NTPC­BHEL POWER PROJECTS PRIVATE LTD (A Joint Venture company of NTPC & BHEL) Power supply arrangement and Lighting works in YSR Puram Manufacturing unit OF NTPC BHEL POWER PROJECTS Pvt.Ltd. IN THE STATE OF Andhra Pradesh TECHNICAL SPECIFICATION VOLUME ­II PACKAGE: NESCL/NBPPL/CS­MV­503 CLAUSE NO.
INDEX
SECTION DESCRIPTION CHAPTER­I: E1: PROJECT SYNOPSIS E2: SCOPE OF WORKS E3: GENERAL TECHNICAL CONDITIONS CHAPTER –II E0: GENERAL CONSTRUCTION PRACTICES. E1: DISTRIBUTION TRANSFORMER E2: 33KV SWITCHGEAR E3: 33KV XLPE CABLE E4: BATTERY & BATTERY CHARGER E5: ENERGY METER (CT PT OPERATED) E6: LT SWITCHGEAR E7: LT POWER & CONTROL CABLES E8: DG SETS E9: LT BUS DUCT E10: CABLE LAYING E11: AUXILIARY ITEMS E12: MISCELLANEOUS E13: SITE TESTING AND COMMISSIONING E14: BUILDING AND AREA LIGHTING Lighting & Electrification works
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INDEX
CHAPTER –III (DRAWINGS) 1
SLD­power scheme 2
PCC­1 3
PCC­2 4
PCC­3 5
Main Lighting Panel 6
PLOT LAYOUT CHAPTER –IV E­1 INDICATIVE MAKES E­2 MQP E­3 FQP Lighting & Electrification works
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1.00.00 INTRODUCTION 2.00.00 NTPC BHEL Power Projects Pvt. Ltd. (NBPPL) is constructing a manufacturing unit near Tirupati (Andhra Pradesh). The scope of the subject package covers area & building lighting and power supply arrangement works. PROJECT SITE DETAILS Address of the site: NTPC BHEL Power Project Pvt.Ltd.,
YSR PURAM, MANNAVARAM VILLAGE,
SRI KALAHASTI MANDAL
CHITTOR DIST A.P.‐517620 Nearest Rly. Station : Tirupati Nearest Airport 3.00.00 SERVICE CONDITIONS 3.01.00 All outdoor Equipment/material to be supplied against this specification shall be suitable for satisfactory continuous operation under tropical conditions. 3.02.00 For equipments / materials, the requirements are specified in the respective volumes of technical specification. : Tirupati Power supply arrangement & Lighting works
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1.00.00 SCOPE 1.01.00 Bill of Quantity for the works has been indicated in the relevant clause. Bidder’s scope shall include all items that are necessary for completion of the listed works (including fitting accessories, painting, putty for rework in case of damage of existing facilities etc.) based on Bid Documents and relevant Indian Standards & Codes and the various provision of Indian Electricity Act etc., all works shall be executed by the Bidder in complete compliance to the specifications except incase any specific deviation sought in the bid, which is subsequently discussed and agreed to by the Owner. 1.02.00 The materials/equipment covered under this package shall be supplied complete in all respects, including all components, fittings and accessories that are necessary their efficient performance and satisfactory maintenance under the various operating and atmospheric conditions. Such parts shall be deemed to be within the scope of the Contract, whether specifically included or not in the Specification or in the Contract Schedules. The Contractor shall not be eligible for any extra charges for such fittings, etc. The details of the materials / equipment required have been indicated in Bid Proposal Sheets (BPS), Volume­
IB of the bid document. 1.03.00 The specification given in the Chapter “Scope of Works” shall be executed successfully by the bidder. Bidders are advised to include the cost of all the materials/ services (required to complete the works successfully as per TS), although not specifically mentioned in BPS. 2.00.00 GENERAL TECHNICAL CONDITIONS 2.01.00 Bidders are requested to carefully examine and understand the specifications and seek clarifications, if required, to ensure that they have understood the specifications. Such clarifications should be sought at least 15 days before the scheduled date of the opening of the bids. The bid should not include any sections like clarifications, interpretations and/or assumptions. If the Bidder feels that, in his opinion, certain features brought out in his offer are superior to what has been specified, these may be highlighted separately. 2.02.00 Whenever a material or article is specified or described by the name of a particular brand, manufacturer or trade mark, the specific item shall be understood as establishing type, function and quality desired. 3.00.00 Engineering Data to be furnished in the bid 3.01.00 Bidder shall enclose with his bid one set of technical documents, for each of the material under his scope, comprising of guaranteed technical particulars & data sheets, engineering drawings, type and routine tests reports etc. which shall be Power supply arrangement & Lighting works
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in confirmation with the type, make & rating of the equipment indicated in the offer. 4.0.00 Engineering Data to be firmed up at the time Award of Contract 4.01.00 In case of successful bidder, the Guaranteed Technical Particulars and Data Sheets furnished in the bid shall be firmed up at the time of award. Bidder shall furnish design documents and engineering drawings of individual equipment as applicable for the subject package, for review and approval by Owner. A drawing submission / approval schedule, keeping in view the overall work schedule, shall be finalised at the time of award. 4.02.00 All engineering data submitted by the Contractor after final process including review and approval by the NESCL shall form part of the Contract Document and the entire works performed under these specifications shall be performed in strict conformity, unless otherwise expressly requested by the NESCL in writing. 4.03.00 4.03.01 Arrangement by the Contractor Contractor shall make his own necessary arrangements for the following and for those not listed anywhere else: a)
Construction power supply at all work areas b)
Boarding & lodging arrangement for their personnel. c)
Fire protection and security arrangements during construction stage 4.03.02 Bidder shall execute the package works in accordance with the inputs (related to conduit layout & wiring, cable layout etc.) provided by site‐in‐charge. 5.00.00 5.01.00 SPARES 5.02.00 Commissioning Spares The Contractor shall supply spares which he expects to consume during installation testing and commissioning of system. The quantity of these spares shall be decided based on his previous experience, such that site works shall not be hampered due to non‐availability of these spares. Contractor shall submit a complete list of such spares along with the bid, the cost of which shall be deemed to have been included in the lump sum proposal price of the package. Tools & Tackles Power supply arrangement & Lighting works
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The Contractor shall also supply at site one set of all special tool & tackles, etc. which are required by the Owner’s maintenance staff to maintain the works successfully at no extra cost. The list of such tools and tackles shall be enclosed with the offer. 6.00.00 Drawings 6.01. All drawings submitted by the Contractor including those submitted at the time of bid shall be in sufficient detail to indicate the type, size, arrangement, dimensions, material description, Bill of Materials, weight of each component, break‐up for packing and shipment, fixing arrangement required, the dimensions required for installation and any other information specifically requested in the Specifications. 6.02. Each drawing submitted by the Contractor shall be clearly marked with the name of the Purchaser, the unit designation, the Specification title, the Specification number and the name of the Project. All titles, noting, markings and writings on the drawing shall be in English. All the dimensions should be to the scale and in metric units. 6.03 The drawings submitted by the Contractor shall be reviewed by NESCL and shall be modified by the Contractor if any modifications and /or corrections are required by NESCL. The Contractor shall incorporate such modifications and or corrections and submit the final drawings for approval. Any delays arising out of failure by the Contractor to rectify the drawings in good time shall not alter the completion date. 6.04 The drawings submitted for approval to NESCL shall be in quadruplicate. One print of such drawings shall be returned to the Contractor by NESCL marked “approved / approved with corrections”. The Contractor shall thereupon furnish NESCL additional print as stipulated in Technical Specification along with one reproducible in original of the drawings after incorporating all corrections. 6.05 Further work by the Contractor shall be strictly in accordance with these drawings and no deviation shall be permitted without the written approval of the Purchaser, if so required. 6.06 NESCL’s review of data/drawings furnished by the bidder will cover only general conformance of the data to the specifications and drawings. This review by NESCL may not indicate a thorough review of all dimensions, quantities and details of the equipments, materials, any devices or items indicated or the accuracy of the information submitted. This review and/or approval by NESCL shall not be considered by the Contractor, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these Specifications and documents. Power supply arrangement & Lighting works
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6.07 All manufacturing and fabrication work in connection with the equipments / materials prior to the approval of the drawings shall be at the Contractor’s risk. The Contractor may make any changes in the design which are necessary to make the equipments conform to the provisions and intent of the Contract and such changes will again be subject to approval by NESCL. Approval of Contractor’s drawing or work by NESCL shall not relieve the Contractor of any of his responsibilities and liabilities under the Contract. 6.08 The drawings and data specific to the subject project package shall become owner’s property. Under no circumstances, the Contractor shall use/offer above designs/ drawings/data sheets to any other authority. 6.09 Detailed drawing for erection of equipment showing dimensions and items proposed to be used shall be furnished for reference. 6.10 The following is the general list of the documents and drawings that are to be approved by the Employer after award of contract: i)
ii)
Work Schedule (Master Network) Plan. All equipment drawings like switchgear, breakers, switches, surge arrestors, insulators, conductors, cables, transformers, PCC panels, DCDB, LTDB, connectors & clamps, poles etc. iii)
Switchgear room layout drawings. iv)
Typical General Arrangement and foundation drawings for all equipments pertaining to Sub‐Stations. iv) Quality Plan for individual equipment for both manufacturing and Field Quality Assurance. vii) Detailed Guaranteed Particulars and Data Sheets for individual equipments with make, type and rating. viii) Earthing of all the above pole structures to be shown in respective drawings. 6.11 The final schedule indicating location of poles and other details shall be submitted for the approval of the NESCL. After approval, the Contractor shall submit four sets of the approved drawings and documents along with one set of reproducible of drawings to NESCL for record purpose. Further, after completion of the works, bidder shall prepare and furnish six sets of as‐built drawings of the complete 33kV & LT System for Owners reference & record. Bidder shall also prepare a project completion report enclosing the above as‐
built documents and submit to owner for reference & record. Power supply arrangement & Lighting works
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7.00 Design Co­ordination The Contractor shall be responsible for the selection and design of appropriate materials/items to provide the best coordinated performance of the entire system. The basic design requirements are detailed out in this Specification. The design of various components, sub‐assemblies and assemblies shall be so done that it facilitates easy field assembly and maintenance. 8.00 Manufacturing Schedule The Contractor shall submit to NESCL his manufacturing, testing and delivery schedules of various items within two weeks from the date of the Letter of Award in accordance with the delivery requirements stipulated. Schedules shall also include the materials and items purchased from outside Contractors, if any. 9.00 Reference Standards The Codes and/or Standards referred to in Specifications shall govern, in all cases wherever such references are made. In case of a conflict between such Codes and/or Standards and the specifications, latter shall govern. Such Codes and/or Standards, referred to shall mean the latest revisions, amendments/changes adopted and published by the relevant agencies. Other internationally acceptable Standards that ensure equivalent or better performance than those specified shall also be accepted. 10.0
List of Standards Sl. No. Title Indian Standards International & Internationally Recognized Standards 1
Circuit Breaker IS : 13118 IEC : 62271‐100, IEC : 427 , IEC:56 2
Current Transformer IS : 2705 IEC : 185, BS : 3938 3
Surge Arrestor IS : 3070 IEC : 99‐4 4
Common clauses for Switchgear IEC : 694 5
Post Insulator IS : 2544 IEC : 168 6
Degree of Protection IS : 3589, IS : 1239 Power supply arrangement & Lighting works
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7
Specification for Zinc IS : 209 8
Methods of Chemical Analysis IS : 406 9
Methods of high voltage testing IS : 2071 10
‐ General Requirements and IS : 2486 Part‐I BS : 3288 11
‐ Dimensional Requirement IS : 2486 Part‐II IEC‐120 12
‐ Locking Devices IS : 2486 Part‐III IEC‐372 13
Recommended practice for hot dip galvanization of iron and steel IS : 2629 14
Testing of uniformity of zinc coated articles IS : 2633 15
Hexagonal Bolts and Nuts IS : 2633 16
Characteristics of string insulator units IS : 3188 ISO : R947 & ISO : R272 17
ISO Metric Screw Threads IS : 4218 ISO : R68, SR‐26, R‐262, R‐965 18
Determination of weight of coating on zinc coated iron & steel articles IS : 6745 19
Thermal Mechanical Performance test on String Insulators units IEC : 575 20
Radio Interference Voltage of high Power supply arrangement & Lighting works
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voltage Apparatus Method of measurements 107/1964, CISPR
21
Electrical relays for power system protections IS : 3231 IEC‐255 Part‐I to III, BS : 142 22
Indicating Instruments IS : 1248, IS : 2419 BS‐89, IEC : 5 23
Energy Meters IS : 722 BS : 5585, IEC : 521 24
General requirements for switchgear and control gear for voltage not exceeding 1 kV IS : 4237 25
Marking and IS : 375 arrangements for switchgear busbars, main connection and auxiliary 26
Specification for static protection relay IS : 8686 27
Cross link polythelene PVC cable for working voltage upto and including 1100 Volts 7096 (Part‐I) 28
Conductors for insulated electrical cables and flexible cords IS : 8130 29
Recommended current rating for cables IS : 3961 30
PVC Insulation and sheath of electrical IS : 5831 Power supply arrangement & Lighting works
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cables 31
Mild steel wires, IS : 3975 strips and tapes for armouring of cables 32
PVC insulated electric cables for voltages upto and including 1100 Volts IS : 1554 (Part‐I), IS : 894 33
Joints and Terminations of Polymeric Cables for Working Voltages from 6.6 kV up to and Including 33 kV IS 13573 IEEE : 383, ASTMD : 2893 34
Power Cables ‐ Dimensions for Moulds for Cast Resin Based Outdoor Terminations for Voltages Above 1100 Volts and up to and Including 11000 Volts IS 12909 35
Glands BS : 6121 36
Rigid steel conduits IS:9537 (Part‐2) for electrical wiring 37
Flexible steel conduits for electrical wiring IS : 3480 38
Fitting for rigid steel conduits for elec. Wiring IS : 2667 39
Accessories for IS : 3837 rigid steel conduits for electrical wiring Power supply arrangement & Lighting works
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Mild Steel Tube IS : 1239 41
Guide for safety procedures and practices in practices in electrical works IS : 5216 42
MS wire for general IS : 280 engineering purpose 43
Compression type tubular terminal end for aluminium conductors insulated cables IS : 8309 44
Cold rolled carbon sheet steel IS : 513 45
Indian Electricity Act IS : 513 46
Indian Electricity Rules 47
National Electricity Safety Code IEEE : 80 48
Installation & Maintenance of cables IS : 1255 49
Colours for ready mixed paints & enamels IS : 5 50
Code of practice for earthing IS : 3043 51
Code of practice for protection of building and allied structure against lightning IS : 2309 52
Specification for bushings IS : 2099 IEC : 137 Power supply arrangement & Lighting works
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53
Requirements for boxes, cabinets 54
Degree of IS : 4691 protection provided by enclosures for motors 55
Test on motors IS:325, IS : 12075 56
Ferrules IS : 10942 57
Specifications for fuses IS:9224, IS: 8724 58
Requirements for electric power connectors IS : 5561 59
GLS Lamps IS : 418 60
Adopters for flexible steel conduits IS : 4649 61
Specification for structural steel standard quality IS : 226 62
Method of chemical IS : 228 analysis of pig iron, cast iron, plain carbon and low alloy steel 63
Code of practice for IS : 806 use of steel tubes in general building construction 64
Code of practice for Ultrasonic testing by pulse Echo method IS : 3664 65
Specification for hot IS : 4759 dip coating on structural steel and other allied Power supply arrangement & Lighting works
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products
66
Specification for hot IS : 1367 dip galvanized coatings on fasteners 67
Specification for hexagon bolts for steel structure IS : 6639 68
Specification for Rolled Steel IS : 808 69
Specification for covered electrodes for metal arc welding of structural steel IS : 814 70
Code of practice for IS : 816 manual metal arc welding for general construction in mild steel 71
Code of practice for manual metal arc welding of mild steel IS : 9595 72
Specification for IS : 1161 steel tubes for structural purposes 73
Specification for hexagonal bolts, screws nuts and lock nuts grade C IS : 1363 74
Specification for bolts, screws, nuts and lock nuts (Grade A&B) IS : 1364 75
Technical supply conditions for threaded steel IS : 1367 Power supply arrangement & Lighting works
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fasteners
76
Code for practice for finishing of Ferrous IS : 1477 77
Method of Tensile IS : 1608 Testing of steel products other than sheet, wire and Tube 78
Method of Tensile IS : 1599 Testing of steel products other than strip, wire and tube 79
Plugs and sockets IS : 1293 80
Switches for domestic and similar purposes IS : 3854 81
Code of practice for elect. Wiring installation IS : 732 82
Code of practice for general construction in steel IS : 800 83
Industrial luminaire IS : 1777 with metal reflectors 84
Industrial lighting fitting with plastic reflectors IS : 3287 85
Specification for flood light IS : 10322 86
Specification for new insulating oils IS : 335 87
Ready mixed paint, air drying, red oxide, zinc chrome IS : 2074 Power supply arrangement & Lighting works
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priming
88
Spacers and spacer dampers for twin horizontal bundle conductors IS : 10162 89
Method of measurement of building and civil engineering works Part‐I earthwork IS : 1200 90
Safety code for excavation wok IS : 3764 91
Specification for paving Bitumen IS : 73 92
Ordinary and low heat Portland cement IS : 269 93
Coarse and fine aggregates from natural sources for concrete IS : 383 94
Code of practice for IS : 456 plain and reinforced concrete 95
Methods of test for IS : 516 strength of concrete
96
Methods of IS : 1199 sampling and analysis of concrete 97
General requirements for concrete vibrators immersion type IS : 2505 98
Screed board concrete vibrators IS : 2506 99
Concrete vibrating tables IS : 2514 Power supply arrangement & Lighting works
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100
Methods of IS : 3025 sampling and test (physical and chemical) for water used in industry) 101
Code of practice for concrete structures for the storage of liquids IS : 3370 102
Methods of tests for IS : 3342 routine control for water used in industry 103
Admixture of concrete IS : 9103 104
Cold worked steel high strength deformed bars to concrete reinforcement IS : 1786 105
Code of practice for IS : 2502 bending and fixing of bars for concrete reinforcement 106
Integral cement water proofing compound IS : 2645 107
Planning of (single side band) power line carrier system IEC : 663 108
Specification for static protective relays IS : 8686 IEC‐255 (Part‐5 & 6) 109
Surge withstand capability & dielectric strength ANSI, IEEEC37.90 110
Control switches (LV switching IEC : 337 Power supply arrangement & Lighting works
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devices for control and auxiliary circuits) 111
Transducers IEC : 688‐1 112
Methods of test for concrete poles for overhead power & telecom lines IS:2905 113
Code of practice for selection, handling & erection of concrete4 poles for overhead power & telecommunication line IS: 7321 114
Aluminium conductors for overhead transmission purpose IS:398 115
Specification for IS:731 porcelain insulators for overhead power lines with nominal voltage greater than 1000V 116
Power transformer IS: 2026 117
Outdoor three phase distribution transformer IS: 1180 118
High voltage switches AB Switches IS:9920 119
Specification for IS:9921 alternating current disconnectors(Isolator)
120
Static watthour meter class‐1 & 2 13779 121
Capacitor 13925 Power supply arrangement & Lighting works
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Conduits, Pipes and Accessories IS:2667 Fittings for rigid steel conduit for electrical wiring. IS:3837 Accessories for rigid steel conduits for electrical wiring. IS:9537 Conduits for electrical installations. Lighting Fixtures and Accessories IS:1258 Bayonet lamp holders. IS:3323 Bi‐pin lamp holders for tubular fluorescent lamps. IS:3324 Holders for starters for tubular fluorescent lamps. IS:10322 Luminaries. Lighting Panels, Switch­boxes, Receptacles and Junction Boxes IS:13947 Degree of protection provided by enclosures for low‐voltage switchgear and control gear. IS:1293 Plugs & socket outlets of rated voltage upto and Including 250volts & rated current upto and including 16 Amps. IS:2551 Danger notice plates. IS:13947 Low voltage switchgear and control gear IS:3854 Switches for domestic and similar purposes. IS:6875 Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto and including 1000 V AC and 1200 V DC. IS:13703 Low voltage fuses for voltages not exceeding 1000V AC or 1500 V DC. Power supply arrangement & Lighting works
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Lighting Wires/Cables IS:694 PVC insulated cables for working voltages upto and including 1100 V IS:3961 Recommended current ratings for cables. (PVC Insulated and PVC sheathed heavy duty cables and light duty cables). IS:8130 Conductors for insulated electric cables and flexible cords. IS:10810 Methods of tests for cables. Electrical Installation Practices & Miscellaneous IS:6665 Code of practice for industrial lighting. National Electrical Code Indian Electricity Rules. Indian Electricity Act IS:5 Colour for ready mixed paints & enamels. IS:280 Mild steel wires for general engineering purposes. IS:374 Electric ceiling type fans & regulators. IS:732 Code of practice for electrical wiring installations. IS:1255 Code of practice for installation and maintenance of power cables Upto and including 33KV rating. IS:2062 Steel for general structural purposes IS:2629 Recommended practice for hot‐dip galvanizing of iron and steel. IS:2633 Methods for testing uniformity of coating of zinc coated articles. IS:4736 Specification for Hot‐dip Zinc Coatings on Mild Steel Tubes Power supply arrangement & Lighting works
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11.00 Quality Assurance 11.01 To ensure that the equipments under the scope of this Contract whether manufactured within the Contractor’s Works or at his Sub‐Contractor’s premises is in accordance with the specifications, the Contractor shall adopt suitable Quality Assurance Programme to control such activities at all points necessary. 11.02 Indicative quality plans of manufacturing & Field activities for some of the items are attached with the bid document. Field quality plan shall necessarily cover the procedure and precautions to be adhered by the field personnel during erection of equipment Bidders may also bring out in case their proposed MQP/FQP is in variance with the indicative Quality plans provided in Chapter‐IV of Vol‐II‐B(Standard Technical Specification). Bidder shall submit detailed MQP & FQPs of individual equipment supplied. for which standard QP has not been provided, after award of contract for approval of Employer. 11.03 Such Programme shall be outlined by the Contractor and shall be finally accepted by NESCL after discussions before the award of Sub‐Contract. A Quality Assurance Programme of the Contractor shall generally cover but not limited to the following. (a) His organization structure for the management and implementation of the proposed Quality Assurance Programme. (b) Documentation control system. (c) Qualification data for key personnel; (d) The procedure for purchases of materials. Parts/components and selection of Sub‐Contractor’s services including vendor analysis, source inspection, incoming raw material inspection, verification of material purchases etc. (e) System for shop manufacturing including process controls. (f) (g) Control of calibration and testing of measuring and testing equipments. (h) Inspection and test procedure for manufacture. (i) System for indication and appraisal of inspection status. (j) System for quality audits. Control of non‐conforming items and system for corrective action. Power supply arrangement & Lighting works
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(k) System for authorizing release of manufactured product to the Purchaser. (l) (m) System for handling storage and delivery and (n) A Quality Plan detailing out the specific quality control procedure adopted for controlling the quality characteristics of the product. The Quality Plan shall be mutually discussed and approved by the NESCL after incorporating necessary corrections by the Contractor as may be required. 11.04 Quality Assurance Documents The Contractor shall submit all the Quality Assurance Documents as stipulated in the Quality Plan at the time of NESCL’s inspection. NESCL’s duly authorized representative reserves the right to carry out Quality Audit and Quality surveillance of the systems and procedures of the Contractor’s/his sub‐vendor’s Quality Management and Control Activities. 11.05 NESCL’s Supervision The manufacturing of the product shall be carried out in accordance with the specifications. The scope of the rights of the NESCL’s pursuant to the contract, will include but not be limited to the following: (a) Interpretation of all the terms and conditions of these Documents and Specifications. (b) Review and interpretation of all the Contractor’s drawings, engineering data etc. (c) Witness or authorize his representative to witness tests at the manufacturer’s works or at site, or at any place where work is performed under the Contract. (d) Inspect, accept or reject any equipment, material and work under the Contract, in accordance with the Specifications & approved MQP. (e) Issue certificate of acceptance and/or progressive payment and final payment certificate. (f) System for maintenance of records. Review and suggest modification and improvement in completion schedules from time to time; and Power supply arrangement & Lighting works
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(g) Supervise the Quality Assurance Programme implementation at all stages of the Works. 11.06 Inspection, Testing and Inspection Certificate 11.06.01 NESCL’s duly authorized representative and/or outside inspection agency acting on behalf of NESCL shall have at all reasonable times access to the Contractor’s/Sub‐contractor’s premises or works and shall have the power at all reasonable times to inspect and examine the materials and workmanship of the product during its manufacture and if part of the product is being manufactured or assembled at other premises or works, the Contractor shall obtain from NESCL and/or his duly authorized representative permission to inspect as if the equipment/materials were manufactured or assembled on the Contractor’s own premises or works. 11.06.02 The Contractor shall give NESCL’s Inspector fifteen (15) days written notice of any material being ready for testing. Such tests shall be to the Contractor’s account except for the expenses of the Inspector. NESCL’s Inspector, unless witnessing of the tests is virtually waived, will attend such tests within fifteen (15) days of the date of which the equipment is notified as being ready for test/inspection or on a mutually agreed date, failing which the Contractor may proceed with the test which shall be deemed to have been made in the Inspector’s presence and he shall forthwith forward to the Inspector duly certified copies of tests in triplicate. 11.06.03 NESCL’s Inspector shall, within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Contractor, of any objection to any drawing and all or any equipment and workmanship which in his opinion is not in accordance with the Contract. The Contractor shall give due consideration to such objections and shall make the modifications that may be necessary to meet the said objections. 11.06.04 When the factory tests have been completed at the Contractor’s or Sub‐
Contractor’s works, NESCL’s Inspector shall issue a certificate to this effect within fifteen (15) days after completion of tests but if the tests are not witnessed by NESCL’s Inspector, the certificate shall be issued within fifteen (15) days of receipt of the Contractor’s Test Certificate by NESCL’s Inspector. The completion of these tests or the issue of the certificate shall not bind NESCL to accept the equipment should it, on further tests after erection, be found not to comply with the Contract. 11.06.05 In all cases where the Contract provides for tests whether at the premises or works of the Contractor or of any Sub‐Contractor, the Contractor except where otherwise specified shall provide free of charge such item as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonable demanded by NESCL/ Inspector or his authorized representative to carry out Power supply arrangement & Lighting works
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effectively such tests of the equipment in accordance with the Contract and shall give facilities to NESCL/ Inspector or to his authorized representative to accomplish testing. 11.06.06 The inspection by NESCL and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the agreed Quality Assurance Programme forming a part of the Contract. 11.07 Testing Expenses 11.07.01 Type test charges, if any shall be borne by the bidder for the subject contract. The charges so incurred shall not be reimbursed / paid by NESCL. 11.07.02 Bidders shall indicate the Govt. approved & National test laboratories in which they propose to conduct the type tests. They shall ensure that the tests can be completed in these laboratories within the time schedule and as per the requirement of specifications guaranteed by them. 11.07.03 The entire cost of testing for the acceptance test and routine tests and tests during manufacture specified in the technical specifications for materials/equipment shall be treated as included in the quoted unit price except for the expenses of the Inspector / NESCL’s representative. 11.07.04 In case of failure in any type test, repeat type tests are required to be conducted, then all the expenses for deputation of Inspector/NESCL’s representative shall be deducted from the contract price. Also if on receipt of the Contractor’s notice of testing NESCL’s representative/Inspector does not find “plant” to be ready for testing. The expenses incurred by NESCL for re‐deputation shall be deducted from the contract price. 12.00.00 ELECTRICAL SYSTEM DATA Sl. No. Description of the Parameter 33 kV System 1. System Operating Voltage 33 kV 2. Maximum operating voltage of the system (rms) 36 kV 3. Rated frequency 50 Hz 4. No. of phases 3 6. Min. creepage distance 25 mm/kV (900 mm) 8. Rated short circuit current 25 kA for 1 sec.
Power supply arrangement & Lighting works
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9. System neutral earthing Solidly earthed 13.00.00 GUARANTEED TECHNICAL PARTICULARS (GTP) 13.01.00 Standard guaranteed technical particulars for most of the equipments have been provided in Chapter‐II. Bidders are instructed to submit these standard GTPs & GTP’s for other equipments for which standard GTP has not been enclosed, duly signed by them in one original and four (4) copies along with the bid as per the formats provided. Any deviation to the standard GTP provided may be brought out in the signed GTP to be submitted with the bid. In case the bidder does not submit the duly signed standard GTP along with the bid it shall be inferred that the standard GTP has been accepted by the bidder. The Bidder shall also furnish any other schedule information as in their opinion is needed to give full description and details to judge the item(s) offered by them. 13.02.00 The data furnished in Guaranteed Technical Particulars should be the minimum or maximum value (as per the requirement of the specification) required. A Bidder may guarantee a value more stringent than the specification requirement. However, for testing purpose or from performance point of view, the material shall be considered performed successfully if it achieves the minimum/maximum value required as per the technical specification. No preference whatsoever shall be given to the bidder offering better/more stringent values than those required as per specification. 14.00 Equipment Performance Guarantee 14.01 The performance requirements of the items are detailed separately in this Specification. These guarantees shall supplement the general performance guarantee provisions covered under General Terms and Conditions of Contract in clause entitled “Guarantee”. 14.02 Successful bidder shall complete the guarantee data sheet, duly signed by his authorized representative during finalization of contract documents. The data shall form part of contract agreement and shall be refused, in case of any variation of parameter, during testing, inspection and final commissioning checks. 14.03 Liquidated damages for not meeting specified performance shall be assessed and recovered from the Contractor. Such liquidated damages shall be without any limitation whatsoever and shall be in addition to damages, if any payable under any other clause of Conditions of Contract. 14.04 Responsibility of the Contractor shall be on total basis for all the items and at no instance of the Contract, the responsibility shall pass on as to Sub‐Vendor/Sub‐
Supplier. Power supply arrangement & Lighting works
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15.00 DATA CHECK LIST FOR SUBMISSION 15.00 Bidder shall enclose all the documents required by the bid document in proper format for information at evaluation of the bids. 15.00 An indicative check list showing items for which various data are to be furnished in the prescribed format is enclosed. 16.00 PACKING a) Bolts, nuts, washers and other attachments shall be packed in double gunny bags accurately tagged in accordance with the contents. b) The packing shall be properly done to avoid losses/damages during transit. Each bundle or package shall be appropriately marked. 17.00 CHECK LIST The following check list is given for the benefit of bidder to complete his bid document in line with the specification requirements. Sl. No. Item Guaranteed Drawings Type Test Technical Reports Particulars & Data Sheet 1. 33/0.4 kV, 2.5 MVA Distribution Transformers + + + 2. 33 kV switchgear (VCB) + + + 3. 33 kV XLPE Cable + + + 4. 30 kV Surge Arrestors
+ + + 5. Steel Tubular Poles + + 6. LT XLPE Cable + + + 7. Control Cable + + ‐ 8. Energy Meter (3 Ph) CT & PT operated 0.5 class + + + 9. Battery & Charger + + + Power supply arrangement & Lighting works
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+ ‐ 10. Control Panel + + + 11. ACDB & DCDB + + + : : To be submitted with the bid. Not Required. Power supply arrangement & Lighting works
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SCOPE OF WORKS
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1.00.00 1.01.00 1.02.00 GENERAL This package envisages following works to be implemented around the area as envisaged in project synopsis This scope specification / of works intends to cover but not restricted to the following activities, services and works. i) Complete design and detailed engineering activities for all the systems, sub‐systems, equipment, material services etc ii) The project also envisages that the successful bidder shall engage OEMs for transformer, DG sets, HT&LT switchgear and APFC panels at the time of testing & commissioning. Bidder shall incorporate the cost of this service in the cost of respective equipment itself, and shall not claim separately. iii) Providing engineering data (inputs), drawings and O&M manuals for Owner’s review, approval and records. iv) Supply, testing, packing, transportation and insurance from the source to the site. v) Receipt, storage, insurance, preservation and conservation of equipment at the site. vi) All civil and structural works including horizontal boring which may be required for Road Crossing or any other crossings. vii) Fabrication, pre‐assembly (if any), erection, testing and putting into satisfactory operation of all the equipment/material including successful commissioning. vii) The Bidder shall be responsible for providing all material, equipment and all other associated services specified or otherwise which are required to ensure operability, maintainability and the reliability of the complete work covered under this specification. viii) All services & activities required to be provided contractually, by the bidder, during warranty period. The technical specification shall be read together with all sections and chapters, as per the index, for completeness scope of work and services. For individual equipment specifications reference shall be made to the relevant sections of this specification given under Chapter‐II of Technical Specification Volume‐II. Power supply arrangement & Lighting works
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2.00.0
2.01.0
Guaranteed Technical Parameters (GTP) of different equipments is given at the end of each section of technical specification for individual item. The GTPs are divided into two parts i.e. Part‐A and Part‐B. Parameters indicated in Part‐A of GTP are to be complied by the equipments to be supplied and no separate approval from owner in respect of these parameters is envisaged. Wherever, Part‐B is provided, the bidder shall fill up the parameters and submit for approval of owner either in the bid or at the time of award. Tender drawings are provided in Vol‐II, Chapter‐III of technical specification. Indicative makes are provided in Chapter‐IV Section‐E‐1. Detailed Scope of works The entire scope of works is categorized for convenience, as follows a) Lighting works b) Power supply arrangement works Lighting works: The contractor shall be responsible for completing the lighting of area and several buildings/ sheds (listed below) in the site area. Any building may be added or deleted during execution depending on the requirement. 1
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Switchgear room Administrative Building Canteen Building Emergency DG Building Compressor Building Dispensary and Medical Open area toilet block Security and time office Autoo pool Fire tender house Fabrication Plant Open storage yard Permanent store Shipping yard Campus Area The lighting works include following works, i) Fixing of fittings‐ this includes supply & fixing of of eye hooks, screws, bolts, down rods etc. as required to the wall, roof or any other surface. The fittings shall be supported with GI chain link & the wiring from the ceiling Power supply arrangement & Lighting works
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shall be taken to the fitting through flexible vinyl pipes for recess mounting of fittings. ii) The package also covers supply & mounting of following items a. Recessed mounting type CFL fitting with lamps, wall bracket lamps, decorated basin lights, garden lights including fittings and all other accessories required for mounting. b. Ceiling fans including down pipe extension wherever required; exhaust fans. c. Providing sockets, industrial sockets, d. Providing & laying telephone network cable and telephone sockets e. Street lighting with double swan neck type of fitting with steel tubular poles, including excavation, concreting & painting of the poles. f. All accessories required for mounting of all items g. Garden lighting (including foundation and painting). iii) The scope also covers instalaltion of outdoor type of feeder pillars at vairous locations and cabling from Main Lighting Panel or any other suitable panel. Cabling from feeder pillar panel to High bay mast lights is not covered under the scope of this project. iv) The Scope also covers supply of wire & cables required for wiring in the existing PVC conduits in the ceiling. But, PVC conduits, battens and any other type of partitions required for wiring in the walls/ roof/ surface are also covered under the scope. v) The contractor shall coordinate with various agencies working at site like civil agency for providing false ceiling & ventilation, A/C etc for providing/ obtaining interface to complete the scope of works. 2.02.0
vi) Any damage or dismantling done by the contractor shall be made good and reinstated to the original condition. This may require cementing, plastering, painting or any other related activity. vii) Street light panel shall be fitted with a timer(confirming to relavent IS) for automatic switch on and off. Steel tubular poles for street lights shall be confirmed to IS:2713 Part‐II. Power package: The contractor shall be responsible for completing the power supply arrangement from the APSPDCL meter point to 33kV switchgear room and the LT power supply to various buildings and equipment. For the arrangement and scheme, SLDs provided herewith, may be referred. i) Supply, installation & commissioning of Power supply arrangement & Lighting works
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a. 3 no. of 33/0.4kV 2.5MVA distribution transformers including foundation and fire walls. OLTC shall be controlled by Low Tension APFC panels, which are also covered under the scope of works. b. 4000A LT busduct from distribution transformers to PCC panels. c. 2x1000kVA + 1x500kVA DG sets including AMF panels with Digital Energy meter. Each DG set shall also be proivded with 990ltrs of fuel oil tank. The scope also covers i. All the required foundation/ structures required for DG sets and their fuel oil tanks along with necessary piping and valves and their installation ii. Piping and installation required for exhaust with support arrangement iii. Supply & erection of exhaust silencer. iv. Supply, laying, jointing & termination of LT XLPE cable from DG sets to their panels inside the switchgear room. ii) Supply, installation & commissioning following equipment (inside 33kV switchgear room) a. 33kV indoor switchgear (VCB) panels b. LT switchgear (PCC panels: PCC‐1, PCC‐2, PCC‐3 & Main Lighting Panel) as per SLD attached herewith. c. 110V 120Ah Battery & Battery charger (Lead Acid VRLA type) d. LT capacitor APFC panels. e. AMF panels of DG sets. iii) Supply & laying (including jointing and termination) of 33kV XLPE cable (burried) from APSPDCL meter point to 33kV switchgear room and thereto 33/0.4kV distribution transformers. iv) Supply & laying (including jointing and termination) of LT XLPE cable from Distribution transformer and DG sets upto Lighting DB and various PCC panels. Electrical works: i) The length of 33kV & LT cables and LT busduct mentioned in BPS may be varied as per site conditions, and shall be fianlized during Detailed Engg. ii) Supply, erection and commissioning of indication, control and protection system for all 33 KV switchgear panels. iii) Metering with CT/PT operated energy meters with 0.5 class accuracy, as per discription in technical specification in volume‐II shall be provided on all 33 KV switchgear panels. iv) Supply, erection and commissioning of LT switchgear including connection to Battery & Battery Charger system through power cable. v) All structural material (flats, channels etc.) for mounting of panels/ equipment on trenches including covering with chequered plates are included in the scope of the contract. Bidders shall inbuilt the cost in the bid for relavent items like busduct, PCC/33kV swgr./ APFC/ AMF panels/ Battery charger etc. Power supply arrangement & Lighting works
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Civil works: i) Fire walls as per IS:1646 shall be constructed between the Distribution transformers‐ 02 no.s of 230mm width. ii) 33kV& LT cables shall be burried in ground, whereas they shall be drawn in cable trenches within the buildings. iii) In case of road crossings, 33kV& LT cables shall be laid through GI pipes by carrying out horizontal boring through the roads. iv) To carry out all civil works including equipment foundations, Trenches, supply & erection of equipment as well as bus bar support structures are in contractor’s scope. v) Painting and finishing. vi) All protection measures to prevent any damage to the adjoining structures/ facilities. 3.00.00 System Design and Engineering 3.01.0
It is not the intent to specify all aspects of design and construction of equipment mentioned herein. The systems, sub‐systems and equipment shall conform in all respect to high standards of engineering, design and workmanship, and shall be capable of performing in continuous commercial operation. 3.02.0
The Contractor shall be responsible for detailed design and engineering of overall system, sub‐systems, elements, system facilities, equipments, auxiliary services, etc. It shall include proper definition and execution of all interfaces with systems, equipment, material and services of Owner for proper and correct design, performance and operation of the project. 3.03.0
Contractor shall provide complete engineering data, drawings, reports, manuals, etc. for Owner’s review, approval and records. 3.04.0
The Contractor shall carry out earth resistivity measurements at the Switchgear room (based on four electrode method). 3.05.0
Relay setting calculations shall be submitted by the Contractor and approved by Owner. 3.06.0
For all civil and structural works, the Contractor shall carry out design calculations; prepare all the detailed construction and fabrication drawings. 4
Project Management & Supervision 4.01.0
The Contractor shall be responsible for the overall management and supervision of works. He shall provide experienced, skilled, knowledgeable, and competent personnel for all phases of the project, so as to provide the Owner with a high quality system. Power supply arrangement & Lighting works
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4.02.0
A project execution schedule called Master Network (MNW) in the form of PERT chart/network and based on ‘Work break down structure’ shall be prepared by the Contractor for Owner’s approval. The MNW shall identify milestones of key events for each work/component in the areas of engineering, procurement, manufacture, dispatch, erection and commissioning. 5
Testing and Commissioning 5.01.0
The scope includes testing and commissioning of all equipment, sub‐systems and systems of the project and putting them into successful commercial operation. The scope shall include but not limited to the requirements given elsewhere in the specification. 5.02.0
The Contractor shall be responsible to provide all necessary testing and commissioning personnel, tools and plant, test equipment, etc. 6
Interface Coordination 6.01.0
The Contractor shall identify all interface issues with Owner and other agencies, and shall be responsible for such interfacing, coordination and exchange of all necessary information. 7
GENERAL REQUIREMENTS & INSTRUCTIONS 7.01.0
All the raw materials such as steel, zinc for galvanizing, reinforcement steel and cement for foundation, coke and salt for earthing, bolts, nuts, washers, danger plates etc. required shall be in the scope of contractor. Bidders shall clearly indicate in their offer, the sources from where they propose to procure the raw materials and the components. 7.02.0
Bidder may note that even though the supply and erection of individual equipments, structures have been provided in the BPS all the activities pertaining to completion of scope of works including design, supply, erection, interconnection, testing and commissioning are included in the scope of the contractor. 7.03.0
Bidder is required to follow statutory regulations stipulated in Electricity Act 2003, Indian telegraph act 1889, I.E. Act 1910, Electricity (Supply) Act 1948, Indian Electricity Rules 1956 with all amendments till date and other local rules and regulations referred in this specification. 7.04.0
The bidder shall comply with all the statutory rules and regulations prevailing in the state of concerned state including those related to safety of equipment and human beings. 7.05.0
The successful bidder shall acquire electrical license from the concerned State Government / statutory body, as required for executing the works. Power supply arrangement & Lighting works
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7.06.0
The Bidder shall do complete coordination with all local & statutory agencies for execution of complete works including obtaining clearance for energizing of the HT systems upon completion of erection. 7.07.0
The bidder shall be responsible for transportation to site of all the materials to be provided by the Contractor as well as proper storage and preservation of the same at his own cost, till such time the erected line is taken over by the Owner. 7.08.0
Bidder shall set up required number of stores along the line and the exact location of such stores shall be discussed and agreed upon with NESCL. 7.09.0
The Contractor shall submit to the Owner all drawings for review. He shall list the detailed requirements of interface between Contractor’s work and the material and services to be supplied by Owner 7.10.0
Any deviation or variation from the scope requirement and/or intent of this specification shall be clearly mentioned under Deviation Schedule of the Bid Proposal Sheets irrespective of the fact that such deviations/variations may be standard practice or a possible interpretation of the specification by the Bidder. Except for the deviations/variations which are accepted by the Owner before the award of the contract, it will be the responsibility of the Bidder to fully meet the intent and the requirements of the specification within the quoted price. No other departure from the specification except for the declared deviation indicated by the Bidder in his proposal shall be considered. The interpretation of the Owner in respect of the scope, details and services to be performed by the Bidder shall be binding, unless specifically clarified otherwise by the Owner in writing before the award of contract. 7.11.0
Failure of any equipment to meet the specified requirements of tests carried out at works or at site shall be sufficient cause for rejection of the equipment. Rejection of any equipment will not be held as a valid reason for delay in the completion of the works as per schedule. Contractor shall be responsible for removing all deficiencies, and supplying the equipment that meet the requirement. 8
QUALIFYING REQUIREMENTS Qualifying Requirements are specified in Annexure­A of Special Condition of Contract, Volume‐IA of bid document. 9
METHODOLOGY OF PROCUREMENT 9.01.0
All equipment shall be sourced from reputed manufacturers only who have designed manufactured, routine & type tested for relevant Indian Standards. An Indicative list of manufacturers is provided herewith at Chapter‐IV Section E‐1. Power supply arrangement & Lighting works
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9.02.0
All the equipment of make, type, & rating to be supplied under the scope shall meet the above requirement of design & type testing & satisfactory operation. To establish the compliance, bidder shall furnish in the bid complete details of the identical equipment along with associated complete type test reports in each case carried out at national/NABL accredited laboratories within last five years. 9.03.0
In case the reports are more than Ten (10) years old or found incomplete upon scrutiny by owner; the bidder shall carry out such tests at his own cost & risk. 10
QUALITY ASSURANCE, INSPECTION AND TESTS 10.01.0
The bidder shall have a quality assurance Programme (QAP) for the turnkey execution encompassing quality assurance at manufacturers’ works, storage, erection, testing and commissioning activities. Typical quality plans for manufacturing (MQP) and field (FQP) activities have been included in the bid documents at Chapter –V. Bidder shall submit the individual quality plan for various equipment after placement of award and obtain approval of NESCL. 10.02.0
Individual MQPs and FQPs pertaining to each equipment shall be submitted by bidder after award for review and approval by Owner. Bidder shall strictly adhere to the provisions or approved MQP & FQPs. 10.03.0
The bidder shall offer proven and type tested equipment for the project. The type test certificates shall be complete as per the relevant I.S., carried out at independent third party laboratories like ERDA, CPRI etc. and shall not be older than 5 years as on the date of bid opening. For MS material shall be procured from manufacturers having in house facilities of fabrication, galvanizing. The manufacturer should also have the facility of heat treatment and should be approved by NESCL. The hardware fitting suppliers should have in house facility of galvanizing for better quality control. 10.04.0
The bidder shall submit complete type test reports for each of the equipments offered in his bid for approval of the owner and include one copy of all such test reports in the bid. In case during post award detail engineering stage if any equipment is found to be not type tested or partially type tested, as per I.S., the bidder shall carry out complete type test for the items at his own cost. 10.05.0
All routine and acceptance tests shall be carried out as per approved MQP. The bidders shall arrange to give sufficient advance intimation of the manufacturing and testing schedules to facilitated timely inspection of the equipments by the purchasers. The bidder shall provide six sets of tests reports to Employer on successful completion of the tests. Power supply arrangement & Lighting works
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10.06.0
The Manufacturing Quality Plans for each equipment submitted by supplier shall cover detailed checks at various stages of raw material, bought out items, in process, final testing, etc. and packing, prior to dispatch. 10.07.0
The submitted Quality Plan shall be in line with manufacturer’s plant standards, national/international standards, Approved Data Sheet and contract specification. This shall also contain statutory testing requirements, if any. CHP stages are identified by NESCL on MQP. 10.08.0
Field Quality Plan for each equipment shall be in line with the manufacturer’s practices, national/international standards, manuals, and approved data sheet and contract specification. This shall also contain statutory testing requirements, if any. 10.09.0
Field Quality Plan (FQP) is intended to cover all activities at site from material receipt and storage, handling, pre‐assembly, assembly up to completion of erection activities of equipment. 11
BILL OF QUANTITY 11.01.0
The Bill of Quantity for subject Scope of Works is indicated in the relevant Schedule of the Bid Proposal Sheet, Volume‐IB of bid document. 11.02.0
The bill of quantities indicated in the specifications is an estimate done by NESCL. However, it shall be the responsibility of the contractor to carry out survey & freeze the quantities required & obtain approval of NESCL for the finalized quantity within 15 days from the date of issue of LOI. The contractor shall be responsible to ensure satisfactory and timely completion of the scope of work. 11.03.0
It shall be binding on the contractor to complete the work in accordance with the specification as per the actual quantity requirements and as per the rates quoted in the bid. Bidder shall note that the excess quantities shall be disposed/ returned as per the relevant clauses of SCC. 12
WORK SCHEDULE For Work Schedule refer the relevant Schedule of the Bid Proposal Sheet Power supply arrangement & Lighting works
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GENERAL CONSTRUCTION PRACTICES
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1.00.00
STRUCTURAL WORKS 1.01.00
All the support structures shall be of Joist with two coats of red oxide primer followed by two coats of Zinc rich paint. 1.02.00
Minimum strength of structural concrete shall be M20 conforming to IS: 456. 2.00.00
EQUIPMENT ERECTION 2.01.00
The slings shall be of sufficient length to avoid any damage to insulator due to excessive swing, scratching by sling ropes etc. 2.02.00
For cleaning the insulators only muslin or leather cloth shall be used. 2.03.00
Handling equipment, sling ropes etc. should be tested before erection and periodically for strength. 2.04.00
The Contractor shall arrange at site all the equipment, instruments and auxiliaries required for testing and commissioning of equipment. 3.00.00
STORAGE OF EQUIPMENT The Contractor shall provide and construct adequate storage shed for proper storage of equipment. Weather sensitive equipment shall be stored indoors. All equipment during storage shall be protected against damage due to acts of nature or accidents. The storage instruction of the equipment manufacturer/Owner shall be strictly adhered to. 4.00.00
INSTALLATION OF CABLES 4.01.00
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 cables in bottom tiers. 4.02.00
All power cables shall be laid with a minimum center to center distance equal to twice the diameter of the cable. 4.03.00
Power and control cables shall be securely fixed to the supports. 4.04.00
Cables shall not be bent below the minimum permissible limit. The minimum bending radius of power cables shall be 12D and that of control cables shall be 10D, where D is overall diameter of cable. 4.05.00
Where cables cross roads, drains and rail tacks, the cables shall be laid in HDPE pipes with horizontal boring, buried at not less than one meter depth. 4.06.00
In each cable run some extra length shall be kept at a suitable point to enable one (for LT Cables) or two (for H.T. cables) straight through joints to be made, should the cable develop fault at a later date. Power supply arrangement & Lighting works
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4.07.00
Selection of cable drums for each run shall be so planned as to avoid using straight through joints & splicing. 4.08.00
Control cable terminations inside equipment enclosures shall have sufficient lengths so that switching of termination in terminal blocks can be done without requiring any splicing. 4.09.00
Metal screen and armour of the cable shall be bonded to the earthing system of the station, wherever required. 4.10.00
All due care shall be taken during unreeling, laying and termination of cable to avoid damage due to twist, kink, sharp bends, etc. 4.11.00
Cable ends shall be kept sealed to prevent damage. 4.12.00
Inspection on receipt, unloading and handling of cables shall generally be in accordance with IS: 1255 and other Indian Standard codes or practices. 4.13.00
Wherever cables pass through floor or through wall openings or other partitions, wall sleeves with bushes having a smooth curved internal surface shall be used so as not to damage the cables. These sleeves shall be supplied, installed and properly sealed at no extra charges. 4.14.00
The erection work shall be carried out in a neat workmanlike manner and the areas of work shall be cleaned of all scrap materials after the completion of work in each area every day. Contractor shall remove the RCC/steel trench covers before taking up the work and shall replace all the trench covers after the erection work in that particular area is completed or when further work is not likely to be taken up for some time. 4.15.00
In case the outer sheath of a cable is damaged during handling/installation, the Contractor shall repair it at his own cost, and to the satisfaction of the Engineer‐
in‐ Charge. In case any other part of a cable is damaged, the same shall be replaced by a healthy cable, at no extra cost i.e. the Contractor shall not be paid for supply, installation and removal of the damaged cable. 4.16.00
All cable terminations shall be appropriately tightened to ensure secure and reliable connections. The Contractor shall cover the exposed part of all cable lugs whether supplied by him or not with insulating type, sleeve or paint. 5.00.00
CONDUITS, PIPES AND DUCT INSTALLATION 5.01.00
Contractor shall supply and install conduits, pipes as specified and as shown in detailed drawings. Flexible conduit should be used between fixed conduit and equipment terminal boxes. Where vibration is anticipated, the flexible conduit shall be as per the relevant IS. 5.02.00
Contractor shall have his own facility for bending cutting and threading the conduits at site. Cold bending should be used. 5.03.00
All conduit/pipes shall be extended on both sides of wall/floor/openings. Exposed conduits/pipes shall be adequately clamped at an interval of about 1 Power supply arrangement & Lighting works
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meter. The fabrication and installation of supports and the clamping are included in the scope of work. 5.04.00
For underground runs, Contractor shall excavate and back fill as necessary. 6.00.00
JUNCTION BOXES 6.01.00
Contractor shall supply and install, wherever required, junction boxes complete with terminals. 7.00.00
INDOOR & OUTDOOR LIGHTING 7.01.00
Average lux level measured at equipment level to be maintained in various areas and types of fittings to be use are given as under. Location Avg. Lux level Street light 10 Transformer area (outdoor) 20 Switchgear room 150 Battery room 150 8.00.00
FIRE FIGHTING EQUIPMENT 8.01.00
Fire Buckets Filled With Sand Buckets filled with sand shall be installed. There shall be 3 no. of buckets. The buckets shall be hanging on a MS stand. The buckets and the stand shall be as per relevant standards and will be filled with sand. 8.02.00
Fire Extinguishers Fire extinguishers of the following types shall be provided in the switchgear room. •
Carbon dioxide type – 1nos ‐22.5Kg capacity mounted on trolley •
Dry chemical powder type‐ 2nos‐ 5Kg portable type Portable type extinguishers shall be provided with suitable clamps for mounting on walls or columns for dry chemical powder type. All extinguishers shall be painted with durable enamel paint of fire red colour conforming to relevant Indian Standards. Carbon dioxide (CO2, type) extinguisher shall conform to IS: 2878.Dry chemical powder type extinguisher shall conform to IS: 2171. The trolley mounted carbon dioxide mobile fire extinguisher shall operate in the vertical position, mounted on solid rubber tyre trolley wheels. Power supply arrangement & Lighting works
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9.00.00
SIGN BOARD A sign board of size 4ftx3ft of 1.5mm thick (minimum) MS sheet shall be fitted near or at the main gate as per approved drawing. 10.00.00
EARTHING 10.01.00
General 10.02.00
Exact location of earthing conductor, earth electrodes and test pits and earthing connections shall be designed to suit the site conditions. Soil resistivity measurements to be taken. Neutral points of system of different voltages, metallic enclosures and frame works associated with all current carrying equipment and extraneous metal works associated with electric systems shall be connected to a single earthing system unless stipulated otherwise. Earthing system installation shall be strict in accordance with the latest edition of Indian Electricity Rules, relevant Indian Standards and codes of practice and regulations existing in the locality where the system is installed: 10.03.00
10.04.00
a) Code of practice for earthing IS: 3043 b) Code of practice for protection of building and allied IS: 2309 structures against lightning. c) Indian Electricity Rules 1956 10.05.00
Each earthing lead from the neutral of the power transformer shall be directly connected to two pipe electrodes in treated earth pits, which in turn and shall be connected to station earthing grid. Earthing of all equipment support structures, equipment, switchyard fence etc. shall be made through rod electrodes. Cement concrete pit with a cast iron cover hinged to a cast iron frame shall be used for pipe electrodes. 11.00.00
DETAILS OF EARTHING SYSTEM Item Size Material Conductor above ground and 50x6mm GS Flat Galvanized mild steel earthing leads (for equipment structures etc.) Rod Electrode (untreated pit) 25 mm dia. Mild steel Pipe Electrode (treated pit) 100 mm internal dia. & 13mm thick(IS 3043) Cast Iron Power supply arrangement & Lighting works
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12.00.00
Equipment and Structure Earthing 12.01.00
Earthing pads shall be provided by the supplier of apparatus/equipment at accessible position. The connection between earthing pads and the earthing gird shall be made by short and direct earthing leads free from kinks and splices. In case earthing pads are to be provided on the item to be earthed, same shall be provided in consultation with Engineer‐in‐charge. Whether specifically shown in drawings or not, steel/ RCC columns, metallic stairs etc. shall be connected to the nearby earthing grid conductor by earthing leads. Electrical continuity shall be ensured by bonding different sections of hand rails and metallic stairs. Metallic pipes, conduits and cable tray sections for cable installation shall be bounded to ensure electrical continuity and connected to earthing conductors at regular interval. Apart from intermediate connections, beginning points shall also be connected to earthing system. Metallic conduits shall not be used as earth continuity conductor. A separate earthing conductor shall be provided for earthing lighting fixtures, receptacles, switches, junction boxes, lightning conduits, etc. Wherever earthing conductor crosses or runs along metallic structures such as gas, steam, conduits, pipe and steel reinforcement in concrete it shall be bonded to the same. Light poles, junction boxes on the poles, cable and cable boxes/glands lockout switches, etc. shall be connected to the earthling conductor running along the supply cable which, in turn, shall be connected to the earth in grid conductor at minimum two points, whether specifically shown or not. Earthling conductor shall be buried 2000 mm outside the switchyard fence. Every alternate post of the fence and gates shall be connected to earthing grid to ensure continuity. Flexible earthling connectors shall be provided where flexible conduits are connected to ensure continuity. 12.02.00
12.03.00
12.04.00
12.05.00
12.06.00
12.07.00
12.08.00
12.09.00
13.00.00
JOINTING 13.01.00
Earthling connections with equipment earthling pads shall be bolted type and joint faces shall be galvanized. Contact surfaces shall be free from scale, paint enamel, grease, rust or dirt. Two bolts shall be provided for making each connection. Equipment bolted connections after being checked and tested, shall be painted with anti‐corrosive paint/ compound. Connection between equipment earthling lead and main earthling conductors, and between main earthling conductors shall be welded/brazed type. For rust protection, the welds should be treated with red lead and afterwards thickly coated with bitumen compound to prevent corrosion. Steel to copper connections shall be brazed type and shall be treated to prevent moisture ingression. Resistance of the joint shall not be more than the resistance of the equivalent length of the conductor. 13.02.00
13.03.00
13.04.00
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13.05.00
13.06.00
13.07.00
GENERAL CONSTRUCTION PRACTICES
All ground connections shall be made by electric are welding. All welded joints shall be allowed to cool down gradually to atmospheric temperature before putting any load on it. Artificial cooling shall not be allowed. Bending of large diameter rod/thick conductor shall be done preferably by gas heating. All arc welding with large diameter conductors shall be done with low hydrogen content electrodes. 14.00.00
Power Cable Earthing 14.01.00
Metallic sheaths and amour 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. 15.00.00
Storage and Handling of Cable Drums 15.01.00
Cable drums shall be unloaded, handled and stored in an approved manner. Rolling of drums shall be avoided as far as practicable. For short distances, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In absence of any indication the drums may be rolled in the same direction it was rolled during taking up the cables. 16.00.00
Cable Terminations and Connections a) The termination and connection of cables shall be done strictly in accordance with cable and termination kit manufacturer’s instructions, drawing and/or as directed by the Owner. b) 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. c) 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. d) The Contractor shall tag/ferrule the control cable cores at all terminations, as instructed by the Owner. In panels where a large number of cables are to be terminated and cable identification may be difficult, each core ferrule may include the complete cable number as well. Spare cores shall be similarly tagged with cable numbers and coiled up. e) Control cables shall have stranded copper conductor. Bare portion of the solid conductors shall be tinned after removing the insulation and shall be terminated directly without using cable lugs. f) All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively closed. Power supply arrangement & Lighting works
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g) 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 with the approval of the Owner. Power supply arrangement & Lighting works
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1.00.00 SCOPE OF WORK 1.01.00 This specification covers design, engineering, manufacture, inspection, testing at manufacturers works including type testing before dispatch, supply and delivery at destination, three phase station transformers, oil filled, naturally cooled, 50 Hz, outdoor type. 2.00.00 APPLICABLE STANDARDS 2.01.00 Station transformers shall comply with the latest version of following Standards along with the amendments. i) Indian Standard Specification IS : 2026. 3.00.00 RATINGS AND TYPE 3.01.00 The kVA ratings and types of station transformer shall be as follows : MVA Ratings No. of Phases 2.5 Three phase Nominal System No Load Voltage Ratio Voltage (ph‐ph) 33kV 33/0.433 kV 4.00.00 TERMINATION The transformers shall be terminated (as per SLD provided herewith) on •
•
33kV 3Cx300 sq.mm XLPE cable on primary side, and LT bus duct of 4000A rating on secondary side. 5.00.00 WINDING CONNECTIONS & VECTORS The transformer shall have vector notation of Dyn11 type. 6.00.00 TAPS ON‐Load Taps shall be provided at ±10% in steps of 1.25% on the HT Side. OLTC shall be operated using a signal from LT APFC panels for maintaining voltage regulation within standard limits. 7.00.00 WINDING 7.01.00 Material Super enamel covered copper conductor/DPC copper conductor shall be used. Power supply arrangement & Lighting works
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7.02.00 Electrical Grade Epoxy Dotted insulation paper shall be used for inter‐layer insulation of the HV and LV coils. 7.03.00 Current density of copper conductor for HV and LV winding shall be not more than 2.5 A/mm2. 7.04.00 Conductor used for HV and LV winding shall be from continuous wire without any joint or brazing, as far as possible. 7.05.00 Angle shaped End Rings made from pre‐compressed board should preferably be used between the end coils and core. 7.07.00 Construction of winding shall be adequately designed to withstand the short circuit test not withstanding the type of conductor being used. 8.00.00 CORE 8.01.00 The type of Core and Core material shall be as given below: i) ii) The design of magnetic circuit shall be such as to avoid static discharges development of short circuit paths within itself or in the earthed clamping structure. iii) Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure and the action of hot transformer oil. iv) The core shall be constructed from new high grade, non‐aging Cold Rolled Grain Oriented (CRGO) silicon steel laminations conforming to grade M4 or better. The bidder shall provide saturation curve of the core material proposed to be used. v) vi) All parts of the core shall be of robust design, capable of withstanding any shocks to which they may be subjected during handling, lifting, transportation installation and service. Clamping of core and winding assembly with tank should be done by angle iron pieces, welded to tank walls and not to be done with flat iron pieces. The core shall be stack type. Core material shall be directly procured either from the manufacturer or through their accredited marketing organization of repute and not through any agent. The complete design of core must ensure permanency of the core losses with continuous working of the transformers. The value of the flux density allowed in the design and grade of lamination used shall be clearly stated in the offer. Power supply arrangement & Lighting works
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vii) Adequate arrangement shall be provided to enable the core and winding to be properly supported. Use of seconds CRGO steel for core construction is strictly prohibited. 8.02.00 Core Clamping 8.02.01 Core clamping shall be with top & bottom clamps made of sheet steel, clamped with H.T. steel tie rods or steel belts/tape for proper clamping. 8.02.02 M.S. core clamps shall be painted with varnish or oil resistant paint. 8.02.03 Provision shall be made in bottom core clamp/plate to arrest movement of active part. 9.00.00 PERMISSIBLE FLUX DENSITY & OVERFLUX 9.01.00 The flux density at rated voltage and frequency shall not exceed 1.69 tesla. The maximum flux density in any part of the cores and yoke at normal voltage and frequency shall be such that the flux density with + 12.5 % voltage variation from rated voltage and frequency variation of +5% shall not exceed 1.9 Tesla. The transformer shall be suitable for over fluxing due to combined effect of voltage and frequency. The supplier shall furnish necessary design data in support of this stipulation. The no‐load current at Rated Voltage and at 112.5 percent Rated Voltage shall not exceed values as per IS. 9.02.00 The core and coil assembly shall be securely held in position to avoid any movement under short‐circuit conditions. 10.00.00 SYSTEM SHORT CIRCUIT LEVEL The transformer fault level shall be as per IS. 11.00.00 TRANSFORMER TANK 11.01.00 Construction 11.01.01 The transformer tank shall be made of good quality steel sheet of adequate thickness and shall be suitably stiffened to provide sturdy and robust construction to withstand extreme pressure conditions. The tank shall be capable of withstanding pressure upto (+) 80 Kpa and (‐) 70 Kpa (gauge pressure) without any deformation. 11.01.02 The tank cover shall have plasticised surface at the top to guard against birdage faults. Alternatively, suitable insulating shrouds shall be provided on the bushing terminals. Power supply arrangement & Lighting works
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11.02.00 Pressure Relief Device Pressure relief device shall be provided. 11.03.00 Sealing Gaskets All sealing washers/gaskets shall be made of oil and heat resistant nitrile rubber. Gaskets made of natural rubber or cork sheet are not permissible. Rubberized cork sealing gaskets may be accepted, subject to clearance for quality. 11.04.00 Conservator 11.04.01 The transformer shall be provided with conservator. 11.04.02 The conservator shall be provided with a drain plug and a filling hole with cover. In addition, the cover of main tank shall be provided with an air release plug to enable trapped air to be released plug to enable trapped air to be released unless the conservator is so located as to eliminate the possibility of air being trapped within the main tank. 11.04.03 The inside diameter of the pipe connecting the conservator to the main tank shall be within 20 to 50 mm and it should project into the conservator in such a way that its end is approximately 20 mm above the bottom of the conservator so as to create a sump for collection of impurities. The minimum oil level 0
(corresponding to‐5 C should be above the sump level. 11.05.00 Each transformer shall be fitted with a transparent type breather in which Silica gel is the dehydrating agent. The breather is so designed that the passage of air through the Silica gel and the external atmosphere is not continuously in contact with silica gel. 12.00.00 PAINTING PROCEDURE The paint material and procedure for the station transformer shall be as per details given below: 12.01.00 All paints shall be applied in accordance with the paint manufacturer’s recommendations. Particular attention shall be paid to the following : a. Proper storage to avoid exposure as well as extremes of temperature. b. Surface preparation prior to painting. c. Mixing and thinning Power supply arrangement & Lighting works
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d. Application of paints and the recommended limit on time intervals between coats. e. Shelf life for storage. 1. All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush marks or other defects. 2. All primers shall be well marked into the surface, particularly in areas where painting is evident, and the first priming coat shall be applied as soon as possible after cleaning. The paint shall be applied by airless spray according to the manufacturer’s recommendations. However, wherever airless spray is not possible, conventional spray be used with prior approval of purchaser. 12.02.00 Cleaning and Surface Preparation 1. After all machining, forming and welding has been completed, all steel work surfaces shall be thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to any painting. 2. Steel surfaces shall be prepared by Sand / Shot blast cleaning or Chemical cleaning and process including Phosphating to the appropriate quality. 3. The Pressure and Volume of the compressed air supply for the blast cleaning shall meet the work requirements and shall be sufficiently free from all water contamination prior to any painting. 4. Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly adherent mill‐scale and shall only be used where blast cleaning is impractical. 12.03.00 Protective Coating As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given suitable anticorrosion protection. 12.04.00 Paint Material Followings are the type of paints that may be suitably used for the items to be painted at shop and supply of matching paint to site: 3. The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings and similar such items. Power supply arrangement & Lighting works
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1. Heat resistant paint (Hot oil proof) for inside surface. 2. For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2 coats of Synthetic Enamel paint. The color of the finishing coats shall be dark admiral gray conforming to No. 632 of IS 5:1961. 12.05.00 Painting Procedure 1. All painting shall be carried out in conformity with both specifications and with the paint manufacturer’s recommendations. All paints in any one particular system, whether shop or site applied, shall originate from one paint manufacturer. 2. Particular attention shall be paid to the manufacturer’s instructions on storage, mixing, thinning and pot life. The paint shall only be applied in the manner detailed by the manufacturer e.g. brush, roller, conventional or airless spray and shall be applied under the manufacturer’s recommended conditions. Minimum and maximum time intervals between coats shall be closely followed. 3. All prepared steel surfaces should be primed before visible re‐rusting occurs or within 4 hours whichever is sooner. Chemical treated steel surfaces shall be primed a s soon as the surface is dry and while the surface is warm. 4. Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking or general softness) the supplier shall remove the unsatisfactory paint coatings and apply another. As a general rule, dry film thickness should not exceed the specified minimum dry film thickness by more than 25 %. In all instances, where two or more coats of the same paints are specifies, such coatings may or may not be of contrasting colors. 5. Paint applied to items that are not be painted, shall be removed at supplier’s expense, leaving the surface clean, un‐stained and undamaged. 12.06.00 Damages Paint Work 1. Any damage occurring to any part of the painting scheme shall be made good to the same standard of corrosion protection and appearance as that originally employed. 2. Any damaged paint work shall be made good as follows: 3. The damaged area, together with an area extending 25 mm around its boundary, shall be cleaned down to bare metal. Power supply arrangement & Lighting works
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a) A priming coat shall immediately applied, followed by a full paint finish equal to that originally applied and extending 50 mm around the perimeter of the originally damaged. b) The repainted surface shall present a smooth surface. This shall be obtained by carefully chamfering the paint edges before & after priming. 12.07.00 Dry Film Thickness 1. To the maximum extent practicable, the coats shall be applied as a continuous film of uniform thickness and free of pores. Over‐spray, skips, runs, sags and drips should be avoided. The different coats may or may not be of same color. 2. Each coat of paint shall be allowed to harden before the next is applied as per manufacturer’s recommendations. 3. Particular attention must be paid to full film thickness at edges. 4. The requirement for the dry film thickness (DFT) of paint and the material to be used shall be as given below: Sl. No. Paint type Area to be 1. Powder paint Thermo setting powder Liquid Paint Zinc chromite (primer) Synthetic Enamel (Finish Coat) Hot Oil paint a) 2. a) b) c) Inside
No. of coats 01
Total dry film 20 microns
Outside
01
60 microns
Outside
02
45 microns
Outside
02
35 microns
Inside
01
35 microns
13.00.00 TRANSFORMER OIL 13.01.00 New insulating oil of petroleum origin shall be used. The oil shall be of low viscosity type and completely free from additives. Power supply arrangement & Lighting works
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13.02.00 Transformer oil shall comply with IS : 335. 13.03.00 The requirements have been given in two parts. A) For new transformer oil in drums / tankers. B) For oil after it is filled in the transformer (the values shall be applicable after 3 days from the date of filling). 13.04.00 New Oil The important characteristics of new oil shall be as follows: Characteristics Requirement 1. Flash point Pensky Marten (closed), Min. 140 0 C 2. Neutralization value a) Total acidity, Max. 0.03 mg KOH/g b) Inorganic acidity/alkalinity Nil 3. Corrosive Sulphur Non ‐ Corrosive 4. Electric Strength (breakdown voltage) Min. a) New unfiltered oil 30 kV (ms) b) New oil after filtration 50 kV (ms) 5. Dielectric dissipation factor (tan delta) at 900 C (Max.) 0.005 6. Specific resistance (resistivity) a) At 900 C (Min.) 30x1012 ohm‐cm b) At 270 C (Min.) 500x1012 ohm‐cm 7. Oxidation stability a) Neutralization value after oxidation (Max.) 0.4mg KOH/g b) Total sludge after oxidation (Max.) Power supply arrangement & Lighting works
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8. Ageing Characteristics a) Specific resistance (resistivity) i) at 270 C 2.5x10 12 ohm‐cm (Min.) ii) at 900 C 0.2x10 12 ohm‐cm (Min.) b) Dielectric dissipation factor (tan delta) at 900C 0.20 Max. c) Total acidity in mg KOH/g 0.05 Max. d) Total sludge 13.05.00 Characteristics of oil in the Transformer The important characteristics of the transformer oil after it is filled in the transformer (after 3 days of filling) shall be as follows: Characteristics Specification 1. Electric strength (Breakdown voltage) 30 kV Min. 2. Dielection dissipation factor (tan delta) at 900C 0.01 Max. 3. Specific delta resistance (resistivity) at 270 C (Ohm‐cm) 10x1012 4. Flash point, P.M (Closed) 5. Interfacial tension at 270 C 6. Neutralization value (total acidity) 7. Water content, PPM 13.06.00 Tests All tests to verify the characteristics as incorporated in this specification shall be carried out in accordance with IS:335‐1983 or its latest version. 14.00.00 Drawings The Bidder shall furnish two sets of following drawings for owner’s approval before commencing the erection of Station Transformer. General outline Power supply arrangement & Lighting works
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drawings of the complete equipment with technical parameters and Drawings showing clearance from ground and other live objects. 16.00.00 FITTINGS 16.01.00 The following standard fittings shall be provided a) An extended pipe for filling of oil at the top with welded cover. The pipe shall be suitably threaded over a sufficient length so that it may be possible to provide a refilling connection after removing the welded cover. b) Two earthing terminals c) Cable junction box for 33kV cable termination. e) Two lifting lugs (on Tank body) f) Rating and terminal marking plate(s). 16.02.00 The following standard fittings shall be provided for three phase station transformers only. a) Oil level gauge indicating three positions of oil marked as follows: ‐ Minimum (‐50C) ‐ 300C ‐ Maximum (980C) b) Plain breathing device comprising an inverted U‐pipe with wire gauze at the open end or Silica gel breather, as required by the purchaser. c) Drain‐cum‐Sampling valve (Steel) of the type shown in Fig. 1 welded to the tank. The special tool for operating this value shall be supplied with the transformer. d) Thermometer pocket 17.00.00 MOUNTING ARRANGEMENT The under‐base of all transformers shall be provided with two 75x40mm channels 460mm long with holes (at a centre‐to‐centre distance of 415mm) to make them suitable for fixing on a platform or plinth. For mounting dimensions, Fig 3 of REC Specification 2 / 1971 can be referred. Power supply arrangement & Lighting works
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18.00.00 RATING AND TERMINAL MARKING PLATE The transformer shall be provided with non‐detachable rating marking plate(s) of weather proof material, fitted in a visible position and showing the complete information given in Clause No. 15.2 of IS : 2026 (Part–I)–1977. 19.00.00 LIMITS OF TEMPERATURE RISE The temperature rise shall not exceed the limits of 550C (measured by resistance) for transformer windings and 450C (measured by thermometer) in top oil above the ambient temperature of 500C, when tested in accordance with IS: 2026 (Part‐2). The percentage impedance at 750C shall be 4.5% subject to tolerance as per IS: 2026. 20.00.00 LOSSES & IMPEDANCE VALUES The bidder shall furnish the maximum guaranteed values of no load and load losses (at 750C) with no plus tolerance in the data requirement sheet and also in Schedule‐7 of SCC. Loss capitalization shall be applicable as per SCC. 21.00.00 TESTS 21.01.00 ACCEPTANCE TEST Routine & acceptance test shall be done as per IS: 1180 21.02.00 Type Test The supplier shall offer transformers of identical design & rating which has been type tested as per relevant IS. The type tests should have been conducted within last ten years from a national test house or from similar reputed test house. The bidder shall furnish type test reports for each type rating. If the type tests conducted within last ten years is incomplete or not conducted within last five years the party shall arrange to carry out such tests at his own cost & risk in the presence of employer/owners representative. For short circuit withstand capability, successful bidder shall submit the design calculation. Even if such tests have been conducted within last ten years employer/owner reserves the right to repeat such tests for which the cost shall be borne by employer/owner. Power supply arrangement & Lighting works
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22.00.00 INSPECTION All routine tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall provide the inspector, representing the purchaser, all the data, drawings and calculations without approved to satisfy him that material is being used in accordance with the specification and relevant standards. The purchaser has the right to have any tests carried out at his own cost, by an independent agency, whenever there is a dispute regarding the quality of supply. 23.00.00 GENERAL TECHNICAL PARTICULARS: GTP of Station Transformers are enclosed herewith in two parts (Part A and Part B). The successful bidder shall supply Station Transformers as per Part A of GTP and additional details which are stipulated in Part B of the GTP shall be filled and submitted for review and approval along with the bid. Make shall be NESCL Corporate Quality Assurance (CQA) approved. Part A: Sl.No.. 1 2 3 Description Continuous max. rating as per this specification.
Nominal Voltage ratio of transformer
Method of Connection HV / LV
4 Max.Hot Spot Temp.Deg.C. (Ambient air temp on which above is based) Deg.C. 5 6 7 8 9 10 Rating 2.5 MVA 33/0.433 kV
Dyn11 115.90C over maximum ambient of 500C a) Max. Observable Oil temp. Deg.C.(ambient air temp. on which above is based) Deg.C. b) Max. Winding Temperature at an ambient temp. of % Impedance voltage at normal ratio between HV & LV windings Type of transformers
Impulse test voltage level HV Windings LV Windings Characteristics of transformer oil
Whether transformer will be transported with oil? Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
a) 400C b) 350C As per IS 2026 Part‐
I Stack Core 75kV/Type M4 or better stack core. peak NA As per IS:335
YES CHAPTER-II
SECTION-E1
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DISTRIBUTION TRANSFORMERS
CLAUSE NO.
Part­B Sl.No.. Description 11 Name of the manufacturer and place manufacturer Rating 12 Fixed losses at normal voltage ratio (watts) at 750C(Max.) 13 Load losses at normal voltage ratio
(watts) at 750C(Max.) 14 Total losses at normal voltage ratio (watts) at 750C(Max.) 15 20 Efficiency at normal voltage i) Unity Power Factor a) At 50% Load b) At 75% Load c) At full Load ii) 0.8 Power Factor a) At 50% Load b) At 75% Load c) At full Load Regulation as percentage of normal voltage. A) At unity power factor% b) At 0.8 Power factor lagging% Type of Insulation used in a) HV Windings b) LV Windings Type of Insulation used in a) Core bolts b) Core bolt washers c) End plates d) Core lamination Total content of oil in liters
21 Type of transformers tank
23 I) Approx. overall dimensions a) Height mm b) Breadth mm c) Width mm ii) Tank dimensions a) Diameter mm b) Height mm Weight of insulated conductor a) HV (min.) kg. b) LV (min.) kg. Weight of core (min.) kg.
16 17 18 19 24 25 Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E1
PAGE
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DISTRIBUTION TRANSFORMERS
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26 27 Weight of complete transformer arranged for transport kg. a) With oil b) Without oil Tank cover sealing
28 Gasket material
29 30 Painting i)External ii) Internal Core window height (App.) Watts
31 Center to center distance of the core 32 No. of L.V. Turns (App.)
33 No. of H V turns (App.)
34 36 Wt. Of the LV winding for Transformer (App/job) kg. Wt. Of the HV winding for Transformer (App/job) kg. No. of LV Coils/phase 37 No. of HV coils. phase 38 Height of LV Windings mm
39 Height of HV Windings mm
40 ID/OD of LV Winding mm
41 ID/OD of HV Winding(app.) mm 42 Size of the duct in LV winding mm
43 Size of the duct in HV winding mm
43 44 Size of the duct between mm HV Z& LV HV winding to LV clearance mm
45 HV winding to tank clearance mm
46 Calculated impendence %
47 HV to earth creepage distance mm
35 Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E1
PAGE
14 OF 14
33kV SWITCHGEAR
CLAUSE NO.
1.00.00
1.01.00
1.02.00
1.03.00
1.04.00
1.05.00
1.06.00
GENERAL REQUIREMENTS The equipment offered by the Bidder shall be complete in all respects. Any material and component not specifically stated in this specification but which are necessary for trouble free operation of the equipment and accessories specified in this specification shall be deemed to be included unless specifically excluded. All such equipment / accessories shall be supplied without any extra cost. Also all similar components shall be interchangeable and shall be of same type and rating for easy maintenance and low spare inventory. Specific reference in this specification and documents to any material by trade name, make or catalogue number shall be construed as establishing quality and performance requirements. Equipment shall be installed in a neat workman‐like‐manner so that it is leveled, plumbed, squared and properly aligned and oriented. Tolerances shall be as established on Contractor’s drawings or as stipulated by Employer. No equipment shall be permanently bolted down / tag welded to foundation until the alignment has been checked and found acceptable by the Engineer. Contractor shall furnish all supervision labor, tools, equipment rigging materials, bolts, wedges, anchors, concrete inserts etc. in proper time, required to completely install, test and commission the equipment. Manufacturer’s and Employer’s instructions and recommendations shall be correctly followed in handling, erection, testing and commissioning of all equipment. Contractor shall move all equipment into the respective rooms through the regular door or openings specifically provided for this purpose. No parts of structure shall be utilized to lift or erect any equipment without prior permission of Engineer. Switchgear shall be installed on finished surfaces, concrete or steel sills. Contractor shall be required to install and align any channel sills which form part of foundations. Power bus enclosure, ground and control splices of conventional nature shall be cleaned and bolted together with torque wrench of proper size or by other approved means. Tape or compound shall be applied where called for in drawings. Contractor shall take utmost care in handling instruments, relays and other delicate mechanisms. Wherever the instruments and relays are supplied loose along with switchgear, they shall be mounted only after the associated switchgear panels have been erected and aligned. The blocking materials, employed for safe transit of instrument and relays shall be removed after ensuring that panels have been completely installed and no further movement of the same would be necessary. Any damage shall be immediately reported to Engineer. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E2
Page 1
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1.07.00
1.08.00 2.00.00
All foundation work for all switchgear panels will be carried out by Bidder. Minor modifications to foundations shall be carried out by the Contractor at no extra cost. In case of scheme modification during detail engineering the payment shall be regulated based on number of incomers, Bus coupler, Voltage transformer Outgoing line feeders etc. envisaged based on unit rates quoted by the bidders. CODES AND STANDARDS All standards, specification and codes of practices referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS Codes, Standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards and codes a) IS: 14697 AC Static Energy meters. b) IS: 996 Single phase small AC and universal electrical motors. c) IS: 1248 Direct Acting indicating analogue electrical measuring instruments and Accessories. d) IS: 13947 Degree of protection provided by enclosures for low voltage switchgear and control gear. e) IS: 2544 Porcelain post insulators for systems with nominal voltages greater than 1000 Volts. f) IS: 2705 Current transformers. g) IS: 3156 Voltage Transformers h) IS: 6005 Code of practice for phosphating of iron and steel. i) IS: 3427 Metal enclosed switchgear and control gear j) IS: 5082 Specification for wrought aluminium and aluminium alloy bars, rods, tubes and selections for electrical purposes. k) IEC: 61850 Communication Standard for Numerical relays l) IEC: 61131‐
3 Automation Standard for Numerical relays m) IS: 9046 AC contactors for voltages above 1000 volts and upto Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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and including 11000 Volts.
2.01.00
n) IS: 13703 Low voltage fuses o) IS: 9385 HV fuses p) IS: 9431 Specification for indoor post insulators of organic material for system with nominal voltages greater than 1000 volts upto and including 300 kV q) IS: 9921 A.C. disconnectors (isolators) and Earthing switches for voltages above 1000 V r) IS: 11353 Guide for uniform system of marking and identification of conductors and apparatus terminals. s) IS: 13118 Specification for high voltage AC circuit breakers. t) IEC: 60099‐
4 Metal oxide surge arrestor without gap for AC system u) IEC: 62271‐
100 High voltage alternating current circuit breakers. v) IEC: 62271‐
200 High voltage metal enclosed switchgear and control gear. w) IEC: 60947‐
7‐1 Terminal blocks for copper conductors (x) IS :513 (2008) Cold Rolled Low Carbon Steel Sheets and Strips Installation shall conform to Indian Electricity Act and Indian Electricity Rules as amended upto date. The Indian Electricity Act and Indian Electricity Rules can be obtained from : Kitab Mahal State Emporium Building, Baba Kharag Singh Marg, New Delhi ‐ 110 001 INDIA. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E2
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2.02.00
3.00.00
Equipment conforming to any other internationally accepted standards will also be considered if they ensure performance and constructional features equivalent or superior to the standards listed above. In such case, the Bidder shall clearly indicate the standard(s) adopted. The Bidder shall furnish copy in English of the latest revision of the standards along with the copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. TECHNICAL PARAMETERS 1 2 3 4 5 6 7 8 9 10 11 12 Nominal System voltage
33 kV
Highest System voltage 36 kV
Rated Frequency 50 Hz
Number of phases/ poles Three
System neutral earthing Solidly Earthed
One minute power frequency withstand voltage
‐ for Type tests 70
‐ for Routine tests 70
1.2/50 microsecond 170 kV (peak)
Impulse withstand voltage Maximum system fault 31.5 kA (rms)
level including initial motor contribution Short time rating for bus 31.5 kA (rms) for one (1) sec. bars, ckt. breakers, current transformers and swgr. Assembly. Dynamic withstand rating 78.75 kA (peak)
‐ Trip and closing coils 110 V DC
‐ Spring charging motor 110 V DC
‐ Space heaters 240 V AC single phase with neutral solidly earthed Maximum ambient air 50 deg. C
temperature BUS BARS 1. Continuous current rating at 500C ambient: Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
As Per BOQ/E0
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E2
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2. Temper Rise allowed above 400C for plain joints 550C for Silver ambient plated joints SWGR. CUBICLE CONSTRUCTIONAL REQUIREMENTS 1. Color finish IS:5 shade 631
2. Cable entry a) Power Cables
Bottom
b) Control Cables
3. Employer's Earthing conductor Bottom
Galvanized steel strip
CIRCUIT BREAKERS 1. The circuit breakers current rating shall be selected from the load current given in SLD which is at an ambient of 50 deg. C. 2. Short circuit breaker 33 kV
Current a) A.C. component
31.5 kA
b) D.C. component
As per IS: 13118 or IEC‐62271 3. Short Circuit making current 78.75 kA (peak) 4. 5. 6. 7. Operating Duty Total break time Total make time Operating Mechanism B‐3 Min‐MB‐3 Min‐MB Not more than 4 cycles Not more than 5 cycles Motor wound spring charged stored energy type as per IEC‐62271 CURRENT TRANSFORMER 1. Class of Insulation
Class E or better 2. Rated output of each Adequate for the relays and devices connected, core but not less than five (5) VA. 3. Accuracy class Protection & Class PS for differential & REF and core balance Measurement CTs; 5P20 for other protection CTs. Required Accuracy for metering is 0.2 for all feeder bays Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
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4. Minimum primary earth fault current to be detected by core balance current Transformer 3 Amperes VOLTAGE TRANSFORMERS 1. 2. 3. Rated Voltage Factor Class of insulation
Other parameters (Burden and Accuracy) 1.2 continuous for all VTs, and 1.9 for 30 seconds for star connected VTs. Class E or better BUS PT‐0.2 Class, VA req. adequate for application. Line PT‐0.2 Class for sync./3P for door interlocks, VA req. adequate for application. 4.00.00
4.01.00
GENERAL TECHNICAL REQUIREMENTS Switchgear Panel (a.) The switchgear boards shall have a single front, single tier, fully compartmentalised, metal enclosed construction complying with clause No. 3.102 of IEC 62271‐200, comprising of a row of free standing floor mounted panels. Each circuit shall have a separate vertical panel with distinct compartments for circuit breaker / contactor truck, cable termination, main busbars and auxiliary control devices. The adjacent panels shall be completely separated by steel sheets except in busbar compartments where insulated barriers shall be provided to segregate adjacent panels. However, manufacturer's standard switchgear designs without interpanel barriers in busbar compartment may also be considered. (b.) The circuit breakers / contactors and bus VTs shall be mounted on withdrawable trucks which shall roll out horizontally from service position to isolated position. For complete withdrawal from the panel, the truck shall rollout on the floor or shall roll out on telescopic rails. In case the later arrangement is offered, suitable trolley shall be provided by the Bidder for withdrawal and insertion of the truck from and into the panel. The number of trolleys to be provided shall be as specified. Testing of the breaker / contactor shall be possible in Isolated position by keeping the control plug connected. (c.) The trucks shall have distinct SERVICE and ISOLATED positions. It shall be possible to close the breaker / contactor compartment door in isolated position also, so that the switchgear retains its specified degree of protection. While switchboard designs with doors for breaker / contactor compartments Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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would be preferred, standard designs of reputed switchgear manufacturers where the truck front serves as the compartment cover may also be considered provided the breaker / contactor compartment is completely sealed from all other compartments and retains the IP‐4X degree of protection in the Isolated position. In case the latter arrangement is offered, the Bidder shall explain how this sealing is achieved and shall include blanking covers one for each size of panel per switchboard in his total bid price. (d.) The switchgear assembly shall be dust, moisture, rodent and vermin proof, with the truck in any position SERVICE, ISOLATED or removed, and all doors and covers closed. All doors, removable covers and glass windows shall have gaskets all round with synthetic rubber or neoprene gaskets. (e.) The VT/ relay compartments shall have degree of protection not less then IP 5X in accordance with IS 13947. However, remaining compartments can have a degree of protection of IP 4X. All louvers, if provided, shall have very fine brass or GI mesh screen. Tight fitting gourmet / gaskets are to be provided at all openings in relay compartment. Numerical Relays shall be fully Flush mounted on the switchgear panels at a suitable height. (f.) The switchgear construction shall be such that the operating personnel are not endangered by breaker operation and internal explosions, and the front of the panels shall be specially designed to withstand these. Pressure relief device shall be provided in each high voltage compartment of a panel, so that in case of a fault in a compartment, the gases produced are safely vented out, thereby minimizing the possibility of its spreading to other compartments and panels. The pressure relief device shall not however reduce the degree of protection of panels under normal working conditions. To demonstrate that the pressure relief device operates satisfactorily the Contractor shall carryout the test in line with IEC 62271‐200 Annex ‐ A, as a type test. However, such test at reduced prospective fault currents shall also be acceptable provided the satisfactory operation of pressure relief device can be demonstrated. (g.) Enclosure shall be constructed with rolled steel sections. The doors and covers shall be constructed from cold rolled steel sheets of 2.0 mm thickness. Gland plates shall be 2.5 mm thick made out of hot rolled or cold rolled steel sheets and for non magnetic material it shall be 3.0 mm. (h.) The switchgear shall be cooled by natural air flow and forced cooling shall not be accepted. (i.) Total height of the switchgear panels shall not exceed 2600 mm. The height of switches, pushbuttons and other hand operated devices shall not exceed 1800 mm and shall not be less than 700 mm. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
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(j.)
Necessary guide channels shall be provided in the breaker compartments for proper alignment of plug and socket contacts when truck is being moved to SERVICE position. A crank or lever arrangement shall preferably be provided for smooth and positive movement of truck between Service and Isolated positions. (k.) Safety Switchgear construction shall have a bushing or other sealing arrangement between the circuit breaker / Contactor compartment and shutters complying with IEC 62271‐200 shall be provided to cover up the fixed high voltage contacts on busbar and cable sides when the truck is moved to ISOLATED position. The shutters shall move automatically, through a linkage with the movement of the truck. Preferably it shall however, be possible to open the shutters of busbar side and cable side individually against spring pressure for testing purpose after defeating the interlock with truck movement deliberately. In case, insulating shutters are provided, these shall meet the requirements of IEC 62271‐200 and necessary tests as per IEC 62271‐200 Clause 5.103.3.3 shall be carried out. A clearly visible warning label "Isolate elsewhere before earthing" shall be provided on the shutters of incoming and tie connections which could be energised from other end. (l.) the busbar / cable compartments, so that there is no air communication around the isolating contacts in the shutter area with the truck in service position. (m.) The breaker / contactor and the auxiliary compartments provided on the front side shall have strong hinged doors. Busbar and cabling compartments provided on the rear side shall have separate bolted covers with self retaining bolts for easy maintenance and safety. Breaker / Contactor compartment doors shall have locking facility. Suitable interlock shall be provided, which will ensure that breaker is OFF before opening the bolted covers /back doors. For Incomer/Tie panels suitable interlock shall be provided to prevent opening of any compartment doors which has any of the MV (33kV/11kV) equipment, in case the incoming supply is ON. (n.) In the Service position, the truck shall be so secured that it is not displaced by short circuit forces. Busbars, jumpers and other components of the switchgear shall also be properly supported to withstand all possible short circuit forces corresponding to the short circuit rating specified. (o.) Suitable base frames made out of steel channels shall be supplied along with necessary anchor bolts and other hardware, for mounting of the switchgear panels. These shall be dispatched in advance so that they may be installed and leveled when the flooring is being done, welding of base frame Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E2
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to the insert plates as per approved installation drawings shall be in Bidder's scope. (p.) The switchboard shall have the facility of extension on both sides. Adopter panels and dummy panels required to meet the various busbar arrangements, cable / bus duct termination and layouts shall be included in Bidder's scope of work. 4.02.00
(q) The 33 kV incomer switchgear shall have facility to receive lugs of 3CX240 sq mm XLPE cable. ( r) Bus duct inter connection is also includes in the Bidder Scope of Work. The interconnection shall be top entry type with required enclosure and bus duct site. Adequate support shall be provided for this inters connection by higher from roof. Circuit Breakers a) b) c) d) The circuit breakers shall be VCB type.
They shall comprise of three separate, identical single pole interrupting units, operated through a common shaft by a sturdy operating mechanism. Circuit breaker shall be restrike free, stored energy operated and trip free type. Motor wound closing spring charging shall only be acceptable. An antipumping relay shall be provided for each breaker, even if it has built‐in mechanical anti‐pumping features. An arrangement of two breakers in parallel to meet a specified current rating shall not be acceptable. During closing, main poles shall not rebound objectionably and mechanism shall not require adjustments. Necessary dampers shall be provided to withstand the impact at the end of opening stroke. Slow closing facility shall preferably be provided for checking and adjustment of arc chutes and poles when the breaker is completely withdrawn and isolated. Plug and socket isolating Contacts for main power circuit shall be silver plated, of self aligning type, of robust design and capable of withstanding the specified short circuit currents. They shall preferably be shrouded with an insulating material. Plug and socket contacts for auxiliary circuits shall also be silver plated, sturdy and of self aligning type having a high degree of reliability. Thickness of silver plating shall not be less than 10 microns. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E2
Page 9
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e) f) g) h) i) All working part of the mechanism shall be of corrosion resisting material. Bearings which require greasing shall be equipped with pressure type grease fittings. Bearing pins, bolts, nuts and other parts shall be adequately secured and locked to prevent loosening or change in adjustment due to repeated operation of the breaker and the mechanism. The operating mechanism shall be such that failure of any auxiliary spring shall not prevent tripping and shall not lead to closing or tripping of circuit breaker. Failure of any auxiliary spring shall also not cause damage to the circuit breaker or endanger the operator. Mechanical indicators shall be provided on the breaker trucks to indicate OPEN / CLOSED conditions of the circuit breaker, and CHARGED / DISCHARGED conditions of the closing spring. An operation counter shall also be provided. These shall be visible without opening the breaker compartment door. The rated control supply voltage shall be as mentioned elsewhere under Technical parameters. The closing coil and spring charging motor shall operate satisfactorily at all values of control supply voltage between 80 and 120 percent of the rated voltage. The shunt trip coil shall operate satisfactorily under all operating conditions of the circuit breaker upto its rated short circuit breaking current at all values of control supply voltage between 80 and 120 percent of the rated voltage. The trip coil shall be so designed that it does not get energised when its healthiness is monitored by two indicating lamps (Red) and one trip coil supervision relay. The time taken for charging of closing spring shall not exceed 30 seconds. The spring charging shall take place automatically preferably after a closing operation. Breaker operation shall be independent of the spring charging motor which shall only charge the closing spring. Opening spring shall get charged automatically during closing operation. As long as power supply is available to the charging motor a continuous sequence of closing and opening operations shall be possible. One open‐close‐ open operation of the circuit breaker shall be possible after failure of power supply to the motor. Spring charging motors shall be capable of starting and charging the closing spring twice in quick succession without exceeding acceptable winding temperature when the control supply voltage is anywhere between 85% and 110% of the rated voltage. The initial temperature shall be as prevalent in the switchgear panel during full load operation with 50 deg. C ambient air temperature. The motor shall be provided with short Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E2
Page 10
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j) k) 4.03.00
4.03.01
4.03.02
4.03.03
4.03.04
circuit protection. Motor windings shall be provided with class E insulation or better. The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in a hot, humid and tropical climate. Circuit breaker shall be provided with inter pole barriers of insulating materials. The use of inflammable materials like Hylam shall not be acceptable. Control and Interlocks The basic control scheme shall be developed as per the schematic logics in the relay. The schematics shall be developed in soft inside the relay. Facilities shall be provided for mechanical tripping of the breaker/ contactor and for manual charging of the stored energy mechanism for a complete duty cycle, in an emergency. These facilities shall be accessible only after opening the compartment door. Each panel shall have two separate limit switches, one for the Service position and the other for Isolated position. Each of these limit switches shall have at least four (4) contacts which shall close in the respective positions. Auxiliary Contacts of breaker / contactor may be mounted in the fixed portion or in the withdrawable truck as per the standard practice of the manufacturer, and shall be directly operated by the breaker / contactor operating mechanism. Auxiliary contacts mounted in the fixed portion shall not be operable by the operating mechanism, once the truck is withdrawn from the service position, but remain in the position corresponding to breaker / contactor open position. Auxiliary contacts mounted on the truck portion, and dedicated for Employer's use shall be wired out in series with a contact denoting breaker / contactor service position. With truck withdrawn, the auxiliary contacts shall be operable by hand for testing. 4.03.05
The contacts of all limit switches and all breaker / contactor auxiliary contacts located on truck portion and fixed portion shall be silver plated, rated to make, carry and break 1.0A 110V DC (Inductive) / 10A 240V AC. Contacts of control plug and socket shall be capable of carrying the above current continuously. 4.03.06
Movement of truck between SERVICE and ISOLATED positions shall be mechanically prevented when the breaker / contactor is closed. An attempt to withdraw a closed breaker / contactor shall not trip it. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E2
Page 11
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4.03.07
4.03.08
4.03.09
4.03.10
4.04.00
Closing of the breaker / contactor shall be possible only when truck is either in ISOLATED or in SERVICE position and shall not be possible when truck is in between. Further, closing shall be possible only when the auxiliary circuits to breaker / contactor truck have been connected up, and closing spring is fully charged. It shall be possible to easily insert breaker / contactor of one typical rating into any one of the panels meant for same rating but at the same time shall be prevented from inserting it into panels meant for a different type or rating. Indications shall be provided in the relay console flush mounted on the panel front as brought out in the specification elsewhere. It shall be possible to easily make out whether the truck in SERVICE OR ISOLATED POSITION even when the compartment door is closed. Suitable synchronization scheme to be developed for momentary paralleling of Incomer and bus coupler, Incomer and DG source. All the synchronization relay, no volt relay etc required for bus coupler is in the scope of bidder. The details of the synchronization scheme shall be finalized during detailed engineering. Busbars and Insulators (a.) All busbar and jumper connections shall be of high conductivity aluminium alloy. They shall be adequately supported on insulators to withstand electrical and mechanical stresses due to specified short circuit currents. Busbar cross‐section shall be uniform throughout the length of switchgear. Busbars and other high voltage connection shall be sufficiently corona free at maximum working voltage. Contact surfaces at all joints shall be silver plated or properly cleaned and non‐oxide grease applied to ensure an efficient and trouble free connection. All bolted joints shall have necessary plain and spring washers. All connection hardware shall have high corrosion resistance. Bimetallic connectors or any other technically proven method shall be used for aluminum to copper connections. (b.) Busbar insulators shall be of arc and track resistant, high strength, non‐
hygroscopic, non‐combustible type and shall be suitable to withstand stresses due to over‐voltages, and short circuit current. Busbar shall be supported on the insulators such that the conductor expansion and contraction are allowed without straining the insulators. In case of organic insulator partial discharge shall be limited to 100pico coulomb at rated voltage x 1.1 / 3 . Use of insulators and barriers of in‐flammable material such as Hylam shall not be accepted. Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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(c.) Successful Bidder shall furnish calculation establishing adequacy of busbar sizes for the specified continuous and short time current ratings. (d.) All busbars shall be color coded. 4.05.00
(e.) The temperature of the busbar and all other equipment, when carrying the rated current continuously shall be limited as per the stipulations of relevant Indian Standards, duly considering the specified ambient temperature (50 deg. C). The temperature rise of the horizontal and vertical busbars when carrying the rated current shall in no case exceed 55 deg. C for silver plated joints and 40 deg. C for all other type of joints. The temperature rise at the switchgear terminals intended for external cable termination shall not exceed 40 deg. C. Further the switchgear parts handled by the operator shall not exceed a rise of 5 deg. C .The temperature rise of the accessible parts / external enclosure expected to be touched in normal operation shall not exceed 20 deg.C Earthing and Earthing Devices a) A copper / galvanized steel earthing bus shall be provided at the bottom and shall extend through out the length of each switch board. It shall be bolted/ welded to the framework of each panel and each breaker / contactor earthing contact bar. b) The earth bus shall have sufficient cross section to carry the momentary short‐circuit and short time fault currents to earth as indicated under switchgear parameters without exceeding the allowable temperature rise. c) Suitable arrangement shall be provided at each end of the earth bus for bolting to Employer's earthing conductors. All joint splices to the earth bus shall be made through at least two bolts and taps by proper lug and bolt connection. d) All non‐current carrying metal work of the switchboard shall be effectively bonded to the earth bus. Electrical continuity of the whole switchgear enclosure frame work and the truck shall be maintained even after painting. e) The truck and breaker / contactor frame shall get earthed while the truck is being inserted in the panel and positive earthing of the truck and breaker / contactor frame shall be maintained in all positions i.e. SERVICE and ISOLATED as well as throughout the intermediate travel. The truck shall also get and remain earthed when the control plug is connected irrespective of its position. f) All metallic cases of relays, instruments and other panel mounted Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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equipment shall be connected to earth by independent stranded copper wires of size not less than 2.5 sq. mm. Insulation colour code of earthing wires shall be green. Earthing wires shall be connected to terminals with suitable clamp connectors and soldering shall not be acceptable. Looping of earth connections which would result in loss of earth connection to other devices, when a device is removed is not acceptable. However, looping of earth connections between equipment to provide alternative paths of earth bus is acceptable. g) VT and CT secondary neutral point earthing shall be at one place only on the terminal block. Such earthing shall be made through links so that earthing of one secondary circuit may be removed without disturbing the earthing of other circuits. h) Separate earthing trucks shall be provided by the Contractor for maintenance work. These trucks shall be suitable for earthing the switchgear busbars as well as outgoing / incoming cables or busducts. The trucks shall have a voltage transformer and an interlock to prevent earthing of any live connection. The earthing trucks shall in addition have a visual and audible annunciation to warn the operator against earthing of live connections. As an alternative to separate earthing trucks the Bidder may also offer built‐in earthing facilities for the busbars and outgoing / incoming connections, in case such facilities are available in their standard proven switchgear design. The inbuilt earthing switches shall have provision for short circuiting and earthing a circuit intended to be earthed. These switches shall be quick make type, independent of the action of the operator and shall be operable from the front of the switchgear panel. These switches shall have facility for padlocking in the earthed condition. i) Interlocks shall be provided to prevent : 1) Closing of the earthing switch if the associated circuit breaker truck is in Service position. 2) Insertion of the breaker truck to Service position if earthing switch is in closed position. 3) Closing of the earth switch on a live connection. Three (3) nos. voltage capacitive dividers shall be provided on each phase of the section intended for earthing and three (3) nos. "RED" neon lamps connected to these on the panel front for visual indication. 4) Energising an earthed Section: Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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4.06.00
Complete details of arrangement offered shall be included in the bid, describing the safety features and interlocks. j) The earthing device (truck / switch) shall have the short circuit withstand capability equal to that of associated switchgear panel. 4 NO + 4 NC of auxiliary contacts of the earthing device shall be provided for interlocking purpose. k) All hinged doors shall be earthed through flexible earthing braid. Painting All sheet work shall be pretreated, in tanks, in accordance to IS: 6005.Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline water and dried. Powder coated paint shade 631 as per IS: 5 shall be used as per IS: 13871. The Phosphate coating shall be “Class –C” as specified in IS: 13871. The phosphate surface shall be passivated and electrostatic Powder Painting shall be used. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peal able compound by spraying method to protect finished surfaces from scratching, grease, dirt and oily spots during testing, transportation, handling and erection. 4.07.00
Instrument Transformers (a.) All current and voltage transformers shall be completely encapsulated cast resin insulated type, suitable for continuous operation at the ambient temperature prevailing inside the switchgear enclosure, when the switchboard is operating at its rated load and the outside ambient temperature is 50 deg. C. The class of insulation shall be E or better. (b.) All instrument transformers shall withstand the power frequency and impulse test voltage specified for the switchgear assembly. The current transformer shall further have the dynamic and short time ratings at least equal to those specified for the associated switchgear and shall safely withstand the thermal and mechanical stress produced by maximum fault currents specified when mounted inside the switchgear for circuit breaker modules. However, current transformer mounted in fuse backed contactor module shall have the dynamic and short time rating compatible with the let through current of the fuses. (c.) The parameters of instrument transformers specified in this specification are tentative and shall be finalised by the Employer in due course duly considering the actual burden of various relays and other devices finally selected. In case the Bidder finds that the specified ratings are not adequate Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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for the relays and other devices offered by him, he shall offer instrument transformer of adequate ratings without any commercial implication. (d.) All instrument transformers shall have clear indelible polarity markings. All secondary terminals shall be wired to separate terminals on an accessible terminal block. (e.) Current transformers may be multi or single core and shall be located in the cable termination compartment. All voltage transformers shall be single phase type. The bus VTs shall be housed in a separate panel on a truck so as to be fully withdrawable. (f.) Core balance CTs (CBCT) shall be provided on outgoing motor and transformer feeders having CT ratio more than 50/1A. These CBCTs shall be mounted inside the switchgear panel. The window size of CBCT's shall be based on the overall diameter of the cables, to be finalised during detailed engineering. The CBCT shall be of circular window type. (g.) All voltage transformers shall have suitable HRC current limiting fuses on both primary and secondary sides. Primary fuses shall be mounted on the withdrawable portion. Replacement of the primary fuses shall be possible with VT truck in ISOLATED position. The secondary fuses shall be mounted on the fixed portion and the fuse replacement shall be possible without drawing out the VT truck from Service position. (h.) Line Voltage transformer of 0.2 classes for 33 kV line incomer is to be provided for measurement and metering purpose. Price of Line VT is to be included in Incomer panel. For synchronization. 1‐Ph 0.5 VT (separate) is acceptable. 4.08.00
Control Supply and Space Heater Supply (a.) Each switchboard shall be provided with two (2) Nos. of 110V DC feeders by the Employer for the control supply. (b.) The arrangement for receiving the above supply and distributing it to individual panels shall be provided by the Bidder in line with the drawing is enclosed. The diodes shall have a minimum peak inverse voltage of 1000 Volts. (c.) Bidder shall provide one 240V/63A single phase to neutral AC supply feeder per switchboard/Switchboard section for space heater supply. Bidder shall provide necessary switch and fuse to receive, isolate and distribute to each panel. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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4.09.00
(d.) Each sub circuit shall have separate fuses. Fuse size shall be determined so as to achieve selective clearance between main circuit and sub circuit in case of fault. Potential circuits for protection and metering shall also be protected by separate fuse. (e.) All fuses shall be of HRC link type conforming to IS: 13703 / 9385 mounted on suitable fuse bases. Fuses shall have operation indicators for indicating blown fuse condition. Fuse carrier base shall have imprints of the fuse rating and voltage. All accessible live connection to fuse bases shall be adequately shrouded. (f.) All DC circuits shall be fused on both poles. Single phase AC circuits shall have fuses on line and link on neutral. Space Heater (a.) Each switchgear panel shall be equipped with thermostatically controlled space heater(s), suitably located in breaker / contactor and cable compartments to prevent condensation within the enclosure. The space heater shall be connected to 240V single phase AC auxiliary supply available in the switchgear, through switches and fuses provided separately for each panel. (b.) A 240V single phase 50 Hz AC plug point shall be provided in the interior of each cubicle with ON‐OFF switch for connection of hand lamp. 4.12.00 Terminal Blocks (a.) Terminal blocks shall be 650V grade, 10Amps rated, made up of unbreakable polyamide 6.6 grade. The terminals shall be either screw type or screw‐less (spring loaded) / cage clamp type with lugs. Marking on terminal strips shall correspond to the terminal numbering in wiring diagrams. All metal parts shall be of non‐ferrous material. In case of screw type terminals the screw shall be captive, preferably with screw locking design. (b.) Terminal blocks for CT and VT secondary leads shall be of stud type, made up of unbreakable polyamide 6.6 grade. They shall be provided with links to facilitate testing, isolation star / delta formation and earthing. Terminal blocks for CT secondary shall have the short circuiting facility. The terminals for remote ammeter connection etc. shall also be disconnecting type only. All metal parts shall be of non‐ferrous material. Screws shall be captive. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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(c.) At least 10% spare terminals for external connections shall be provided on each panel and these spare terminals shall be uniformly distributed on all terminal blocks. Space for adding another 10% spare terminals shall also be available in each panel. (d.) There shall be minimum clearances of 250 mm between the terminal blocks and the cable gland plate and 150 mm between two rows of terminal blocks. (e.) All panel wring for external connections shall terminate on separate terminal blocks which shall be suitable for connecting two (2) stranded copper conductors of 2.5 sq. mm on each side, or alternatively, the terminal blocks shall have the possibility of double shorting space to facilitate looping. 4.13.00 Switchgear Wiring (a.) All Switchgear panels shall be supplied completely wired internally upto the terminal block ready to receive Owner's external cabling. All inter cubicle wiring and connections between panels of same switchboard including all bus wiring for AC and DC supplies shall be provided / done by the Contractor. (b.) All internal wiring shall be carried out with 650 V grade, single core, 1.5 sq. mm. stranded copper wires having minimum of seven strands per conductor and color coded, PVC insulation. CT circuits shall be wired with 2.5 sq. mm. wires which otherwise are similar to the above. Extra flexible wires shall be used for wiring between fixed and moving parts such as hinged doors. (c.) All wiring shall be properly supported neatly arranged, readily accessible and securely connected to equipment, terminals and terminal blocks. Wiring troughs or gutters be used for this purpose. (d.) Internal wire terminals shall be made with solderless crimping type tinned copper lugs which shall firmly grip the conductor. Insulation sleeves shall be provided over the exposed parts of lugs. (e) Printed single tube ferrules marked to correspond with panel wiring diagram shall be fitted at both ends of each wire. The wire identification marking shall be in accordance with IS: 375. Red Ferrules should be provided on trip circuit wiring. (f)
Interconnection to adjacent panels shall be brought out to a separate set of terminal blocks located near the slots or holes, meant for the interconnecting wires. Arrangement shall permit neat layout and easy interconnections to adjacent panels at site and wires for this purpose shall be provided by Contractor looped and bunched properly inside the panels. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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(g) Contractor shall be fully responsible for the completeness and correctness of the internal wiring and for the proper functioning of the connected equipment. (h) The Contractor shall provide the necessary clamps wiring troughs etc. for all wiring inside the switchgear enclosed including the Employer's power and control cables. 4.14.00
4.15.00 Power Cable Termination (a). Cable termination compartment shall receive the stranded Aluminium conductor, XLPE insulated, shielded, armored / unarmored, PVC jacketed, single core / three core, unearthed / earthed grade power cable(s). (b) A minimum clearance of about 600 mm shall be kept between the cable lug bottom ends and gland plates for stress cone formation for XLPE cables. Interphase clearance in the cable termination compartment shall be adequate to meet electrical and mechanical requirement besides facilitating easy connections and disconnection of cables. Dimensional drawing of cable connection compartment showing the location of lug, glands, CTs, gland plates etc. and the electrical clearances available shall be submitted for Employer's approval during detail engineering. (c) Cable termination compartment shall have provision for termination of power cables of sizes as indicated during detailed engineering with removable undrilled gland plates. For all single core cables gland plates shall be of nonmagnetic material. Cable entry shall be from bottom. Any change will be intimated later. (d) Supply of the cable termination kit and cable terminations shall be in scope of contractor. Name Plates and Labels a.
Each switch board shall have a name plate for its identification. All enclosure mounted equipment hall be provided with individual engraved name plates for clear equipment identification. All panels shall be identified on front as well as backside by large engraved name plates giving the distinct feeder description along with panel numbers. Back side name plates shall be fixed in panel frame and not on the rear removable cover. b.
Name plate shall be of non‐rusting metal or 3‐ply lamicoid with white engraved letterings, on black background. Inscriptions and lettering shall be subjected to Employer's approval. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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c.
4.16.00 Suitable stenciled paint mark shall be provided for identification of all equipment, located inside the enclosure, as well as for door mounted equipment, from the back side in addition to plastic sticker labels, if provided. These labels shall be located directly by the side of the respective equipment, shall be clearly visible and shall not be hidden by equipment wiring. Labels shall have device number as mentioned in wiring drawings. Type of labels and fixing of labels shall be such that they are not likely to peel off / fall off during prolonged use. Module Description Depending on functional requirement each switchgear panel has been categorized under specific modules, defined hereafter. Each module shall be complete with all necessary hardware as required functionally and as per approved control schematic drawings. 4.16.01 Circuit Breaker Module All circuit breaker modules shall have the following accessories : ‐ 4.16.02 Current / Voltage transformers as per requirement Relays as per relevant clauses / single line diagrams Spring charging motor, with its protection and control Auxiliary contacts. Terminal blocks Refer module drawings at Part ‐ E P.T. Module Type ‐ G Item Description 1 phase VT* Fuses (VT Primary) Module G 3 3 Fuses (VT Secondary) 6 * 33 kV System the VT ratio is 33/ 3 KV / 110/ 3 V Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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4.16.03 Contactor Module – CC All Contactor modules shall have the following accessories : -
Power Contactors with HRC Fuses -
Auxiliary contacts. Current / Voltage transformers as per requirement Numerical Relays as per relevant clauses / single line diagrams Spring charging motor, with its protection and control 5.00.00
TESTS 5.01.00
Type Tests Terminal blocks Circuit breaker, circuit breaker panels and earthing device (Truck/ switch) of each voltage class and current should be type tested as per the relevant IS/ IEC. All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owner’s approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in the case of type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract at no additional cost to the owner either at third party lab or in presence of client /owners representative and submit the reports for approval. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No design Change”. Minor changes if any shall be highlighted on the endorsement sheet. For all important components like Surge Arrestors, Numerical relays, Ethernet switches, Data concentrators & Fibre Optic cables, the contractor shall only submit the reports of all the type tests as per applicable standards and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the owner either at third party lab or in presence of client/owner’s representative and submit the reports for approval. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No design Change”. Minor changes if any shall be highlighted on the endorsement sheet. 5.02.00
Two (2) protected soft copies on CD‐ROM of the approved test results shall be furnished with the equipment. These shall include complete reports and results of the routine tests and type tests (if the latter is carried out) on equipment. If the type tests are not conducted, the CDs shall contain copies of the results of type tests carried out on similar equipment earlier. 5.03.00
Testing to observe compliance to degree of protection, shall be checked for each switch board enclosure and bus bar chambers during routine inspection shall be as under. (a.) IP ‐4X It shall not be possible to insert a one (1) mm. dia steel wire into the enclosure from any direction, without using force. (b.) IP‐5X It shall not be possible to insert a thin sheet of paper under gaskets and through enclosure joints. 5.04.00
Routine Tests Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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All acceptance and routine tests as per the specification and relevant standards IEC 62271‐200 & IEC 62271‐100 shall be carried out. Charges for these shall be deemed to be included in the equipment price An indicative lists of tests / checks is mentioned as QA chapter on HT switchgear. However, the manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 6.00.00
COMMISSIONING CHECKS / TESTS After installation of panels, power and Control wiring and connections, Contractor shall perform commissioning checks as listed below to verify proper operation of switchgear / panels and correctness of all equipment in all respects. In addition the Contractor shall carry out all other checks and tests recommended by the manufacturers. 6.01.00
General a.
b.
Check name plate details according to specification. Check for physical damage c. d.
Check tightness of all bolts, clamps and connecting terminals Check earth connections. e.
Check cleanliness of insulators and bushings f.
Check heaters are provided g.
H.V. test on complete switchboard with CT & breaker / contactor in position. h.
Check all moving parts are properly lubricated. i.
Check for alignment of busbars with the insulators to ensure alignment and fitness of insulators. j.
Check for interchange ability of breakers / contactors. k.
Check continuity and IR value of space heater. l.
Check earth continuity for the complete switchgear board. Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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6.02.00
Circuit Breaker / Contactors (a)
Check alignment of trucks for free movement. (b)
Check correct operation of shutters. (c)
Check slow closing operation (if provided) (d)
Check control wiring for correctness of connections, continuity and IR values. (e)
(f)
Manual operation of breakers completely assembled. Power closing / opening operation, manually and electrically at extreme condition of control supply voltage. (g)
Closing and tripping time. (h)
Trip free and anti‐pumping operation. (i)
(j)
IR values, resistance and minimum pick up voltage of coils. Simultaneous closing of all the three phases. (k)
Check electrical and mechanical interlocks provided. (l)
Checks on spring charging motor, correct operation of limit switches and time of charging (m)
Check SF6 pressure / vacuum (as applicable) (n)
All functional checks. 6.03.00
Current Transformers (a)
Megger between windings and winding terminals to body. (b)
(c)
Polarity tests. (d)
Magnetisation characteristics & secondary winding resistance. (e)
Spare CT cores, if any to be shorted and earthed. 6.04.00
Ratio identification checking of all ratios on all cores by primary injection of current. Voltage Transformers Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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(a)
(b)
Insulation resistance test. (c)
(d)
Polarity test. Ratio test on all cores. 6.05.00
Cubicle Wiring (a)
(b)
Check all switch developments. (c)
All the wires shall be meggered to earth. (d)
Functional checking of all control circuit e.g. closing, tripping interlock, supervision and alarm circuit including proper functioning of component / equipment. (e)
Check terminations and connections. (f)
Wire ducting. (g)
Gap sealing and cable bunching. Line connections as per connection diagram. It should be made sure that the wiring is as per relevant drawings. All interconnections between panels shall similarly be checked. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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CLAUSE 33kV XLPE CABLES 1.00.00
1.01.00
CODES & STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS : codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes : IS:7098 (Part ‐
II) Specification for Cross linked polyethylene insulated PVC sheathed cables. Part‐II: For working voltages from 3.3 KV upto and including 33 KV. IS : 3975 Low Carbon Galvanized steel wires, formed wires and tapes for armouring of cables. IS : 4905 Methods for random sampling. IS : 5831 PVC insulation and sheath of electrical cables. IS : 8130 Conductors for insulated electrical cables and flexible cords. IS : 10418 Specification for drums for electric cables. IS : 10810 Methods of tests for cables. ASTM‐D ‐2843 Standard test method for density of smoke from the burning or decomposition of plastics. IEC‐754 (Part‐
I) Tests on gases evolved during combustion of electric cables. IEC‐332 Tests on electric cables under fire conditions. Part‐3: Tests on bunched wires or cables (Category‐B). 2.00.00
TECHNICAL REQUIREMENTS 2.01.00
The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground (buried) installation with chances of flooding by water. 2.02.00
Cables shall be flame retardant, low smoke (FRLS) type designed to withstand all mechanical, electrical and thermal stresses developed under Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503 TECHNICAL SPECIFICATIONS VOL­II CHAPTER­II SECTION­E3 Page 1 of 6 CLAUSE 33kV XLPE CABLES steady state and transient operating conditions as specified elsewhere in this specification. 2.03.00
Aluminium conductor used in power cables shall have tensile strength of more than 100 N/ sq.mm. Conductors shall be multi stranded. 2.04.00
XLPE insulation shall be suitable for continuous conductor temperature of 90 deg. C and short circuit conductor temperature of 250 deg C. 2.05.00
The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS: 5831. 2.06.00
For single core armoured cables, armouring shall be of aluminium wires. For multicore armoured cables armouring shall be of galvanised steel as follows : ‐ Calculated nominal dia of cable under armour i) Upto 13 mm
2.07.00
Size and Type of armour 1.4mm dia GS wire ii) Above 13 & upto 25mm
0.8 mm thick GS formed wire / 1.6 mm dia GS wire iii) Above 25 & upto 40 mm
0.8mm thick GS formed wire / 2.0mm dia GS wire iv) Above 40 & upto 55mm
1.4 mm thick GS formed wire/2.5mm dia GS wire v) Above 55 & upto 70mm
1.4 mm thick GS formed wire/3.15mm dia GS wire vi) Above 70mm
1.4 mm thick GS formed wire / 4.0 mm dia GS wire The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum resistivity of 0.028264 ohm‐sq.mm./mtr at 20 deg.C. The types and sizes of aluminium armouring shall be same as mentioned for galvanised steel at 2.06.00 above. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503 TECHNICAL SPECIFICATIONS VOL­II CHAPTER­II SECTION­E3 Page 2 of 6 CLAUSE 33kV XLPE CABLES 2.08.00
The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over‐riding of armour wires / formed wires. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface of GS wires/formed wires. 2.09.00
Distinct extruded PVC inner sheath of black colour as per IS:5831 shall be provided for the cables as follows: a). For all multicore cables. b). For single core armoured cables , where armouring is not being used as metallic screen. 2.10.00
Outer sheath shall be of PVC black in colour. In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables shall have the following FRLS properties. (a.) Oxygen index of min. 29 (Test method as per IS 10810 Part‐58) (b.) Acid gas emission of max. 20% as per IEC‐754 (Part‐I) (c.) Smoke density rating shall not be more than 60% during Smoke Density Test as per ASTMD‐2843. 2.11.00
Cores of three core cables shall be identified by colouring of insulation or by providing coloured tapes helically over the cores, with Red, Yellow & Blue colours. 2.12.00
In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath : (a.) Cable size and voltage grade ‐ To be embossed (b.) Word 'FRLS' at every 5 metre ‐ To be embossed (c.) Screen Fault current _ _ _KA for _ _ _ Sec. ( Value of current & time shall be indicated as per BOQ) (d.) Sequential marking of length of the cable in metres at every one metre ‐ To be embossed / printed Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503 TECHNICAL SPECIFICATIONS VOL­II CHAPTER­II SECTION­E3 Page 3 of 6 CLAUSE 33kV XLPE CABLES The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible. 2.13.00
All cables shall meet the fire resistance requirement as per Category‐B of IEC‐
332 Part‐3. 2.14.00
Allowable tolerances on the overall diameter of the cables shall be +\‐2 mm maximum over the declared value in the technical data sheets. 2.15.00
In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable. 2.16.00
The cross‐sectional area of the metallic screen strip/tape/wires shall be considered in sizing calculations. 2.17.00
The eccentricity shall be calculated as ((tmax –tmin) /tmax) X 100 and the ovality shall be calculated as ((dmax –dmin) /dmax) X 100 Where t‐max/t‐min is the maximum/minimum thickness of insulation and d‐
max/d‐min is the maximum / minimum diameter of the core. 2.18.00
3.00.00
3.01.00 The eccentricity of the core shall not exceed 10% and ovality not to exceed 2% . CONSTRUCTIONAL FEATURES 19/33 KV Grade Power Cables: Cables shall conform to IS 7098 Part‐II. These cables shall be multi‐stranded, compacted circular copper conductor, XLPE‐insulated, metallic screened suitable for carrying the system earth fault current (31.5kA for 1 sec) as specified in B.O.Q, PVC outer sheathed. The conductor screen and insulation screen shall both be of extruded semiconducting compound and shall be applied along with the XLPE insulation in a single operation of triple extrusion process so as to obtain continuously smooth interfaces. Method of curing for 19/33 KV Cables shall be “dry curing/ gas curing” For the single Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503 TECHNICAL SPECIFICATIONS VOL­II CHAPTER­II SECTION­E3 Page 4 of 6 CLAUSE 33kV XLPE CABLES 4.00.00
core armoured cables, the armouring shall constitute the metallic part of the screening CABLE DRUMS 4.01.01
Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof cover. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti‐termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS: 10418. 4.01.02
Each drum shall carry manufacturer's name, purchaser’s name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled. 4.01.03
The standard drum length for power cables shall not be less than 500 meters. The length per drum shall be subjected to a maximum tolerance of +/‐ 5% of the standard drum length. The Employer shall have the option of rejecting cable drum with shorter lengths. For each size, the variance of total quantity, adding all the supplied drum lengths, from the ordered quantity, shall not exceed +/‐2% and the payment shall be made based on the actual cable length supplied within this limit. 5.00.00
TYPE, ROUTINE AND ACCEPTANCE TESTS 5.01.00
TYPE TESTS 5.01.01 All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owner’s approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. 5.01.02 However if the contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in the case of type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503 TECHNICAL SPECIFICATIONS VOL­II CHAPTER­II SECTION­E3 Page 5 of 6 CLAUSE 33kV XLPE CABLES at no additional cost to the owner either at third party lab or in presence of client /owners representative and submit the reports for approval. 5.01.03 All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. 5.01.04
he type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No design Change”. Minor changes if any shall be highlighted on the endorsement sheet. 5.01.05
All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price 5.01.06
The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No design Change”. Minor changes if any shall be highlighted on the endorsement sheet. 5.01.07
The reports for the type tests as per relevant IS shall be submitted during detailed engineering 5.02.00
All types and sizes of cables being supplied shall be subjected to routine tests and acceptance tests according to relevant standards. Indicative list of tests/ checks, Routine and Acceptance tests shall be as per Quality Assurance & Inspection table of H.T. Cables enclosed. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503 TECHNICAL SPECIFICATIONS VOL­II CHAPTER­II SECTION­E3 Page 6 of 6 BATTERY & BATTERY CHARGER
CLAUSE NO.
LEAD­ACID VRLA BATTERY (110V, 120Ah) The bidder shall offer Battery of Lead‐Acid Plante VRLA Battery as per BOQ given in the specification. The Battery Chargers shall be accordingly suitable for the type of battery offered. Battery & battery charger shall be used for control voltage required for 33kV & LT switchgear. 1.00.00 CODES & STANDARDS 1.01.00 All standards, specification and codes of practice, referred to herein, shall be the latest edition including all applicable official amendments and revisions as on date of opening of bid. 1.02.00 In case of conflict between this specification and those (IS Codes Standards etc.) referred to herein, the former shall prevail. All works shall be carried out as per the following standards and codes: IS: 266 Specification for sulphuric acid IS : 1069 Specification for water for storage batteries IS : 1146 Specification for rubber & plastic containers for lead acid storage batteries. IS : 1652 Specification for stationary cells and batteries, lead acid type (with plant positive plates). IS : 3116 Specification for sealing compound for lead acid batteries. IS : 8320 General requirements and methods of tests for lead acid storage batteries. Indian Electricity Rules Indian Electricity Acts IS : 6071 Specification for synthetic separators for lead acid batteries. 1.03.00 Equipment complying with other internationally accepted standards such as IEC, BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards along with copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E4
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2.00.00 GENERAL TECHNICAL REQUIREMENTS 2.01.00 PRINCIPAL PARAMETERS: a.
The Battery sets to be supplied by the supplier shall meet the requirement of BS‐6290(Part‐IV)1997 and IEC 896‐2 / BSEN6089.2, IEEE‐1188/1189 with latest edition or equivalent and shall be suitable for continuous operation for the climatic conditions specified in the specification. The batteries shall be suitable for float quick charging. The floating voltage shall be regulated to within 1% of the normal voltage when the required load is discharged by the battery. b.
Battery sets shall be maintenance free, sealed type in thermoplastic containers with minimum expected life of 15 years. The batteries shall include battery mounting racks and other equipment required to provide a complete operational battery sub system. Battery sets shall be capable of operating at a peak ambient temperature of 50 Deg.C. without degradation of performance and deterioration of expected life. The average ambient temperature shall be 35 Deg.C.. The offered battery shall be compact and shall require no regular maintenance. All safety equipment required for installation shall be provided by the manufacturer. c.
Depending upon the situation, the batteries may be required to provide a back‐up for 8, 24 or 48 hours. The Bidder shall furnish detail battery sizing calculations along with all arrangements and supporting structures, for each type of DC supply units being proposed, along with the bid. In all cases the battery is normally not allowed to discharge beyond 80% of rated capacity of the battery at 10 hours rate of discharge. d.
The manufacturer supplying the cells/batteries as per this document shall be responsible to replace/repair free of charge, the battery/cell becoming faulty, owing to defective workmanship or material as per the provisions of the bid document. e.
All electrical and mechanical equipments shall be designed and manufactured so that no damage will result in transportation, installation and operation of the equipment under the climatic conditions to which it will be subjected. 3.0 SPARES: The tenderer shall also state in his tender the spares required for normal operation for a period of 5 years. Each spare shall be individually packed and marked both the part number (where applicable) as well as the description of item. Item‐wise prices of spares be listed in the tender. The quantity of spare parts recommended for procurement for 5 years of normal operation shall be stated in the tender. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E4
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4.0 MATERIAL AND CONSTRUCTION: 4.1 GENERAL : The storage batteries should be fabricated with Flat pasted type positive plates and Flat pasted type negative plates as per relevant Standards and shall be assembled in hard containers of durable and robust construction. The design of battery shall be as per field proven practices. Partial plating of cells is not permitted. Paralleling of cells externally for enhancement of capacity is not permitted. The cells shall be so designed to be suitable for Horizontal Stacking. 4.2 CONTAINERS : The containers material shall have chemical and electro‐ chemical compatibility and shall be acid resistant. The material shall meet all the requirements of VRLA batteries and be consistent with the life of battery. The container shall be fire retardant and shall have an Oxygen Index of at least 28%. The porosity of the container shall be such as not to allow any gases to escape except from the regulation valve. The tensile strength of the material of the container shall be such as to handle the internal cell pressure of the cells in the worst working condition. Cell shall not show any deformity or bulge on the sides under all working conditions. The container shall be capable of withstanding the rigours of transport, storage and handling. The containers shall be enclosed in a steel tray. 4.3 CELL COVERS: The cell covers shall be made of suitable material compatible with the container material and permanently sealed with the container. It shall be capable to withstand internal pressure without bulging or cracking. It shall also be fire retardant and shall comply with the provisions set forth in clause of 5.2 above. Fixing of Pressure Regulation Valve & terminal posts in the cover shall be such that the seepage of electrolyte, gas escapes and entry of electro‐static spark are prevented. 4.4 PRESSURE REGULATION VALVE: Each cell shall be provided with a pressure regulation valve. The valve shall be self re‐sealable and flame retardant. The valve unit shall be such that it cannot be opened without a proper tool. The valve shall be capable to withstand the internal cell pressure specified by the manufacturer. 4.5 TERMINAL POSTS: Both the positive and negative terminals of the cells shall be capable of proper termination and shall ensure its consistency with the life of the battery. The surface of the terminal post extending above the cell cover including bolt hole shall be coated with an acid resistant and corrosion retarding material. Terminal posts or any other metal part which is in contact with the electrolyte shall be made of the same alloy as that of the plates or of a proven material that does not have any harmful effect on cell performance. Both positive and negative posts Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E4
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CLAUSE NO.
4.6 4.7 4.8 4.9 BATTERY & BATTERY CHARGER
shall be clearly and unambiguously identifiable. All exposed metal parts(connectors, terminals etc) shall be protected with heat shrinkable silicon sleeves for reducing the environmental impact including a corrosive environment. 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 connections 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. The area of cross‐section of the connectors shall be rated at 2 Amp/sq.mm minimum at 6 hour rate of discharge. Nuts and bolts for connecting the cells shall be made of copper, brass or stainless steel. Copper or brass nuts and bolts shall be effectively lead coated to prevent corrosion. Stainless steel bolts and nuts can be used without lead coating. All exposed metal parts (connectors, terminals etc.) shall be protected with heat shrinkable silicon sleeves for reducing the environmental impact including a corrosive environment. FLAME ARRESTORS : Each cell shall be equipped with a Flame Arrestor to defuse the Hydrogen gas escaped during charge and discharge. Material of the flame arrestor shall not affect the performance of the cell. SEPARATORS: The separators used shall be glass mat or synthetic material having high acid absorption capability, resistant to sulphuric acid and good insulating properties. The design of separators shall ensure that there is no misalignment during normal operation and handling. STAND/SUPPORTING RACK: Necessary stands/supporting racks for fixing and installing the batteries shall be supplied with cell insulators and stand insulators. These racks/stands shall be so designed that cells are placed within easy reach at convenient height to facilitate easy maintenance. Minimum number of screw should be used primarily for anchoring. The joining of the frames should not leaves crevices and ensure proper and tight fit. Necessary screws etc. should be supplied such that the racks can be fitted without any extra material. Racks shall be constructed so as to permit free access to the floor directly beneath, thus cleaning of both cells and floor is quick and simple task. Racks shall be duly painted with two (2) coats of acid resistance paint and supplied in assembled state with marking. A small quantity of loose paint shall be supplied to enable the purchaser to restore at site Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E4
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4.10 4.11 5.0 5.1 5.2 5.3 BATTERY & BATTERY CHARGER
for any finish which may got damage during transport. One set of battery testing equipment shall be supplied for each battery sets according to BS‐6290 (Part‐IV‐
1997) & IEC‐896‐2/BSEN 6089.2, IEEE‐1188/1189. The 110V 120 AH battery shall be suitable for float charge working with 12 Amps load. The battery voltage shall not vary beyond 1% of the nominal voltage under float charge conditions and while discharging at 10 Hrs. Rating. The battery will be used for feeding light load in the control room when AC supply fails. The battery should be capable of float/quick charge when AC supply is restored. ACCESSORIES: Each battery set shall be supplied complete with all necessary accessories viz. Stand, inter‐ cell connections, cell insulators, stand insulators, cell No. plates with fixing pins, thermometer, cell testing Voltmeter (3‐0‐3V) complete with leads, spanners, rubber syringes, rubber gloves and apron etc. RATINGS: The rating of battery cells shall be 10 hrs. rating corrected to 27 deg.C as defined under Clause No. 4.1 of IS:1651/1991. The Ampere‐hour rating for 110V battery banks shall be 120 AH. Each cell will be of 2 volts. Thus the battery bank for 110 V shall consist of 55 cells respectively. DESIGNATION: The cell shall be designated by symbol as per relevant Standards. MARKING: The following information shall be indeligibly and durably marked on the outside of the cell. a) Nominal voltage. b) Manufacturer's type and trade name. c) AH capacity at 10 hour rate. d) Voltage for float operation at 20 deg.C.with tolerance of () 1%. e) Month & Year of manufacture. f) Country of origin. The cells and batteries may also be marked with the ISI certification mark, if any. CAPACITY REQUIREMENT AND DIMENSIONS : When the battery is discharged at 10 hour rate, it shall deliver 80% of C (rated capacity, corrected at 27 Deg Celsius) before any of the cells in the battery bank reaches 1.85 V/cell. The capacity (corrected at 27 Deg.Celcius) shall also not be less than 70% of C and not more than 120% of C before any cell in the battery bank reaches 1.75 V/cell. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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CLAUSE NO.
5.4 5.5 5.6 BATTERY & BATTERY CHARGER
The battery shall be capable of being recharged from the fully exhausted condition (1.75V/cell) at the specified float voltage. The battery design shall permit the charging of the battery at 2.45V/cell (when two cells shorted). All the cells in a battery shall be designed for continuous float operation at the specified float voltage throughout the life. 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 minute of discharge : 1.98V (b) After Six hours of discharge : 1.92V (c) After 8 hours of discharge : 1.85V (d) After 10 hours of discharge : 1.75V The bidder shall provide the Tables & Graphs showing relation of the closed circuit voltage, impedance and the residual capacity of each cell in the battery, when it is discharged to the end voltage of 1.75V/cell at C/10 and C/8 rate of discharge. A table and graph showing the relation between the impedance and residual capacity of each cell shall also be provided by the bidder. EXPECTED BATTERY LIFE: The battery for float applications shall be capable of giving more than 1200 DOD (upto 80%) cycles at an average temperature of 35 Deg.C Celsius. DOD (Depth of Discharge) is defined as the ratio of the quantity of electricity (in Ampherehour) removed from a cell or battery on discharge to its rated capacity. CHEMICAL REQUIREMENTS: Oxygen recombination efficiency of cell/battery shall be higher than 95% for charge current C/10 under normal working conditions. The cell pressure shall be sufficient for 99% gas recombination when working at C/10 rate of charge and ambient temperature of 27Deg. Celsius. Under normal operating conditions grid corrosion shall not be more than 0.05 mm/year. Throughout its life, in the operating condition of C/10 rate of charge and C/8 rate of discharge in average ambient temperature of 35 Deg. Celcius, shedding of active material shall not lead to short circuit. The growth of positive plate shall be less than 8% of the total plate area throughout the specified life. While operating in the normal operating conditions, the cell or battery shall not lead to dry out, throughout the life of the battery. Manufacturer shall supply the necessary data to support the requirement. The battery shall not exhibit thermal runaway while working in the average ambient temperature of 35 Deg.C, operating range of 0 to 50 Deg.C and at a charge rate of C/10 and discharge rate of C/8. Manufacturer’s Identification Systems Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
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The following information shall be indelibly marked on outside of each cell. i) Manufacturer’s name and trade marks ii) Country and year of manufacture. iii) Manufacturer type designation. iv) AH capacity at 10 hour discharge rate. v) Serial number 6.00.00 TESTS 6.01.00 It shall conform to type tests and all routine, and acceptance tests shall be carried out as per relevant Indian standards. 6.02.00 Tests shall have to be carried out in the presence of Employer’s representative, if desired by the Employer. 6.03.00 Routine Tests All the routine tests listed below shall be carried out on cells containers hardware being supplied as per the latest issue of IS:1146 and IS:1652. A) Container i) Verification of constructional requirements. ii) Verification of marking and packing. iii) High voltage tests. B) Cells and Batteries i) Verification of constructional requirements. ii) Verification of markings iii)
Verification of dimensions. iv)
Checking of polarity and absence of short circuit. 6.04.00 Type Tests Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E4
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All type tests listed below should have been carried out on cells containers, hardware of each type being supplied, as per the latest issue of IS:1146 or IS:1652. A) Container (Rubber and Plastic containers) i) High voltage test ii) Drop Ball test iii) Plastic Yield Test Acid resistance test iv) Hydraulic thrust endurance test. B) Cells and Batteries The following tests shall be carried out in the sequence given below : i) Tests for capacities for 10 hr and 30 minutes discharge rates and test for voltage during discharge. ii) Ampere hours and watt‐hour efficiency test. iii)
Tests for retention of charge. iv)
Endurance tests. Type tests shall be carried out on three cells selected randomly. Two cells shall undergo all tests except capacity and endurance tests while the other would undergo only capacity and endurance test. 6.05.00 Acceptance Tests All acceptance tests as listed below shall be carried out on sample cell selected at random by the employer before despatch and at site after completion of installation. i) Verification of markings. ii) Verification of dimensions. iii) Test for capacities for 10 hrs discharge rate along with the test for voltage during discharge. The Contractor shall arrange for all necessary equipment, including the variable resistor, tools, tackles and instruments. If a battery fails to meet the guaranteed Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E4
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requirements the Employer shall have the option of asking the Contractor to replace the same. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E4
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BATTERY CHARGER (415V input 110V output) 1.00.00 CODES AND STANDARDS 1.01.00 All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards and codes. ANSI‐C 37.90a Guide for surge withstand capability tests. IS:5 Colours for ready mix paints. IS : 694 PVC Insulated Cable for working voltages upto and including 1100 V. IS : 1248 Specification for Direct acting indicating analogue electrical measuring instruments. IS : 2147 Degree of protection provided by enclosures for low voltage switch gear and control gear. IS : 13947 Specification for low voltage switch gear and control gear. IS : 3231 Electrical relays for power system protection. IS : 3842 Application guide for Electrical relays for AC System IS : 3895 Mono‐crystalline semi‐conductor Rectifier Cells and Stacks. IS : 4540 Mono crystalline semi‐conductor Rectifier assemblies and equipment. IS:6005 Code of practice for phosphating of Iron and Steel. IS:6619 Safety Code for Semi‐conductor Rectifier Equipment. IS:6875 Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto 1000 V AC or 1200 V DC. IS : 9000 Basic environmental testing procedures for electronic and electrical items. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E4
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CLAUSE NO.
IS:13703 Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC. EEUA‐45D Performance requirements Annunciation System. Indian Electricity Rules Indian Electricity Act. 1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, VDE. etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards along with copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. 2.00.00 EQUIPMENT DESCRIPTION 2.01.00 BATTERY CHARGER FOR LEAD ACID VRLA TYPE BATTERY a) The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Trickle mode i.e. Trickle charging the associated DC lead‐acid Batteries while supplying the D.C. loads. The Batteries shall be Trickle charged at 2.15 to 2.25 Volts per cell. All chargers shall also be capable of Boost Charging the associated D.C. Battery at 2.0 to 2.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, at an ambient air temperature of 50°C. b) Battery Chargers shall have a selector switch for selecting the battery charging mode i.e. whether Trickle or Boost charging. c) All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature which may arise during changeover from Auto to Manual mode or vice‐versa under normal operating condition. d) Soft start feature shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters which shall cause, when the voltage control is in automatic mode, a gradual Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
for electrical CHAPTER- II
SECTION-E4
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CLAUSE NO.
lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall niether damage the Charger nor shall it cause blowing of any of the changer fuses. The Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage shall build up automatically when working in automatic mode. e) When on automatic control mode during Trickle charging, the Charger output voltage shall remain within +/‐1% of the set value for AC input voltage variation of +/‐10%, frequency variation of +3/‐5%, a combined voltage and frequency (absolute sum) variation of 10% and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire Trickle charging output range specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Trickle charging mode. f) During Boost charging, the Battery Chargers shall operate on constant current mode (When automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. The charger output voltage shall automatically go on rising, when it is operating on boost mode, as the battery charges up. For limiting the output voltage of the charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage anywhere in the output range specified for boost charging mode. All voltage and current setting potentiometers shall be vernier type. g) Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits in clause 2.01.00 (e), shall be less than fifteen seconds. h) Momentary output voltage of the Charger, with the Battery connected shall be within 94% to 106% of the voltage setting during sudden load Change from 100% to 20% of full load or vice‐versa. Output voltage shall return to, and remain, within the limits specified in clause 2.01.00 (e) in less than 2 seconds after the above mentioned change. i) The Charger manufacturer may offer an arrangement in which the voltage setting device for Trickle charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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trickle charging mode is also used as Boost charging current setting device. j) Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 1% irrespective of the DC load, even when they are not connected to a battery. k) The DC System shall be ungrounded and float with respect to the ground potential when healthy. An earth fault relay shall be provided by the Employer in the DC distribution board for remote annunciation. 2.02.00 Printed Circuits Boards (PCB) PCB shall be made of glass epoxy of 1.6 mm thick, fire resistant, bonded with 99.8% pure copper foil, free of wrinkles, blisters, scratches and pinholes. The contact surface of the edge connectors of the PCBs shall be plated with hard gold to a minimum thickness of 5 microns. Component identification shall be printed on PCB by silk screen method. All PCBs shall be tropicalised and masked. 2.03.00 Contactors All Battery Chargers shall have an AC contactor on the input side. It shall be of air break type and suitable for continuous duty. The operating coil shall be rated for 415 Volts AC. 2.04.00 Thermal Overload Relay A thermal overload relay incorporating a distinct single phasing protection (using differential movement of bimetal strips) shall also be provided for the AC input. The relay shall trip the above contactor. 2.05.00 Rectifier­Transformers and Chokes The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating of the rectifier‐transformers and chokes shall correspond to the rating of the associated rectifier assembly. The rectifier‐transformers and chokes shall have class‐B insulation with temperature rise limited to class‐A insulation value. 2.06.00 Rectifier Assembly The rectifier assembly shall be full wave bridge type and designed to meet the duty as required by the respective Charger. The rectifier cells shall be provided with their own heat dissipation arrangement with natural air cooling. The rectifier shall utilise diodes/thyristors and heat sinks rated to carry 200% of the load current continuously and the temperature of the heat sink shall not be permitted to exceed 85°C absolute duly considering the maximum charger panel Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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inside temperature. The Contractor shall submit calculations to show what maximum junction temperature will be and what the heat sink temperature will be when operating at 200% and 100% load current continuously duly considering the maximum surrounding air temperature for these devices inside the charger panel assuming air ambient temperature of 50°C outside the panel. Necessary surge protection devices and rectifier type fast acting fuses shall be provided in each arm of the rectifier connections. 2.07.00 Instruments D.C. voltmeter, D.C. ammeter and A.C. voltmeter in 96 mm square shall be provided for all Chargers. The instruments shall be flush mounted type, dust proof and moisture resistant. The instruments shall have easily accessible means for zero adjustments. The instruments shall be of 1.5 accuracy class. 2.08.00 Air Break Switches All Chargers shall have AC input and DC output switches of air break, single throw, load break and fault make type. The contacts of the switches shall open and close with a snap action. Switches shall be rated for 120% of the maximum continuous load. ‘ON’ & ‘OFF’ position of the switch shall be clearly indicated. 2.09.00 Control and Selector Switches Control and selector switches shall be of rotary stayput type with escutcheon plates showing the functions and positions. The switches shall be of sturdy construction and suitable for mounting on panel front. Switches with shrouding of live parts and sealing of contacts against dust ingress shall be preferred. The contact ratings shall be atleast the following : i) Make and carry continuously ‐ 10 Amps. ii) Breaking current at 220 V DC ‐ 0.5 Amp. (inductive) iii) Breaking current at 240 V AC ‐ 5 Amp. At 0.3 p.f. 2.10.00 Fuses Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse carriers which are mounted on fuse bases. Wherever it is not possible to mount fuses on fuse carriers, fuses shall be directly mounted on plug in type bases. In such cases one insulated fuse pulling handle shall be supplied for each charger. Kick‐off fuses (trip fuses) with alarm contacts shall be provided for all D.C. fuses. 2.11.00 Indicating Lamps Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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Three (3) indicating lamps shall be provided to indicate A.C. supply availability. The indicating lamp shall be of panel mounting, LED type and capable of clear status indication under the normal room illumination. The lamp covers shall be preferably screwed type, unbreakable and moulded from heat resistant material. 2.12.00 Blocking Diode Blocking diode shall be provided in the output circuit of each Charger to prevent current flow from the D.C. Battery into the Charger. 2.13.00 Annunciation System Visual indications through indicating lamps/LEDs or annunciation facia as per EEUA‐45D shall be provided in all Chargers for the following: i) A.C. supply failure ii) Rectifier fuse failure iii)
Surge circuit fuse failure iv)
Filter fuse failure v)
Load limiter operated vi)
Charger trip vii)
Battery on Boost Potential free NO contacts of all above conditions shall be provided for following remote alarms in the Employer’s Unit Control Board: a) Battery on boost b) Charger trouble (this being a group alarm initiated by any of the faults other than ‘Battery on Boost’) 2.14.00 Name Plates and Marking The name plates shall be made of non‐rusting metal/3 ply Lamicoid and shall have black back‐ground with white engraved letters and secured by screws. These shall be provided near top edge on the front as well as on rear side of Charger. Name plates with full and clear inscriptions shall also be provided on and inside the panels for identification of the various equipments. 3.00.00 CONSTRUCTION Power supply arrangement & Lighting works
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3.01.00 The Chargers shall be indoor, floor mounted, self supporting sheet metal enclosed cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and hardware. The Charger shall be fabricated using cold rolled sheet steel shall not less than 1.6 mm and shall have folded type of construction. The panel frame shall be fabricated using cold rolled sheet steel of thickness not less than 2.0 mm. Removable undrilled gland plates of at least 3.0 mm sheet steel and lugs for all cables shall be supplied by the Contractor. The lugs for cables shall be made of electrolytic copper with tin coat. Cable sizes shall be advised to the Contractor at a later date for provision of suitable lugs and gland plates. The Charger shall be tropicalised and vermin proof. Ventilation louvers shall be backed with fine brass wire mesh. All doors and covers shall be fitted with synthetic rubber gaskets. The Chargers shall have hinged double leaf doors provided on front and/or backside for adequate access to the Charger internals. All the Charger cubicle doors shall be properly earthed. The degree of protection of Charger enclosure shall be at least IP‐42. 3.02.00 All indicating instruments, control & selector switches and indicating lamps shall be mounted on the front side of the Charger. Design of panels shall be based on the following dimensions. a) Overall height b) Operating handles (highest ‐ and lowest positions reached by operator’s hands), protective mechanical indicators Maximum 1800 mm Minimum 350 mm c) Doors and panel handles and locks Maximum 1800 mm Minimum 300 mm 3.03.00 Electronic equipments shall be of modular design consisting of plug in modules in standard 19 inches metallic racks with metallic card guides. The cards should be provided with proper handles. Card to card wiring should be preferably through a mother board. Unplanned jumpering and track modifications are not permitted. Mechanical interlocks to prevent wrong insertion of cards should be provided. Each card shall have its junction and test points identified. Maintenance aids such as extension printed wiring boards and jumper leads shall be provided. 3.04.00 The layout of Charger components shall be such that their heat losses do not give rise to excessive temperature within the Charger panel surface. Location of the electronic modules will be such that temperature rise of the location, in no case, will exceed 10°C over ambient air temperature outside the Charger. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
‐ ‐ Maximum 2350 mm TECHNICAL SPECIFICATION
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3.05.00 Each Charger panel shall be provided with an illuminating lamp and one 5 Amp. Socket. Switches and fuses shall be provided separately for each of the above. 3.06.00 Locking facilities shall be provided as following: a) For locking Trickle/Boost selector switch in the trickle position only. This would be used for having key mechanical interlock between Trickle/Boost selector switch and isolator in D.C. distribution board which is being procured separately by the employer. b) The Charger enclosure door locking requirements shall be met by the application of padlocks. Padlocking arrangement shall allow ready insertion of the padlock shackle but shall not permit excessive movement of the locked parts with the padlock in position. 3.07.00 Wiring 3.07.01 Each Charger shall be furnished completely wired upto power cable lugs and terminal blocks ready for external connection. The power wiring shall be carried out with 1.1 KV grade PVC insulated cables conforming to IS:1554 (Part‐I). The control wiring shall be of 1.1KV grade PVC insulated stranded copper conductors of 2.5 sq.mm. conforming to IS:694. Control wiring terminating at electronic cards shall not be less than 1.0 sq. mm. Control terminal shall be suitable for connecting two wires with 2.5 sq.mm. stranded copper conductors. All terminals shall be numbered for ease of connections and identification. At least 20% spare terminals shall be provided for circuits. 3.07.02 Power and control wiring within panels shall be kept separate. Any terminal or metal work which remains alive at greater than 415 V, when panel door is opened, shall be fully protected by shrouding. 3.07.03 An air clearance of at least ten (10) mm shall be maintained throughout all circuits, except low voltage electronic circuits, right upto the terminal lugs. Whenever this clearance is not available, the live parts should be insulated or shrouded. 3.08.00 Painting All sheet work shall be pretreated, in tanks, in accordance to IS: 6005.Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline water and dried. Powder coated paint shade 631 as per IS: 5 shall be used as per IS: 13871. The Phosphate coating shall be “Class –C” as specified in IS: 13871. The phosphate surface shall be passivated and electrostatic Powder Painting shall be used. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peal able compound by Power supply arrangement & Lighting works
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spraying method to protect finished surfaces from scratching, grease, dirt and oily spots during testing, transportation, handling and erection. 4.00.00 TESTS 4.01.00 The Battery Charger shall conform to type tests and routine test shall be carried out on Battery Chargers as per relevant latest Indian Standards. The Employer reserves the right to witness any or all the tests. 4.02.00 Type Tests Following type tests should have been carried out on each rating and type of Battery Charger for which reports are to be submitted. a) Complete physical examination. b) i) Temperature rise test at full load. ii) Temperature rise test of rectifier assembly at 200% of full load. c) Insulation resistance test. d) High voltage (power frequency) test on power and control circuits except low voltage electronic circuits. e) Ripple content test at i) No load ii) Half load iii) Full load f) Automatic voltage regulator operation test at specified A.C. supply variations at i) No load ii) Half load iii) Full load g)
Load limiter operation test h)
Efficiency and power factor measurement. Power supply arrangement & Lighting works
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i)
Input and output surge withstand capability test. Surge Voltage as per ANSI‐C37.90a shall be applied for period not less than 2 sec. At the following points of the Charger operating at 50 deg. C at full load : i) Across each A.C. input phase ii) Across AC input line to ground. iii) Across D.C. output terminals. iv) Across each D.C. output terminal to ground The Charger shall not exhibit any component damage and there shall be no change in performance as per clause 4.02.00 (f) and (g). j) Environmental Tests Steady state performance tests (clause 4.02.00 (f) and (g) ) shall be carried out before and after each of the following tests. i) Soak Test The electronic modules shall be subjected to continuous operation for a minimum period of 72 hours. During last 48 hours, the ambient temperature shall be maintained at 50 deg. C. The 48 hour test period shall be divided into four equal 12 hour segments. The input voltage during each 12 hours shall be nominal voltage for 11 hours followed by 110% of nominal voltage for 30 minutes, followed by 90% of nominal voltage for 30 minutes. ii) Degree of protection test. 4.03.00 Routine Tests 4.03.01 Following routine tests shall be carried out on all Rectifier transformers. 4.03.02 a) Temperature rise test. b) Insulation resistance test. c) High voltage (power frequency) test. Following routine tests shall be carried out on all Battery Chargers: a) Complete physical examination. Power supply arrangement & Lighting works
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b) Temperature rise test at full load. c) Insulation resistance test. d) High voltage (power frequency) test. e) Ripple content test at i) No load ii) Half load iii) Full load f) Automatic voltage regulator operation test at specified A.C. supply variations at i) No load ii) Half load iii) Full load g) Load limiter operation test h) Checking of proper operation of annunciation system. i) Dynamic response test Overshoot/Undershoot in out put voltage of the charger as a result of sudden change in load from 100% to 20 % and 20% to 100% shall be measured. j) Burn in Test ‐ shall be carried out on all electrical modules as panels with module as routine test. During the test panel/ module shall be subjected to ambient temperature of 50 deg. C for 48 hours in energised condition. The temperature rise inside the cubicle shall not exceed 10 deg. during the temperature rise test. k) Degree of protection test ‐ the charger shall be checked for gasketing arrangement as per drawing. 4.03.03 Following routine tests shall be carried out on annunciation system. a) Annunciation Assembly & module shall be functionally tested as per EEUA‐45D. b) Burn in test shall be carried out as per Cl. 4.03.02 (j). Power supply arrangement & Lighting works
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4.03.04 The Contractor shall furnish for inspection, the type and routine tests certificates for the following components whenever required by the Employer. Makes of these components (not restricted to) shall be subject to Employer’s approval. i) Relays ii) Instruments iii) SCR iv) Diodes v) Chokes and transformer. vi) Annunciator. 5.00.00 COMMISSIONING 5.01.00 The contractor shall carryout the following commissioning tests and checks after installation of the equipment at site: a) Complete physical examination. b) Checking of proper operation of annunciation system. c) Temperature rise test at full load. d) Insulation resistance test. e) Automatic voltage regulator operation. f) Load limiter operation. g) Dynamic response test. 5.02.00 Overshoot/Undershoot in output voltage of the Charger as a result of sudden change in load from 100% to 20% and 20% to 100% shall be measured with the Batteries connected/disconnected. Output voltage of the Charger connected with Battery shall be within 94% to 106% of the voltage setting in above conditions and shall return to, and remain, within the limits specified in clause 2.01.00 (e) or 2.02.00 (e) in less than 2 seconds (as applicable). Power supply arrangement & Lighting works
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1.00.00 SCOPE This specification of Static Energy Meter/ Multi Function Meter (MFM) covers design, engineering, manufacture, inspection, testing at manufacturers works including type testing before dispatch, supply and delivery of three phase 4 wire tri‐vector meter, complying with DLMS/COSEM as per IS:1559. 2.00.00 APPLICABLE STANDARDS Sl. No. Standards Description 1. IS : 14697 Specification for AC Static Transformer operated Watt Hour & VAR‐Hour meters, classes 0.5 S 2. IS:15959 DLMS/ COSEM compliance. 3. IEC : 60687 AC Static Watt‐Hour Meters for Active Energy 4. IEC : 62056‐21 (Latest Version) Data exchange for Meter Reading and Direct Local Data Exchange 5. IEC : 61000‐4‐5 (2001‐04) For Electro Magnetic Compatibility – Testing and Measurement techniques, Surge immunity test 6. IEC : 61358 Criteria for selection for tests LIKE Acceptance, Inspection. ANSI/IPC‐A‐610 Workmanship standard for Acceptability of Electronic Assemblies (A standard developed by Institute for Interconnecing and packaging Circuits). 2.01.02 Climatic Conditions i) Temperature ii) Humidity iii) Max. Altitude above MSL : 3.00.0
Design and Constructional features Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
: 10oC to 55o C (in shade) : Upto 95% RH non‐condensing 500 meters TECHNICAL SPECIFICATION
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3.01.00 Location & Mounting The Energy meters shall be supplied suitable for indoor installation. Enclosure shall have IP‐51 protection. All the feeder meters to be suitable for mounting on Simplex type Vertical Panel with rear door, Energy Meter flush mounted and clearly visible, with disconnecting type TBs, fully wired, for placing inside sub‐
station control room. 3.02.00 Design Meter shall be designed with application specific integrated circuit (ASIC) or micro controller; shall have no moving part; electronic components shall be assembled on printed circuit board using surface mounting technology; factory calibration using high accuracy (0.1 class) software based test bench. All components used shall be approved by reputed testing authority at national level or other international recognized testing authority. 3.03.00 Manufacturing Process, Assembly and Testing Meters shall be manufactured using latest and ‘state of the art’ technology and methods prevalent in electronics industry. All inward flow of major components and sub assembly parts (CT, PT, RTCs/Crystal, LCDs, LEDs, power circuit electronic components etc.) shall have batch and source identification. Multi‐layer ‘PCB’ assembly with ‘PTH’ (Plated through Hole) using surface mounted component shall have adequate track clearance for power circuits. SMT component shall be assembled using automatic ‘pick‐and‐place’ machines with in process 7 stages, Re‐flow Soldering oven, for stabilized setting of the components on ‘PCB’. For soldered PCBs, cleaning and washing of cards, after wave soldering process is to be carried out as a standard practice. Assembly line of the manufacturing system shall have provision for testing of sub‐assembled cards. Manual placing of components and soldering, to be minimized to items, which cannot be handled by automatic machine. Handling of ‘PCB’ with ICs/C‐MOS components, to be restricted to bare minimum and precautions to prevent ‘ESD’ failure to be provided. Complete assembled and soldered PCB should under go functional testing using computerized Automatic Test Equipment. Power supply arrangement & Lighting works
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Test points should be provided to check the performance of each block/stage of the meter circuitry. Testing at intermediate and final stage to be carried out with testing instruments, duly calibrated with reference standard, with traceability of source and date. 3.04.00 Displays 7 digits parameter identifier, backlit Liquid Crystal Display (LCD) of minimum 10 mm height, wide viewing angle. Auto display cycling push button required with persistence time of 12 Seconds. Sequence of display of various instantaneous electrical parameters shall be as desired by Owner at the time of order. Normal display shall be Active energy value, on release of push button, at any of the display parameter during scrolling. 3.05.00 Calibration of Meter Meters shall be factory calibrated using high accuracy test bench. Energy Meter shall have test output device, accessible from the front, and be capable of being monitored with suitable testing equipment while in operation at site. Resolution of the device shall enable the starting current test in less than 10 minutes. Accuracy of test bench at works shall be as per the guidelines provided in IS : 12346. 3.06.00 Self­Diagnostic Features The meter shall have self‐diagnostic features to check its circuits for any malfunctioning. The bidder shall furnish the details of the self‐diagnostic features. 3.07.00 Construction 3.07.01 Meter Case and Cover a) To ensure high reliability, long trouble free life, safety against electric shock, spread of fire and effects of excessive temperature, the meter casing and cover shall be made of high quality industrial grade polycarbonate material or better material having adequate strength, which is unbreakable, corrosion resistant & inert to chemicals, flame retardant, immune to ultra violet radiation and meet UV ageing test as per relevant ASTM standards. b) The bidder shall indicate hardness, melting temperature and tensile yield strength of the material and necessary test certificate of the same shall be furnished. Power supply arrangement & Lighting works
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c) The meter shall be provided with adequate shielding to withstand external magnetic influence from all directions as per latest amendments of CBIP 88 report. d) Meter cover shall be continuously ultra sonically welded with meter base from all sides. Suitable locking arrangement shall be provided between the base and cover of the meter. 3.08.00 Sealing Arrangement 3.08.01 Two sealing screws shall be provided for proper fixing of the meter cover so that access to the working part shall not be possible without breaking the seal. 3.08.02 Necessary provision shall be kept for fixing the utility seal also. 3.08.03 Terminal block shall be provided with separate sealing facility by testing group of utility. 3.09.00 Terminal Block and Cover 3.09.01 The terminal block shall have adequate insulating properties and mechanical strength. The terminal block shall be made from best quality non‐hygroscopic, flame retardant polycarbonate material (capable of passing the flammability tests give in IS :11731) with nickel‐plated brass studs for connecting terminals. 3.09.02 The terminal block base shall be of same material as meter case or any other superior industrial plastic material having sufficient thickness to cover its back and provide enough strength for the purpose of tightening of screws. Clamping screws should be provided inside the terminal cover and should have metallic sleeve moulded within the block to avoid damage during tightening of the screws. 3.09.03 The terminals in the terminal block shall be of long socket type suitable for connection of cables with aluminium conductors along with suitable lugs (lugs to be provided by the supplier) having cross sectional area, with adequate length. Double screw arrangement shall be provided to achieve adequate termination. All terminals and connecting screws and washers shall be of tinned / nickel plated brass material. 3.09.04 The terminal cover shall be transparent with minimum thickness 2.5 mm and the material shall be same as that of meter case. It shall be of extended type and accommodate, in addition to the terminal block, a suitable length of external cable along with its insulation. 3.10.00 Name Plate and Marking: 3.10.01 Every meter shall have a nameplate clearly visible and indelible and distinctly marked in accordance with IS : 14697 (latest version). The following information shall appear on a nameplate preferably placed within the meter. Power supply arrangement & Lighting works
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1. Manufacturer’s name & trade‐mark and place of manufacture. 2. Serial number and year of manufacture. 3. Designation of type. 4. Number of phases and number of wires for which the meter is suitable. 5. Guarantee period. 6. Owner’s name & meter number. 7. Principal unit in which the meter records. 8. Reference voltage & frequency in Hz. 9. Basic current and rated maximum current. 10. Meter constant (pulse rate of testing signal). 11. Class index. 12. Project Name. 4.00.00 OPERATIONAL REQUIREMENTS 4.01.00 Performance under Influence Quantities As per IS 14697. Accuracy for measurement & display of instantaneous quantities shall conform to IS14697. 4.02.00 Additional Technical Features 4.02.01 Output Device i)
Energy Meter shall have test output, accessible from the front, and be capable of being monitored with suitable testing equipment while in operation at site. ii)
Operation indicator must be visible from the front. iii)
Test output device shall be provided in the form of LED/LCD. Resolution of the test output device shall be sufficient to enable the starting current test in less than 10 minutes. Nameplate shall indicate the ‘impulse/ Unit’ with appropriate resolution. 4.02.02 Cumulative Energy Register Power supply arrangement & Lighting works
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Meter should have provision for automatic recording of cumulative kWh & MD KW at say 24.00 hours on the last day of the month for each of the past six calendar months and same to be stored in the register/ memory. 4.03.00 Temperature Conditions As per Is 14697; Meter to perform satisfactorily under Non‐Air Conditioned environment in switchgear room. 4.04.01 Real Time Internal Clock (RTC) of Energy Meter RTC shall be pre‐programmed for 30 Years Day/date without any necessity for correction. Maximum drift shall not exceed +/‐ 300 Seconds per year. Time & date setting shall only be possible through one of the following: (a)
Common Meter Reading Instrument (CMRI) or Meter testing work bench and this shall need password enabling for Consumer meter; From Base billing system computer thro’ ‘WAN’ or Sub‐station data logger ‘PC’ through ‘LAN’. 4.04.02 Clock Day/Date Synchronisation Synchronisation of Energy Meter ‘RTC’ Time/Date shall be possible thro’ password/Key code enabled command from remote server or sub station ‘PC’ as per the arrangement. Master Clock reference shall be obtained from Main server or local ‘PC’. Synchronisation shall be carried only if the ‘RTC’ drift is within ±10 minutes. Error log to be recorder by the system S/W if the ‘RTC’ time is out of range. 4.05.00 Quantities to be Measured & Displayed As per Appendix G of IS 14697. a)
Maximum kVA or kW demand with elapsed time. b)
Instantaneous kW, kVA, PHASE WISE kW & kVA, OVERALL pf, MD reset count, frequency, time & date, RTC battery health; In addition, present status of abnormality shall also be possible to be displayed. Tamper details shall be stored in internal memory for retrieval by authorized personnel through either of the following: i)
Common Meter Reading Instrument (CMRI) and this shall need password enabling. Power supply arrangement & Lighting works
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ii)
From Base billing system computer thro’ ‘WAN’ or Sub‐station data logger ‘PC’ through ‘LAN’. 4.06.00 Demand Integration Period (DIP) i)
Energy Meter shall continuously monitor and calculate the average maximum demand for each demand interval time of 30 minutes and maximum of these in a calendar month shall be stored along with date and time when it occurred; ii)
It shall however be possible to change the demand integration period (DIP), from 30 to 15 minutes at site, with proper security; iii)
The Maximum demand of past six months shall be stored in the memory with date and time. iv) It shall be also possible to retrieve this data through communication port and MRI. v) There shall be no resetting button for MDI data and resetting shall be possible, on request by Sub‐Station data logger system thro’ LAN after retrieval of update data or via MRI optical port, with password enabled access, only. 4.07.00 Time of Day (TOD) Registers 6 or 8 different TOD energy registers as per clause G‐8 of IS 14697 are required. Time block settings shall be advised to the supplier at least 4 weeks before commencing delivery. Change of time period for TOD metering shall be with password enabling from CMRI or from base computer for LAN operated meters. 4.08.00 Load Survey Data Registers Storage in Non volatile memory for 40 days, 30 minute demand of any of the flow parameters of kW, kVA, kVAR (or Pf), Average of 3 voltages and phase currents shall be provided. 4.09.00 Communication Facilities & Standards Data architecture and communication protocols shall enable easy multi‐vendor exchange of data without usage of any converting/translating equipment. Energy meters shall be compatible with DLMS (Device language message specification)/COSEM (Companion Specification for Energy Metering (IEC 62056, EN 13757‐1). For this, the data structure adopted within the energy meter shall be on an internationally acceptable method. The data structure/coding details shall be Power supply arrangement & Lighting works
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furnished to the Owner. All necessary software required for down loading the information to a user friendly ‘Windows’/LINUX based operating system of Base billing computer system, Substation data logger ‘PC’ system thro’ CMRI as well as ‘LAN’ shall be furnished in required number of copies (On CD) without any additional cost to the Owner. Local communication port: a)
Meter shall be provided with ‘RS 485’ port for periodic data transfer thro’ ‘LAN’ to sub‐station data logger/Computer; b)
Energy Meter shall operate on industry standard ‘MODBUS’ protocol and shall be individually addressable c)
‘RS485’ communication port shall be suitable for interfacing multiple Energy Meters. It shall be possible to download stored meter data, on polling basis with the aid of a software schedule by addressing one meter at a time and downloading the stored data into the sub station data logger/Computer. e) Energy meter shall have a galvanically isolated optical communication port as per IEC 62056‐21 or any other internationally accepted port in front of the meter for data transfer to or from a hand held data Collection Device (Common Meter Reading Instrument ‘CMRI’ ‐ conforming to CBIP technical report‐111) with proper security and without error. f) one number CMRI ‘Unit’ at each sub‐section is to be supplied under this Project as per the specification stated at (e) above. 4.11.00 Accuracy 4.11.01 Accuracy test shall be conducted on energy meter before & after the burn in test by the manufacturer. 4.11.02 In case any drift is noticed in the accuracy of the meter, which is beyond the permissible limits, the concerned meter shall be with‐drawn from service and Bidder shall supply a new meter without any extra cost as a replacement (with in one month of receipt from owner), during the guarantee period i.e. 2 years from supply. 5.00.00 Inspection, Testing and Dispatch 5.01.00 Type Tests i)
The meter offered should have successfully passed all type tests described in the IS 14697 Type test certificate shall be submitted along with the offer and the same shall not be more than 36 months old on the Power supply arrangement & Lighting works
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date of opening tender. Make & type of major components used in the type‐tested meter shall be indicated in the type test certificates. 5.02.00 Acceptance and Routine Tests i)
Criteria for selection for such tests and performance requirements shall be as per IS 14697. 5.03.00 Quality Assurance Plan 5.03.01 The bidder (manufacturer) shall have a comprehensive quality assurance program at all stages of manufacture for ensuring products giving reliable, trouble free performance. The bidders (manufacturers) quality assurance plan shall be submitted along with bid document, which would be reviewed in detail by the owner in case of award and accepted with modifications, as felt necessary. A sampler manufacturing quality plan document is enclosed in this specification. 5.03.02 The bidder’s quality assurance programme shall generally cover the following. i) Bidder organization structure for the management and implementation of the proposed quality assurance programme. ii) Quality System Manual. iii) Design Control System. iv) Documentation Control System. v) vi) System for process controls and fabrication and assembly controls. vii) Inspection and test procedure both for manufacture and field activities. viii) Control of calibration and testing of measuring /testing equipments. ix) System for Quality Audits. x) 5.03.03 The Bidder shall accordingly furnish along with the bid i) A comprehensive quality assurance plan which is in practice (for both product & process). ii) A detailed list of bought out items with name of the manufacturer and details about in coming quality control. The procedure for purchase of materials, parts, components, source inspection, incoming raw‐material inspection, verification of materials purchased etc. System for handling storage and delivery. Power supply arrangement & Lighting works
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iii) Quality assurance plan of bidders’ collaborators in case of foreign collaborators. 5.03.04 Owner reserves the right to carry out quality audit and quality surveillance of the systems and procedure of the bidders’ quality management & control activities. The bidders shall provide all necessary assistance to enable the owner to carry out such audit & surveillance. 6.00.00 MANUFACTURING AND TESTING FACILITIES 6.01.00 The following Manufacturing and testing facilities shall be available. The factory shall be completely dust proof. The testing rooms shall be temperature and humidity controlled as per relevant Standards. The testing and calibrating equipment should be automatic and all test equipment shall have their valid calibration certificates Power supplies used in testing equipment shall be distortion free with sinusoidal waveforms and maintaining constant voltage current and frequency as per the relevant Standards. 6.02.00 During the manufacturing of the meters following minimum checks shall be carried out. a. Meter frame dimension tolerance shall be minimum. b. The pressure coil shall be made totally encapsulated and care shall be taken to avoid ingress of dust and moisture inside the coil. c. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated. d. The meters shall be batch tested on automatic, computerized test bench and the results shall be printed directly without any human errors. e. The current coil shall be made with the help of jigs and fixtures. f. The potential coil shall be made with automatic computerized machine. 7.00.00 MOUNTING AND FIXING ARRANGEMENT DRAWINGS / DATA SHEET 7.01.00 Manufacturer shall ensure following technical points: i)
Meter shall be suitable for mounting on Simplex type Vertical panel with rear door; CAT‐M4 disconnecting type TBs to be used for Current circuit; Panel wiring to be properly dressed and harnessed; External cables to enter panel from bottom gland plate using double compression glands. Power supply arrangement & Lighting works
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ii)
External cabling and inter‐connection from existing CT/PT to Energy Meter panel shall be shall be in the scope of the contractor/bidder; iii)
‘LAN’ cabling from Energy Meters to ‘PC’/CPU at Sub station shall be in the scope of the contractor/bidder; iv) Energy Meter terminals block shall be adequately sized with regard to maximum conductor dimension, commensurate with current rating of Energy Meter v) ‘RS 232’ to ‘RS 485’ when used shall be suitably wounded in side the panel and its cable shall be terminated for external connection One copy of test report, approved data sheet and operating manual shall be dispatched with the meter. 4 copies of these documents shall be submitted to owner’s engineering department for record. Guaranteed Technical Parameter The following guaranteed technical parameters shall be applicable. Sr No 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 Description Type Standard to which the meter conforms: Guarantee Period from the date of first installation Rated Voltage: Basic Current(Ib): Power factor Range
Meter shall display in Primary Quantity as per adopted CT ratio Maximum Continuous Current : Frequency : Completely type tested as per Indian Standard IS Minimum starting current : Accuracy class. :
Test Output device
Operation indicator
Power consumption in voltage and current circuit Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
THREE PHASE METER CT /PT Operated Energy meter Static Three Phase ,CT operated meter for unbalance load current IS‐14697:1999
24 Months
63.5 V(Ph‐N),110V(Ph‐PH) 1A 0.5 lag‐Unity‐0.8 lead As per approved SLD of substation where meter to be fitted (2Ib) As per IS 14697 50Hz +/‐ 5% 14697
0.1% of Ib
0.5 Class LED
LED/LCD
As per IS‐14697 TECHNICAL SPECIFICATION
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15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Limits of error at all Power factor of unity/0.5 at multiples of rated currents. Compliance to IS‐14697 for Change in error due to a) Variation in frequency: b) Variation in Temperature
Should be Compliant to EMC & EMI as Basic insulation level: Impulse withstand Voltage Details of meter case: Degree of protection against dust and water : Details of alpha‐numeric LCD display i.No. of digits
Tamper protection features (List out) Tamper immune features (List out) Whether test output provided Limits of error at variaous Power factors of unity/0.5and Loads Meter & Terminal Cover sealing Type Test Certificate
As per IS‐14697 As per IS‐14697 As per IS‐14697 One minute Power frequency withstand Voltage : As per IS‐14697 As per IS‐14697 The energy meter shall be calibrated to measure the actual energy in CT primary. The necessary multiplying factor has to be incorporated inside the energy meter. Power supply arrangement & Lighting works
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SCOPE: The section covers specification for Power Control Cubicles (PCCs), Lighting Panels, Lighting Distribution Board, APFC panel, DG control& relay panels, AC Distribution Boards (ACDBs), 110 V DC Distribution Boards (DCDBs) panels and any other similar panels involved in the package. All these boards are indoor type. Feeder Pillar panel shall be of Outdoor type. 1.00.00
General Requirements 1.01.01
The requirements, conditions, appendices, etc. stated in any other bid documents shall apply to and shall be considered as a part of this specification as if bound together. In case of any discrepancy between conditions specified in any other volume and this volume, the requirements, specified in this volume shall prevail. 1.01.02
The equipment offered by the Bidder shall be complete in all respects. Any material and component not specifically stated in this specification but which is necessary for trouble free operation of the equipment and accessories specified in this specification shall be deemed to be included unless specifically excluded. All such equipment /accessories shall be supplied without any extra cost. Also, all similar components shall be interchangeable and shall be of the same type and rating for easy maintenance and low spare inventory. 1.01.03
Bidder shall furnish the technical information and data as mentioned elsewhere. Bids not furnishing the same are liable to be rejected. 1.01.04
All drawings, schedules and annexure appended to this specification shall form part of the specification. Specific reference in this specification and documents to any material by trade name, make, or catalogue number shall be construed as establishing standard of quality and performance and not as limiting competition. The bidder may offer other similar equipment provided it meets the specified standard design and performance requirements. 2.00.00 CODES AND STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as published one month prior to the date of opening of bids. In case of conflict between this specification and those (IS codes, Standards etc.) referred to herein, Power supply arrangement & Lighting works
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the former shall prevail. All work shall be carried out as per the following codes and standards. IS: 13947 IS: 13947‐1 / IEC‐60947‐1 Air‐Break Switches, air break disconnectors, air break disconnector and fuse combination units for voltages not exceeding 1000V AC or 1200 V DC. General Requirements for Switchgear and Control gear for voltages not exceeding 1000 V. IS: 13947–1 Degree of protection provided by enclosures for low voltage Switchgear and Control gear IS: 3043 Code of practice for earthing. IS: 3072 Code of practice for installation and maintenance of Switchgear
IS: 8623 (3 parts) / IEC: 60439 Specification for factory built assemblies of Switchgear & Control gear for voltages upto and including 1000 V AC & 1200 V DC. 3.00.00 SYSTEM PARAMETERS FOR SWITCHGEAR DESIGN 415VAC +/‐ 10 % (SOLIDLY GROUNDED) 50 Hz +3%/‐5% 110V DC NOMINAL ISOLATED TYPE 4.00.00 TEMPERATURE RISE The temperature rise of the horizontal and vertical busbars and main bus link including all power draw out contacts when carrying 90% of the rated current along the full run shall in no case exceed 55 deg. C with silver plated joints and 40 deg. C with all other types of joints over an ambient of 50 deg C. The temperature rise of the accessible parts/external enclosures expected to be touched in normal operation shall not exceed 20 deg.C. The temperature rise of manual operating means shall not exceed 10 deg. C for metallic & 15 deg. C for insulating material. The above temperature rise limits are applicable for busducts also without any current derating. 5.00.00 OPERATIONAL REQUIREMENTS 5.01 All switchgear/ panels/ modules/ push buttons shall have prominent engraved Power supply arrangement & Lighting works
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identification plates. 5.02 All non‐current carrying metal work of panels shall be effectively bonded to earth bus of galvanised steel, extending throughout the panel. Positive earthing shall be maintained for all positions of chassis and breaker frame. 5.03 It should be possible to carryout maintenance on a feeder with adjacent feeders alive. 6.00.00 Control, Protection & Metering Requirements 6.01 Control circuits shall operate at suitable voltage of 110V DC. Necessary control supply transformers having primary and secondary fuses shall be provided for each panel, 2 x 100% per bus section. The auxiliary bus bars for control supply shall be segregated from main bus bars. The control supplies shall be monitored. 6.02 Contractor shall fully co‐ordinate overload and short circuit tripping of breaker with upstream and downstream breakers/fuses/MCCBs motor starters. Various equipments shall meet requirement of Type‐II class of coordination as per IEC. 6.03 All incomers and feeders with ACBs shall be provided with Static Energy meters (Multi‐function Meters). 6.04 All outgoing feeders shall be provided with CT Operated Digital Amp meter (class 0.5) of LCD display type and with Flush mounting of 96 X 96 mm. 7.00.00 DESIGN AND CONSTRUCTIONAL FEATURES 7.01.00 All switchboards i.e., Power Control Cubicle (PCCs), Lighting Panels, APFC panel, AC Distribution Boards (ACDBs), 110 V DC Distribution Boards (DCDBs) panels shall have following features: 1. Shall be of metal enclosed, indoor, floor mounted and freestanding type. 2. All frames and load bearing members shall be fabricated using mild steel structural sections or pressed and shaped cold rolled sheet steel of thickness not less than 2mm. Frame shall be enclosed in cold rolled sheet steel of thickness not less than 2.0 mm. Doors and covers shall also be of cold rolled sheet steel of thickness not less than 2.0 mm. Stiffeners shall be provided wherever necessary. Removable gland plates of thickness 3mm (hot/cold rolled sheet steel) or 4 mm (non‐magnetic material) shall be provided for all panels. All switchboards/ panels shall be of dust and vermin proof. All cutouts shall have EPDM/ Neoprene gaskets. All Panels/ DBs shall be of single‐front type and shall be provided with 3. 4. 5. Power supply arrangement & Lighting works
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6. 7. 8. single‐leaf, hinged or bolted covers at the rear. The bolts shall be of captive type. The covers shall be provided with "DANGER" labels. All panel doors shall open by 90 deg or more. All DBs shall be of fixed module type. All switchboards/ panels shall have following distinct vertical sections.
a) Completely enclosed bus bar compartment for horizontal and vertical busbars. b) Completely enclosed switchgear compartments (one for each circuit housing circuit breakers, motor starter or switch‐fuse feeder). c) Compartment for cable alley or cable box for power and control cables. d) For cable connection to circuit breaker, a separately enclosed cable compartment shall also be acceptable. e) Compartment for relays and other control devices associated with a circuit breaker, wherever necessary. f) The switchboards/Panels of 1600A & above rating shall be of DOP IP42 & of IP52 for less than 1600A rating. g) All draw out modules shall have distinct service, test and isolated positions with provision of external pad locking facility in each position. Power contacts shall get disconnected in both test and isolated positions whereas the control contacts shall get disconnected in isolated position only. PAINTING: All sheet work shall be pretreated, in tanks, in accordance to IS: 6005.Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline water and dried. Powder coated paint shade 631 as per IS: 5 shall be used as per IS: 13871. The Phosphate coating shall be “Class –C” as specified in IS: 13871. The phosphate surface shall be passivated and electrostatic Powder Painting shall be used. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peal able compound by spraying method to protect finished surfaces from scratching, grease, dirt and oily spots during testing, transportation, handling and erection. Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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9. 10. 11. 12. 13. 14. Busbars shall be of high conductivity aluminium EC grade and shall be sleeved type with color coding. The cross section of the horizontal bus bars shall be uniform throughout
the length of the switchboard and both horizontal as well as vertical bus bars shall be adequately supported and braced to withstand the stresses due to the specified short circuit currents. Neutral bus bar short circuit strength shall be same as the main bus bars. Minimum air clearance in air between phases and phase‐earth shall be 25 mm for busbars and cable terminations. For all other components, the Clearances shall be at least 10mm. Wherever above is not possible except for horizontal and vertical busbars, insulation shall be provided by anti tracking sleeving or barriers. However for horizontal and vertical busbars, clearances specified above shall be maintained even when busbars are insulated/sleeved. In case of DC DBs/ fuse boards, the busbar system shall be insulated or physically segregated with barriers to prevent interpole short circuit. Busbar insulators shall be of track‐resistant high strength non‐hygro‐
scopic, non‐combustible type and suitable to withstand stresses due to over‐voltages and short circuit current. Insulators and barrier of inflammable material such as Hylam shall not be accepted. All busbars shall be color coded as per IS: 375.
Terminal Blocks Terminal blocks shall be 650V grade, 10Amps rated, made up of unbreakable polyamide 6.6 grade. The terminals shall be screw type or screw‐less (spring loaded) / cage clamp type with lugs. Marking on terminal strips shall correspond to the terminal numbering in wiring diagrams. All metal parts shall be of non‐ferrous material. In case of screw type terminals the screw shall be captive, preferably with screw locking design. 15. 16. The panels shall be designed to offer adequate level of safety to operating/ maintenance personnel. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate suitable for wall mounting shall be provided for each panel room describing various safe operating procedure/safety precautions for safe operation and maintenance of switchgear/Panels. All current and voltage transformers as required for metering & protection specified shall be completely encapsulated cast resin insulated type. The Power supply arrangement & Lighting works
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accuracy shall be as follows:
CTs PTs Protection 5P20,5VA 3P
Metering 0.5 0.5
7.03.00 Indicating lamps shall be cluster LED type. Panels shall have bottom cable entry. 7.04.00 Earth bus and earthing a)
b)
c)
A galvanized steel earth bus shall be provided at the bottom of panel and shall extend throughout the length of each switchboard Suitable arrangements shall be provided at each end of the horizontal earth bus for bolting to Employer's earthing conductors. The horizontal earth bus shall project out of the switchboard ends and shall have predrilled holes for this connection All hinged doors having potential carrying equipment mounted on it shall be earthed by flexible wire/ braid. 8.00.00 CIRCUIT BREAKERS 8.01 Circuit breakers shall be three pole/ four pole, microprocessor/ microcontroller based, air break, horizontal draw out type (Electrically, Draw out type). 8.02 8.03 8.04 8.05 8.05.01 8.05.02 8.05.03 All ACBs shall have Icu = Ics = Icw for 1 sec. All ACBs should be tested for “combined sequence” as per IS/IEC:60947‐II and manufacturers shall submit test certificates from CPRI/ ERDA or any national lab. All 4 pole ACBs shall have fully rated neutral pole. ACB Protections: All ACBs shall be provided with inbuilt microprocessor/ microcontroller based Release with following protections: a) Overload with adjustable time delay b) Short circuit with selectable time delay and HighSet. c) Earth fault with selectable time delay. d) Current unbalance e) Reverse power Release shall have LED display for display of all electrical parameters. Release shall have password protected settings to avoid unauthorized access. Power supply arrangement & Lighting works
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8.05.04 8.05.05 8.05.06 8.06
8.07
8.08
8.09
8.10
8.11
8.12
8.13
Release shall have RS485 communication port for Breaker control and communication on MODBUS protocol. Release shall display the last 5 trip data. All ACBs shall be provided with anti pumping feature and Trip Circuit Supervision relay. Circuit breakers along with its operating mechanism shall be provided with suitable arrangement for easy withdrawal. Suitable guides shall be provided to minimize misalignment of the breaker. There shall be "SERVICE", "TEST" and "FULLY WITHDRAWN" positions for the breakers. In "Test" position the circuit breaker shall be capable of being tested for operation without energising the power circuits i.e. the power contacts shall be disconnected, while the control circuits shall remain undisturbed. Locking facilities shall be provided so as to prevent movement of the circuit breaker from the "SERVICE", "TEST" or "FULLLY WITHDRAWN" position. It shall be possible to close the door in "Test" position. All circuit breakers shall be provided with "4 NO" and "4NC" potential free auxiliary contacts. These contacts shall be in addition to those required, for internal mechanism of the breaker and should be directly operated from breaker operating mechanism. In case the manufacturer does not have a proven arrangement for providing the required number of circuit breaker auxiliary contacts on the fixed portion of the cubicle, necessary electrically reset latched relays shall be provided complete with all wiring in series with service position limit switch contacts, for multiplying the circuit breaker mounted auxiliary contacts and provide 4 NO and 4 NC contacts. Separate limit switches, each having required numbers of contacts shall be provided in both "SERVICE" and "TEST" position of the breaker. Suitable indications shall be provided on all circuit breakers to show "OPEN", "CLOSE", "SERVICE ", "TEST" AND "SPRING CHARGED" positions. Main poles of the circuit breakers shall operate simultaneously in such a way that the maximum difference between the instants of contacts touching during closing shall not exceed half a cycle of rated frequency. All circuit breakers shall be provided with the following interlocks : a)
Movement of a circuit breaker between "SERVICE" and "TEST” position shall not be possible unless it is in open position. Attempted withdrawal of a closed circuit breaker shall preferably not trip the circuit breaker. In case the offered circuit breaker trips on attempted withdrawal as a standard Power supply arrangement & Lighting works
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interlock, it shall be ensured that sufficient contact exists between the fixed and drawout contact at the time of breaker trip so that no arcing takes place even with the breaker carrying its full rated current. 8.14
8.15
8.16
8.17
b)
Closing of a circuit breaker shall not be possible unless it is in "SERVICE” position, "TEST" position or in "FULLY WITHDRAWN" position. c)
Circuit‐breaker cubicles shall be provided with safety shutters operated automatically by the movement of the circuit breaker carriage, to cover the stationary isolated contacts when the breaker is withdrawn. It shall however be possible to open the shutters intentionally against pressure for testing purposes. d)
A breaker of particular rating shall be prevented from insertion in a cubicle of a different rating. e)
Circuit breakers shall be provided with coded key / electrical interlocking devices, as per requirements. f)
All ACBs shall be provided with Door interlock and Mechanical Operation counter. Circuit breaker shall be provided with anti‐pumping feature (soft) and trip free feature, even if mechanical anti‐pumping feature is provided. Mechanical tripping shall be possible by means of front mounted Red "trip" push‐button. In case of electrically operated breakers these push buttons shall be shrouded to prevent accidental operation. Complete shrouding / segregation shall be provided between incoming and outgoing bus links of breakers. In case of bus coupler breaker panels the busbar connection to and from the breaker terminals shall be segregated such that each connection can be approached and maintained independently with the other bus section live. Dummy panels if required to achieve the above feature shall be included in the Bidder's scope of supply. Circuit breaker shall be provided with Power operated mechanism as follows. 1. Power operated mechanism shall be provided with a universal motor suitable for operation on 110 V DC / 240 AC Control supply, with voltage variation from 90% to 110% rated voltage. Motor insulation shall be class "E" or better. 2. The motor shall be such that it requires not more than 30 seconds for fully charging the closing spring at minimum available control voltage. 3. Once the closing springs are discharged, after one closing operation of circuit breaker, it shall automatically initiate recharging of the spring. Power supply arrangement & Lighting works
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4. The mechanism shall be such that as long as power is available to the motor, a continuous sequence of closing and opening operations shall be possible. After failure of power supply at least one open‐close‐open operation shall be possible. 5. Provision shall be made for emergency manual charging and as soon as this manual charging handle is coupled, the motor shall automatically get mechanically decoupled. 6. All circuit breakers shall be provided with closing and trip coils. The closing coil shall operate correctly at all values of voltage between 187V DC to 242V DC. The trip coil shall operate satisfactorily at all values of voltage between 154V DC to 242V DC. 7. Provision for mechanical closing of the breaker only in "Test" and "WITHDRAWN" positions shall be made. Alternately, the mechanical closing facility shall be normally made inaccessible; accessibility being rendered only after deliberate removal of shrouds. 8.18
Telescopic Trolley: 1no. Telescopic trolley or suitable arrangement shall be provided for maintenance of circuit‐breaker module in a cubicle. The trolley shall be such that the top most breaker module can be withdrawn on the trolley and can be lowered for maintenance purpose. The telescopic trolley shall be such that all type, size and rating of breaker can be withdrawn /inserted of particular switchgear. 9.00.00 9.01.00 MCCB: This specification includes manufacturing, design, testing and supply of 3‐pole/ 4‐pole, 50 Hz, AC, Thermal magnetic release type LT moulded case circuit breakers (MCCB) of drawout type of modules. 9.02.00 MCCB’s shall meet following technical requirements a)
The rated voltage of the circuit breakers shall be 415V. b) All MCCBs shall have Ics = Icu c)
MCCBs above 63A rating shall be provided with copper spreader terminals. d) MCCBs upto 100A rating shall have adjustable Thermal and fixed Magnetic protection settings. MCCBs above 100A rating shall have both adjustable Overload and adjustable short circuit setting. 10.00.00 10.01.00 APFC panels: Low tension detuned APFC panels shall be indoor mounted, contactor switched type with detuning harmonic filters. Power supply arrangement & Lighting works
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10.02.00 10.03.00 10.04.00 10.05.00 10.06.00 Capacitor duty contractors shall be used for switching. Capacitors shall be heavy duty type. Detuning series filter of 7% shall be connected. Capacitor shall be rated for 480V or more, because of detuning. Switchgear a) Incomer of 800kVAR panel shall be 1600A 3P ACB and Incomer of 250kVAR panel shall be 630A 3P MCCB. b) Steps outgoing: SDFs, contactors c) APFC Relays: Microprocessor based 11.00.00 TYPE TESTS 11.01.00 GENERAL (a.) All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owner’s approval the reports of all the type tests as listed in this specification and carried out within last ten (10) years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. (b.) In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost either at third party lab or in presence of client/ owners’s representative and submit the reports for approval. (c.) All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. (d.) The type test reports once approved for any projects shall be treated as reference. 11.02.00 L. T. SWITCHGEAR The following type test certificates on each type of L.T. Switchgear shall be submitted. (a.) Short time withstand test. (b.) Temperature rise test. Power supply arrangement & Lighting works
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(c.) Class II ‐ Protection co‐ordination test for any three ratings of panel as selected by employer. (d.) Test sequence –1 & combined test sequence on each rating of circuit breaker mounted inside the panel. (e.) Degree of protection tests 11.03.00 MCCB: The following type and routine tests shall be carried out on the circuit breaker in accordance with the IS 13947: Part 1 & 2: 1993 11.03.01 Type Tests Type tests shall include the following: a) Verification of temperature rise limits. b) Verification of dielectric properties. c) Verification of rated short‐circuit making and breaking capacities. d) Verification of the ability to carry rated short‐time with stand current. e) Verification of mechanical operation and of mechanical and electrical endurances. f) Verification of overload performance. g) Verification of operating limits and characteristics of over current opening releases. 11.03.02 Routine Tests Routine tests shall include the following: a) b) Calibration of releases and c) 12.00.00 INSPECTION 13.00.00 Detailed drawing showing the layout and arrangement (with internal view) of the panels/ DBs shall be prepared and submitted to NESCL for approval before commencement of manufacturing and supply. ACCESSORIES TO BE SUPPLIED BY BIDDER 1. Breaker/ Draw‐out MCC module lifting and handling trolley – 02no.s Mechanical Operation test Dielectric tests 2. Test cabinet with coupling cables for testing the breaker in drawout position Power supply arrangement & Lighting works
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– 1 no. 3. Racking in/ out handle for breakers 4. Racking in/ out handle for drawout MCC modules ‐ 4no.s ‐ 4 no.s ­­­*­­­*­­­­ Power supply arrangement & Lighting works
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1.00.00 1.01.00 1.02.00 1.03.00 1.04.00 1.05.00 1.06.00 1.07.00 1.08.00 1.09.00 1.10.00 2.00.00 GENERAL All power and control cables will be armoured. They shall be designed to withstand all mechanical, electrical and thermal stresses under steady state and transient operating conditions. The cables shall be suitable for laying in racks, ducts trenches, conduits and underground buried installation with uncontrolled back fill and chances of flooding by water. The Aluminium/copper wires used for manufacturing the cables shall be true circular in shape before stranding and shall be uniformly good quality, free from defects. All Aluminium used in the cables shall be of H2 grade. The fillers and inner sheath shall be of non‐hygroscopic, fire retardant material, softer than insulation and outer sheath shall be suitable for the operating temperature of the cable. Progressive sequential marking of the length of cable in metres at every one metre shall be provided on the outer sheath of all cables. For control cables only round wire armouring shall be used. All the cables shall pass fire resistance test as per IS:5831. The cables shall have outer sheath of a material with an oxygen index of not less than 29 and a temperature index of not less than 250 Deg. C. The normal current rating of all PVC insulated cables shall be as per IS:3961. All cables shall conform to type test and shall be subjected to routine and acceptance tests listed in the relevant IS. Repaired cables shall not be accepted. Allowable tolerance on the overall diameter of the cables shall be as per IS. L.T. POWER CABLES The PVC insulated 1100 V grade cables shall conform to IS:1554 (Part‐I)‐1976 and its amendments, read along with this specification and shall be suitable for a steady conductor temperature of 70°C. The conductor shall be stranded Aluminium. The insulation shall be extruded PVC to type‐A of IS:5831. A distinct inner sheath shall be provided in all multicore cables. For multicore armoured cables, the inner sheath shall be of extruded PVC. The outer sheath shall be extruded PVC to Type ST‐I of IS:5831 for all cables. Power supply arrangement & Lighting works
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3.00.00 3.01.00 3.02.00 4.00.00 4.01.00 4.02.00 4.03.00 4.04.00 5.00.00 5.01.00 L.T. CONTROL CABLES The 1100 V grade control cables shall conform to IS:1554 (Part‐I) 1976 and its amendments, read along with this specification. The conductor shall be stranded copper. The insulation shall be extruded PVC to type A of IS:5831. A distinct inner sheath of extruded PVC shall be provided in all cables. The outer sheath shall be of extruded PVC to type ST‐I of IS:5831 and shall be Grey in colour except where specifically advised by the Owner to be black. Cores shall be identified as per IS:1554 (Part‐I) for the cables upto five (5) cores & for cables with more than five (5) cores the identification of cores shall additionally be done by printing legible alphabets on all cores. The alphabets shall be white, and shall be printed at about 100 mm interval all along the cable length. Cables without such core identifications will not be accepted. CABLE DRUMS Cables shall be supplied in wooden or steel drums of heavy construction and drum shall be properly seasoned sound and free from defects. Wood preservative shall be applied to the entire drum. A layer of water proof paper shall be applied to the surface of the drums and over the outer most cable layer. A clear space of at least 40 mm shall be left between the cables and the logging. Each drum shall carry the manufacturer’s name, purchaser’s name and address, contract number, item number and type, size and length of the cable, net and gross weight stencilled on both sides of drum. A tag with same information shall also be attached to the leading end of the cable. An arrow and suitable wordings shall be marked on one end of the reel indicating the direction in which it should be rolled. Packing shall be sturdy and adequate to protect the cables, from any injury due to mishandling or other conditions encountered during transportation, handling and storage. Both cable ends shall be sealed with PVC/rubber caps so as to eliminate ingress of water during transportation and erection. TESTS All types and sizes of cables shall conform to type tests and shall be subjected to all routine and acceptance tests as per relevant IS /IEC. Make shall be NESCL Corporate Quality Assurance (CQA) approved Power supply arrangement & Lighting works
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DIESEL GENERATOR SET 1.0 CODE AND STANDARDS All standards, specification and code of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standard etc.) referred to herein, the former shall prevail. All work shall be carried out as per following standards codes. DIESEL ENGINE BS‐ 5514 and as per standard practice of Diesel engine manufacturer’s association of USA. Internal combustion engines IS ‐10000 (12 parts) Speed of diesel generator BS649 / 195B Alternator IS‐4722/ IEC‐60034,BS5000 Permissible limits of noise level of rotating machines IS 12065 Measure, evaluation and limit of IS 12075 vibration severity of rotating electrical machines shaft 65 mm dia or higher 1.1 Diesel fuels – specifications IS1460 Recommended practice for hot‐dip galvanizing of iron and steel IS 2629 Methods for testing uniformity of coating of zinc coated articles IS 2633 Code of practice for fire safety IS 3034 The installation work shall conform to Indian electricity act and Indian electricity rules as amended up to the date this specification is issued. The fuel oil installation shall meet all statutory requirement of Govt. Of India as amended up to the date of bid opening. Any approval required from statutory authorities shall be obtained by the bidder. Nothing in this specification shall be construed to relieve the contractor of this responsibility. Power supply arrangement & Lighting works
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1.2 2.0 Equipment complying with other internationally accepted standards such as ASA, IES, BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such case the bidder shall clearly indicate the standards (s) adopted and also furnish a copy in English of the latest revision of the standards along with copies of all official amendments in force as on date of opening of bid. Bidder shall clearly bring out the salient features for comparison. GENERAL TECHNICAL REQUIREMENTS a)
The equipments furnished under this specification have to operate under the meteorological conditions as mentioned in the project synopsis. b) The generating set shall be designed so that it is capable of reaching its full voltage and frequency and be ready to take full load within 30 seconds of remote starting impulse being received. c) The DG set shall be located in open. If required, the contractor shall have to take necessary approval of the installation from statutory authorities. The exhaust shall be discharged through a silencer and stack outside the enclosure at a sufficient height complying the state pollution control board requirements. (Refer: The Gazette of India, Part II, Section 3, Sub‐Section (i), No. 318, Ministry of Environment and Forests Notification, New Delhi, the 9th July, 2002). Necessary lightning protection shall be provided by the bidder for the stack. d) Critical speed of the machine shall not be less than 120% of the normal speed. All couplings shall be capable of withstanding the maximum generator sudden short circuit torque. e) The engine shall be supplied with all necessary silencer, exhaust & ventilation ducting, piping, valves and fittings for the fuel oil, lubricating oil, engine starting; air inlet and engine exhaust system, along with expansion joints, drain plugs, flanges and their support structure etc. f) Maintenance and erection tools and tackles for all the equipment shall be provided by the Contractor. Equipment's Description 3.0 3.1.1 Diesel Engine a) b) The diesel engine shall be of stationary type, four stroke with vertical in line or "V” type cylinder arrangement and turbo charged water cooled. Rating Power supply arrangement & Lighting works
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i. BHP rating of the engine shall be Prime Power as per ISO 8528‐1. The DG sets shall be able to deliver specified net electrical output while supplying power / driving all electrical and mechanical auxiliaries connected to alternator terminals and engine shaft. The DG sets shall also be suitable for 12 hours continuous running of which one hour at 10% overload at rated speed. ii. The successful bidder shall have to furnish supporting calculations to arrive at diesel engine rating for owner's approval. c) Rated speed The engine rated speed shall not exceed 1500 RPM. d) Lubrication e) Fuel system i. The engine shall have a closed cycle lubricating system with positive oil pressure and a crank chamber for collection / storage of the lubricating oil during oil circulation. No moving part shall require lubrication by hand or any other external sources either prior to starting of the engine or when it in operation. ii. A lubricating oil filter shall be provided for operation under normal conditions for period of a more than 250 hours without the necessity of its replacement or cleaning. iii. Necessary temperature and pressure gauges and other instruments shall be supplied and fitted on the lubrication system. iv. In case manufactures recommend lube oil pump for intermittent priming, one electric motor driven pump shall be provided along with a suitable rating starter in control panel. i. The engine shall be capable of running on diesel fuel oil as per IS1460. ii. The fuel consumption of the engine at full and three quarters of its rated power output shall be indicated by the Bidder. f) Air Intake System The diesel engine shall be provided with dry type air filters having low resistance to air passage, high dust retaining efficiency and provision for Power supply arrangement & Lighting works
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g)
easy cleaning. Filters shall be suitable for achieving satisfactory engine operation and life under tropical humid conditions, with sulphur‐dioxide and trioxide fumes, abrasive dust and coal particles of 5 to 100 microns present in the atmosphere. Dry type air filter 15 micron size with 90% efficiency or better. Cooling System Jacket water cooling system shall be offered in closed cycle and shall have heat exchanger located in front of the engine. The heat exchanger shall be provided with cooling tower complete with piping. Forced water circulation by means of pump driven by the engine shaft shall be employed. The heat exchanger tubes shall be of copper with sufficient heat transfer area. h) The Governor shall be of A 1 type as per B8‐5514 in order to take care of heavy duty motor starting. It shall have necessary characteristics to maintain the speed substantially constant even with sudden variation in load. However, a tripping shall be provided if speed exceed the maximum permissible limit. i) Turbo Charger It shall be of a robust construction, suitable of being driven by engine exhaust, having a common shaft for the turbine and blower. It shall draw air from filter of adequate capacity to suit the requirements of the engine. Engine Governor j) Quietness of Operation The engine shall be designed to achieve maximum quietness of operation. For this purpose, an efficient Industrial silencer shall be provided for the exhaust. Noise level of the set shall not exceed 105 dB at one meter distance. k) Engine vibration level shall not exceed 250 microns. I) Starting i. The starting of the engine shall be done by electrical self starting. The cranking device shall be designed in such a way that the engine starts automatically and reaches rated speed within 30 seconds of starting impulse being received. The fuel oil system and the lubricating oil shall also start operating simultaneously and automatically as soon as a Power supply arrangement & Lighting works
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starting impulse is received to obviate any chance of seizure of the piston and bearing as well as air locking in fuel supply system. ii. The source of energy shall be 24 voltage batteries which will be under Bidder scope of supply. iii. 2x100% air compressor to meet the entire compressed air requirements of DG set shall be provided with one electric motor driven and another with diesel engine driven with manual crank, pressure switches (two nos. for alarm and two nos. for start / stop) relief valve, piping, valves and accessories. iv. Starter Motor The starter motor shall conform to IS:4722. v. Battery & Charger a. The battery shall conform to the requirements of IS: 7372 b. A suitable battery charger using semiconductor rectifier shall be provided for recharging the battery fully with in fifteen hours. The charger shall be provided with a suitable DC Voltmeter and an Ammeter on the control panel and an automatic voltage stabilizer to enable it to work satisfactorily when connected to a single phase 240 V, AC supply with ±10% voltage variation. The battery charger shall have necessary filter to reduce the ripple factor less than 3 and drooping characteristic by means of choke and/or suitable input transformer impedance to automatically reduce the charging current as the battery gradually charges up to prevent over charging of the battery. vi. The battery shall be sized for three (3) cranking and the engine manufacturer's recommendation for the same shall be furnished. The charger shall also be protected by a suitable current device. vii. The battery and battery charger shall also feed control supply to DG control panel. m) Piping Valves and Fittings Each engine shall be supplied with all piping, valves, 990Litre fuel oil tank along with piping and fittings, lubricating oil, engine starting, air inlet and engine exhaust system, along with expansion joints, drain plugs, flanges etc. n) Ancillary Equipment The following equipment shall be supplied: Power supply arrangement & Lighting works
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i) ii) Flywheel 990Litre fuel tank complete with Fuel piping iii) Tachometer / RPM indicator iv) Lubricating oil cooler (where applicable) v) Exhaust silencer and piping vi) Fuel and lubricating oil filters, air filters. vii) Temperature gauges for water and lubricating oil and pressure gauges for lubricating oil viii) Hand barring gear. ix) Necessary foundation and base channels for the engine, alternator and for all other equipment included in this package. x) Base frames xi) Platforms and hand railing and access ladder (where applicable) xii) Starting equipment xiii) Protective equipment, preferably in the form of fuel cut‐off solenoid and suitable relays to protect the engine against low lubrication oil pressure. xiv) Drain taps in the cooling water system and the lubricating oil system. xv) Lifting attachment for lifting the complete set or the engine and alternator separately. xvi)
Bidder shall offer the engine cooling system (with heat exchanger or with radiator) as per the standard practice of the manufacturer. In case the manufacturer’s design envisages a heat exchanger, then cooling tower of adequate capacity along with necessary pumps and piping is included in Bidder’s scope. Bidder shall furnish all the relevant details along with the bid. xvii)
Any other ancillary equipment not specifically mentioned in the specification but are necessary for proper operation and maintenance of the set and safety of operating personnel. Power supply arrangement & Lighting works
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3.1.2 Alternator a) The alternator shall be of totally enclosed screen protected and self air cooled type conforming to the requirements of IS : 4722. b) The continuous rating of the alternator under the specified ambient condition shall at least equal the prime power output specified for the DG set plus the power requirements of all electrical auxiliaries connected to the alternator terminal including excitation (if it is taken from alternator terminals). The parameters for the alternator shall be as given below: c) i) Voltage : 415V ii) Frequency : 50 Hz iii) Power factor :0.8 lag. All insulated winding conductors of the alternator shall be of copper. The overall alternator winding insulation shall be of class 'F' epoxy thermosetting type but limited to class 'B' operation from temperature rise consideration. The winding shall be given power house treatment i.e. two coats of varnish in between) followed by final coat of resin. d) Exciter e) The alternator shall be synchronous self‐excited, self regulated, foot mounted with ball and roller bearing on end shields. The alternator shall conform to IS: 4722/BS‐2613 and will be suitable for tropical conditions. Automatic voltage regulator shall be provided to keep the terminals voltage with in ± 1 % of the set value. The setting range available on voltage regulator shall be ± 10%. The excitation system shall be complete with all necessary accessories. Neutral point The neutral of DG‐shall be connected but not earthed. f) Terminal Box and Connection The alternator output terminals shall be enclosed in a terminal box mounted in an accessible position on the alternator frame. As far as possible connections between the exciter and alternator shall be contained within the machine frame and connections carrying A.C and D.C shall be segregated from each other. The terminal box shall be of sufficient size to conveniently terminate the size and number of the cables. Suitable tinned copper pads shall be Power supply arrangement & Lighting works
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provided for power cable termination along with all necessary hardware and cable lugs. For single phase cables, gland plate shall be of non magnetic and shall be of removable type. The terminal box shall be of weather proof construction with a degree of protection IP54 as per IS :2147. 3.01.03 Diesel Generator Control Panel a) General i) ii) The control panel shall be of robust construction and suitable for indoor application. It should be floor mounting free standing type and made of 2.0mm thick cold rolled sheet steel. Neoprene gaskets shall be provided between all openings and joints. The control panel shall have IP‐52 degree of protection as per IS: 2147. The control panel shall be of unit type construction, compact and neat, provided with hinged door with locking arrangement. iii) All cables shall have bottom entry. Separate cable chamber shall be provided in the control panel for all incoming and outgoing cables. Enough space shall be provided in the control panel for easy access during maintenance and repairs. iv) A tinned copper bar of adequate dimension shall be provided for earth connection complete with nuts and bolts as required for external connection to earth. v) CT shorting links, test terminal blocks etc. shall be provided. All the equipment mounted inside the control panel shall be identified by lamicoid labels/ stenciling by paint. vi) Panel shall be provided with panel illumination lamp operated by the door switch and thermostat‐controlled space heater. Control panel shall be furnished complete with all accessories and wiring for safe and trouble free operation of the system. vii) PAINTING: All sheet work shall be pretreated, in tanks, in accordance to IS: 6005.Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline water and dried. Powder coated paint shade 631 as per IS: 5 shall be used as per IS: 13871. The Phosphate coating shall be “Class –C” as specified in IS: 13871. The phosphate surface shall be passivated and Power supply arrangement & Lighting works
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electrostatic Powder Painting shall be used. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peal able compound by spraying method to protect finished surfaces from scratching, grease, dirt and oily spots during testing, transportation, handling and erection. b) Control of Diesel Generator Sets Diesel generator is required to start up and come into operation automatically whenever a remote staring impulse is received in the event of failure of normal power supply. Diesel generator shall be capable of being stopped manually from remote as well as local. However, interlock shall be provided in the DG control panel to prevent shutting down operations as long as the circuit breaker at generator output is closed. Failure to Start. A three attempt starting facility either by using two impulse timers and a summation timer or by using microprocessor based controller for engine shall be provided and if the voltage fails to develop within 30seconds from receiving he first start impulse, the set shall lockout automatically and a visual alarm shall be given. c) Fuses All fuses shall be of HRC cartridge link type. Screw type fuses are not acceptable. Fuses shall be as per IS:9224. d) Relays A voltage relay shall be provided. The relay shall operate at about 90% of voltage. e) The control panel shall have the following provision for the control of diesel generator set: i) Starting and stopping of the set. ii) Fine adjustment of speed. iii)
Adjustment of output voltage. Power supply arrangement & Lighting works
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iv) v) speed and voltage control Local/ remote selector switch to facilitate remote starting and stopping of the generator set. vi) D.C Ammeter and D.C voltmeter for 24 V DC system and for diesel generator field circuit (if applicable) vii) Voltmeter and Ammeter for diesel generator output. viii) Frequency meter. ix) Motorised potentiometer for remote voltage control. Engine speed raise/lower motor on governor for speed control. x) Auto In/ Out selector switch. xi) The requirement of CT, VTs, relays, timers, auxiliary contacts shall be as per the system requirement but not limited to the enclosed control schemes. xii) The bidder shall supply any other control and indications, annunciations, alarm and trip contacts, fault indications, etc for Diesel Generator set though not specifically mentioned here but which the supplier may recommend and are required to make system complete for satisfactory operation of DG sets. xiii) Auto synchroniser. f) Indicating lamps Pilot indicating lamps shall be provided for the following. i)
Charger‐ ON/OFF ii)
Electrical protection Trip iii)
iv)
v)
vi)
Set shutdown due to 'engine over heating'. Set shut down due to 'low oil pressure'. Set shut down due to 'lack of fuel.' Set failed to start in 30 sec. after receiving the first start impulse. Power supply arrangement & Lighting works
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vii)
Over speed trip. viii)
High lube oil temperature ix)
220 V DC Supply healthy x)
Earth fault. xi)
AC Supply to Charger ‘ON’ xii)
Incomer to emergency switchgear from DG closed. xiii)
Indicating lamps shall be of the panel mounting filament type with series resistor and of low power consumption. Lamps shall be provided with series resistor built‐in lamp assembly. 4.00.00 TYPE TESTS 4.00.01 All equipment to be supplied shall be of type tested design. During detail engineering, the contractor shall submit for Owner's approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. 4.00.02 However if the contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in the case of type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract at no additional cost to the owner either at third party lab or in presence of client/owners representative and submit the reports for approval. 4.00.03 All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. 4.00.04 The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No design change”. Minor changes if any shall be highlighted on the endorsement sheet. 4.01.00 Type test reports for the following type tests shall be submitted: 4.01.01 Type test reports on Engine This shall be as per BS‐5514 Part‐1 : List A, B & C (Table 5,6 & 7). Power supply arrangement & Lighting works
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4.01.02 Type test reports on Alternator (a.) Measurement of resistance (b.) Phase sequence test (c.) Regulation test (d.) Measurement of open circuit and short circuit characteristics (e.) Efficiency test (f.) Temperature Rise Test (g.) Momentary overload test (h.) Over speed test (i.)
High Voltage test (j.)
Insulation resistance test (both before and after High Voltage Test) (k.) Noise level as per IS:12065 (l.)
Vibration as per IS: 12075. (m.) Determination of Deviation of voltage waveform from sinusoidal. (n.) Degree of protection test on control panel for IP‐52 (o.) Battery and battery charger as per relevant standards. 4.02.00 COMMISSIONING CHECKS In addition to the checks and test recommended by the manufacturers, the contractor shall supervise the following commissioning test to be carried out on each set at site. 4.02.01 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 Project Manager without exceeding the specified DG set rating. During the load test half hourly records of the following be taken: (a.) Ambient temperature. (b.)
Exhaust temp. if exhaust thermometer is fitted. (c.)
Cooling water temp. at a convenient point adjacent to the water output from the engine jacket. (d.)
Lubricating oil pressure. Power supply arrangement & Lighting works
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4.02.02 (e.)
Speed. (f.)
Voltage, wattage and current output. (g.)
Oil tank level. Insulation Resistance Test for Alternator Insulation resistance in mega‐ohms between the coils and the frame of the alternator when tested with a 500 V megger shall not be less than IR= 2x (rated voltage in KV) + 1. 4.02.03 Insulation Resistance of Wiring Insulation resistance of control panel wiring shall be checked with 500V megger. The IR shall not be less than one mega ohm. 4.02.04 FUNCTIONAL TESTS Functional tests on control panel. Functional tests on starting provision on the engine. Functional tests on all field devices. Functional tests on DG Set complete with AVR and speed governor. 4.02.05 MEASUREMENT OF VIBRATION The vibration shall be measured at load as close to maximum achievable load and shall not exceed 250 microns. Any modification/rectification required to bring down the vibration level with in allowable limits specified by the manufacturer shall be done by the contractor. 4.02.06 NOISE LEVEL (SOUND PRESSURE LEVEL) CHECK Noise level measurement shall be done generally following the guidelines given in IS:12065. The measurement shall be carried out with a calibrated integrating sound level meter as per IS:9779 5.00.00 INSTALLATION OF DG SETS 1. The installation, testing and commissioning of Diesel‐Generator sets shall be carried out by the Contractor strictly in accordance with the applicable Codes of practice, the manufacturer's instructions, drawings etc., and/or as directed by the Employer. 2. The Contractor shall install and commission the DG set, control panels, along with other accessories, starting equipment (Battery & battery Power supply arrangement & Lighting works
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charger/ compressed air system), fuel oil tank and fuel oil piping upto the DG sets. Minor civil works like fixing of anchor bolts, grouting etc. wherever required shall be done by the Contractor. 3. The Contractor shall provide all tools, equipments and instruments required for installations, testing and commissioning. 5.00.00 Quality Assurance checks An indicative list of tests / checks is mentioned at relevant QA table. However, manufacturer will furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. The cost of tests / checks in the quality plan shall be included in the price of the equipment. 6.00.00 GUARANTEED TECHNICAL PARTICULARS FOR DIESEL ENGINE & ALTERNATOR Bidder shall furnish the point wise confirmation/information against each point Sl.No. DESCRIPTION QUOTED DATA A. Diesel Engine 1. Rating : a) Continuous duty rating of the Diesel engine at site/NTP conditions in bhp/KW b) Maximum engine rating at site with 10% over load in KW. 2. Make of Engine and model no. 3. Cylinders : a) Number of Cylinders b) Cylinder length c) Cylinder diameter 4. Engine rpm 5. Aspiration 6. Cooling 7. Type of Starting 8. Type of fuel used 9. Specific fuel consumption ( Guaranteed) in At site At NTP KG/KWH condition a) At full load b) At 3/4th load c) At half load d) At 1/4the load 10. Lube oil consumption in Grams/Hour 11. Lube oil sump capacity in litres. variation + 12. Output at Site conditions after duration at Inlet Power supply arrangement & Lighting works
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temperature 450C. of Engine.( As per BS649 :1958 ). variation + 13. Governing characteristics : 14. Minimum acceptable lube oil temperature at start up. 15. Maximum period for which the engine can operate without raw cooling water supply. 16. Jacket water system : a) Make up tank capacity in liters. 17. Type of Governor 18. Overall dimensions ( LxBxH ), mm 19. Weight (kg) B. Alternator 1. Continues Rated Output of the generator/alternator in ‐ KW. 2. Continues current rating in AMP. 3. Site KW after deration 4. Generated Voltage 5. Number of phases 6. Standard 7. Class of Insulation for Alternator, Stator rotor. 8. AC Power factor 9. Rated speed (rpm) 10. Make of Alternator 11. Model No. 12. Efficiency a) At full load variation + b) At 3/4th load variation + c) At half load variation + d) At 1/4th load variation + 13. Type of Excitation a) Rated voltage b) Rated current c) Response ratio 14. Field current at rated output and voltage 15. Temperature rise above ambient (500C ) a) Stator b) Rotor c) Cores 16. AVR ‐ Type 17. Degree of protection 18. Full load losses variation + 19. Transient and sub‐transient reactance (per unit) a) x’ d variation + b) x” d variation + Power supply arrangement & Lighting works
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20. Short Circuit Ratio. 21. Overall dimensions (LxBxH), mm 22. Weight (kg) Power supply arrangement & Lighting works
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LT BUSDUCT
1.00. SCOPE This section covers Design, manufacture, inspection, transportation to site, installation, testing and commissioning of Low tension bus duct for interconnection between Distribution transformers and respective PCC panels (PCC‐1, PCC‐2, and PCC‐3). 2.00. GENERAL The layout of the bus ducts shall be in line with the drawings/site conditions and shall be got approved by Engineer‐in‐charge. All parts and accessories shall have appropriate match mark and part numbers for easy identification and installation at site. 3.00. STANDARDS The bus duct works shall conform to up‐to date amendments and relevant standards/code as applicable. 4.00. DESIGN Bus duct shall be Non‐segregated phase suitable for 415 volts, 3 Phase& Neutral, 50 Hz, AC supply and indoor, outdoor installation as per the requirement. Continuous current rating of bus duct shall be 4000A and the fault current rating shall be 70kA for 1 sec. 5.00. CONSTRUCTION 5.01 ENCLOSURE All the three phases shall be enclosed in a weather proof, dust tight enclosure, Outdoor section of the bus duct shall be completely rain proof. Weather resistant type circumferential gaskets shall be provided for making the joints with adjacent enclosures dust – proof and impervious to moisture suitable inspection opening with gaskets shall be provided for access to support insulator, lugs joints etc. Bus duct enclosure shall be made of 14 SWG. (2mm) CRCA sheet steel. The degree of enclosure protection shall be IP 52 for indoor application and IPW‐
55 with canopy for outdoor section of the bus duct. All ventilation openings shall be screened and drains shall be filtered to prevent entrance of dust and vermin. For continuous operation at specified ratings, temperature rise of the bus duct and auxiliary equipment shall be limited to the site permissible values stipulated in relevant standards and/or this specification. Bus duct and auxiliary equipment shall be capable of withstanding the mechanical forces and thermal stresses of the short‐circuit currents without any damage of deterioration of material. The L.T. bus ducts shall be self cooled and shall not be equipped with blower or any other type of forced ventilation. Power supply arrangement & Lighting works
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DETAILED SPECIFICATIONS 6.00. 6.01 BUSBARS 6.01.1 Material Bus bars shall be made up of high conductivity electrolytic quality aluminum as specified in BOQ with maximum temperature limited to 85 deg. C (i.e. 35 deg. C rise over 50 deg. C ambient). 6.01.2 Current density The Aluminum bus bars shall be of sufficient cross section. The design current density of 1Amp/Sq. mm for aluminum bus bars shall be maintained. However, the design shall be suitable for the fault level specified at Cl.No. 1.00.00 of this Section. 6.01.3 Neutral bar rating The rating of the neutral bar shall be minimum 100% of the phase bar. 6.01.4 Joints Adequate contact pressure shall be ensured by means of two bolt connection with plain & spring washers and locknuts. All bus joints shall be silver plated. Bimetallic connectors shall be provided for connections between dissimilar metals. The bus conductor shall be designed for bolted connections throughout the run. Joints for the bus bar shall be bolted but joints of construction with double cover fish plates and with adequate contact area. 6.01.5 Insulation & supports Bus bars and connections shall be fully insulated for working voltage with heat shrink colour coded PVC insulating sleeves. Bus insulators shall be flame‐retardant, non‐hygroscopic, track resistant type with high creepage surface materials like fiber glass reinforced thermosetting plastic/ epoxy/ FRP. The supports shall be made of single piece. They shall withstand without any damage or deformation the thermal and dynamic stresses due to short circuit currents. 6.01.6 Color coding Bus bars shall be colour coded for easy identification (Red, Yellow, Blue for three phases and Black colour for neutral for A.C 3 phase system). Heat shrinkable, colour coded PVC insulation sleeve shall be used for this purpose. Power supply arrangement & Lighting works
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6.01.7 Lay out sequence They are so positioned that the sequence of R‐Y‐B‐N bars shall be from left to right, top to bottom or front to rear, when viewed from the front of switchgear assembly. 6.01.8 Clearances & creepage distances As far as possible, large phase and ground clearances and creepage distances shall be provided on the bus bar system to minimize possibilities of fault. The clearance mentioned below shall be minimum and maintained even at the connection point. Phase to Phase – 35 mm Phase to Neutral – 28 mm Phase to Earth – 28 mm 6.02 HARD WARE Zinc passivated or any other superior quality standard size hard ware to be used for all joints/connections/terminations at switchgear & control gear, bus bars, ground bus , interconnections/wiring etc. 6.03 Convenience of maintenance The system shall be maintenance friendly. i.e. it should be possible to easily connect/ tighten/disconnect etc. 6.04 Inspection Covers Inspection covers shall be provided at suitable intervals as required. 6.05 Disconnect Link Removable bolted disconnect link shall be provided in the bus for the purpose of isolation. Disconnect link shall consist of a removable section of conductor and shall be so constructed as to permit easy removal or reinsertion without alignment difficulties. The bus on both sides of the link shall be rigidly supported so that the disconnect link is equal in mechanical strength to any other section of the bus. A minimum clearance of 300 mm (12”) shall be provided between the disconnected bus sections with the link removed. 6.06 Ventilation The bus duct shall be natural cooled. 6.07 Joints, Expansion/Flexible joints The bus bar shall be supported in such a way that the expansion/contraction does not have undue strain on the bus and at the terminals at both ends. Circumferential neoprene gaskets shall be provided for dust tight joints with Power supply arrangement & Lighting works
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adjacent enclosure section. The bus enclosure shall have extended bellows or equivalent means to allow for temperature changes and vibrations. Flexible joints shall be provided in enclosures at all points where the bus duct terminates at equipment to withstand vibration, expansion/contraction and at suitable intervals in any straight run of the bus duct where expansion and contraction would otherwise result in stresses in the supporting structures. Flexible connections shall be provided between bus sections to allow for expansion and contraction of the conductor. Flexible connection shall also be provided at all equipment terminations. All contact surfaces shall be silver plated to ensure an efficient and trouble free connection. 6.08 Other points Shipping length of the bus duct shall be not more than three (3) meters in length. Filtered drains for drainage of condensate shall be provided at the lowest points and at such locations where accumulation of condensate can be expected. 6.09 GROUND BUS Two numbers of Earth bars shall run along the full length of bus duct made up of size 50mm X 5 mm Aluminium, strip. This ground bus shall be fixed to the bus duct on the external side. It shall have provision to connect main earth/loop earth conductors with bolts, nuts, washers & spring washers. Metallic parts of the bus duct & associated structures etc. shall be bonded to the ground bus for effective earthing. One end of the earth bus shall be joined to the LT Panel side body earth lead and the other end shall be joined to the transformer body earth. 7.0 INSTALLATION All supporting structures required for hanging and/or supporting the complete bus duct shall be provided including related civil works. These include all types of supports, brackets, beams, channels, rods, clamps, hardware, etc to support with wall, roof, truss etc. Bus ducts running along the wall should be supported at intervals not exceeding 1.5m. In case of branching, there should be a support on all branches at a distance of 30 cms from the point of branching. Support should not be less than 40mm X 40mm X6mm MS angle secured in an approved manner. Supports may also be formed as brackets fixed to walls where runs are along with walls. Supports shall be grouted on the walls. In case of ceiling suspended bus ducts, supports made of 40mm X 40mm X6mm MS angle iron shall be provided. The horizontal interval between two such supports should not be more than 1200mm. However, additional supports to be given at the bends and termination points. These duct supports shall be Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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suspended from the C.I/MS. boxes or suitable approved suspension device provided in the ceiling by means of 12 mm diameter MS rods. Where fish plates are available, the same can be used for bus duct support works. Where there is no such provision, good quality anchor fasteners of size not less than 8mm shall be used in the ceiling. Seal‐off bushings complete with wall frame and support plates shall be provided where the bus duct penetrates the building wall. The seal is to prevent free exchange of air between two portions of the bus duct part of which is indoor while the other is outdoor. Silica‐gel breather shall be provided on both portions of the bus duct between the seal of bushings. CONNECTIONS & TERMINATIONS All matching flanges, seal‐off bushings, gaskets, fittings, hardware and supports required for termination of the bus duct at the switchgears, transformers and other equipment shall be provided. Flexible connections both for conductor and enclosure shall be provided. a) At all equipment termination to provide for misalignment up to 25 mm (1”) in all directions. b) Between bus duct supported from building steel to prevent transmission of vibration. The equipment terminal connections shall be readily accessible and shall provide sufficient air gap for safe isolation of equipment during testing. If the material of bus conductor and that of the equipment terminal connectors are different then suitable bi‐metallic connectors shall be furnished. 8.0 PAINTING All sheet work shall be pretreated, in tanks, in accordance to IS: 6005.Degreasing shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid. After pickling, the parts shall be washed in running water. Then these shall be rinsed in slightly alkaline water and dried. Powder coated paint shade 631 as per IS: 5 shall be used as per IS: 13871. The Phosphate coating shall be “Class –C” as specified in IS: 13871. The phosphate surface shall be passivated and electrostatic Powder Painting shall be used. The paint thickness shall not be less than 50 microns. Finished parts shall be coated by peal able compound by spraying method to protect finished surfaces from scratching, grease, dirt and oily spots during testing, transportation, handling and erection. 9.00 TESTS 9.01 Factory Test Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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LT BUSDUCT
The routine/acceptance tests shall be witnessed at the manufacturer’s works by NESCL representative. Test shall be carried out as per IS. 9.2 TYPE TESTS Bus duct shall be got manufactured by only reputed bus duct manufacturers having type tested as per IS by CPRI or other govt. testing laboratory on similar bus duct (s) with minimum 50KA short circuit current with stand capacity and the type test certificate shall be produced to the NESCL inspector at the time of factory test. 9.3 SITE TESTS In addition to the tests at manufacturer’s premises, all relevant pre‐
commissioning checks and tests shall be done at site before energizing the bus duct. The following tests are to be particularly done before cable jointing or connecting the bus duct. 1. Physical inspection for breakages/damages/orderliness. 2. Insulation resistance test with 500 V Megger. The insulation resistance shall not be less than 100 mega ohms. 3. Earth continuity test. All test results are to be recorded and reports should be submitted to the department. 10. COMMISSIONING After the satisfactory installation & testing, the Bus duct shall be commissioned. 11. Drawing, Data & Manuals:­ 11.1 To be submitted with the bid. a) Technical Particulars of each rating. b) General arrangement drawing – plan and section. 11.2 To be submitted after award of contract:‐ a) Dimensional general arrangement drawings with cross sections of bus duct layout including supporting arrangement. b) Calculation for short circuit forces justifying the proposed arrangement and temperature rise for bus and enclosure. c) Detailed material list with part number. d) Typical details of bus insulator assembly, rigid and flexible connections, grounding provision, termination arrangement at equipment end etc. e) Technical particulars of each rating. f) Type test report. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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CABLE LAYING
1.00. 33kV cable 33kV XLPE cable from APSPDCL metering point to 33kV switchgear room and upto the distribution transformers shall be layed buried under ground, generally as per IS: 1255. However, minimum 1.2 mtr. of depth shall be dug; a layer of minimum 75mm of sand bedding shall be provided at the bottom of trench, over which cables shall layed. Further a layer of min. 75mm of sand bedding shall be provided over the cables. This bedding shall be lined with bricks (of height of min. 150mm) on both sides of the cable. RCC slabs of 75mm width, with marking of “Power Cable” shall be placed over the bricks sand bedding; and then back filled with soil and the same shall be compacted. C.I. / MS Cable markers shall be provided enrooted with a spacing of not more than 20mtrs with marking “33kV Cable”. 2.00. LT cable For laying of LT power cable, the same laying procedure cited above, shall be generally followed. Instead of slabs, bricks may be used. The laying depth as per IS:1255. Cable marker shall be marked with “LT Power Cable”. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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1.00.00 CLAMPS & CONNECTORS 1.01.00 Clamps & connectors shall conform to IS: 5561. 1.02.00 Constructional Features 1.02.01 The clamps and connectors shall be made of materials listed below: a) For connecting equipment terminals Bimetallic connectors made of copper with aluminium alloy casting conforming to designation A6 of IS:617 with 2 mm thick Bimetallic liner and shall be tested as per IS:617. c) For connecting GS shield wire Galvanized mild steel d) Bolts, Nuts & plain washers Hot dip galvanized mild steel e) Spring washers for items ‘a’ to ‘c’ Electro‐galvanized mild steel suitable for at least service condition 4 as per IS: 1573. 1.02.02 All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be blurred and rounded off. 1.02.03 No current carrying part of a clamp or connector shall be less than 10 mm thick. They shall be designed and manufactured to have minimum contract resistance. 1.02.04 For Bimetallic clamps or connectors, copper alloy liner of minimum 2 mm thickness shall be provided. 1.02.05 Flexible connectors, braids or laminated strips made up of copper/aluminum for the terminal clamps for equipment, shall be suitable for both expansion or through (fixed/sliding) type connection of IPS Aluminum tube as required. In both the cases the clamp height (top of the mounting pad to center line of the tube) should be same. 1.02.06 Size of the terminal/conductor for which the clamp/connector is suitable shall be embossed/punched (i.e. indelibly marked) on each components of the clamp/connector, except on the hardware. 1.02.07 Clamp shall be designed to carry the same current as the conductor and the temperature rise shall be equal or less than that of the conductor at the specified ambient temperature. The rated current for which the clamp/connector is designed with respect to the specified reference ambient temperature, shall also be indelibly marked on each component of the clamp/connector, except on the hardware. 1.02.08 Clamps and connector shall be designed corona controlled. Power supply arrangement & Lighting works
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2.00.00 EARTHING CONDUCTORS 2.01.00 All conductors burred in earth and concrete shall be mild steel. All conductors above ground level and earthing leads shall be galvanized steel. The galvanizing shall conform with requirements stipulated in Sec. GTR of this specification. 2.02.00 Parameters 2.02.01 Main Earthing Conductor a) long ‐ G.I. pipe (in treated earth pit) (100 mm internal dia and 13 mm thickness 3 m Perforated pipe) b) Above ground ‐50x6 GS Flat 2.03.00 Earthing Leads a) Columns and other auxiliary structures 50x6 mm GS Flat b) Cable trenches 50x6 mm GS Flat 2.04.00 Earth wire Earth wire of suitable size shall be used & the material of the wire shall conform to IS 12776: 2002 Specification for Galvanized Strand for Earthing Buried in Earth ‐ Rod electrode (25 mm dia 3m long MS) 3.00.00 Cable Support Structures & Accessories 3.01.00 The Contractor shall fabricate and install mounting arrangements for the support and installation of all the cables on angles & trays in the trenches, as shown in the drawing enclosed with specification. 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 general constructional practice. 3.01.01 All nuts, bolts, washers etc. to be supplied by the Contractor shall be hot dip galvanized after fabrication. 3.01.02 The Contractor shall perform all tests and inspection to ensure that material and workmanship are according to the relevant standards. 3.01.03 The cable trench & trays shall be as per attached tender drawing 4.00.00 BUSHINGS, HOLLOW COLUMN INSULATORS, SUPPORT INSULATORS Power supply arrangement & Lighting works
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4.01.00 Bushings shall be manufactured and tested in accordance with IS:2099 & IEC:137 while hollow column insulators shall be manufactured and tested in accordance with IEC 233/IS 5284. The support insulators shall be manufactured and tested as per IS: 2544/IEC 168/IEC‐273. The insulators shall also conform to IEC 815 as applicable. 4.02.00 Support insulators/bushings/hollow column insulators shall be designed to have ample insulation, mechanical strength and rigidity for the conditions under which they will be used. 4.03.00 Porcelain used shall be homogenous, free from laminations, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. 4.04.00 Glazing of the porcelain shall be uniform brown in colour, free form blisters, burns and other similar defects. 4.05.00 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 when operating at normal rated voltage. 4.06.00 The design of the insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall be lead to deterioration. All ferrous parts shall be hot dip galvanized. 4.07.00 Contractor shall make available data on all the essential features of design including the method of assembly of shells and metal 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. 4.08.00 Post type insulators shall consist of a porcelain part permanently secured in metal base to be mounted on supporting structures. They shall be capable of being mounted upright. They shall be designed to withstand all shocks to which they may be subjected to during operation of the associated equipment. 4.09.00 Bushing porcelain shall be robust and capable of withstanding the internal pressures likely to occur in service. The design and location of clamps, the shape and the strength of the porcelain flange securing the bushing to the tank shall be such that there is no risk of fracture. All portions of the assembled porcelain enclosures and supports other than gaskets, which may in any way be exposed to the atmosphere shall be composed of completely non hygroscopic material such as metal or glazed porcelain. 4.10.00 All iron parts shall be hot dip galvanized and all joints shall be air tight. Surface of joints shall be trued, porcelain parts by grinding and metal parts by machining. Insulator/bushing design shall be such as to ensure a uniform compressive pressure on the joints. 4.11.00 Parameters of bushings/Hollow column insulators/support insulators: Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
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a) Rated Voltage 33 kV b) Impulse withstand voltage (Dry & Wet) kVp ± 170 c) Power frequency withstand voltage (dry and wet) kV (rms) 75 d) Total creepage distance 900 mm e) Pollution level (as per IEC 71) Class‐III, Heavy Insulator shall also meet requirement of IEC ‐ 815 as applicable, having alternate long & short sheds. 5.00.00 CONTROL CABINETS, JUNCTION BOXES, TERMINAL BOX MARSHALLING BOX / KIOSK 5.01.00 All types of boxes, kiosks and cabinets shall generally conform to IS: 5039/IS: 8623, IEC 439 as applicable and as given below. 5.02.00 The cabinets/boxes/kiosks shall be of sheet Steel/Aluminium and shall be dust, water and vermin proof. Sheet steel used shall be at least 2.0 mm thick cold rolled/ 2.5 mm thick hot rolled. The boxes shall be spray/powder coated with coating thickness of minimum 50 microns. The paint shade shall be as per IS: 5. 631 shade. The paint should pass adhesion test. The box shall be properly braced to prevent wobbling. There shall be sufficient reinforcement to provide level surfaces, resistance to vibrations and rigidity during transportation and installation. In case of Aluminium enclosed box, the thickness of Aluminium shall be such that it provides adequate rigidity and long life as comparable with sheet steel of specified thickness. 5.03.00 The enclosures of the cabinets/boxes/kiosks shall provide a degree of protection of not less than IP 55 as per IS: 13947. 5.04.00 The cabinets/boxes/kiosks shall be free standing floor mounting type or wall mounting type or pedestal mounting type as per requirements. 5.05.00 The cabinets/boxes/kiosks shall be provided with at least double hinged doors with padlocking arrangement. The distance between two hinges shall be adequate to ensure uniform sealing pressure against atmosphere. 5.06.00 All doors, removable covers and plates shall be gasketed all around with neoprene gaskets. The neoprene gasket shall be tested in the presence of Owner’s representative. All gasketted surfaces shall be smooth, straight and reinforced if necessary to minimize distortion and to make a tight seal. 5.07.00 All cabinets/boxes/kiosks shall be designed for the entry of cable from bottom by means of weather proof and dust‐proof connections. Boxes and cabinets shall be so designed with adequate clearances to avoid interference between the wiring entering from below and any terminal blocks or accessories mounted within the box or cabinet. Suitable cable gland plate on the base of the marshalling kiosk projecting at least 150mm above the base shall be provided for this purpose. Necessary number of Double Compression type cable glands of suitable sizes shall be supplied. This removable gasketted gland Power supply arrangement & Lighting works
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plate shall have provision for some glands if needs to be provided in the future. The glands shall project at least 25 mm above the gland plate to prevent the entry of moisture in the cable crutch. 5.10.00 A 240V, single phase, 50 Hz ac plug and socket of industrial grade shall be provided in the cabinet with On‐Off switch for connection of hand lamps. Plug and socket shall be of industrial grade. 5.11.00 For illumination of cabinets a lamp with socket and a door operated switch shall be provided. 5.12.00 All control switches shall be of rotary switch type and toggle/piano switches shall not be accepted. 5.13.00 Positive earthing of the cabinet shall be ensured by providing two separate earthing pads. The earth wire/flat shall be terminated on to the earthing pad and secured by the use of star or self etching washers. Earthing of hinged door shall be done by using a separate earth wire. 5.16.00 Terminal Block 5.16.01 All internal wiring to be connected to the external equipment shall terminate on terminal blocks, preferably vertically mounted on the side of cabinet, junction box, terminal box and marshalling box. 5.16.02 The terminal blocks shall be made of moulded, non‐inflammable thermosetting plastic. The material of terminal block moulding shall not deteriorate because of varied conditions of heat, cold humidity, dryness etc. that would be anticipated at the location where the equipment is proposed to be installed. 5.16.03 The terminal shall be such that maximum contact area is achieved when a cable is terminated. The terminal shall have a locking characteristic to prevent cable from escaping from the terminal clamp unless it is done intentionally. The terminal blocks shall be non‐disconnecting stud type equivalent to Elmex type CAT‐M4. 5.16.04 The conducting part in contact with cable shall be tinned or silver plated. 5.16.05 The terminal blocks shall be of extensible design. 5.16.06 The terminal blocks shall be of 1100 V grade and shall be rated to carry continuously the maximum current that is expected to be carried by the terminals. 5.16.07 The terminal blocks shall be fully enclosed with removable covers of transparent, non‐deterioration type plastic material. Insulating barriers shall be provided between the terminal blocks. These barriers shall not hinder the operator from carrying out the wiring without removing the barriers. 5.16.08 The terminals shall be provided with the marking tags for wiring identification. 5.16.09 The boxes shall be provided with 20% spare terminals unless otherwise specified. Unless otherwise specified, terminal blocks shall be suitable for connecting the following conductors on each side. Power supply arrangement & Lighting works
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a) All circuits except CT/VT Minimum of two 2.5 sq.mm. copper flexible b) All CT/VT circuits Minimum of 4 nos. of 2.5 sq.mm copper flexible c) AC/DC Power supply circuits One of 16 sq. mm. aluminium. 5.16.10 There shall be a minimum clearance of 250 mm between the first row of terminal block and the cable gland plate or side of the box. Also the clearance between two rows of terminal blocks shall be a minimum of 150 mm. 5.16.11 The arrangements shall be in such a manner so that it is possible to safely connect or disconnect terminals on live circuits and replace fuse links when the cabinet is live. Cabinet wiring should be suitable for 60 deg. C as the space heaters will keep the temperature 10 deg. C higher than the ambient. 5.16.12 For the Control and Relay Panels the terminal blocks for current transformer and voltage transformer secondary lead shall be provided with test links and isolating facilities. Also current transformer secondary leads shall be provided with short circuiting and earthing facilities. 5.17.00 Wiring 5.17.01 All wiring shall be carried out with 1100 V grade stranded copper wires. The minimum size of the stranded conductor used for internal wiring shall be as follows: a) All circuits except CT circuits 2.5 sq.mm. b) CT circuits 4 sq.mm. (minimum number of strands shall be 3 per conductor). 5.17.02 All internal wiring shall be securely supported, neatly arranged readily accessible and connected to equipment terminals and terminal blocks. 5.17.03 Wire terminations shall be made with solder less crimping type of tinned copper lugs which firmly grip the conductor and insulation. Insulated sleeves shall be provided at all the wire terminations. Engraved core identification plastic ferrules marked to correspond with the wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wires shall not fall off when the wires and shall not fall off when the wire is disconnected from terminal blocks. 5.17.04 All wires directly connected to trip circuit breaker shall be distinguished by the addition of a red coloured unlettered ferrule. Number 6 & 9 shall not be included for ferrules purposes. 5.17.05 All terminals including spare terminals of auxiliary equipment shall be wired upto terminal blocks. Each equipment shall have its own central control cabinet in which all contacts including spare contacts from all poles shall be wired out. Interpole cabling for all equipment’s shall be carried out by the Contractor. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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6.00.00 CABLE GLANDS AND LUGS 6.01.00 Cable glands shall be Double compression type, tinned/Nicked plated (coating thickness not less than 20 microns in case of tin and 10 to 15 microns in case of nickel) brass cable glands for all power and control cables. They shall provide dust and weather proof terminations. They shall comprise of heavy duty brass casting, machine finished and tinned to avoid corrosion and oxidation. Rubber components used in cable glands shall be neoprene and off tested quality. Required number of packing glands to close unused openings in gland plates shall also be provided. 6.02.00 Cables lugs shall be tinned copper solder less crimping type conforming to IS:8309 and 8394 suitable for aluminum or copper conductor (as applicable). The cable lugs shall suit the type of terminals provided. The cable lugs shall be of Dowell make or equivalent. 7.00.00 CONDUITS, PIPES AND ACCESSORIES 7.01.00 The Contractor shall supply and install all rigid conduits, mild steel pipes, flexible conduits, hume pipes, etc. including all necessary sundry materials, such as tees, elbows, check nuts, bushing reduces, enlargers, wooden plugs, coupling caps, nipples, gland sealing fittings, pull boxes, etc. 7.02.00 Rigid conduits shall be flow‐coat metal conduits. The outer surface of the conduits shall be coated with hot‐dip zinc and chromate conversion coatings. The inner surface shall have silicone epoxy ester coating for easy cable pulling. Mild steel pipes shall be hot‐dip galvanized. All rigid conduits/ pipes shall be of a reputed make. 7.03.00 Flexible conduits shall be heat‐resistant lead coated steel, water‐leak, fire and rust proof. Power supply arrangement & Lighting works
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BOLTS AND NUTS 1.00.00 SCOPE This specification covers manufacture, testing and supply of hot dip galvanized ISI Marked bolts and nuts with hexagonal heads & washers. 2.00.00 APPLICABLE STANDARDS Bolts & nuts of size M12‐M24 ‐ IS: 12427 & IS 14394 Bolts & nuts of size M10 & lower ‐ IS: 1363 Galvanization of bolts IS: 1367 (Part‐13) Bolts & Nuts below M12 shall also be HDG or in line with IS: 1367 (part‐13) Spring lock washers – IS: 3063 Electro galvanizing of spring washers: IS: 1573 Plain washers: IS: 2016 Technical supply conditions for threaded steel fasteners – IS: 1367(Part‐17) for inspection, sampling & acceptance procedure 3.00.00 GENERAL REQUIREMENTS 3.01.00 Bolts having length up to 10 times the diameter of the bolt shall be manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. 3.02.00 Bolts of size M12 to M24 shall conform to IS: 12427 & shall be 5.6 property class, grade C. 3.03.00 Bolts of size M10 & lower shall conform to IS: 1363 & shall be 5.6 property class, grade C. 3.04.00 Thread length of all the sizes bolts shall be as specified in IS 1363‐(Part‐1). Fully threaded bolts shall not be acceptable. 3.05.00 All the bolts & nuts shall be hot dip galvanized. 3.06.00 Flat washers and spring washers shall be provided wherever necessary and shall be of positive lock type. Spring washers shall be hot dip galvanized or electro‐galvanized. 3.07.00 The bolts and nuts shall be delivered in weight and the size corresponding to weight shall be as per the Table‐I 4.00.00 PRE­DESPATCH INSPECTION Power supply arrangement & Lighting works
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The bidder shall arrange to carryout acceptance tests in presence of owner’s inspecting officer in his own laboratory. In case testing facilities are not available at his works he will make necessary arrangements for carrying out these tests at a Govt. recognized lab at his own expense(s) and will provide all testing arrangement for Owner’s representative to witness the tests. 4.01.00 Acceptance Tests Sampling & tests shall be done as per IS ‐1367(Part‐17) for all sizes of both bolts & nuts. The following tests shall be carried out as acceptance test. 1. Dimensional particulars (Sampling in accordance with IS: 2614 for both bolts & nuts). 2. 3. 4. Tensile strength test on full size Proof load test on full size bolts Brinell or Rockwell or Vicker’s Hardness tests for bolts. 5. Shear test 6. Head soundness tests for bolts (no fracture). 7. Thickness & mass of zinc coating measurement for bolt, nut & washers 8. Uniformity of zinc coating bolt, nut & washers 5.00.00 MARKINGS On the bolt head, there shall be identification marking of the manufacturer as well as property class If possible property class shall also be marked on Nuts also. Further “ISI” mark shall be marked on Gunny Bags for proper identifications. Table‐I L D M5 M6 M8 M10 16 11160 6729 3144 1557
20 8361 6157 2923 1466
25 7575 5574 2673 1366
30 6784 4950 2415 1278
35 6218 4464 2202 1184
40 5675 4065 2024 1103
45 5219 3731 1872 1033
50 4854 3448 1742 970 Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
BOLT WITH NUTS ‐ NOS. PER 50 KGS. M12 M16 M20 M24 M27 M30 M33 M36 M39 M42 M45 M
1022
952 897 467 268 837 438 255 780 413 241 144 729 390 230 138 685 367 220 132 TECHNICAL SPECIFICATION
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55 60 65 70 75 80 90 100 110 120 130 140 150 160 170 180 190 200 220 240 26 280 300 320 340 360 380 400 3205 2995 2808 2645 2500 2369 1628 1529 1440 1362 1291 1228 1118 1026 915 866 822 782 746 713 655 606 563 526 495 467 442 420 400 381 364 349 322 299 279 261 246 646 611 580 552 526 500 458 423 393 367 344 324 306 290 276 263 251 240 221 204 190 178 167 158 149 142 135 128 347 328 312 297 284 274 252 233 217 203 190 179 170 161 153 146 139 133 123 114 106 99 93 88 83 79 75 72 210 199 189 180 172 165 151 140 131 122 115 108 103 99 94 90 86 82 76 70 65 61 57 54 51 48 46 44 127 122 118 113 109 105 97 91 80 72 68 65 60 55 51 47 44 42 39 37 35 34 32 31 87 84 82 79 76 71 67 60 54 51 49 45 42 39 36 34 32 30 28 27 26 25 23 58 55 51 46 42 40 38 35 33 30 28 27 25 24 23 21 20 20 19 46 43 40 37 33 32 30 28 26 24 23 22 20 19 18 17 17 16 15 32 29 27 26 25 23 21 26 24 22 21 20 19 17 Power supply arrangement & Lighting works
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EARTHING CONDUCTOR (GS FLAT) 1.00.00 SCOPE This specification covers manufacture, testing and supply of Galvanised Steel Flat for Earthing arrangements. 2.00.00 APPLICABLE STANDARDS Materials shall conform to the latest applicable Indian standards. In case bidders offer Steel Section and supports conforming to any other international specifications which shall be equivalent or better than IS, the same is also acceptable. S.No. Standard No. Title 1 IS: 2062 Grade ‘A’ Quality Specification for M.S. Angles, M.S. Channel and M.S. Flat 2 IS: 2062 Grade ‘A’ Chemical and Physical composition of material 3 IS: 1852 Rolling and Cutting Tolerances for Hot Rolled Steel products 3.00.00 RAW MATERIAL The Steel Sections shall be re‐rolled from the BILLETS/INGOTS of tested quality as per latest version of IS: 2830 or to any equivalent International Standard and shall be arranged by the bidder from their own sources. The Chemical composition and Physical properties of the finished materials shall be as per the relevant standards. Unless otherwise specified all the channels shall be ISLC as per Indian Standard. 4.00.00 TEST Steel Sections shall be tested in IS approved Laboratory or standard Laboratory of the Bidder country having all facilities available for conducting all the tests as prescribed in relevant IS to any equivalent International Standard or from any recognized and reputable International laboratory or Institutions. The Bidders are required to specifically indicate that; (i) They hold valid IS (or equivalent) License. (ii) Steel Sections offered are bearing requisite IS certification or equivalent marks. Power supply arrangement & Lighting works
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MISCELLANEOUS ITEMS
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The Bidders are required to submit a copy of the valid IS (or equivalent) License clearly indicating size and range of product against respective ISS or any equivalent International Standards along with their offer. 5.00.00 PHYSICAL & CHEMICAL PROPERTIES Length The GS Flat to be supplied shall be in 5.5 metres to 13 metres lengths. Weighment The weighment of GS Flat shall be witnessed by the consignee at the time of taking delivery. The weight recorded in the material receipt certificate issued by the consignees shall be final. 5.01.00 Chemical Composition and Physical Properties of M.S. Angles, M.S. Channels and M.S. Flat conforming to IS : 2062/84L composition Chemical Composition For Fe 410 WA Grade 1 C — 0.23% MAX. 2 Mn — 1.5% MAX. 3 S — 0.045% MAX. 4 P — 0.045% MAX. 5 SI — 0.40% MAX. 6 CE (Carbon Equivalent) — 0.42% MAX. 5.02.00 Mechanical Properties 1. 2. Tensile strength Kgf/mm2 – 42, N/Min, Yield stress Min. for thickness/diameter ‐ < 20 mm ‐ 20 – 40 mm ‐ 26 kgf/m2 OR 250 N/mm2 24 Kgf/mm2 OR 240 N/mm2 3. 4. > 40 mm Elongation % Bend Test (Internal Dia) ‐ ‐ ‐ 23 kgf/mm2 OR 230 N/mm2 23% Min‐3t (t – is the thickness of the material) 6.00.00 MARKING Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
410 CHAPTER-II
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It is desirable that the Bidder should put his identification marks on the finished materials. The mark shall be in “legible English letters” given with marking dies of minimum 18 mm size. 7.00.00 INSPECTION AND TEST CERTIFICATES The materials to be supplied will be subject to inspection and approval by the purchaser’s representative before dispatch and / or on arrival at the destination. Inspection before dispatch shall not, however, relieve the bidder of his responsibility to supply the Steel Sections strictly in accordance with the specification. (i) (ii) The purchaser’s representative shall be entitled at all reasonable time during manufacture to inspect, examine and test at the bidder’s premises the materials and workmanship of the Steel Sections to be supplied. (iii) As soon as the Steel Sections are ready for testing, the bidder shall intimate the purchaser well in advance, so that action may be taken for getting the material inspected. The materials shall not be dispatched unless waiver of inspection is obtained or inspected by the purchaser’s authorized representative. (iv) Test certificates shall be in accordance with latest version of the relevant Indian Standards or any equivalent International Standards. (v) The acceptance of any batch/lot shall in no way relieve the bidder of any of his responsibilities for meeting all the requirements of the specification and shall not prevent subsequent rejection of any item if the same is later found defective. All conductors burred in earth and concrete and above ground level shall be galvanized steel. Galvanised steel shall be subject to four one minute dips in copper sulphate solution as per IS: 2633 /1922. Method of galvanizing: S. No. Tests For GS Flat 1 Dip test 4 dips of 1 minute each 2 Mass of zinc coating 300 gram/Sq.m minimum Pre dispatch inspection shall be performed to witness following tests: 1. The bidder shall abide by all the statutory provisions, acts such as the Indian Electricity Act, Indian Factory Act, Indian Boiler Act etc., and corresponding rules and regulations as may be applicable and as amended from time to time. Freedom from defects, Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E12
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MISCELLANEOUS ITEMS
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2. Verification of dimensions 3. Galvanization tests 4. Mechanical tests 5. Chemical composition tests These tests are to be performed and certified at Govt. recognized laboratory. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
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SECTION-E12
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MISCELLANEOUS ITEMS
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CABLE GLANDS AND LUGS 1.00.00 SCOPE This specification covers manufacture, design and supply of Cable Glands and Lugs. 2.00.00 APPLICABLE STANDARDS Cable glands: BS 6121 Cable lugs shall conform to IS : 8309 and 8394 suitable for aluminium conductor. 3.00.00 GENERAL REQUIREMENTS 3.01.00 Cable glands and Lugs shall be Double compression type, tinned/Nickel plated (coating thickness not less than 20 microns in case of tin and 10 to 15 microns in case of nickel) brass cable glands for all power cables. They shall provide dust and weather proof terminations. They shall comprise of heavy duty brass casting, machine finished and tinned to avoid corrosion and oxidation. Rubber components used in cable glands shall be neoprene and of tested quality. Required number of packing glands to close unused openings in gland plates shall also be provided. 3.02.00 The cable glands shall be tested as per BS: 6121. The cable glands shall also be duly tested for dust proof and weather proof termination. Cables lugs shall be crimping type conforming to IS: 8309 and 8394 suitable for aluminum conductor. The cable lugs shall suit the type of terminals provided. The cable lugs shall be as per NESCL QA & I approved makes/sources. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E12
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MISCELLANEOUS ITEMS
CLAUSE NO
GALVANISED MILD STEEL CHANNEL, ANGLE AND FLAT 1.00.00 SCOPE This specification covers design, manufacture, testing and dispatch to Owner’s stores of Galvanized M.S. channel, angle and flat for use in structures & steel sections used in manufacture of AB switches, HG fuses, , stay clamps & other items for use in distribution system . 2.00.00 APPLICABLE STANDARDS Angles & Channels shall be rolled sections only with standard cross sections as specified in IS: 6, SP6 Part‐1 Materials shall conform to the latest applicable Indian standards. In case bidders offer Steel Section and supports conforming to any other international specifications which shall be equivalent or better than IS, the same is also acceptable. S.No. Standard No. 1 IS: 2062 Grade ‘A’ Quality Specification for M.S. Angles, M.S. Channel and M.S. Flat 2 IS: 2062 Chemical and Physical composition of material 3 IS: 1852 Rolled Rolling and Cutting Tolerances for Hot Steel products 3.00.00 GENERAL REQUIREMENTS 3.01.00 Raw Material The Steel Sections shall be re‐rolled from the billets/ingots of tested quality as per latest version of IS: 2830 or to any equivalent International Standard. 3.02.00 Length The GS Flat to be supplied shall be in 5.5 metres to 13 metres lengths. 3.03.00 Chemical Composition and Physical Properties of M.S. Angles, M.S. Channels, and M.S. Flat conforming to IS : Conforming to IS : 2062/84. Grade‐A Title Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
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CLAUSE NO
Chemical Composition Chemical Composition For Fe 410 WA Grade 1 C — 0.23% MAX. 2 Mn — 1.5% MAX. 3 S — 0.045% MAX. 4 P — 0.045% MAX. 5 SI — 0.40% MAX. 6 CE (Carbon Equivalent) — 0.42% MAX. 3.04.00 Mechanical Properties 1. Tensile strength Kgf/mm2 2. Yield stress Min. for thickness/diameter < 20 mm ‐ 26 kgf/m2 OR 250 N/mm2 20 – 40 mm ‐ 24 Kgf/mm2 OR 240 N/mm2 >40 mm ‐ 23 kgf/mm2 OR 230 N/mm2 3. Elongation % ‐ 23% 4. Bend Test (Internal Dia) ‐ Min‐3t (t–is the thickness of the material) 3.05.00 Tolerance Variation in ordered quantity for any destination and over‐all ordered quantity shall be only to the extent of ± 2%. Rolling and weight tolerances shall be as per latest version of IS: 1852 or to any equivalent International Standard. 4.00.00 Galvanization Zinc Zinc shall conform to grade Zn 99.9 specified in IS 209‐1966 & IS: 4826‐1979 with up to date amendments. Zinc Coating Zinc coating shall be in accordance with IS: 4826‐1979 (Col. 4.2.1) for heavily coated hard quality. Galvanizing Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
‐42 410 CHAPTER-II
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Galvanizing shall be as per IS 2629‐1966, IS: 4826‐1979 with up to date amendments. Uniformity of Zinc Coating Uniformity of Zinc coating shall be as per IS 2633‐1972 (Col. 4.2.1 to 4.2.3) with up to date amendments. 4.00.00 TEST Steel Sections shall be tested in IS approved/ NABL accredited Laboratory or at manufacturers own laboratory having all facilities available for conducting all the tests as prescribed in relevant IS. 5.00.00 MARKING Manufacturer shall put his identification marks on the finished materials. The mark shall be in “legible English letters” given with marking dies of minimum 18 mm size. 6.00.00 INSPECTION AND TEST CERTIFICATES The materials to be supplied will be subject to inspection and approval by the purchaser’s representative before dispatch and/or on arrival at the destination. Inspection before dispatch shall not, however, relieve the bidder of his responsibility to supply the Steel Sections strictly in accordance with the specification. 1. The purchaser’s representative shall be entitled at all reasonable time during manufacture to inspect, examine and test at the bidder’s premises the materials and workmanship of the Steel Sections to be supplied. 2. As soon as the Steel Sections are ready for testing, the bidder shall intimate the purchaser well in advance, so that action may be taken for getting the material inspected. The materials shall not be dispatched unless waiver of inspection is obtained or inspected by the purchaser’s authorized representative. 3. Test certificates shall be in accordance with latest version of the relevant Indian Standards or any equivalent International Standards. 4. The acceptance of any batch/lot shall in no way relieve the bidder of any of his responsibilities for meeting all the requirements of the specification and shall not prevent subsequent rejection of any item if the same is later found defective. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
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DANGER PLATE 1.00.00 SCOPE This Specification covers manufacture, testing and supply to the owner’s stores of Danger Notice Plates to be displayed in accordance with Rule No. 35 of Indian Electricity Rules, 1956. 2.00.00 APPLICABLE STANDARDS The danger Notice Plates shall comply with IS: 2551‐1982 3.00.00 DIMENSIONS 3.01.00 Size of Danger Notice shall be 250 x 200 mm 3.02.00 The corner of the plate shall be rounded off. 4.00.00 LETTERINGS All leterings shall certainly spaced. The dimension of the letters, figures and their respective position shall be as shown in Fig. 1 to 4 of IS 2551. The size of letters in the words in each languages and spacing earmarked for them. 5.00.00 LANGUAGES 5.01.00 Under Rule No. 35 of Indian Electricity Rules, 1956, the owner of every medium, high and extra high voltage installation is required to affix permanently in a conspicuous position a danger notice in Hindi or English and, in addition, in the local languages, with the sign of skull and bones. 5.02.00 The type and sizes of lettering to be done in Hindi is indicated in the specimen danger notice plates shown in Fig. 2 and 4 and those in English are shown in Figs. 1 and 3 of IS 2551 5.03.00 Adequate space has been provided in the specimen danger notice for having the letterings in local languages for the equivalent of ‘Danger’ : 415 “11000’ and ‘volts’. 6.00.00 MATERIAL AND FINISH The plates shall be made from mild steel sheet of at least 1.6 mm thick and vitreous enameled white, with letters, figures and the conventional skull and cross‐ bones in signal red colour (refer IS:5‐1978) on the front side. The rear side of the plate shall also be enamelled. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E12
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7.00.00 TESTS The following tests shall be carried out: i) ii) Dimensional check as per IS: 2551‐1982. iii) Test for weather proofness as per IS:8709‐1977 (or its latest version) 8.00.00 MARKING Maker’s name and trade mark and the purchaser’s name shall be marked in such a manner and position on the plates that it does not interfere with the other information. 9.00.00 PACKING The plates shall be packed in wooden crates suitable for rough handling and acceptable for rail / road transport. Visual examination as per IS: 2551‐1982. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER-II
SECTION-E12
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SITE TESTING AND COMMISSIONING
CLAUSE NO.
1.00.00 INTRODUCTION 1.01.00 An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the field QP/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. 2.00.00 GENERAL CHECKS a) Check for physical damage. b) Visual examination of zinc coating/plating. c) Check from name plate that all items are as per order/specification. d) Check tightness of all bolts, clamps and connecting terminals using toque wrenches. e) For oil filled equipment check for oil leakage, if any. Also check oil level and top up. f) Check ground connections for quality of weld and application of zinc rich paint over weld joint of galvanized surfaces. g) Check cleanliness of insulator and bushings. h) All checks and tests specified by the manufactures in their drawings and manuals as well as all tests specified in the relevant code of erection. i) Pressure test on all pneumatic lines at 1.5 times the rated pressure shall be conducted. 5.00.00 CURRENT TRANSFORMERS a) Insulation Resistance Test b) Polarity test. c) Ratio identification test‐checking of all ratios on all cores by primary injection of current. d) Dielectric test of oil (wherever applicable) e) Magnetizing characteristics test. 6.00.00 VOLTAGE TRANSFORMERS a) Insulation resistance test b) Polarity test c) Ratio test d) Dielectric test of oil (if applicable) Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E13
PAGE
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SITE TESTING AND COMMISSIONING
CLAUSE NO.
7.00.00 PHASING OUT The phasing out of all supplies in the Sub station system shall be carried out. 8.00.00 POWER CONNECTORS a) Physical check for finish b) Electrical clearance check c) Testing of torque by torque wrenches on all bus power connectors and other accessories. d) Milli volt drop test on all power connectors. e) Sag and tension check on conductors. 9.00.00 INSULATORS Visual examination for finish, damage, creepage distance etc. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E13
PAGE
2 OF 2
CLAUSE NO.
BUILDING & AREA LIGHTING
1.00.00
GENERAL 1.01.00
This specification covers the general description of design, manufacture and construction features, testing, supply, installation and commissioning of the Building Lighting and Area lighting equipment. 2.00.00
CODES AND STANDARDS 2.01.00
All standards and codes of practice referred to herein shall be the latest edition including all applicable official amendments & revisions as on date of bid opening. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards & codes. 2.02.00
Lighting Fixtures and Accessories IS:15111 CFL lamps IS:1913 General and safety requirements for luminaries. IS:2148 Flame proof enclosures of electrical apparatus. IS:418 Tungsten filament general service electric lamps. IS:1258 Bayonet lamp holders. IS:1534 Ballast for fluorescent lamps. IS:1569 Capacitors for use in tubular fluorescent, high pressure mercury vapour and low pressure sodium vapour discharge lamp circuit. IS:1777 Industrial luminaire with metal reflectors. IS:2149 Luminaire for Street lighting. IS:2215 Starters for fluorescent lamps. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
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2.03.00
BUILDING & AREA LIGHTING
IS:2418 Tubular fluorescent lamps for general lighting services. IS:3323 Bi‐pin lamp holders for tubular fluorescent lamps. IS:3324 Holders for starters for tubular fluorescent lamps. IS:3646 Code of practice for interior illumination. IS:4013 Dust‐tight electric lighting fittings. IS:6616 Ballasts for high pressure mercury vapour lamps. IS:8224 Electric Lighting fittings for Division 2 areas. IS:9900 High Pressure mercury vapour lamps. IS:9974 High Pressure Sodium vapour lamps. IS:10276 Edison screw lamp holders. IS:10322 Luminaires. IS:13021 AC Supplied Electronic Ballasts for tubular fluorescent lamps. Lighting Panels, Switch­boxes, Receptacles and Junction Boxes IS:13947 Degree of protection provided by enclosures for low‐voltage switchgear and control gear. IS:1293 Plugs & socket outlets of rated voltage upto and Including 250volts & rated current upto and including 16 Amps. IS:2551 Danger notice plates. IS:13947 Low voltage switchgear and controlgear IS:3854 Switches for domestic and similar purposes. Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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IS:6875 Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto and including 1000 V AC and 1200 V DC. IS:13703 Low voltage fuses for voltages not exceeding 1000V AC or 1500 V DC. 2.04.00
2.05.00
Conduits, Pipes and Accessories IS:2667 Fittings for rigid steel conduit for electrical wiring. IS:3837 Accessories for rigid steel conduits for electrical wiring. IS:9537 Conduits for electrical installations. Lighting Wires/Cables IS:694 PVC insulated cables for working voltages upto and including 1100 V IS:3961 Recommended current ratings for cables.(PVC Insulated and PVC sheathed heavy duty cables and light duty cables). 2.06.00
IS:8130 Conductors for insulated electric cables and flexible cords. IS:10810 Methods of tests for cables. Electrical Installation Practices & Miscellaneous IS:1944 Code of practice for lighting of public thorough fare IS:3646 Code of practice for interior illumination. IS:5572 Classification of Hazardous areas (other than Mines)having flammable gases and Vapours for electrical installation IS:6665 Code of practice for industrial lighting. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E14
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CLAUSE NO.
BUILDING & AREA LIGHTING
National Electrical Code Indian Electricity Rules. Indian Electricity Act IS:5 Colour for ready mixed paints & enamels. IS:280 Mild steel wires for general engineering purposes. IS:374 Electric ceiling type fans & regulators. IS:732 Code of practice for electrical wiring installations. IS:1255 Code of practice for installation and maintenance of power cables Upto and including 33KV rating. IS:2062 Steel for general structural purposes IS:2629 Recommended practice for hot‐dip galvanizing of iron and steel. IS:2633 Methods for testing uniformity of coating of zinc coated articles. IS:4736 Specification for Hot‐dip Zinc Coatings on Mild Steel Tubes IS:2713 Tubular steel poles for overhead power lines. IS:3043 Code of practice for earthing IS:5216 Guide for safety procedures and practices in electrical work. IS:5571 Guide for selection of electrical equipments for hazardous areas. IS:802 Code of practice for use of structural steel in overhead transmission line towers‐Fabrication Galvanising, inspection & packing. BS:6121 Mechanical cable glands Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
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CLAUSE NO.
3.00.00
BUILDING & AREA LIGHTING
LIGHTING SYSTEM DESCRIPTION The Lighting package covers the illumination of various indoor and outdoor areas in the project area. Lighting system of 415V, 3Phase, 4wire, will be fed from lighting panels (LPs) which in turn will be fed from the Main Lighting Panel (MLP). 4.00.00
EQUIPMENT DESCRIPTION 4.01.00
Lighting Fixture, Lamps & Accessories a) All lighting fixtures and accessories shall be designed for continuous operation for its life under atmospheric conditions existing at site. b) Lighting fixtures and accessories shall be suitable for operation on 240 V, AC, 50 Hz supply with supply voltage variation of +/‐10%, frequency variation of +/‐ 5% and combined voltage and frequency variation (absolute sum ) of 10% . c) Power factor of fluorescent lamp fixtures shall be not less than 0.90 for FH type fixture & 0.95 with electronic ballast for other florescent fixtures and that of High Pressure Sodium Vapour and Mercury Vapour (HPSV & HPMV) lamp fixtures shall not be less than 0.85. Suitable power factor improvement capacitors shall be provided for this purpose. Capacitors shall be hermetically sealed to prevent seepage of moisture. d) All lighting fixtures shall be complete with lamp(s), lamp holder (s), terminal blocks, clamps, locking arrangements, fixing brackets etc. Control gears shall be provided as applicable / specified. The fixtures shall be fully wired upto terminal block. The internal wiring of the fixtures shall be done with suitable thermo‐plastic or silicon rubber insulated copper conductor wires of suitable size and type. However, the normal cross section of conductor shall be not less than 0.5 Sq. mm and minimum thickness of insulation shall be 0.6 mm. The wiring shall be Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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capable of withstanding the maximum temperature to which it will be subjected under specified service conditions without deterioration and affecting the safety of the luminaire when installed and connected to the supply. All fixing /locking screws, washers, nuts, brackets, studs etc, shall be zinc plated and passivated. e) All fluorescent fixtures shall be provided with terminal blocks of ELMEX‐
EP/or Equivalent make inside the fixture for loop in loop out at Fixture. The terminal block shall be suitable for 4 sq. mm. wire termination. f) All lighting fixtures shall be provided with an external, brass/GI earthing terminal suitable for connecting 14 SWG, GI earthing wire. All metal or metal enclosed parts of the housing and accessories shall be bonded and connected to the earthing terminal as so to ensure satisfactory earthing continuity through out the fixture. g) The lighting 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. h) Generally all lighting fixtures (except for street light & post top lantern type fixture) shall be provided with 20 mm dia. Conduit knock‐out for connection to the incoming supply. i) Twin fluorescent lamp fixtures shall be wired in lead lag circuit to minimise stroboscopic effect. j) High bay fixtures shall be suitable for pendant mounting and provided with safety chain. Flood lights shall have suitable base plate/frame/mounting brackets for mounting on structural steel members. k) The reflectors shall be manufactured from CRCA sheet steel or aluminium as specified. The aluminium reflectors shall be made of high purity Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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aluminium sheet, polished electrochemically brightened and anodized or proven alternate arrangement of anodizing. l) Lamp holders for fluorescent tubes shall be of spring loaded, low contact resistance, bi‐pin rotor type, resistant to wear and suitable for holding in normal position under condition of shock and vibration. Live parts of the lamp holder shall not be exposed during insertion or removal of the lamp or after the lamp has been taken out. Lamp holders for incandescent, HPMV & HPSV lamps shall be of porcelain screwed type. m
Starters shall have bi‐metal electrodes and high mechanical strength. Starters shall be replaceable without disturbing the reflector or lamps and )
without use of any tool. Starter shall have brass contacts and radio interference suppressing capacitor. Lamps a) Incandescent, HPMV & HPSV lamps shall be provided with screwed type caps. b) The lamps shall be capable of withstanding small vibrations and the connections at lead‐in wires and filaments/electrodes shall not break under such circumstances. c) Incandescent (GLS) lamps shall be of ‘clear’ type unless otherwise specified. d) All fluorescent fixtures shall have ‘T5’ type fluorescent lamps except for ‘FH’ type. The louvers of these fixtures shall be designed for ‘T5’ type fluorescent lamps. All fluorescent lamps shall have ‘cool day light’ color designation. The mirror optics type fluorescent fixtures shall have no irridescence effect. The life of T5 fluorescent fixture shall be rated for 18,000 burning hours. e) High pressure mercury vapour (HPMV) lamps shall be of elliptical shape, colour corrected type with special fluorescent coating to increase lumen out put and improve colour rendition. Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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f) High pressure sodium vapour (HPSV) lamps shall be of elliptical shape and provided with external ignitor for rapid restart facility. However for street light & flood light fixture type SF1 & SF4, lamps shall be of tubular shape & provided with external ignitor for rapid restart facility. Halogen lamps shall be of tungsten filament, quartz glass type with ceramic base. 4.02.00
Ballasts a) All HPSV and HPMV lamp fixtures shall be provided with wire‐wound ballasts. All fluorescent/CFL fixtures except for Class‐I, Div‐II fittings/ increased safety fittings (Div‐II/Hazardous Area) type fixtures shall be provided with electronic ballasts. b) Wire‐wound Ballasts shall have annealed copper wire wound coil, electrical grade silicon sheet steel laminations and hermetically sealed with suitable insulating compound housed in sheet steel enclosure finished stove enameled grey outside. Class of insulation shall be suitable for temp. rise of winding. End connections and taps shall be brought out in a suitable terminal block rigidly fixed to the ballast enclosure. Ballast shall be suitable for use on nominal voltage of 240 V +/‐ 10%, 50 Hz supply. Ballast for HPSV and HPMV lamps shall be provided with tap settings of 220 & 240 V. Separate ballast shall be provided for each lamp in case of multi‐lamp fixtures. Ballasts shall be free from hum. c) Electronic ballasts shall be capable of satisfactory performance in adverse environment. Electronic ballasts shall consist of AC/DC Convertor, high frequency power oscillator and low pass filter. The ballast shall be suitable for use on nominal voltage of 240 V+ 10%, 50 Hz supply. The filter circuit shall suppress the feed back of high frequency signals to the mains. The electronic ballasts shall have the THD of 10% or less. d) Ignitors for HPSV lamps shall be of solid state electronic type e) Controlgear box compartment for HPSV & HPMV fixtures shall be complete with ballast, capacitor, electronic ignitor (for HPSV lamps only) etc. fully wired upto terminal block, housed in cast aluminium or CRCA Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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sheet steel enclosures as specified, finished powder coated grey shade RAL9002. The box shall be provided with hinged door and neoprene/synthetic rubber gasket to achieve IP‐54 degree of protection & shall have loop in loop out facility suitable for 20 mm conduit entry. 4.03.00
Make of Lighting fixtures shall be subject to Employer’s approval. 4.04.00
Neoprene/EPDM/synthetic rubber gasket shall be provided to achieve specified degree of protection. 4.05.00
Flood light fixtures shall be provided with graduated disc facilities for aiming angle of luminaries. 4.06.00 Brief descriptions of various types of lighting fixtures, alongwith type of installation, make & type and areas of application etc. are enclosed at Appendix ‐ A to this Section. 4.07.00 Fans & Regulator Ceiling Fans, to be provided in non air‐conditioned office/control room area, shall be suitable for operation on 240 V +/‐10%, 50 Hz, AC supply comprising of class ‘E’ insulated copper wound single phase motor, aerodynamically designed well balanced AL blades (3 Nos.), down rod, die cast aluminium housing, capacitor, suspension hook, canopies etc. finished in stove enameled white or with electro static powder coating. Power factor of fans shall not be less than 0.9. i. 4.08.00 Fan regulators shall be stepped electronic type suitable for operation on 240V +/‐10% AC supply. Cost of regulator shall be included in cost of ceiling fan. Lighting Panels (LPs) (a) Lighting panels shall be constructed out of 2 mm thick CRCA sheet steel. The door shall be hinged and the panel shall be gasketted to achieve specified degree of protection. The panel shall be provided with terminal blocks for incoming and outgoing circuits, earthing terminals, M.S. mounting brackets suitable for surface mounting on wall/column/structure, allenkeys with bolts as locking arrangements, circuit directory plate & circuit diagram fitted on the inside of the door etc. Removable gland plates shall be provided for Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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CLAUSE NO.
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entry of cables/conduits. Canopy shall be provided slope towards the rear side of the panel. (b) Wiring inside the panel shall be carried out with 1100 V grade. PVC insulated stranded copper wires of adequate size. On both ends of each wire engraved identification ferrules shall be provided. (c) All MCBs/Isolators/Switches/Contactors etc. shall be mounted inside the panel and a fibre glass sheet shall be provided inside the main door such that the operating knobs of MCBs etc., shall project out of it for safe operation against accidental contact. (d) Equipment mounted inside the panel shall be provided with individual labels with equipment designation/rating. Front of the panel shall be provided with label engraved with designation of the panel as furnished by the employer. Labels shall be made of 3 ply lamicoid/engraved PVC having white letters on black background (e) Terminal bocks shall be 1100 V grade, clip‐on stud type, made up of polymide 6.6 or better suitable for terminating multicore 35 or 70 Sq. mm. stranded aluminium conductor incoming cable and 10 Sq. mm. stranded aluminium conductor for each outgoing circuits voltage. All terminals shall be shrouded, numbered and provided with identification strip for the feeders. (f) MCB’s shall be current limiting type with magnetic and thermal release suitable for manual closing and automatic tripping under fault condition. MCB knob shall be marked with ON/OFF indication. A trip free release shall be provided to ensure tripping on fault even if the knob is held in ON position. MCB terminal shall be shrouded to avoid accidental contact. (g) Isolators of Lighting panels shall be of TPN, 63 A, continuous duty, load make‐break type suitable for 415 V, 3 phase 4 wire system. Isolator knob shall be marked with ON/OFF indication. Terminals shall be shrouded to avoid accidental contact. The isolator shall be suitable for withstanding let through energy of 125 A HRC fuse. (h) Fuses shall be of HRC plug in type complete with fuse fittings. Fuse fittings shall incorporate fully insulated shrouded contacts. Visible indication of operation of fuse shall be provided. (i) Synchronous timers shall be quartz controlled electronic type, complete with rechargeable nickel cadmium cell, 24 hours range day Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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dial, NO/NC contacts etc. and suitable for operation on 240V AC supply. (j) 4.09.00 The exterior side of panel, shall be powder coated with shade RAL9002 and the interior side of the panels shall also be with shade RAL9002. Switch Box Switch boxes shall be made of 1.6 mm thick, MS sheet with 3 mm. thick decorative, perspex cover. Switchbox shall be hot dip galvanized (a) Provided with earthing terminal, mounting holes and screws, specified number of conduit knockouts on both the top and the bottom sides etc. The switch boxes shall be suitable for surface/flush mounting. (b) Switches shall be decorative Piano Key Type single pole, quick make quick break, suitable for operation on 240 V AC supply. (c) Sockets shall be decorative and of 3 or 5pin type, suitable for 240 V AC supply. (d) Switch box shall be adequately sized to accommodate switch/fan regulators/sockets and terminal blocks. All switch box mounted items shall be fully wired upto terminal blocks located inside the box by 1100 V grade PVC insulated flexible copper wire. (e) Terminal blocks provided for all incoming and outgoing wires shall be of 1100V grade, made up of unbreakable polymide 6.6 or better, suitable for loop‐in loop‐out of 10 sq. mm. stranded aluminium wire and tap off of 1.5 sq.mm. copper wire. 4.10.00 Receptacles: a) Receptacle boxes shall be fabricated out of 2mm thick MS sheet hot dip gavanised or of not less than 2.5 mm thick die‐cast aluminium alloy or fabricated out of 2mm thick CRCA sheet with electro static powder coating. The boxes shall be provided with two nos. earthing terminals, and gasket to achieve degree of protection, terminal block for loop‐in loop‐out, of wire/cable of specified size, mounting brackets suitable for surface mounting on wall/column/structure, conduit entry/gland plate etc. Receptacles shall be with IP‐55 degree of Protection. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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(b) The ON/OFF switches shall be rotary type, heavy duty, double break, AC 23 category, suitable for AC supply. (c) Plug & socket shall be of shrouded die‐cast aluminium. Socket shall be provided with lid safety cover. (d) Robust mechanical interlock shall be provided for receptacles type RA such that the switch can be put ON only when the plug is fully engaged and plug can be withdrawn only when the switch is in OFF position. (e) Wiring inside the box shall be carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of adequate size (f) Terminal block shall be of 1100 V grade, clip on stud type, made up of unbreakable polymide 6.6 or better, suitable for terminating specified cable size. All the terminals shall be shrouded. 4.11.00 Junction boxes 4.11.01 Junction box (JB) shall be made of fire retardant material. Material of JB shall be Thermoplastic or thermosetting or FRP type. The box shall be provided with the terminal blocks, mounting bracket and screws etc. The cable entry shall be through galvanized steel conduits of 20mm diameter. The JB shall have suitable knockouts on four sides for conduits. The JB shall be suitable for surface mounting on ceiling/structures. The JB cover shall be either hinged or chain supported. The JB shall be of grey color RAL 7035. All the metal parts shall be corrosion protected. Terminal block shall be stud type suitable for loop‐in loop‐
out of up to 2 numbers of 10 sq.mm aluminium conductors and tap off of 1.5 sq. mm copper conductors. The JB shall have internal provision to maintain earth continuity of connected metal conduits and shall have provision for lighting fixture earthing. Junction box surface should be such that it is free from crazings, blisterings, wrinkling, colour blots/striations. Their should not be any mending or repair of surface. JB’s shall be provided with captive screws so that screws don’t fall off when cover is opened. JB’s mounting brackets should be of powder coated MS. Type test reports shall be furnished for the following Type tests. (a) Impact resistance for impact energy of 2 Joules (IK07) as per BS EN50102 (b) Thermal ageing at 70deg C for 96 hours as per IEC60068‐2‐2Bb. (c) Class of protection shall be IP 55. (d) HV test. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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CHAPTER- II
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4.11.02 Junction boxes for street lighting poles and lighting masts shall be made of 1.6 mm. thick CRCA sheet steel. The door shall be hinged and the box shall be gasketed to achieve IP: 55 degree of protection. The box shall be hot dip galvanised provided with HRC fuse units, terminal block for loop in loop out, earthing terminals, mounting brackets, allen keys with bolts as locking arrangement, cable gland plate at bottom etc. Wiring shall be carried out with 1100 V grade PVC insulated flexible copper wire of adequate size. Top of the box shall be arranged to slope towards rear side of the junction box. The junction box shall be of following type : 4.11.03 Fuses shall be HRC, plug in type, complete with bakelite fuse fittings. ON/OFF switch shall be TPN, rotary type, load break suit able for 415V AC system. 4.11.04 Terminal blocks shall be of 1100 V grade clip‐on, stud type made up of unbreakable polymide 6.6 or better with adequate current rating and size. The terminals shall be shrouded and numbered. 4.12.00 Pull­out Boxes Pull out boxes shall be provided at approximately 6 (six) metre interval in a conduit run .Boxes shall be suitable for mounting on Walls, Columns, Structures, etc. The bolts, nuts, screws, etc. required for the installation shall be included in the installation rates. Pull‐out boxes shall have cover with screw and shall be provided with good quality gasket lining. Pull out boxes used outdoor shall be weather proof type suitable for IP: 55 degree of protection and those used indoor shall be suitable for IP: 52 degree of protection. Pull out box & its cover shall be hot dip galvanised. Bidder shall include the cost of pull out boxes in the installation rates for conduits & accessories. 4.13.00 Lighting Wires Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed, stranded copper/aluminium wire for fixed wiring installation. colour of the PVC insulation of wires shall be Red, Yellow, Blue and Black for R,Y,B phases & neutral, respectively and white & grey for DC positive & DC negative circuits, respectively. 4.14.00 Lighting Poles The poles shall be of ERW tubes of specified lengths, stepped tubular or swaged tubular and joined together. Lighting poles shall be painted with two coats of red Oxide and Zinc chromate in Synthetic compound primer on the exposed outside Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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surface and with Bituminous paint all along the inside of the pole and outside portion which shall be embedded in foundation at manufacturing stage. Poles shall be smooth cylindrical and swan neck or straight as specified. Poles shall be complete with base plates & taper plugs, and necessary pipe reducer/fixing brackets for fixing the light fixture as per drawing enclosed. 4.15.00 Lighting Masts Lighting Mast shall be of continuously tapered polygonal cross section hot dip galvanised presenting a pleasing appearance. The Mast shall be with lantern carriage to enable raising/lowering for ease of maintenance, including the Head Frame, Double Drum Winch, continuous stainless steel wire rope, in built power tool, luminaires, suitable aviation warning light, lightning along with necessary power cables within the mast. The mast shall be delivered only in three/ four sections & shall be joined together by slip stressed fit method at site. No site welding or bolted joints shall be done on the mast. a) The Mast together with the fixtures shall be capable of withstanding the appropriate wind loads as per IS:875. The Mast shall be fabricated from special steel plates conforming to BS‐EN10‐025 and folded to form a polygonal section. b) Lantern Carriage shall be fabricated suitably and hot dip galvanised for fixing and holding flood light fixtures and their control gear boxes. Lantern carriage shall be provided with 16 nos. twin 400W HPSV flood light fixtures c) Carriage shall be provided with JB to facilitate interconnection to lighting fixtures. d) A suitable winch arrangement shall be provided to lower & raise the Lantern Carriage Assembly. Winch shall be of completely self sustaining type without the need for brake shoe, springs or clutches. The min. working load shall not be less than 750 kg. The winch drum shall be grooved to ensure perfect seat for stable and tidy rope lay with no chances for slippage. Winch shall be operated by an internally mounted three phase motor/power tool with necessary reduction gear mechanism. A handle for manual operation of winch shall also be provided. An adequate door opening shall be provided at the base of the Mast. e) Lighting mast shall be complete in all respect and shall be provided with feeder piller complete with power/control circuit alongwith 32A TPN MCB, contactors, timers, MCB’s, motor protections (O/L & single phase), start/stop PB with indication lamps. Feeder piller shall have provision of receiving 4Cx16 sq mm. cable. Feeder piller shall be made up of 1.6 mm Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
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CRCA sheet steel with IP 55 degree of protection & shall be powder coated. All necessary cables between feeder piller & JB & between JB & fixtures are also included in the scope of mast and same shall be of proven design f) A finial (heavy duty, hot dip galvanized) with a height of 1.2M shall be provided at the centre of the head frame for providing lighting protection. It shall be solidly bolted with the mast body to provide a conducting path. Earthing terminals shall be provided for earthing the mast. g) Lighting Mast shall also be provided with suitable aviation warning lights. 4.16.00 Painting I. All sheet steel work for lighting panels, lighting fixtures etc. shall be treated in tanks in accordance with IS 6005. Degreasing shall be done by alkaline cleaning. Rust and scale shall be removed by pickling with acid. After pickling, the parts shall be washed in running water and rinsed in slightly alkaline hot water and dried. After phosphating the surfaces shall be rinsed and passivated. Treatment as per IS:6005 shall be provided followed by powder painting with final shade of RAL9002 shall be done. II
All welds, bolt holders, conduit/cable entry holes etc. made during installation shall be wire brushed and touched up with metal primer of lead oxide and zinc chromate in synthetic medium 4.17.00 GALVANISING I. Galvanizing of switch boxes, junction boxes, conduits, other steel components and accessories shall conform to IS: 2629, IS:4736 and IS: 2633. Galvanizing shall be uniform, clean, smooth, continuous and free from acid spots. Should the galvanizing of the samples be found defective, the entire batch of steel shall have to be regalvanised at Contractor’s cost after pickling. I
5.00.00
The amount of zinc deposit over threaded portion of bolts, nuts, screws and washers shall be as per IS: 1367 (Part‐13). The removal of extra zinc on threaded portion of components shall be carefully done to ensure that the threads shall have the required zinc coating on them INSTALLATION Lighting Fixture Installation Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
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1. Bidder shall submit lighting layout. The type of mounting will generally be indicated on the layout drawings. The exact mounting will be decided at site depending upon the actual space/other facilities available at site. Lighting fixtures shall not be suspended directly from the junction box in the main conduit run. 2. Wooden plugs in walls and ceilings for fixing of lighting fixtures and accessories are not acceptable. A suitable fool‐proof method preferably using nylon rawl plug for fixing these shall be offered and this shall be subject to the Employer’s approval. 3. Lighting fixtures installed on/under platforms in boiler area/pedestals (such as TG pedestals) and other structures which are subject to vibrations shall be provided with suitable vibration dampers/rubber cushions to minimise the variations reaching the lighting fixtures. The arrangement shall be subject to Employer’s approval. 4. The bracket for mounting the lighting fixtures on boiler platforms shall be fabricated at site using 40 mm dia. conduit with a reducing socket to suit the fixture and clamped to the hand rails. However, the clamping of these conduits at points of large vibrations should be avoided. The fixing shall be strong enough to withstand vibration and wind velocity. If a roof over the platform is available, the fixture will be pendant mounted and supported to the structural members of the platform above 5. Flood lights shall be mounted on steel base of structures/walls /columns/masts/poles. Fixing slots shall be provided to turn the fixture by about 5 deg. on both sides. Bolts shall be tightened with spring washers. Terminal connection to the flood lights shall be made through flexible‐conduits 6. In the rooms where false ceiling is provided the lighting fixtures shall be supported separately by false ceiling grid or roof over false ceiling and not by the ceiling board. 7. The installation of lighting fixtures shall include the supply of all steel brackets, channels, angles, supporting, & anchoring material and hardware, steel brackets/hangers for bridging the gap above false ceiling and other accessories 8. To distinguish emergency AC fixtures from normal AC fixtures, red painted circular mark of 1cm. Dia. shall be provided on emergency Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
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fixtures 9. The self contained emergency lighting fixtures shall generally be installed in off site areas on walls/columns/structure as required at site. 10. Fan clamps shall be rigid enough and shall be made to suit the position suitable for reinforced concrete roofs or steel structures as required. Suspension rod shall be of adequate strength to withstand the dead and impact forces imposed on it. 11. Ballasts which, produce humming sound after commissioning at site shall be replaced at free of cost by the contractor 12. All steel installation accessories shall be brushed‐up and shall be painted with red lead primer followed by two coats of aluminium paint/enamel paint to the satisfaction of Project manager 13. The installation price of conduit wherever required for fixture mounting shall be payable separately. 5.01.00
Lighting Panel Installation Lighting panel shall be mounted at a height of 1200 mm from floor level unless otherwise specifically mentioned) on walls/columns/steel structures as indicated in the drawings by fastening to suitable studs. 5.02.00
Installation of Switch Boxes, Receptacles and Junction Boxes I. Switch boxes, Receptacles and Junction boxes shall be adequately supported/mounted on wall/column by means of anchor fasteners/expandable bolts or shall be mounted on angle/plate or other structural supports fixed to floor/wall/ceiling. II. In office areas and control rooms, switch boxes shall be flush mounted in wall and junction boxes shall be recess mounted. III. Mounting height of switch boxes and receptacles from floor level shall be as follows : Item (a) Mounting Height Light control switch box 1500 mm Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
Location CHAPTER- II
SECTION-E14
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(b) 20 A Receptacles 500 mm (c) 6/16 A Receptacles 500 mm Indoor location (d) 20 A Receptacles 900 mm Outdoor location IV. 5.03.00
Indoor location Necessary conduit /cable entry shall be made by drilling/punching during installation depending on the requirement. No gas cutting shall be used. Conduit Installation 1. In corrosive areas like Battery room etc. only epoxy coated GI conduit and accessories shall be installed for wiring purpose. 2. All accessories/fittings required for making the installation complete shall include tees, tees, elbows, check nuts, brass or galvanised steel end caps, pull boxes, saddles, spacers and required supporting steel work. 3. Exposed conduits shall run in straight lines parallel to building columns/beams and walls. Conduits shall be fixed by using metallic saddles/clamp secured to suitable nylon rawl plugs with screws or secured to the building steel at an interval of not more than 1 metre, but either side of couplers or bends or similar fittings. Saddles/clamps shall be fixed at a distance of 30 cm from the centre of such fittings. 4. In rooms with false ceiling, conduits shall be embedded in the wall. Embedded conduits shall be securely fixed in position to preclude any movement. For embedded conduits fixing of standard bends or elbows shall be avoided and all curves shall be made bending the conduits itself. Spacing of embedded conduit shall be such as to permit flow of mortar between them and in no case shall be less than 40 mm. Embedded conduits shall have a minimum mortar cover of 50 mm. Positioning and ensuring proper alignment during concreting by other agencies shall be the responsibility of the contractor. 5. All openings in the floor/wall/ceiling etc, made for conduit installation shall be sealed and made water proof. 6. Size of conduit shall be selected considering no. of wires drawn in line with IS : 732 and as indicated below. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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CHAPTER- II
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a) Size of the Wire Size of the Conduit (in mm) 20 25 40 Maximum Number of Wire b) 1.5 Sq.mm. c) 2.5 Sq.mm. d) 4 Sq.mm. e) 6 Sq.mm. f) 10 Sq.mm. 5 10 21 5 8 19 3 6 16 2 5 12 ‐ 4 8 7. For long conduit runs pull out boxes shall be provided at suitable intervals not exceeding 6 m to facilitate wiring. However pull out boxes need not to be provided wherever junction box exists in circuit. 8. Conduits shall be securely terminated at lighting panels, switch boxes, junction boxes/lighting fixtures by proper fastening with a lock nut on inside and outside. The number of conduits terminating at lighting panel shall not exceed the permissible number considering the glanding area of lighting panel. Conduit termination shall be made water and vermin proof. 9. Conduit lengths shall be jointed by screwed couplers. Running thread equal to twice the length of coupling shall be provided on any one length to facilitate easy dismantling. The contractor shall have at site die for threading conduit. All field threaded ends shall be reamed after threading and anti‐corrosive paint applied. Conduits shall be cleanly cut. The cut ends shall be within three (3) degree of square with a conduit axis. Cut ends shall be reamed and all burrs and sharp edges removed. Conduit joints and connections shall be made thoroughly water‐tight and rust‐proof by application of the thread compound which will not insulate the joints. 10. Conduits shall be kept, wherever possible, at least 300 mm away from hot pipes, heating device etc 11. The entire metallic conduit system whether embedded or exposed shall be electrically continuous and thoroughly grounded. G.I. Pull wire of adequate size shall be laid in all conduits before installation Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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CHAPTER- II
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5.04.00
BUILDING & AREA LIGHTING
12. All conduits installed outdoor shall be sloped towards pull boxes, hand holes/manholes for drainage. Low points of conduits not terminating in pull boxes, hand holes/manholes shall be provided with weep holes for drainage. Care shall be taken to see that no rough edge is left around the weep holes. Where no provision for drainage can be made, both ends of conduit shall be sealed after cable is laid through. Minimum slope of 1 in 400 shall be provided. 13. Each conduit run shall be marked with its designation as indicated on the drawings. Identifications shall be by means of painting so located that each run of conduit is readily identified at each end. Where conduits terminate at panels, switch boxes, junction boxes, or other enclosures, the designations shall also be painted on the inside of the enclosure adjacent to the conduits. Lighting Pole/Mast Installation 1. Installation of poles and masts shall include construction of required foundation. 2. For lighting Poles M 15 PCC foundation shall be made for planting depth of minimum 1/6TH of the pole height. 3. Junction box shall be fixed to the pole with ‘U’ clamps for wiring lighting terminating the cables. 25 mm dia holes shall be made on poles for wiring of lighting fixtures from junction box 4. Junction box type shall be fixed to the mast with clamps for terminating the cables. Junction box type ‘M1’ Shall be fixed on mast platform for fixtures. 5. Flood light fixtures shall be mounted on galvanised M.S base making use of shop drilled holes or by suitable clamps. No cutting or drilling of galvanised structure is permitted. For mounting flood light fixtures on poles, required supporting frame work shall be made. 6. For loop‐in loop out of the cables, 50 mm dia G.I. conduits with minimum 500 mm radius shall be laid along pole mast embedding in PCC foundation. Cost of supply and installation of 50 mm dia G.I. conduit is included the installation cost of pole. 7. G.S. Earthing bolt (Size M6) shall be welded to pole/mast for earthing pole/mast. Fixture and junction box shall be inter connected by earthing Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E14
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wire to pole/mast earthing bolt. Earth connection between pole/mast and earth electrode shall be made by 25x3 mm GS flat. Welding between GS flat and electrode shall be provided with protective coating 8. 2 C X 2.5 mm2 cable from street lighting pole JB to the lighting fixture shall be supplied by the employer. The same shall be laid and terminated by the Contractor. The cost of this work shall be included in the installation price of lighting pole/mast. 9. Lighting poles shall be painted with two coats of aluminum paint after completion of installation 5.05.00
Wiring Installation 5.05.01
Wiring installation of various areas between lighting panels, switch boxes, junction boxes, fixtures, fans, receptacles etc. shall be done in G.I. conduits. However, in fuel oil handing pump house, wiring installation shall be carried out with unarmoured cables to be routed inside the conduits 5.05.02
Lighting fixtures shall generally be group controlled directly from lighting panel. However, in office areas, control shall be provided through switch boxes. 5.05.03
A.C. normal, AC emergency and DC system wiring shall run throughout in separate conduits. Wires of different phase shall run in different conduits. However wires of same phase but of different circuit shall run in same conduit. 5.05.04
A junction box with two way terminal block of suitable size shall be provided near the fixture except the fluorescent fixtures and last fixture in a circuit for loop ‐in‐loop‐out and T‐off connection 5.05.05
All wires in a conduit shall be drawn simultaneously. No subsequent drawing is permissible. Call bell wiring in office area shall also be done by the Contractor 5.05.06
Wires shall not be pulled through more than two equivalent 90 degree bends in a single circuit run. Wherever required, suitable conduit junction boxes/pull boxes shall be provided. 5.05.07
Receptacles and lighting circuit shall be fed from different circuits. The switch controlling these circuits shall be on the phase wire of the circuits 5.05.08
Wiring shall be spliced only at junction boxes/terminal blocks. Maximum two wires shall be connected at each terminal. In vertical run of conduit the wires shall be suitably supported by means of wooden/hard rubber plugs at each pull/junction box. Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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5.05.09
For group controlled lighting fixtures, single phase receptacles and switch boxes, aluminium wire of 4/6/10 sq. mm. shall be used from lighting panel as circuit wiring, as applicable. However, T‐off connection to the lighting fixture shall be done by 1.5 sq.mm. copper. 5.05.10
The wiring between switch box and lighting fixtures and fans shall be done by 1.5 sq.mm. copper wire. 5.05.11
All lighting wires shall be crimped using solderless crimping type tinned copper lugs suitable for the specified type of terminal block. 5.06.00
Ceiling Fans and Regulators 1. The contractor shall install the ceiling fans and regulators at the locations shown in the relevant drawings. The exact locations will however, be decided at site in consultation with Project manager. 2. The fan regulator shall be mounted on the lighting control switch box provided in that area. 3. Hook along with rubber bush shall be supplied and grouted in ceiling for mounting the fan. All necessary, material and hardware for installation shall be supplied by the Contractor. 5.07.00
Foundation & Civil Works 1. Foundations, for Street lighting Poles/Flood Lighting Poles, lighting masts, panel foundation and other civil work including supply of cement, steel and other material as per relevant drawings and specification clauses shall be provided by the contractor. 2. All foundation drawings shall be subject to the Employer’s approval. However, it shall be the responsibility of the Contractor to check these foundations before commencement of installation to ensure their suitability. 3. All final adjustment of foundation levels, chipping and dressing of foundation surfaces, setting and grouting of anchor bolts, sills, inserts and fastening devices shall be carried out by the contractor including minor modification of civil work as may be required for installation . 4. Any cutting of masonary/concrete work, which is necessary, shall be done by the contractor at his own cost and shall be made good to match the original work. The contractor shall obtain approval of the Power supply arrangement & Lighting works
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TECHNICAL SPECIFICATION
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Project manager before proceeding with any cutting of masonary/concrete work. 5.08.00
5. The Contractor shall perform all excavation and backfilling as required for ground connections and casting foundations. 6. Excavation shall be performed upto the required depth. Such sheeting and shorting shall be done as may be necessary for protection of the wall. 7. The contractor shall make use of his own arrangement for pumping out any water that may be accumulated in the excavation. 8. All excavation shall be backfilled to the original level with good consolidation. Steel Fabrication 1. The steel structures supplied and fabricated by the contractor shall be made from standard quality steel sections/flats/plates. The steel structures fabricated shall be free from defects, cleaned of rust, grease, oil etc., and sharp edges shall be removed. 2. The welds shall be wire brushed or cleaned otherwise. The holes shall be touched up with metal primer. 3. All steel fabrications shall be painted with two coats of metals primer (lead oxide and zinc chromate in synthetic medium) followed by the two coats of aluminium paint . 6.00.00
EARTHING OF LIGHTING SYSTEM 6.01.00
Lighting panels, etc. shall be earthed by two separate and distinct connections with Employer's earthing system. Switch boxes, junction boxes, lighting fixtures, fans, single phase receptacles etc. shall be earthed by means of separate earth continuity conductor. The earth continuity conductor 14 SWG GI wire shall be run alongwith each conduit run. Cable armours shall be connected to earthing system at both the ends. Earthing conductors shall be free from pitting laminations, rust scale and other mechanical defects. The various sizes of earthing conductor for various electrical items shall be as follows : Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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SI. No. Item Earth size conductor Earth Electrode size a) Lighting panel 25 x 3 mm G.S. flat b) Lighting pole & masts 25 x 3 mm G.S. flat c) 14 SWG G.S. wire Lighting fixtures fans, switch boxes, junction boxes, single phase receptacles 20 mm dia MS rod ‐ 6.02.00
Connection between earth leads and equipment shall normally be bolted type. Contact surfaces shall be thoroughly cleaned before connections. Equipment bolted connections after being tested and checked shall be painted with anti‐
corrosive paint/compound. 6.03.00
Earthing conductors along their run on column, walls, etc. shall be supported by suitable welding / cleating at an interval of 1000 mm. 6.04.00
20 mm dia M.S. electrode of 3 meter long shall be embedded below permanent moisture level for earthing every mast and every lighting pole. 6.05.00
On completion of installation, continuity of earth conductors shall be checked. 7.00.00
QUALITY ASSURANCE PROGRAM 7.01.00
Bidder shall furnish detailed Quality Assurance Programme and Quality Plans for all materials and accessories to be supplied and installed under the scope of the specification as per General Technical Conditions, chapter ‐ 1 of part‐III of technical specification. The Quality Plans shall include all tests/checks as per relevant National/International Standards and the requirements of this specification including tests listed under clause 8.0.0 of this Section. 8.00.00
TESTS 8.01.00 All equipment to be supplied shall be of type tested design. During detail engineering, the contractor shall submit for Owner's approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
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CLAUSE NO.
BUILDING & AREA LIGHTING
the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. 8.02.00 However if the contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in the case of type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract at no additional cost to the owner either at third party lab or in presence of client/owners representative and submit the reports for approval. 8.03.00 All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. 8.04.00 The type test reports once approved for any projects shall be treated as reference. 8.05.00 Selection of samples for type test, acceptance test & routine test and acceptance criteria for all the items shall be as per relevant I.S 8.06.00 Type test reports of the following items as per relevant standards shall be submitted for approval. SL NO. DESCRIPTION i. Lighting fixtures of each type ii. Lamps of each type and rating.(life cycle and rating test only) iii. Lighting panel of each type (Degree of Protection) iv. Junction Box of each type (Degree of Protection) v. Receptacles of each rating (Degree of Protection) vi. MCB of each rating. 8.07.00 Acceptance Test and Routine Test 8.07.01 All lighting fixtures, lamps and other items shall be subjected to acceptance and routine test, as per relevant specified standards. 8.07.02 Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to physical and dimensional checks. 8.08.00 Galvanizing Tests Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E14
Page 25
of 27
CLAUSE NO.
BUILDING & AREA LIGHTING
8.08.01 The quality of galvanizing shall be smooth, continuous, free from flux stains and shall be inspected visually. 8.08.02 In addition following tests shall be conducted as acceptance tests. (a.) Uniformity of coating ‐ The coating of any article shall withstand four 1minute dips in standard copper sulphate solution without the formation of an adherent red spot of metallic copper upon the basic metal. (b.) The quality of cadmium/zinc plating on items with screw threads shall be free from visible defects such as unplated areas, blisters and modules and shall be inspected visually. (c.) In addition, the plating thickness shall be determined microscopically/ chemically or electronically. 9.00.00
COMMISSIONING CHECKS 1. On completion of installation work, the Contractor shall request the Project manager for inspection and test with minimum of fourteen (14) days advance notice. 2. The Project manager shall arrange for joint inspection of the installation for completeness and correctness of the work. Any defect pointed out during such inspection shall be promptly rectified by the Contractor. 3. The installation shall be then tested and commissioned in presence of the Project manager. 4. The contractor shall provide all, men material and equipment required to carry out the tests. 5. All rectifications, repair or adjustment work found necessary during inspection, testing and commissioning shall be carried out by the Contractor without any extra cost. The handing over the lighting installation shall be effected only after the receipt of written instruction from the Employer/his authorized representative. The testing shall be done in accordance with the applicable Indian Standards and codes of practices. The following tests shall be specifically carried out for all lighting installation. 6. (a) Insulation Resistance. (b) Testing of earth continuity path. (c) Polarity test of single phase switches. (d) Functional checks. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E14
Page 26
of 27
CLAUSE NO.
BUILDING & AREA LIGHTING
7. The lighting circuits shall be tested in the following manner : (a) All switches ON and consuming devices in circuit, both poles connected together to obtain resistance to earth. (b) .Insulation resistance between poles with lamps and other consuming devices removed and switches ON. Power supply arrangement & Lighting works
PACKAGE No.: NESCL/NBPPL/CS-MV-503
TECHNICAL SPECIFICATION
VOL-II
CHAPTER- II
SECTION-E14
Page 27
of 27
INDICATIVE MAKES
CLAUSE NO.
1.00.00
The following is the list of products and indicative makes. Bidder is free to
propose any other equivalent Make meeting Technical Requirements,
Specifications along with required details in support of the same. The same
would be analyzed and accepted if found suitable after discussion between
NESCL and bidder.
Bidders are required to offer reputed equipment / component which is strictly
meeting technical requirements, enclosed specifications along with NIT and
other relevant / latest applicable Standards & Rules.
Sl.No. Item
1 Ceiling/ exhaust fans
2 Lights/ High Mast lights
MCCB/ MCB:
3
VCB & ACB
4
5 Distribution transformer
Battery
&
battery
6 charger
7 Relays
Power Cables (33kV, LT)
& Jointing & termination
8 kits
Control Cables
9
FUSE DISCONNECTOR
SWITCH /
SWITCH FUSE UNITS
10
11 Digital LCD Meter
MAIN DG PANELS / APFC
PANEL/
/ C&R PANEL / RTCC /
MCCB
PANEL / DG AUXILIARY
PANEL
12
LT Bus duct
13
Diesel Engine
14
Alternator
15
Lighting & Electrification works
PACKAGE NO.: NESCL/NBPPL/CS-TT-502
Indicative Makes
Bajaj/ Havells/ CG
Philips / CGL / GE/ Bajaj/ Havells
L & T / SIEMENS / SCHNEIDER/ GE POWER
/ ABB / LEGRAND/ HAVELLS.
L & T / GE POWER / SIEMENS / ABB /
SCHNEIDER.
Kanohar/ VEL/ ABB
HBL NIFE/ EXIDE
L&T / AREVA / ABB / SIEMENS
Raychem/ CCI/ Torrent
CCI / Fort Gloster / Universal / Skytone
L & T / SIEMENS / SCHNEIDER / GE
POWER / ABB / C&S
ENERCON / NEPTUNE / AE / L&T
JAKSON ENGINEERS / L&T / SCHNEIDER /
GE POWER / ABB / C&S /SUDHIR GENSETS
/ SIEMENS
ADVANCE PANEL & SWITCHGEAR PVT.
LTD./ C&S / ADLEC.
Cummins/Caterpillar/Mitsubishi/Perkins.
Stamford/Cummins.
TECHNICAL SPECIFICATION
Chapter-IV
Section-1
Page 1
of 1
INDICATIVE MAKES
CLAUSE NO.
Acoustic Enclosure
Jakson Engineers/Sudhir Engineers
16
Lighting
Distribution
17 Board
Control wires
18
19 AMMETER, VOLTMETER
SELECTOR SWITCH,
PUSH BUTTON
SWITCH / EMERGENCY
SWITCH
20
AVM Pads
21
MS Pipes for
Exhaust/water/fuel
piping
22
Valves
23
HRC FUSES
Legrand/ Schneider
Finolex / national / havells/ Polycab
AE / MECO / UNIVERSAL / RISHAB / IMP
KAY CEE / CONTROL & SWITCH GEARS /
L&T / GE POWER CONTROL / SIEMENS
Dunlop/GERB/ Resistoflex
Jindal/Tata
Kirloskar
L & T / SIEMENS / GE POWER / ABB /C&S /
SCHNEIDER
24
LED INDICATION LAMPS
AE / C&S / EASUN / KAY CEE / SIEMENS/
L&T
CT’S
AE / KAPPA / UNIVERSAL / KAYCEE /IMP/
C&S / L&T / MECO.
SINGLE PHASING
PREVENTOR /
OVER LOAD
PROTECTION UNIT
L&T / GE POWER / SIEMENS / MINILEC /
ABB / SCHNEIDER
CHANGE OVER SWITCH
HH ELCON / C&S / INDO AISAN / HPL / C&S
CONTACTORS
L&T / GE POWER / BCH / SIEMENS / ABB
/ TC / C&S / SCHNEIDER
KWH, PF, FREQUENCY
METER
AE / HAVELLS / L&T /AREVA / SECURE /
GENUS
25
26
27
28
29
30
Lighting & Electrification works
PACKAGE NO.: NESCL/NBPPL/CS-TT-502
TECHNICAL SPECIFICATION
Chapter-IV
Section-1
Page 2
of 2
Annexure-1
List of Approved makes for C&R Panel items
Sl.No Equipment
1
LT AC Auxilliary Contactor
2
LT DC Contactors
3
LT AC/DC Control &
Selector Switch
Make
Location
L&T
GEPC
Telemechanique
Siemens
BCH
Andrew Yule
BCH
Kaycee
GEPC
L&T
Siemens
4
5
Annunciator
Relays
(Electromechanical/Static/N
umerical)
6
LT CT/PT
7
Control Transformer
8
MCB
Procon
IIC
Piri
Pecon
Minilec
Siemens
Mumbai
Pondicherry
Noida
Mumbai
Faridabad
Kolkatta
Faridabad
Mumbai
Hosur
Mumbai
Thane
Chennai
Mumbai
Ahmedabad
Pune
Mumbai
ABB
L&T
Alstom
Bangalore
Hosur
Chennai
Kappa
G&M
Ind Coil
Pragati
AE
Silkaans
Bangalore
Baroda
Mumbai
Thane
Mumbai
Mumbai
Southern Electric
G&M
Ind Coil
Pragati
AE
Logicstat
Chennai
Baroda
Mumbai
Thane
Mumbai
New Delhi
GEPC
Schneider
Standard
Hosur
Nashik
Jalandhar
Page 1 of 3
Remarks
Sl.No Equipment
9
Make
Location
Indo Kopp
Morarji Darmau
Smith (MDS)
Noida
Simco
Alstom
Secure
R C Energy
Capital
Havells /TTL
HPL Socomec
Trichy
Chennai
Udaipur
Delhi
Noida
Ghaziabad
Gurgaon
Siemens
Technik
BCH
RAAS Controls
Vaishno
Concord
Essen
Mumbai
Mumbai
Faridabad
Noida
Delhi
Faridabad
Chandigarh
GEPC
Siemens
L&T
Hosur
Aurangabad
Mumbai
Remarks
Mumbai
Energy Meters
10
Indicating Lamps
11
LT Fuse
12
Push Button
13
Terminal Block
14
Thermal Overload Relay
L&T(Esbee)
Siemens
Telemechanique &
Controls
Technik
Concord
BCH
Connectwell
Essen
Wago
Elmex
Tosha
Technoplast
Siemens
Telemechanique &
Controls
L&T
GEPC
Mumbai
Mumbai
Noida
Mumbai
Faridabad
Faridabad
Mumbai
Chandigarh
Noida
Baroda
Baroda
V.V.Nagar
Mumbai
Noida
Mumbai
Hosur
Page 2 of 3
(for 3-phase and 1-phase)
(for 3-phase and 1-phase)
(for 1-phase only)
(for 1-phase only)
(for 3-phase and 1-phase)
(for 3-phase and 1-phase)
Sl.No Equipment
15
Indicating Meters
16
Cable Glands
17
LT PVC Copper Wires
18
Aluminum Bus bar
Conductor
19
Make
Location
Meco
IMP
AE
Alstom
Rishab
Mumbai
Mumbai
Mumbai
Chennai
Nashik
Commet
Quality Precision
Arup Engg.
Sunil & Co.
Braco
Mumbai
Kolkata
Kolkata
Kolkata
Mumbai
BIS Approved
Makes
INDALCO
BALCO
(STERLITE)
HINDALCO
NALCO
Hindustan Copper
Copper Bus Bars Conductor
Ltd.
Indian Smelting
Sterling Copper
20
HR Sheet/CRCA Sheet
21
Lugs
SAIL
TISCO
Jindal
Essar
Bhushan Steel
Dowell
Mumbai
Page 3 of 3
Remarks
Annexure-1
List of Approved makes for bought out items for Power Transformer
Sl.No.
1
Item Description
Copper Wire Rod
Make
Hindalco Industries
Sterlite Industries
Birla Copper
Indo Gulf
Place/Location
Dahej
Bharuch/Silvassa
Bharuch
Bharuch
2
Paper Insulated Copper
Conductor
KSH International Pvt. Ltd.
Shakti Insulated Wires Ltd.
Amba Conductors
Shree Cables
Bhandari Powerlines Ltd
Delta Trans Conductor
Navi Mumbai
Ankaleshwar
Daman
Bhopal
Manipal
Navi Mumbai
3
CRGO Steel
(Lamination Supplier)
Nippon Steel
Kawasaki Steel
British Steel
ACCIAL ( Special Steel )
A K Steel
TKES
Nissoniwai
Mitshubishi Corp
Uzine Aciedo
Japan
Japan
Japan
Italy
USA
Germany
Japan
Japan
France
4
Tank Fabricators
Kanohar Electricals Ltd.
Jay Tank & Vessels Pvt. Ltd.
Satyam Industries
Gwalior Tanks and Vessels
Electro Mechanical
Mech & Fab
Meerut
Thane
Bhopal
Gwalior
Bhopal
Bhopal
5
Radiator
Kanohar Electricals Ltd.
Hi Tech Switchgears
PE Engrs
TTP
CTR
Meerut
Thane
Hyderabad
Bangalore
Pune
6
Insulating Oil
Savita Chemicals
Apar Industries
Raj Lubricants
Vijai Electricals
Power Oil Corporation
Mumbai
Trombay/Rabele
Chennai
Hyderabad
Silvassa
7
Porcelain Bushing
CJI Porcelain
WSI Chennai
Jayshree Insulators
A S Insulators
Luster Ceramics
Khurja
Chennai
Halol
Baroda
Vadodara
8
Epoxy Bushing
Baroda Bushings
Baroda Mould & Dyes
India Insulator
Baroda
Baroda
Miraj
9
Pressboard
Raman Boards
Weidmann
Senapathy Whirtely
Mitsubishi Paper Mills Ltd
Mysore/Mumbai
Switzerland
Bangalore
Japan
Format No: QS-01-QAI-P-1-F3-R0
1 OF 3
ENGG DIV / QA I
Sl.No.
10
Item Description
Permawood
Make
Techno (M/s VEL)
Place/Location
Hyderabad
Parmalli Wallace
Oriental Veneer
Western India Plywoods
Mysore Polymers
Bhopal
Thane
Kerala
Ramangaram
11
WTI / OTI / RTD
Perfect Controls
Precimeasure Controls Pvt. Ltd.
Pradeep Sales
Accurate Control
Pecon
Chennai
Chinnai/Bangalore
Mumbai
Chennai
Chennai
13
Bushing Current Transformer
Silkaans Electricals
Mahendra Electricals Works
Pragati Electricals
Indcoil
Prayog Electricals
Mumbai
Thane
Mumbai
Mumbai
Pune
14
Silica Gel Breather
Yogya Enterprises
Press & Forge
Instruments & Controls
Sorbead India
Jhansi
Mumbai
Baroda
Vadodara
15
Marshalling Box /
RTCC
Kanohar Electricals Ltd
Trans Electricals
Nitin Associates
Electro Geracle
Ashoka Electronic
Mega Switchgears
WIP
Enterprising Engineer
Indian Switchgears
Meerut
Jalgaon
Pune
Thane
Bhopal
Vadodara
Jhansi
Bhopal
Vadodara
16
Magnetic Oil Gauge
Sukrut Udyog
Atvus Industries
Press & Forge
Yogya Industries
Instruments & Controls
Pune
Calcutta
Mumbai
Jhansi
Baroda
17
Pressure Relief Valve
Sukrut Udyog
Atvus Industries
Qualitrol
Hyoda Gauge Mfg Co Ltd
Pune
Calcutta
USA
Japan
18
Gasket (SRBC)
Gujrat Cork
Nu Cork
Cortica Manufacturers
Bharat Corrub
Talbros Pvt. Ltd.
Rubber Product
Umergaon
Gurgaon
Chennai
Vadodara
Faridabad
Thane
19
Valves
(Radiator/Gun Metal/CI Valves)
Newman
Oswal Valves
Manixon Valves
Tyco
Sarvodaya Industries
Jalandhar
Mumabi
Agra
Halol
Meerut Cantt.
Audco
Chennai
Format No: QS-01-QAI-P-1-F3-R0
2 OF 3
ENGG DIV / QA I
Sl.No.
Item Description
Crane
Intervalve
Petson
Place/Location
Satara
Pune
Coimbatore
Smurfit Munksjo Paper AB
Weidmann
Amtofors
Sweden
Switzerland
Sweden
a LT AC Auxillary Contactor
L&T
Siemens
BCH
Telemechanique
Mumbai
Mumbai
Faridabad
Nodia
b LT AC Control & Selector
Switches
Kaycee
L&T
Siemens
Mumbai
Mumbai
Thane
c MCB
L&T
Schneider
Legrand
Indokopp
Gerrard
Mumbai
Nasik
Mumbai
Noida
Ahmedabad
d Indicating Lamps
Siemens
BCH
Technik
Mumbai
Faridabad
Mumbai
e LT Fuse
Siemens
L&T
Aurangabad
Mumbai
f Push Button
L&T
Siemens
BCH
Technik
Mumbai
Mumbai
Faridabad
Mumbai
g Terminal Block
Connect Well
Elmex
Tosha
Mumbai
Baroda
Baroda
h Thermal Overload Relays
L&T
Mumbai
Siemens
Telemechanique
Mumbai
Noida
20
Insulating Paper
21
Marshalling Box Components
I LT PVC Copper Wires
Make
BIS Approved Makes
22
Terminal Connector
Milind Engineering
Vinayak Industries
Nutan Engineers
PEE VEE Engrs
Klemmen Engg
Mumbai
Mumbai
Baroda
Bangalore
Chennai
23
Gas Operated Relay
(Bucholtz Relay)
Atwus Industries
Press and Forge
Instruments & Controls
Calcutta
Mumbai
Vadodara
Format No: QS-01-QAI-P-1-F3-R0
3 OF 3
ENGG DIV / QA I
Manufacturer
s Name &
Address
Sl.No
MANUFACTURING QUALITY PLAN
QP:No.
ITEM: Distribution
Rev No.
Transformers (3 Phase
Date:
& 1 Phase) +Station
Page
Trfmr
Component &
Charactersitics
Operation
Class
Type of
check
Project:
Package:
Contract:
Main Supplier:
Quantum of check
M
1
1.00
2
RAW MATERIAL
3
1.02
i) CRGO Coils
(M4 or better) a) Thickness and finish
b) Specific Losses
ii ) Amorphous c) Transit Damages
Metal (if
applicable)
a) Width
b) Specific losses
c) Stacking factor
d) Transit Damages
e) Chemical Analysis
4
Major
Major
5
M
7
8
C
9
PIA TPIA RQCC NQM
10
P
V
V
Measure
As per IS:
2500
/AQL 4.0
IS:3024:1997 QC Record
P
V
V
IS:3024:1997 Supplier TC V
Suppliers
Catalouge QC Record V
V
V
V
V
Measure
Major
6
IS:3024:1997 QC Record
Major
Major
C/N
Agency
Measure
Visual
Major
Acceptance Format of
Norm
Record
As per IS:
2500
/AQL 4.0 1sample/lot IS:3024:1997
Major
Major
Reference
Document
-
IS:3024:1997
As per IS:
2500
/AQL
IS:3024:1997
As
per4.0
IS:
2500
Suppliers
/AQL
4.0
1sample/lot
Catalouge
As per IS:
Test
2500
/AQL 4.0
-
Suppliers
Catalouge
Suppliers
Catalouge
QC Record
V
V
V
Test
As per IS:
2500
/AQL 4.0
-
Suppliers
Catalouge
Suppliers
Catalouge
QC Record
V
V
V
Visual
As per IS:
2500
/AQL 4.0
-
Suppliers
Catalouge
Suppliers
Catalouge
QC Record
V
V
V
Test
As per IS:
2500
/AQL 4.0
-
Plant Std
Plant Std
QC Record
V
V
V
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
1.03
Sl.No
2
Copper Wire
Rods
Major
Measure
b) Resistivity/
Conductivity
Major
Measure
c) Elongation
Major
Measure
d) Tensile Strength
Major
Measure
e) Chemical Analysis
Major
Measure
Class
Type of
check
4
5
Major
Visual
Component &
Operation
Charactersitics
1
1.04
3
a) Dimensions &
tolerences (Bare &
Insulated )
3
Kraft Paper
Transit Damages &
Packing Condition
a) Dimension
(Thickness)
b) Density & Substance
c) Tensile strength
4
5
Reference
Document
Acceptance Format of
Norm
Record
C/N
6
M
-
7
IS
12444/ASTM B
49
IS
12444/ASTM B
49
IS
12444/ASTM
B49
IS
12444/ASTM B
49
IS
12444/ASTM B
49
Quantum
of check
Reference
Document
1
sample/lo
t
1
sample/lo
t
1
sample/lo
t
1
sample/lo
t
1
sample/lo
t
-
-
-
-
M
6
As per IS:
2500
/AQL 4.0
C/N
Agency
7
8
IS
12444/ASTM
B 49
IS
12444/ASTM
B 49
IS
12444/ASTM
B 49
IS
12444/ASTM
B 49
IS
12444/ASTM
B 49
C
9
PIA TPIA RQCC NQM
10
QC
Record
P
V
V
QC
Record
V
V
V
QC
Record
V
V
V
QC
Record
V
V
V
QC
Record
V
V
V
Acceptance Format of
Norm
Record
8
9
Agency
M
C PIA TPIA RQCC NQM
10
IS 9335 Pt-I&II IS 9335 Pt-I&II
QC
Record
Major
As per IS:
2500
Measure /AQL 4.01 sample/lot IS 9335 Pt-I&II IS 9335 Pt-I&II
QC
Record
P
V
V
Major
As per IS:
2500
Measure /AQL 4.0
-
IS 9335 Pt-I&II IS 9335 Pt-I&II
QC
Record
V
V
V
Major
As per IS:
2500
/AQL 4.0
-
IS 9335 Pt-I&II IS 9335 Pt-I&II
QC
Record
V
V
V
Test
-
Remarks
11
Electrolytic
Grade
Copper
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
d) Elongation
f) Moisure content
j) Ash content
m) Dielectric Strength
1.05
Insulating Pressa)
Board
Dimension
4
Major
Major
Major
Major
Major
c) Density
Major
d) Tensile strength
Major
e) pH value/ conductivity
of Water extract
Major
f) Electrical strength
Major
g) Shrinkage in air
Major
5
Reference
Document
Acceptance Format of
Norm
Record
C/N
6
Agency
M
7
8
C
9
PIA TPIA RQCC NQM
10
Test
As per IS:
2500
/AQL 4.0
-
IS 9335 Pt-I&II IS 9335 Pt-I&II
QC
Record
V
V
V
Test
As per IS:
2500
/AQL 4.0
-
IS 9335 Pt-I&II IS 9335 Pt-I&II
QC
Record
V
V
V
Test
As per IS:
2500
/AQL 4.0
-
IS 9335 Pt-I&II IS 9335 Pt-I&II
QC
Record
V
V
V
QC
Record
V
V
V
QC
Record
P
V
V
QC
Record
V
V
V
QC
Record
V
V
V
QC
Record
V
V
V
QC
Record
V
V
V
QC
Record
V
V
V
As per IS:
2500
Test
/AQL 4.01 sample/lot IS 9335 Pt-I&II IS 9335 Pt-I&II
As per
relevant
Measure IS/Plant 1 sample/lot
IS:1576
IS:1576
As per
relevant
IS/Plant
Test
Std
IS:1576
IS:1576
As per
relevant
IS/Plant
Test
Std
IS:1576
IS:1576
As per
relevant
IS/Plant
Test
Std
IS:1576
IS:1576
As per
relevant
1
IS/Plant sample/lo
Test
Std
t
IS:1576
IS:1576
As per
relevant
IS/Plant
Test
Std
IS:1576
IS:1576
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
Sl.No
2
3
4
5
i) Ash content
Major
Test
j) Moisture content
Major
Test
Class
Type of
check
4
5
Component &
Operation
Charactersitics
Reference
Document
Acceptance Format of
Norm
Record
C/N
6
Agency
M
1.06
3
Perma Wood
a) Dimension
Major
Measure
b) Surface finish
Major
Visual
c) Electrical Strength
Major
Measure
d) Oil Absorption
Major
Measure
e) Moisture content
Major
Measure
PIA TPIA RQCC NQM
10
8
9
-
IS:1576
IS:1576
QC
Record
V
V
V
-
IS:1576
IS:1576
QC
Record
V
V
V
Quantum
of check
Reference
Document
As per
relevant
IS/Plant
Std
As per
relevant
IS/Plant
Std
Acceptance Format of
Norm
Record
Agency
M
1
C
7
6
7
As per
relevant
IS/Plant
Std
Plant Standard
As per
relevant
IS/Plant 1sample/l
Std
ot
Plant Standard
As per
relevant
IS/Plant
Std
Plant Standard
As per
relevant
IS/Plant 1sample/l
Std
ot
Plant Standard
As per
relevant
IS/Plant
Std
Plant Standard
C
PIA TPIA RQCC NQM
10
8
9
Plant
Standard
QC
Record
P
V
V
Plant
Standard
QC
Record
V
V
V
Plant
Standard
QC
Record
V
V
V
Plant
Standard
QC
Record
V
V
V
Plant
Standard
QC
Record
V
V
V
Remarks
11
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
4
5
6
Plant Standard
Plant
Standard
QC
Record
V
V
V
-
Plant Standard
Plant
Standard
QC
Record
V
V
V
-
Plant Standard
Plant
Standard
QC
Record
V
V
V
-
Plant Standard
Plant
Standard
QC
Record
V
V
V
-
Plant Standard
Plant
Standard
QC
Record
V
V
V
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Measure
h) Tensile Strength
Major
Measure
i) Density
Major
Measure
j) Specific Gravity
Major
Measure
Major
Measure Each Bobbin
As -per
Plant
Measure standard
Heqat Shock
Major
PIA TPIA RQCC NQM
10
-
As per
relevant
IS/Plant
Std
As per
relevant
IS/Plant
Std
As per
relevant
IS/Plant
Std
As per
relevant
IS/Plant
Std
As per
relevant
IS/Plant
Std
Major
Major
C
9
g) Cross breaking
strength
Flexibility & Adherence
Test
M
8
Measure
Major
Agency
7
Major
Elongation
Acceptance Format of
Norm
Record
C/N
f) Compression strength
Enamel
Covered
Conductor(Ro
und and
Dimensions
Reference
Document
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
Resistance Solvence
Cut-through test
BDV
Electrical resistance
Springiness
Resistance to abrasion
Contuinity of instution
4
Major
Major
Major
Major
Major
Major
5
Reference
Document
Acceptance Format of
Norm
Record
C/N
6
Agency
M
7
8
9
C
PIA TPIA RQCC NQM
10
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Measure
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
Temparature index
Resistance to
Refrigators
Solderability
Heat of solvent bording
4
Major
Major
Major
Major
Resistance to Temper oil Major
Loss of mass
Dielectric dissipatin
factor
1.07
Gasket( Nitrile
Rubber)
a) Dimension
Major
5
Reference
Document
Acceptance Format of
Norm
Record
C/N
6
Agency
M
7
8
9
C
PIA TPIA RQCC NQM
10
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
Test
As -per
Plant
standard
Sampling
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
-
IS: 13730 Pt.
16 & 34
IS: 13730 Pt.
16 & 34
QC
Record
V
V
V
-
IS 4253 Pt-II1980
IS 4253 Pt-II1980
QC
Record
P
V
V
As -per
Plant
standard
Major Test/MeasureSampling
As per IS:
2500
/AQL
Major Measure
4.12
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
Sl.No
2
3
4
5
b) Hardness
Major
Measure
c) Tensile strength
Major
Test
d) Compressibility
Major
Test
e) Recovery %
Major
Test
f) Compression Set
Major
Test
g) Flexibility
Major
Test
h) Chloride / Sulphate
content of water extract
Major
Test
Class
Type of
check
Component &
Operation
Charactersitics
1.08
3
Insulating Oil
4
5
a) Appreance of oil
Major
Visual
b) Density at 27Deg C
Major
Measure
Acceptance Format of
Norm
Record
C/N
6
As per IS:
2500 1sample/l
/AQL
ot
As per IS:
2500
/AQL
As per IS:
2500 1sample/l
/AQL
ot
As per IS:
2500
/AQL
As per IS:
2500
/AQL
As per IS:
2500
/AQL
As per IS:
2500
/AQL
4.19
-
Quantum
of check
M
1
Reference
Document
M
Sample
Sample
from
from each each
tanker
tanker
Sample
Sample
from
from each each
tanker
tanker
C
PIA TPIA RQCC NQM
10
7
8
9
IS 4253 Pt-II1980
IS 4253 Pt-II1980
QC
Record
V
V
V
IS 4253 Pt-II1980
IS 4253 Pt-II1980
QC
Record
V
V
V
IS 4253 Pt-II1980
IS 4253 Pt-II1980
QC
Record
V
V
V
IS 4253 Pt-II1980
IS 4253 Pt-II1980
QC
Record
V
V
V
IS 4253 Pt-II1980
IS 4253 Pt-II1980
QC
Record
V
V
V
IS 4253 Pt-II1980
IS 4253 Pt-II1980
QC
Record
V
V
V
IS 4253 Pt-II1980
IS 4253 Pt-II1980
QC
Record
V
V
V
Reference
Document
Acceptance Format of
Norm
Record
C/N
6
Agency
7
8
C
11
For Single
Phase
Transforme
rs-Plant
Standard is
applicable
& For Three
Phase
Transforme
rs-IS 4253
Part-II is
applicable
Agency
M
Remarks
Remarks
PIA TPIA RQCC NQM
9
10
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
Oil samples
taken from
the
Transforme
r at site
shall
confirm to
the
requirement
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
c) Kinematic viscosity
d) Interfacial Tension at
27 Deg C
e) Flash and Pour point
f) Electrical strength
(BDV)
g) Tandelta at 900 c
4
Major
Major
Major
Major
Major
h) Corrosive Sulpher test
(Copper strip 19 hrs @
140Deg C)
Major
i) Oxidation StabilityNeutralisation value of
Oxidation & total sludge Major
5
6
Measure
Measure
Sample
from each
tanker
Measure
Sample
from each
tanker
Measure
Sample
from each
tanker
Measure
Sample
from each
tanker
Measure
j) Resistivity at 27 & 90
Deg C
Major
Measure
k) Water content
Major
Measure
Acceptance Format of
Norm
Record
C/N
Sample
from each
tanker
Measure
Reference
Document
M
7
Sample
from
each
tanker
Sample
from
each
tanker
Sample
from
each
tanker
Sample
from
each
tanker
Sample
from
each
tanker
1 Sample
1 Sample
from
from each each
batch
batch
1 Sample 1 Sample
from each
from
batch
each
Sample
Sample
from
from each each
tanker
tanker
Sample
Sample
from
from each each
tanker
tanker
Agency
8
C
9
PIA TPIA RQCC NQM
10
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
Remarks
11
requirement
of IS:1866.
one sample
per batch
can be
accepted in
case
transformer
manufactur
es is
manufactur
er(processo
r) of
transformer
oil for
quantum of
check
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
Fitting and
Accessories
2.01
Porcelain
Insulators
Major
Measure
m) Accelerated Ageing
test
Major
Measure
a)Dimension
b) Visual Checks
c) Routine testing
2.02
2.03
5
l) Presence of oxidation
inhibitor
n) S.K Value
o) Neutralisation valueTotal Acidity & Inorganic
Acidity (alkalinity)
2.00
4
Dimensions & Routine
Surge Arrestors(LA's) Checks
MS Material
(Plates,Chann
el)
a)Finish Appearance
Reference
Document
Acceptance Format of
Norm
Record
C/N
6
Sample
from each
tanker
1 Sample
from each
batch
M
7
Sample
from
each
tanker
1 Sample
from
each
Sample
from
each
tanker
Sample
from
each
8
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
QC
Record
V
V
V
Measure
Major
Measure
Measure
As per IS:
2500
/AQL 4.0
Visual
As per IS:
2500
/AQL 4.0
Testing
As per IS:
IS:2099 /IS:
IS:2099 /IS:
2500
3347/5621&ap 3347/5621&a
/AQL 4.01 sample/lot
pvd GTP
ppvd GTP
Major
Measure &
Major
Testing
Major
Visual
Remarks
11
-
IS:2099 /IS:
3347
IS:2099 /IS:
3347
QC
Record
P
V
V
-
IS:5621
IS:5621
QC
Record
P
V
V
QC
Record
V
V
V
Lightly
polluted
atmosphere
IS 3345,PtIII Sec-1
1988 for
Porcelain
Parts and
Pt-III,Sec-2
,1982 for
Metal Parts
LA's shall
be procured
from
NESCL
approved
sources
only
IS 3070
IS 3070 Pt-III & IS 3070 Pt-III
Part-III
REC Spec No & REC Spec
1993 1 sample/lot
10/1976
No 10/1976
100%
PIA TPIA RQCC NQM
10
QC
Record
Major
Major
C
9
IS335/NESCL IS335/NESC
Tech Spec
L Tech Spec
Sample
from each
tanker
Sample
from each
tanker
Major
Agency
-
IS 2062 Gr-A
IS 2062 Gr-A
QC
Record
V
V
V
QC
Record
V
V
V
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
Sl.No
1
2.13
2
3
4
5
b)Dimension
Major
Measure
Sampling
c)Chemical composition
Major
Measure
Sampling
d)Tensile Strength
Major
Measure
e)Yield Strength
Major
f)Elongation
Component &
Operation
Charactersitics
2
3
Radiator (for 3 a) Dimension & No.of
Phase only)
Element
b) Paint, Shade, finish
and film thickness
c) Pressure test
Reference
Document
Acceptance Format of
Norm
Record
C/N
M
7
8
-
IS 2062 Gr-A
IS 2062 Gr-A
-
IS 2062 Gr-A
IS 2062 Gr-A
Sampling
-
IS 2062 Gr-A
IS 2062 Gr-A
Measure
Sampling
-
IS 2062 Gr-A
IS 2062 Gr-A
Major
Measure
Sampling
-
IS 2062 Gr-A
IS 2062 Gr-A
Class
Type of
check
Quantum
of check
Reference
Document
4
5
Major
Measure
6
M
As per IS
2500
AQL 4.0
As per IS
Visual/mea 2500
Major
sure
AQL 4.1
Major
Test
d) Adhesion test on paint Major
Test
6
C/N
-
-
Agency
7
Record
QC
Record
QC
Record
QC
Record
C
PIA TPIA RQCC NQM
10
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
Acceptance Format of
Norm
Record
8
Plant Std.
Plant
Std./Apprvd
Drwg/IEEMA
9
Plant Std.
Plant
Std./Apprvd
Drwg/IEEMA
9
As per IS
2500 1sample/l
AQL 4.2 1sample/
ot
Plant Std.
As per IS design/lot
2500
As per
AQL 4.3
TS
DRG.& IS: 101
9
QC
Record
QC
Plant
Std./Apprvd
Drwg/IEEMA
9
Plant
Std./Apprvd
Drwg/IEEMA
9
9
Agency
M
Plant
Std./Apprv
d
Drwg/IEE
MA 9
P
Plant
Std./Apprv
d
Drwg/IEE
MA 9
V
Plant
Std./Apprv
d
Drwg/IEE
MA
9
W
Plant
Std./Apprv
d
Drwg/IEE W
C
PIA TPIA RQCC NQM
10
V
V
V
V
V
V
V
V
Remarks
11
Remarks
11
At radiators
manufactur
ers works
by Trfmr
manufactur
er
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2.14
2.18
3.00
3.01
2
3
5
Major
Measure
1sample/l
ot
b) Tensile Strength
Major
Test
Terminal Connector
a) Dimensiol check
Major
b) Surface finish
c) Routine test
IN-PROCESS-CHECK
Transformer
Tank &
a) Welding procedure
Accessories
Specification
b) Process Qualification
Record
6
-
8
Manufacture
drg./internal
spec.
As per IS
-
IS:1367
IS:1367
Measure
0.1
-
NTPCSpec.
NTPCSpec./
Major
Visual
As per IS
Major
Test
Major
Verify
100%
100%
Major
Test
As per IS
-
100%
-
d) welding electrodes-Mechanical properties
Major
Test
As per IS
-
Major
Major
Visual
Visual
As per IS
100%
-
Major
Measure
-
-
Major
Test
1
1
Major
Visual
-
-
Plant Quality Plant Quality
manual/proced manual/proce
Planture
Quality Plantdure
Quality
manual/proced manual/proce
ure
dure
Plant Quality
manual/proced
ure
AS per
manufacture
procedure/IS:8
14
C
9
QC
Record
Supplier
TC
QC
Record
PIA TPIA RQCC NQM
10
P
V
V
V
V
V
P
V
V
P
V
V
V
V
V
QC
Record
V
V
V
QC
Record
V
V
V
internal drg.
internal drg.
QC
Drg. /IS: 5561 Drg. /IS: 5561 Record
1sample/l
Supplier
As per IS
ot
IS: 5561
IS: 5561
TC
Test
Agency
M
7
Manufacture
drg./internal
spec.
c) Welders qualifications Major
e) Fittup for Butt weld
joints
of tank
f) Visual
chckand
on cover
weldment
g) Dimensional check
after welding
h) DP test on welding
joints of load bearing
member
i) Check for flatness of
gasket surface
Acceptance Format of
Norm
Record
C/N
4
Hardware (fasteners)
a)Dimensional check
Reference
Document
Plant Quality
manual/proce
dure
QW-484
AS per
manufacture
procedure/IS: Supplier
814
TC
manufacture
Drg.
manufacture
Drg.
manufacture
Drg.
manufacture
Drg.
manufacture
Drg.
manufacture
Drg.
Supplier
TC
Supplier
TC
QC
Record
IS:3658
manufacture
Drg.
IS:3659
manufacture
Drg.
QC
Record
QC
Record
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
W
V
V
W
V
V
Remarks
11
WPS
approval,W
elders &
PQR
qualifiction
shall be
done by
Trfmr
manufactur
er for Trfmr
upto 2 MVA
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
4
5
6
M
PIA TPIA RQCC NQM
10
Major
Measure
0.1
-
Major
Visual
1
-
plant std.
plant std.
Measure
spot
check on
random
basis
0.1
NTPC Spec.
NTPC Spec.
QC
Record
W
V
V
Major
Test
spot
check on
random
basis
0.1
NTPC Spec.
NTPC Spec.
QC
Record
W
V
V
Class
Type of
check
4
5
Major
Measure
Sampling
b) Core Dia
Major
Measure
c) Stack Thickness
Major
d) Leg length
e) Window width
n) Primer Coating,Paint
shade thickness Inside
and Outside
o) Paint film adhesion
test
Component &
Operation
Charactersitics
Major
Quantum of check
M
2
3
Core Assembly
(CRGO 3
a) Formation of core
Phase)
section
Reference
Document
8
NESCL Tech
Spec
manufacture
Drg.
manufacture
Drg.
C
9
QC
Record
QC
Record
QC
Record
QC
Record
l) Rim flattness
m) Surface cleaning by
sand/short blasting
3.02
Agency
7
NESCL Tech
Spec
manufacture
Drg.
manufacture
Drg.
k) Vaccum test
1
Acceptance Format of
Norm
Record
C/N
j) Pressure test
Sl.No
Reference
Document
V
V
W
V
V
W
V
V
V
V
V
Acceptance Format of
Norm
Record
C/N
6
W
Agency
M
C PIA TPIA RQCC NQM
10
7
8
9
-
Plant Std
QC Record
P
V
V
Sampling
-
Plant Standard
QC Record
P
V
V
Measure
Sampling
-
Plant Standard
QC Record
P
V
V
Major
Measure
Sampling
-
Plant Standard
QC Record
P
V
V
Major
Measure
Sampling
-
Plant Standard
Plant Std
Plant
Standard
Plant
Standard
Plant
Standard
Plant
Standard
QC Record
P
V
V
Remarks
11
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
Core Assembly
(Amorphous 3
Phase & 1
Spool winding
a)Edge damages &
Foldings
Core cutting
4
5
Major
Visual
Sampling
a)Step over laps
Major
Visual
b)Edge finishing
Major
c)Core Weight
Core forming
a)Dimensions
Core Building
a) Dimensinol Check
b) Assembly of limb
insulation and limb
plates
C/N
M
C
PIA TPIA RQCC NQM
10
9
-
Plant Standard
Plant
Standard
QC Record
P
V
V
Sampling
-
Plant Standard
QC Record
P
V
V
Visual
Sampling
-
Plant Standard
QC Record
P
V
V
Major
Measure
Sampling
-
Plant Standard
QC Record
P
V
V
Major
Measure
Sampling
-
Plant Standard
QC Record
P
V
V
Visual
Sampling
-
Plant Standard
Plant
Standard
Plant
Standard
QC Record
P
V
V
Measure
Sampling
-
Plant Standard
Plant
Standard
QC Record
P
V
V
Test
Sampling
-
Plant Standard
Plant
Standard
QC Record
P
V
V
Major
Measure
1
-
Internal Drg./
Data Sheet
Internal Drg./
Data Sheet QC Record
P
V
V
Major
Visual
1
-
Internal Drg./
Data Sheet
Internal Drg./
Data Sheet QC Record
P
V
V
Visual
1
-
Internal Drg./
Data Sheet
Internal Drg./
Data Sheet QC Record
P
V
V
Visual
1
-
Internal Drg./
Data Sheet
Internal Drg./
Data Sheet QC Record
P
V
V
Visual
1
-
Internal Drg./
Data Sheet
Internal Drg./
Data Sheet QC Record
P
V
V
Major
6
Agency
8
c) Rectangularity of Core
assembly
Major
d) Freedom from
overlaps & air gap at
joints
Major
e) Leaning of core (i.e.
core verticality )
Acceptance Format of
Norm
Record
7
b)Stack Finish
Major
Core Annealing
a)Temperature and Time
interval
Major
Pre core loss testing
a)Pre core losses(if
applicable)
Major
3.03
Reference
Document
Plant
Standard
Plant
Standard
Plant
Standard
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
3.05
3.06
2
Winding
3
Reference
Document
Acceptance Format of
Norm
Record
C/N
M
8
9
PIA TPIA RQCC NQM
10
5
f) Limb and stack
thickness
Major
Visual
1
-
Internal Drg./
Data Sheet
Internal Drg./
Data Sheet QC Record
P
V
V
g) Limb clamping and
binding
Major
Visual
100%
-
Internal Drg./
Data Sheet
Internal Drg./
Data Sheet QC Record
P
V
V
h) Core diameter
Major
Visual
100%
100%
Internal Drg./
Data Sheet
Internal Drg./
Data Sheet QC Record
P
V
V
i) Earthing of Core
Major
Visual
100%
-
Internal Drg./
Data Sheet
Internal Drg./
Data Sheet QC Record
P
V
V
Major
Major
Review
Measure
100%
1
-
Internal Drg.
Internal Drg.
Internal Drg. QC Record
Internal Drg. QC Record
P
P
V
V
V
V
Major
Measure
1
-
Internal Drg.
Internal Drg. QC Record
P
V
V
Major
Major
Measure
Measure
1
1
-
Internal Drg.
Internal Drg.
Internal Drg. QC Record
Internal Drg. QC Record
P
P
V
V
V
V
Major
Measure
1
-
Internal Drg.
Internal Drg.QC Record /TCP
V
V
Major
Measure
1
-
Internal Drg.
Internal Drg. QC Record
P
V
V
Major
Major
Major
Measure
Measure
Measure
1
1
1
-
Internal Drg.
Internal Drg.
Internal Drg.
Internal Drg. QC Record P
Internal Drg.QC Record /TCP
Internal Drg. QC Record P
V
V
V
V
V
V
Major
Major
Measure
Measure
1
1
-
Internal Drg.
Internal Drg.
Internal Drg.QC Record /TCP
Internal Drg. QC Record P
V
V
V
V
Major
Measure
1
-
V
V
Visual
1
-
Internal Drg. QC Record
Internal
Drwg./Tech
Spec.
QC Record
P
Major
Internal Drg.
Internal
Drwg./Tech
Spec.
P
V
V
a) Cleanliness of
Core Coil Assembly
core/visual
7
C
4
a) Brazing procedure &
Brazing qualification
b) Conductor Size
c) Radial Depth of
winding
d) Anchoring and binding
at start & finish
e) No. of turns.
f) Transposition & cross
overs
g) Dimensional check
(OD,ID & axial length)
h) Insulation
arrangement and
alignment
i) winding length
j) Brazed joints
k) Lead and coil
indentification and
marking
l) Free from damages
m) Continuity test for
leads
6
Agency
Remarks
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
4
b) Alignment of Spacers/
Blocks
Major
c) Axial & Radial
Insulation arrangement
d)Electrical clearance
3.07
e) HV & LV Connections
f) Ratio test
a) Cleanliness of
Ovening and Tanking
tank/visual
b) Drying
c) Check tightness of
clamped block and
measurement of winding
height(if applicable)
d) Electrical Clearance
e) Oil filling and air
release
4.00
5
6
1
-
Major
Major
Measure
Measure
1
1
Major
Major
Visual
test
Major
Major
Visual
Physical
Major
Major
Measure
Measure
Physical
7
Internal
Drwg./Tech
Spec.
8
9
Internal
Drwg./Tech
Spec.
QC Record
Agency
M
C
V
V
-
P
P
V
V
V
V
1
1
-
P
P
V
V
V
V
100%
1
0.1
Plant Std
Plant Std
P
P
V
V
V
V
0.1
Internal
Drwg./Tech
Spec./plant std
0.1
Internal
Drwg./Tech
Spec./plant std
1
1
1
2
Internal
Samples/ Drwg./Tech
Lot
Spec./plant std
Plant Std
Plant Std
QC Record
QC Record
Internal
Drwg./Tech
Spec./plant
std
QC Record P
V
Internal
Drwg./Tech
Spec./plant
std
QC Record P
V
Internal
Drwg./Tech
Spec./plant
stdQC Record/Internal PTC V
Remarks
PIA TPIA RQCC NQM
10
P
V
V
V
Clearance on Type Test on Transformer shall be obtained from NESCL Engg.
TYPE TEST
Final Inspection
ROUTINE TEST
5.00
Acceptance Format of
Norm
Record
C/N
Visual
Major
Reference
Document
a) Dimensional check
Critical
b) BDV test on oil taken
from Transformer
Critical
c) Measurement of
winding resistance
Critical
Measure
Measure
Measure
100%
Test Reports P
W
W
W*
W*
V*
NTPC
2
NTPC Spec./IS
Spec./IS
As per Sample/l 1866/IS 2026 1866/IS 2026
plant Std
ot
IEC-60076.
IEC-60076. Test Reports P
W
W
W*
W*
V*
W
W
W*
W*
V*
1
10%
0.1
IS 2026
IS 2026
IS 2026
IS 2026
Test Reports P
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
Sl.No
2
3
4
5
Class
Type of
check
4
5
Critical
Measure
1
e) Measurement of
Impedance voltage/short
circuit impedance and
load loss
Critical
Measure
f) No load loss and No
load current
Critical
g) Insulation Resistance Critical
h) Induced over voltage
withstand test
Critical
i) Separate source
voltage withstand test
Critical
Component &
Operation
Charactersitics
2
3
d) Voltage Ratio &
Voltage vector
relationship
Acceptance Format of
Norm
Record
C/N
6
Reference
Document
8
C
9
Remarks
PIA TPIA RQCC NQM
10
Acceptance Format of
Norm
Record
C/N
6
Agency
M
7
Quantum
of check
M
1
Reference
Document
Agency
M
9
11
Remarks
C PIA TPIA RQCC NQM
10
7
8
0.1
IS 2026
IS 2026
Test Reports P
W
W
W*
W*
V*
1
0.1
IS 2026
IS 2026
Test Reports P
W
W
W*
W*
V*
Measure
100%
10%
IS 2026
IS 2026
Test Reports P
W
W
W*
W*
V*
Measure
100%
10%
IS 2026
IS 2026
Test Reports P
W
W
W*
W*
V*
Measure
100%
10%
IS 2026
IS 2026
Test Reports P
W
W
W*
W*
V*
Measure
100%
10%
IS 2026
IS 2026
Test Reports P
W
W
W*
W*
V*
11
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
4
5
j) Air pressure test
Critical
Measure &
test
k) Paint
Critical
Shade,Thickness,Adhesi
6.00
Dispatch
a) Packing of loose
items
LEGEND :
W*& V*= For first lot comprising of
10% of the entire quantity
Major
Measure
Physical
2
Samples/
Lot%
As per
random
plant std samples
100%
M - MANUFACTURER
C - CONTRACTOR
N - CUSTOMER -- NESCL
P - PERFORM
Acceptance Format of
Norm
Record
C/N
6
10%
Reference
Document
100%
Agency
M
7
8
IS 1180
IS 1180
C
9
Remarks
PIA TPIA RQCC NQM
10
Test Reports P
W
W
W*
W*
V*
GTP, Apprvd. GTP, Apprvd.
P
Drwg.& Tech Drwg.& TechTest Reports
W
W
W*
W*
V*
Plant Std/
Packing list
Plant Std/
Packing list Test Reports P
VWQC-QUALITY CONTROL
PIA-Project Implementing Agency
RQCC-REC Quality Control Cordinator
TPIA-Third Party Inspection Agency
NQM-National Quality Manager
W
V
W*
W*
V*
11
Trfmr with
welded
cover and
with all
fittings
including
bushings in
position
shall be
tested at a
pressure of
80KPa
(Sealed)&
35KPa
(Non
Sealed)
above
atmospheri
c pressure
maintained
inside the
tank for 10
minutes
Packing
List to be
verified
Sl.No
Component &
Charactersitics
Operation
Class
Type of
check
Quantum of check
M
1
2
3
4
5
Reference
Document
Acceptance Format of
Norm
Record
C/N
6
Agency
M
7
8
9
C
PIA TPIA RQCC NQM
10
Remarks
11
As per REC manual clause no. 8.5.4 page no. 25 of 34 RQCC may send his representataive based on random sampling basis. In cas, RQCC is not able to send his
representative, inspection shall be carried out as scheduled in presence of representative of PQCC and TPIA
MANUFACTURE'S NAME & ADDRESS:
STANDARD MANUFACTURING QUALITY PLAN
QP NO:
PROJECT/UTILITY:
REV.NO:
PACKAGE:
DATE:
CONTRACT NO:
MAIN-CONTRACTOR:
ITEM: Battery Charger
SUB-SYSTEM:
Sl.No
Component & operation
Characteristics
Class
Type of
Check
Quantum
of Check
Reference
Document
Acceptance Norms
Format of
Records
1
2
3
4
5
6
7
8
9
A
1.1
1.2
Remarks
M
10
C
N
11
P
W
V
P
W
V
P
V
V
NESCL
SPEC./APPVD.DRG
P
V
V
In House Test
Report
P
V
V
P
V
V
P
V
V
P
V
V
P
V
V
Material- In-Process and
Bought out items
A) Switchgear
Components
Switchs, SFU'S
Instrument ,Transformers,
fuses Contactors, Air
Circuit Breaker, Isolators
Bimetal, Thermal Relays,
MCB'S and MCCB'S
B) Instruments,
Contactors, Lugs, Space
Heater,
Thermostat,Terminal
Block, Lamps, Push
Botton, Small switches,
Name Plates, Feerules,
Labels,Stickers, PVC
Sleeves/Channels
Type Test
MA
Elect.
100%
Routine Test (For
Meters,CT's & PT's
MA
Elect.
100%
Physical Condition
MA
Elect.
100%
Make,Type,Rating etc.
MA
Elect.
100%
Functional Tets
MA
Elect.
100%
1. Physical Condition
MA
VISUAL
100%
C) Relays
NESCL
Spec./ISS
NESCL Spec,
Relevant IS,
Approved Drwg
In House Test
Report or MFR Test
certificate
In House Test
Report or MFR Test
certificate
Test Certificate
No Breakages
Damage
No Breakages/
Damages
In House Test
Report or MFR Test
certificate
2. make
MA Type,Rating etc.
VISUAL
100%
MA
3. Fuctional
MA
Test
ELECT.
100%
MA
VISUAL
100%
1. Physical Condition
1.3
Agency
MA
NTPC
SPEC./APPD.
DRG.
RELEVANT IS:
(IF Applicable)
No
Breakages/Da
mages
In House Test
Report or MFR Test
Test Reports
Test Reports
1.3
1.4
1.5
1.6
C) Relays
D)Transformers &
Reactors
2. make Type,Rating etc.
MA
VISUAL
100%
3. Fuctional Test
MA
ELECT.
100%
1. Routine Test
MA
ELECT.
100%
1.Dimension
MA
Measure
100%
2.Alignment
MA
Measure
sample
E) Fabrication
F) Mounting of Various
items
G) Wiring
1.7
H) Painting
1.8
Final Assembly
Report or MFR Test
certificate
RELV STD. &
NESCL SPEC.
Caladyne In House
Test Report
Apprd. Drgs.
Test Reports
Test Reports
In House Test
In House Test
Report NESCL
Report NESCL Spec.
Spec.
P
V
V
P
V
V
P
V
V
P
V
V
P
V
V
P
V
V
3.Finish/Surface Defect
MA
Visual
100%
4.Surface Condition
MA
Visual
100%
P
V
V
1.Rigidity
2.Tightness
3.Correctness &
Completeness
MA
MA
Visual
Visual
100%
100%
P
P
V
V
V
V
MA
Visual
100%
P
V
V
4. Accessebility
MA
Visual
100%
P
V
V
1.Power
MA
Visual
100%
IS 1554(Pt-1)
IS 1554(Pt-1)
Test Reports
P
V
V
2.Control
MA
Visual
100%
IS 694
IS 694
Test Reports
P
V
V
1.Pre treatment &
Phosphating
MA
Measure
100%
IS:6005
IS:6005 Class C
Test Reports
P
V
V
MA
Measure
100%
IS:6005 Class
C
IS:6005 Class C
Test Reports
P
V
V
3.Coating thickness
MA
Measure
100%
Min 50 microns
Min 50 microns
Test Reports
P
W
W
Workmanship Alignment
Accessibility
MA
Visual
100%
Standard Engg.
Practice
Standard Engg.
Practice
P
V
V
W
V
2.Phosphate coating
B
NESCL
SPEC./APPD.
DRG.
RELEVANT IS
Apprd. Drgs.&
Bill of Material
In House Test
Report
Test Reports
Testing & Inspection
Section-I Type Test
Section -II Routine Test
All Type Test as per
NESCL Tech. Spec.
1.Test on Rectifier
Transformer
a) Temp. rise test
IR Test
HV Test
b)
c)
Clearance on Type Test shall be obtained from NESCL Engg.
MA
Elect.
100%
NESCL
NESCL
TECH.SPEC/ TECH.SPEC/ APPD.
APPD. DRG./IS
DRG./IS
4540/IS2026
4540/IS2027
Test Report
P
Routine test
a)Complete physical
examination
b)Short circuit test at full
load and at no load for
sustained short circuit of
10 sec. ( Min. shall be
carried out ). The charger
shall not trip, no fuse shall
below and charger current
shall be limited to 150% of
the rated current
c) Insualation resistance
test
d) High voltage (Power
frequency ) Test
e)Ripple content test at
i) No load
II) Half Load
III) Full Load
f) Automatic voltage
regulator operation test at
specified A.C supply
variation at
i) No load
II) Half Load
III) Full Load
g) Load limiter operation
test
h) Checking of proper
operation of annuncation
system.
i) Dynamic ressponse test
Overshoot/Undershoot in
out put voltage of the
charger as a result of
suddden change in load
from 100% to 20% and
20% to 100% shall be
measured
MA
Elect.
100%
NESCL
NESCL
TECH.SPEC/ TECH.SPEC/ APPD.
APPD. DRG./IS
DRG./IS
4540/IS2026
4540/IS2027
Test Report
P
W
V
j) Soak test shall be
carried out on all electrical
modules/panels as per
routine test .
k) The charger shall be
checked for gasketing
arrangement as per
drawing
Following routine test shall
be carried as per below
Burn in test shall be
carried out on all electrical
modules as panels with
module as routine
test.During the test panel /
module shall be subjected
to ambient temp. of 50
deg. C for 48 hours in
energised condition. The
temp. rise inside the
cubicle shall not exceed
10 deg. during the temp.
rise test.
Acceptance Tests
2.Tests on assembled
Battery Charger units
a) Complete physical
examination covering
wiring layout, component
layout, Component
indentification
b) Temp. rise at full load
c) IR Test
d) HV Test
e) Ripple content test at
No load
Half
Load
Full
Load
f) Automatic Voltage
regulator operation test at
No load, Half Load ,Full
Load
g) Load limiter operation
test
h)Operational test of
Annunciation system
MA
Elect.
100%
NESCL
NESCL
TECH.SPEC/ TECH.SPEC/ APPD.
APPD. DRG./IS
DRG./IS
4540/IS2026
4540/IS2027
i) Dynamic response Test
K) Functional Check for
float Charging & Boost
Charging Capabilities
l) Provision of suitable
Resistance for conducting
Discharge test for the
battery
Note: Manufacturing, inspection & testing as per IS
694
P= Performed By
V= Verified By
W= Witness of test
MA= Major
P.S= Plant Standard
A.D.S= Approved Data
Sheet
M.I=Minor
M= Manufacturer
N= Customer (NESCL)
C = Contactor
Test Report
P
W
W
P
W
W
FIELD QUALITY PLAN
PROJECT / UTILITY :
CONTRACT No.
CONTRACTOR :
PACKAGE:
ITEM :
SUB SYSTEM :
QAP NO. :
REV. NO.:
DATE :
Quantum/
Reference Documents &
Class Frequenc
Acceptance Standard
y
ERECTION WORK
CABLES
Sr.
No.
CHARACTERISTICS / ITEMS
Type of
Check
Instruments
1
2
3
4
5
6
1
RECEIPT & STORAGE
V
-
B
100%
1.2 Unloading
V
-
B
100%
1.3 Visual exmination
V
-
B
100%
1.4 Proper storage
V
-
B
100%
Instruction Manual/ IS: 1255
-
V
_
B
100%
IS: 1255
Site Record
1.1
1.5
Receiving inspection (Completeness of
documents, test certificates, etc.)
End Sealing ( Cable ends are sealed by PVC
cap to avoid ingress of moisture )
7
Format Of
Records
Remarks
8
9
MRC /
Delivery Challan & NESCL
Check List /
Specification
C / 10
Instruction Manual
Packing list / Instruction
Manual
2 PRE INSTALLATION
2.1 Unloading of Drums
A
Check for drum mounting - cable wheel/ jack
V
-
B
100%
IS: 1255
Site Record
B
Check for cable unwinding - cable wheel/ jack
V
-
B
100%
IS: 1255
Site Record
C
Check for proper unrolling - Cable Wheel/
Jack
V
-
B
100%
IS: 1255
Site Record
D
Check for cable end sealing
V
-
B
100%
IS: 1255
Site Record
2.2 Availability of bricks at site for buried cables
V
-
C
100%
2.3 Excavation of trench for U/G cable laying
V
-
C
100%
Page 1 of 6
Site Record
NESCL Specs./ Standard
Practice
Site Record
FIELD QUALITY PLAN
Quantum/
Reference Documents &
Class Frequenc
Acceptance Standard
y
Sr.
No.
CHARACTERISTICS / ITEMS
Type of
Check
Instruments
1
2
3
4
5
6
2.4 Sand Cushioning for buried cables
V
-
C
100%
2.5 Ascertaining cable route and length
V
-
B
100%
Cable Route
Site Record
2.6 Conformity with cable schedule
V
-
B
100%
Cable Schedule
Site Record
Meggar
A
100%
IS: 1255
Site Record
2.7
Insulation resistance checking - Meggar ( 500
Electrical
V for LT & 1000V for Cables upto 11kV)
7
Format Of
Records
Remarks
8
9
Site Record
2.8 Proper route maintaining during cable laying
V
-
B
100%
Cable Route
Site Record
2.9 identification and dressing of cables
V
-
B
100%
standard Practice
Site Record
2.1 Use of trefoil clamps for single core cables
V
-
B
100%
standard Practice
Site Record
2.11 Proper verticality of multicore cables
V
-
B
100%
standard Practice
Site Record
Page 2 of 6
FIELD QUALITY PLAN
Quantum/
Reference Documents &
Class Frequenc
Acceptance Standard
y
Sr.
No.
CHARACTERISTICS / ITEMS
Type of
Check
Instruments
1
2
3
4
5
6
3.1 Removal of wooden planks from cable drum
V
-
B
100%
3.2 Check cable is not dragged on hard ground
V
-
B
100%
3.3 Check size of cable & cutting of cable length
V
-
B
100%
V
-
B
100%
V
-
B
100%
3.6 Check the cable tray are earthed as per the drawing.
V
-
B
100%
3
7
Format Of
Records
Remarks
8
9
INSTALLATION
Check the separation between different types
of cables laid nearby.
Check the laying of cables as per cable
3.5
schedule.
3.4
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
-
3.7
Check the cable glands, lugs, ferrules, cable
tag/ marker are provided as per requirement.
V
-
B
100%
3.8
Check the cable cable drum/ cable to be laid
for any external damage.
V
-
B
100%
3.9 Check the availability and functionality of the rollers.
V
-
B
100%
V
-
B
100%
V
-
B
100%
V
-
B
100%
-
B
100%
V
-
B
100%
NESCL Specification/
IS:1255
-
V
-
B
100%
NESCL Specification/
IS:1255
-
Check there are no damage / twisting of
cables during laying.
Check that cables are protected from the
3.11
sharp bends while laying.
Check that the power cables are separated
3.12
from the control cables.
3.1
3.13 Check the phase matching t both end after each joint.
V
Check cable tags are provided at required
3.14 intervals/required places and both end as per
cable schedule.
Check the cables are dressed, clamped and
3.15
supported properly as per the drawing.
Page 3 of 6
NESCL Specification/
IS:1255
-
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
NESCL Specification/
IS:1255
-
FIELD QUALITY PLAN
Quantum/
Reference Documents &
Class Frequenc
Acceptance Standard
y
Sr.
No.
CHARACTERISTICS / ITEMS
Type of
Check
Instruments
1
2
3
4
5
6
Electrical
Meggar
B
100%
3.16 Insulation Resistance Check
3.17
Check whether some extra length ( 1.5 mtr.)
is kept in each cable run for future use
Physical
-
B
100%
3.18
Check that all wall openings/ pipes/ sleeves
are sealed to avoid seepage of water
Physical
-
B
100%
-
B
100%
-
B
100%
check that buried cables are covered with
Physical
sand layers and by protective bricks
Ensure that the location of underground cable
3.20
Physical
joints are identified.
3.19
CONTRACTOR'S SIGNATURE
7
NESCL Specifications/
Instruction Manual
NESCL Specifications/
Instruction Manual
NESCL Specifications/
Instruction Manual
NESCL Specifications/
Instruction Manual
NESCL Specifications/
Instruction Manual
Format Of
Records
Remarks
8
9
Site Record
Site Record
Site Record
Site Record
Site Record
NAME & SIGN OF APPROVING AUTHORITY
Page 4 of 6
FIELD QUALITY PLAN
Sr.
No.
CHARACTERISTICS / ITEMS
Type of
Check
Instruments
1
2
3
4
Quantum/
Reference Documents &
Class Frequenc
Acceptance Standard
y
5
6
7
Format Of
Records
Remarks
8
9
Legends :
CLASS OF CHECK:
A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE (AUDIT) BY NESCL, CC.
B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE
C-- MINOR
-- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE
TC : Test Certificate
MRC : Material Reciept Certificate
V : Verify
Turnkey Contractor
All Villages
Tier-I
Project Implementing
Agency (PIA)
All
Villages
All Sub-Stations (New/Augmented)
All SubStations
(New/Au
gmented)
100% BPL connections
100%
BPL
connecti
ons
Third Party
Inspection
Agency
of PIA
50%
Village
s on
rando
m
sampli
ng
100%New
S/S
and
50%
Augme
nted
S/S
5%
Village
s100%B
PL
connec
tions
Page 5 of 6
Tier-II
Tier-III
REC
MOP
10% Villages on random
sampling
1% Villages
on random
sampling
Atleast one New S/S and
one Augmented S/S
Atleast one
New S/S
and one
Augmented
S/S
2.5% Villages-100%BPL
connections
0.5%
Villages100%BPL
connections
FIELD QUALITY PLAN
Sr.
No.
CHARACTERISTICS / ITEMS
Type of
Check
Instruments
1
2
3
4
Quantum/
Reference Documents &
Class Frequenc
Acceptance Standard
y
5
45%Vill
agesAt
least 5
BPL
connec
tions
Page 6 of 6
6
7
Format Of
Records
Remarks
8
9
0.5%Village
7.5%Villages-At least 5 BPL s-At least 5
connections
BPL
connections
STANDARD FIELD QUALITY PLAN
QP No.NESCL/FSQP/TRF/001
Reviewed By:
Approved By:
Format of Records
Remarks
Distribution Transformer (Outdoor Type)
Rev.: …. Date:………
Page 5 of 5
Valid Upto …………..
S.No.
Activity and Operation
Characteristics/ instruments
Class of Check
Type of Check
Quantum of Check
Reference Document
Acceptance Norms
1
2
3
4
5
6
7
8
l) Testing of oil after completion of
filtration.
B
Test
100%
Manufacturer's Instruction
Manual
….
m) Oil level & leakage in transformer tank,
radiators.
B
Test
100%
Manufacturer's Instruction
Manual
….
n) Wiring and termination of cable from
instrument, Bucholz Relay, OTI/WTI,
MOG.
B
Physical
100%
Manufacturer's Instruction
Manual & Wiring Details/
Drgs.
….
o) Tap switch position
B
Physical
100%
Manufacturer's Instruction
Manual & Wiring Details/
Drgs.
….
p) Polarity and connection of CTs with
leads, otherwise CTs secondary to be
shorted.
B
Physical
100%
Manufacturer's Instruction
Manual & Wiring Details/
Drgs.
….
q) IR value between terminal and flange
bushing.
B
Physical
100%
….
….
r) Earthing of Transformer as per drawing
and IE rules.
B
Physical
100%
As per drawing
As per drawing
s) General appearance for paint
condition.(Retouching of paint if required.)
B
Physical
100%
….
….
t) Whole assembly for tightness and general
appearance.
B
Physical
100%
….
….
LEGEND: RECORDS IDENTIFIED WITH "TICK" SHALL ESSENTIALLY BE INCLUDED IN QA DOCUMENTATION
CLASS OF CHECK:
A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE(AUDIT) BY NESCL, CC.
B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE
C-- MINOR
-- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL
SITE
9
D*
10