tripping de ice, and inter locks as per schemes.
15.2.7 Phase angle checks - Measurement of magnitude and phase angle of current transformer
secondary currents and potential transformer secondary voltages.
15.2.8 Punctional checking of all control circuitry - viz., closing, tripping, control, inter lock,
supervision and alarm circuits including proper functioning of the
component equipment.
16.0
COMMISSIONING CHECK LIST FOR RELAYS:
16.
Check name plate details according, To specifications.
16.2
Check for any physical damage.
16.3
Check internal wiring
16.4
MEGGER:
a)
All terminals to body.
b)
A.C. to D.C. terminals.
16.5
Check operating characteristics by secondary injection.
16.6
Check minimum pick up voltage of D.C. coils.
16.7
Check operation of electrical mechanical targets.
16.8
Relay settings.
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16.9
Check C.T. and V.T. connections, with particular reference to their polarities for directional
distance type relays.
17.0
COMMISSIONING CHECK LIST FOR METERS:
17.1
Check
17.2
Check for physical damage.
17.3
Check calibration by comparing with sub standard.
17.4
Megger all insulated portions.
17.5
Check C.T. and V.T. connections with particular reference to their polarities for Power type
meters.
18.0
OTHER EQUIPMENTS : BATTERY & BATTERY CHARGER, 415V, L.T. A.C.
PANELS, DIESEL GENERATOR, DISTRIBUTION TRANSFORMERS:
18.1
The pre-commissioning/commissioning checks and dried out in accordance with the tests
shall be car manufacturer's instruction manual and instructions of the owner. The charge
/discharge cycle of battery shall be strictly followed.
19.0
COMMISSIONING CHECK LIST FOR ELECTRICAL INSTALLATION GENERAL:
19.1.0 Phasing out.
19.1.1 By means of phasing rods, if available or by measuring voltages on voltages transformer
secondary.
19.2.0 FUNCTIONAL CHECKING:
19.2.1 Checking all closing, tripping, super-vision and interlock of control devices.
19.2.2 Check operation of all alarm circuits.
19.3.0 CABLE TESTING:
19.3.1 All I IKV, 415 and 230V power cables are to meggered with suitable meggers to check the
insulation resistance.
19.4.0 EARTHING:
19.4.1 Measure resistance of each earth well/rod by isolated the same from station grid as well as
from other car wells/rods and then measure resistance of two card at a time by D.C. drop
method.
19.4.2 Check continuity, of grid conductor and wires.
19.4.3 Soil resistivity tests.
19.5.0 In addition to the above, any other tests specified manufacturers shall be carried out as the
manufacturer's instructions.
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19.6.0 Test fire detection system if provided.
Check operation of protective relays by putting short circuit bar at different location,
conduct system stability test by primary injection test method.
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