Volum 2

2
Volume
EQUIPMENT SPECIFICATIONS
Damodar Valley Corporation, PSR Section, Electricity Department
DAMODAR VALLEY CORPORATION

Equipment Specification
PSR Section, Electricity Department DVC TOWERS VIP Road Kolkata - 700054 Phone 033 2355 6043 Fax 033 2355 9618
Table of Contents
SPECIFICATION FOR CONTROL AND RELAY PANELS .......................................................... 1 SPECIFICATION FOR CIRCUIT BREAKERS ........................................................................... 24 SPECIFICATION FOR ISOLATORS .......................................................................................... 37 SPECIFICATION FOR INSTRUMENT TRANSFORMERS ....................................................... 44 SPECIFICATION FOR LIGHTNING ARRESTERS .................................................................... 52 SPECIFICATION FOR LT (FRLS) CABLES .............................................................................. 55 SPECIFICATION FOR ALUMINIUM TUBES ............................................................................. 61 SPECIFICATION FOR CONDUCTOR ....................................................................................... 64 SPECIFICATION FOR CONNECTOR ....................................................................................... 70 SPECIFICATION FOR HARDWARE AND ACCESSORIES ...................................................... 74 SPECIFICATION FOR SOLID CORE POST INSULATORS ..................................................... 82 SPECIFICATION FOR DISC INSULATORS .............................................................................. 86 SPECIFICATION FOR LIGHTING ............................................................................................. 96 SPECIFICATION FOR JUNCTION BOXES & OUTDOOR PANELS....................................... 103 SPECIFICATION FOR BATTERY ............................................................................................ 107 SPECIFICATION FOR BATTERY CHARGERS ...................................................................... 111 SPECIFICATION FOR LTAC AND DC, DISTRIBUTION BOARD ........................................... 117 SPECIFICATION FOR SAFETY EQUIPMENT ........................................................................ 126 SPECIFICATION FOR EARTHWIRE ....................................................................................... 132 SPECIFICATION FOR TOWERS ............................................................................................. 136 SPECIFICATION FOR SIMPLEX METERING PANEL ............................................................ 153 SPECIFICATION FOR AIR CONDITIONING EQUIPMENT .................................................... 158 SPECIFICATION FOR LT METERING EQUIPMENT .............................................................. 162
EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT
SPECIFICATION FOR CONTROL AND RELAY PANELS

DAMODAR VALLEY CORPORATION ELECTRICITY DEPARTMENT VIP ROAD KOLKATA - 700054
Scope
This specification covers design, manufacture, assembly, testing at manufac turers works, packing and delivery at site of control and relay panels for 132 KV Chandil Substation.
Standards
Equipment covered by this specification shall conform to the latest edition/revision/amendments of the following Standards: IS:1248 IS:6236 IS:13703 IS:5578 IS:694 IS:11353 IS:3231 IS 12784, Part-1 IS 14570 IEEE C37.90 IEEE C37.90.1 IEEE C37.90.2 IEEE C37.90.3 IEC 60688 IEC 60255-5 Direct Acting Indicating Analogue Electrical Measuring Instruments and their Accessories Direct recording electrical measuring instruments. Low voltage fuses Guide for Marking of insulated conductors PVC insulated cables for working voltages up to and including 1100V. Uniform system of marking and identification of conductors and apparatus terminals Electrical relays for power system protection Electrical measuring transducers for converting ac electrical quantities into dc electrical quantities: Part 1 General purpose transducers Electrical Measuring Transducers for converting a.c. Electrical Quantities to Analogue or Digital Signals IEEE Standard for Relays and Relay Systems Associated with Electric Power Apparatus. IEEE Standard Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus Standard for Withstand Capability of Relay Systems to Radiated Electromagnetic Interference from Transceivers Electrostatic Discharge Tests for Protective Relays Electrical Measuring Transducers for converting a.c electrical quantities to analogue or digital signals. Electrical Relays- Part 5 : Insulation co-ordination for measuring relays and protection equipments-Requirements and tests
IEC 60255-6 IEC 60255-22-2 IEC 60255-22-3 IEC 60255-22-4 IEC 60255-22-6
Electrical Relays-Part 6: Measuring Relays and protection equipments Electrical disturbance tests for measuring relays and protection equipment, Electrostatic Discharge Tests Electrical disturbance tests for measuring relays and protection equipment, Radiated Electromagnetic Field Disturbance Tests Electrical disturbance tests for measuring relays and protection equipment, Fast Transient/burst immunity Tests Electrical disturbance tests for measuring relays and protection equipment - Immunity to conducted disturbances induced by radio frequency fields Electrical relays - Part 25 : Electromagnetic emission tests for measuring relays and protection equipment Communication networks and Systems in Sub-station all relevant latest versions and editions.
IEC 60255-25 IEC 61850
Where the equipment offered conforms to any other standard, the salient points of difference between the standards adopted and IEC recommendation shall be clearly indicated and the English version of the proposed standard shall be furnished.
Function
Control : The panels shall be used for switching in and out transmission lines with adequate indications depicting the status of each equipment. Protection : The panels shall also provide adequate relays for protection of transmission lines, Bus Coupler. Protection Transfer : For 132 KV 2-bus layouts, Protection CTs are located in the Bus Side. For diversion of Line Bays through Bus Coupler, one set of Protection CTs are located in the Bus Coupler Bay. Interlocks : Adequate interlocks to be ensured between breaker and isolators.
Construction
The panels shall be of Duplex or Simplex type as indicated in the Specific Requirements. The panels shall be sheet steel enclosed, dust and vermin proof with minimum degree of protection not less than IP-31. The panels shall be floor mounting freestanding type mounted on a supporting structure so as to form a rigid enclosure suitable for the application. The panels shall be fabricated out of CRCA sheet steel of minimum 3 mm thickness for the front and back covers, doors and load bearing members and 2 mm for the rest. All doors and openings shall be provided with neoprene gaskets. The panel shall be provided with integral base frame. The integral base frame of panels shall be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack welding to the control room floor embedded insert plate/ flat/ channel. Amply dimensioned oblong holes shall be provided at the bottom of all panels for bolting on to the embedded insert channel.
The height and depth of the panels shall match with the height and depth of the existing panels. The bottom of the panels shall have a 100 mm kick plate all around. Cable entry shall be from the bottom unless specified otherwise. A suitable removable undrilled gland plate shall be provided for cable entry. Suitable compression type cable glands as required for cable termination in the control panel shall be supplied. The control and relay panels shall be matched with existing control and relay panels in dimension and colour wherever specified. Simplex type panels shall be with equipment mounted on the vertical front and access to wiring from rear. Door at the rear shall be provided with handles and locking facility. Duplex panel shall consist of a front and a rear panel connected back to back with a walkway in the central corridor having width matching with the existing panels. There shall be complete access through the corridor to the terminal blocks, internal wiring and components mounted on the panel. Separate cable entries shall be provided for front and rear panels. Interconnection between front and rear panels shall be by inter-panel wiring (through the corridor) at the top of the inside of the panel. Adequately sized hinged type access doors shall be provided at both ends complete with door handles, lock and latching facility.
4.1 Component mounting

In case of Simplex Panels, all controls, indications, meters, annunciations, mimic diagram, protective relays having operations indicator and lock out relays requiring hand reset shall be mounted on panel front. However auxiliary relays can be mounted inside, if the space on panel front is limited. All components shall be neatly arranged in a matching manner. In case of duplex panels, controls, indications, meters, annunciations and mimic diagram shall be mounted on the front panel and relays shall be mounted on the rear panel. All equipment mounted on front/rear panels shall be flush mounting type. All meters/ components shall be suitable for vertical/horizontal mounting. All control gear, switches, push buttons etc. shall be within easy reach for proper operations. The meters shall be so located as to enable easy observations of readings. Checking and removal of individual components shall be possible without disturbing the adjacent equipment. It should be possible to test all the protective relays in-situ. The internally mounted components, auxiliary equipment such as transducers, interposing CTs etc. shall be mounted in such a way as to be readily accessible without impeding the access to internal wiring and other components. All control and supply cables will be laid in distributing trenches running under the control panel. Necessary drawing showing cable entry positions and foundation bolt locations shall have to be supplied by the successful Bidders. The control panels shall be supplied complete with channel base grouting bolts, nuts, washers etc.
4.2 Wiring
The wires shall conform IS: 694. All wiring shall be done with PVC insulated, FRLS, 1100V grade, single core, multi-strand
(minimum 7 strands) annealed copper conductors. The wires shall be flame proof and vermin proof. The minimum size for different circuits shall not be less than those as specified below: 1) 2) Current Transformer Circuit Voltage Transformer Circuit : 1 X 2.5 sq. mm. Copper : 1 X 1.5 sq. mm. Copper : 1 X 1.5 sq. mm. Copper for fuse rating of 10 Amps or less.
3) Other Circuit including Control wires
Each wire shall be identified at both ends with wire numbers by means of ferrules. The marking in the ferrules shall be engraved in a manner to ensure long durability. All control wiring shall be enclosed in plastic channels. The terminal blocks shall be located so as to ensure easy access. Split/Disconnecting type terminal blocks shall be provided for all CT terminals. The terminals screws shall be of the Washer type and long enough for connecting following type conductor on each side. Each terminal block shall be capable of terminating the following no. of wires: CT circuits PT/CVT circuits AC/DC supply circuits All other circuits 2 nos 10 mm sq. copper 2 nos 2.5 mm sq. copper 2 nos 2.5 mm sq. copper 2 nos 2.5 mm sq. copper
Each terminal block shall be provided with a terminal block marking strip and shall be shrouded by easily removable shrouds moulded of transparent dielectric material. Provision shall be made on each pillar for holding 20% extra connections both for incoming and outgoing. The terminal blocks shall be suitable for 660 V,10 A rating. There shall be a minimum clearance of 250 mm between the front row of terminal block and the associated cable gland plate on panel side wall. The clearance between two rows of terminals block edges shall be a minimum of 150 mm. All inter-panel wiring within each shipping section shall be the vendors responsibility. Wiring between panels shall be routed through PVC sleeves. For wiring between shipping section, vendor shall provide terminal blocks on adjacent shipping sections and supply suitable jumpering wires.
4.3 Earthing
A continuous 25 mm X 3 mm copper (tinned) earth bus shall be provided along the full length of the panels. Suitable arrangement shall be provided at the two ends for connection to the plant grounding system. Each panel and the equipment mounted on each panel shall be securely connected to the grounding bus. For this purpose the ground wire shall be looped from equipment to equipment and both ends of the ground wire shall be connected to the ground bus. All doors and movable parts shall be connected to the ground bus with flexible copper connections. Current free metallic parts or metallic bodies of equipment shall be earthed with soft drawn single conductor bare copper. The main earth connection for each panel shall be brought out to terminals for connection to the station earthing system.
4.4 Illumination & Space heaters

Fluorescent lamps working on 240 V AC, operated by door switches shall be provided for internal panel illumination. A 240V, single phase, 15/5A, 5 pin socket shall be provided in the panel corridor or interior of each cubicle with on-off switch for connection of hand lamps. This socket shall be metal clad type with a spring loaded flap. Panel space heaters shall operate on 240 V10% AC and shall be supplied complete with onoff switch, fuse and thermostat. A common thermostat shall be provided for the entire panel. The thermostat shall maintain the internal temperature above the ambient temperature to prevent moisture condensation. The watt loss per unit surface of the heaters shall be low enough to keep surface temperature well below visible heat.
4.5 Painting
All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structure shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under surface shall be made free from all imperfections before undertaking painting coat. After preparation of the under surface, the relay and control panel shall be spray painted with two coats of final epoxy paint or shall be powder coated. Colour shade of final paint shall be 631 (light grey) as per IS:5 unless otherwise specified. The spray painted finished panels shall be dried in stoving oven in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, run-off paint etc. All hardware parts shall be cadmium plated or suitably treated to prevent rust and corrosion. If these parts are moving elements these must be greased.
4.6
Mimic diagrams
Mimic diagram shall be provided on all panels. The mimic diagram shall be screwed on to the panels and shall be made of anodised aluminium or plastic of approved fast colour. The mimic shall be 10 mm wide for horizontal run and 5 mm wide for vertical run. If semaphore indicators are used for indicating isolator position, they shall be automatic type and shall be mounted in the mimic in such a way that isolator closed position shall complete the continuity of the mimic. Alternatively red and green lamps may be used for indicating the Closed and Open position of the isolators. In such cases the isolator control switches shall be placed at appropriate positions in the mimic diagram. The mimic diagram shall also incorporate lamps and control switches for all the breakers. Alternatively discrepancy switches with in-built semaphore and position indication lamps may be provided for breaker control/indication. The discrepancy lamp shall perform the following functions: The breaker on-off control shall be through this switch. The lamp will remain steady when the semaphore position corresponds with the breaker position. The lamp will flicker if the semaphore position does not correspond with the breaker position. The colour code for the various voltages shall be as follows:
132 KV - Signal Red to shade 537 of IS : 5. Earth Black
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5.1
5.1.1
Instrumentation
Control
Indicating Instruments
All instruments shall be of switchboard type, back connected, flush mounted, dust proof and tropicalised. The instruments shall be of digital or analogue type. The analogue indicating meters shall be of size 96 X 96 sq.mm. These instruments shall have a scale covering 0-240 and a minimum accuracy class of 0.5. Zero adjustment for pointers must be accessible from the instrument front. Digital panel meters may be used provided they conform to relevant national and international standards. All auxiliary equipment such as transducers, interposing CT/PT, shunts etc that may be required shall be included in the scope of supply. Frequency meter shall preferably be of digital type. Alternatively they may be of analogue type calibrated for 45-0-55 Hz.
5.1.2
Indicating lamps
Super bright LEDs shall be the means for indication. The LEDs shall be suitable for 250 Volt 20% DC supply. LEDS shall be provided with threaded translucent covers to diffuse light. The covers shall preferably be unbreakable, moulded, heat resistant material. The following colour scheme shall be followed for LEDs : SIGNALS FOR Circuit breaker closed Circuit breaker open Circuit breaker auto trip Circuit breaker trip circuit healthy Circuit breaker spring charged Isolator Closed Isolator Open Transmission Line Potential Carrier protection in service Auto Reclose in service CB drive ready Main Protection Healthy Back up Protection Healthy Bus Potential indication ( All Phases) COLOUR Red Green Amber White Blue Red Green White White White White White White White
Colour of lenses for other functions would be indicated during detailed engineering stage.
5.1.3
Control Switches
The control switches shall be of rotary back connected type, having cam operated contact mechanism. Contact mechanism stages shall be protected by transparent non-inflammable cover of moulded dielectric material. The number of way indicated is approximate one and will
be finalised during detailed design keeping at least 20% sufficient spare. Type of Switch Circuit breaker Control Switch Specific Requirement 1) 3 position with spring return to Neutral from both Close and Trip positions. 2) Shall have pistol grip handles and the handle shall turn clockwise for closing operations and anti-clockwise for tripping operations. 3) Red and Green escutcheon plates shall be provided to indicate ON and OFF operations of the switch even when the handle has returned to the normal position after the operation has been carried out. 4) The control springs shall be strong enough to prevent any inadvertent operation due to light touch. 5) The switches would be provided with lost motion and sequence device. 6) The number of ways shall be such as to leave at least 20% spare contacts of each type. Isolator Control Switch 1) 3 position pistol grip type with spring return to neutral and lost motion device. 2) Escutcheon plates shall be provided Auto Reclose Cut Off Switch 4 positions, lockable, oval head, stay put type having Single Phase, Single and Three Phase, Three Phase and Non Auto positions. 2 position (On and Off) oval head, stay put type, lockable 4 position, oval head, stay put type, lockable 2 position , oval head, stay put type, lockable
Carrier Cut Off Switch Setting Group Selection Switch Check Synchronising and Dead Line Charging Selection Switch
The rating of all switches shall not be less than 10 amps continuous and 150 amps momentary direct current.
5.1.4
Annunciation Unit
Solid state type alarm annunciation system shall be provided in each control board by means of visual and audible alarm in order to draw the attention of the operator to the abnormal operating conditions or the operation of some protective devices. The annunciation equipment shall be suitable for operation on the voltages specified. The details of inscriptions for the window block for different panels will be intimated at the time of approval of drawings.
The annunciation shall be of visual and audible type. The visual annunciation shall be provided by annunciation facia flush mounted on the top of the control panels. The audible alarm shall be provided by alarm buzzer or bell. The annunciation facia shall be provided with translucent plastic window for alarm point with minimum size of 35 mm x 50 mm. The facia plates shall be engraved in black lettering with respective inscription which will be approved by the Purchaser. Alarm inscriptions shall be engraved on each window in not more than three lines and size of the lettering shall not be less than 5 mm. Each annunciation window shall be provided with LEDs in parallel to provide safety against lamp failure. Long life LED shall be used. The lamp circuit shall include series resistor of adequate rating. The cover plate of the facia windows shall be flush with the panel and shall be capable of easy removal to facilitate replacement of LED. The transparency of cover plates and wattage of the lamps provided in the facia windows shall be adequate to ensure clear visibility of the inscriptions in the control room having high illumination intensity (500 Lux), from the location of the Operators desk. TRIP AND NON-TRIP facia shall be differentiated. ALL TRIP facia shall have red color and all NON-TRIP facia shall have white color. Sequence of operation of the annunciator shall be as follow : Alarm Condition Normal Abnormal Accept PB pressed Fault Contact Open Close Close Open Reset PB Close Open Lamp test Open Visual Ann. Off Flashing Steady On Steady On On Off Steady on Audible Ann. Off On Off Off On Off Off
Visual and audible annunciation for the failure of DC supply to the annunciation system shall also be provided and this annunciation shall operate on 240 Volts AC supply with separate fuses. On failure of the power supply to the annunciation system for more than 2 or 3 seconds (adjustable), a facia shall light up and a bell shall sound. A separate push button shall be provided for the cancellation of this audible alarm alone but the facia window shall remain steadily lighted till the supply to the annunciation system is restored. The sound of the audible alarm (bell/buzzer) provided for this annunciation shall be different from the audible alarm provided for the annunciation system. A separate voltage check relay shall be provided to monitor the failure of AC supply (240 V AC) to the scheme mentioned in the above Clause. If the failure of supply exists for more than 2 or 3 seconds this relay shall initiate visual and audible annunciation (bell/horn) which shall have distinctly separate tone than that of DC fail. The annunciation system described above shall meet the following additional requirements:
The annunciation system shall be capable of catering to at least 30 simultaneous signals at a time. One self-resetting push button shall be provided on each panel for testing the facia window lamps. Push buttons for testing flasher and audible alarm circuit of annunciation system and for testing the annunciation supply failure monitoring circuit shall also be provided. These testing circuits shall be so connected that when test is being done it shall not prevent the registering of any new annunciation that may land during the test. One set each of the following push buttons shall be provided in the panel front on each panel : Reset push button for annunciation system. Accept push button for annunciation system. Test push button to check the healthiness of the annunciation system. The annunciation shall be repetitive type and shall be capable of registering the fleeting signals. Auxiliary relay for annunciation system shall have adequate auxiliary potential free contacts for use in event logger. The annunciation shall be suitable for operation with normally open fault contacts which closes on the occurrence of a fault. For fault contacts which open on a fault, it shall be possible at site to change annunciations from close to fault to open to fault and vice versa. Special precaution shall be taken by Contractor to ensure that spurious alarm condition does not appear due to influence of external electromagnetic/electrostatic interference on the annunciation wiring and switching disturbances from the neighbouring circuits within the panels.
5.1.5
Transducers
Transducers shall in general conform to IEC 60688. The transducer characteristics shall be linear throughout the range of measurement. The transducer output shall be load independent and suitable for load resistance of 1000-1500 ohms. The transducer shall derive its auxiliary supply from the panel DC source.The voltage, frequency and current transducers shall have an output of 4-20 mA and the active and reactive power transducers (export/import) shall have an output of 4-12-20 mA. Voltage, Current, Watt/ Var transducers shall be of accuracy class 0.5 or better and frequency transducers shall be of accuracy class 0.2 or better. Galvanic isolation shall be provided between input and output circuits. The transducer shall have a response time of less than 1 second and its output AC ripple shall be less than 1%.
5.1.6
Name and identity Plates
All instruments, relays and other electrical devices mounted on the control panel shall be provided with identity plates bearing the Manufacturers name, Serial number, Model number and the electrical rating data. Ten (10) mm wide plastic plates bearing suitable identity shall be fixed in the interior of the switchboard, at the test blocks, at the fuse blocks and at the cable terminals. Similar plates shall be fixed to indicate functions of control switches, push buttons, indicating lamps, relays and other equipment not incorporated in the mimic diagram etc. Suitable identification marks shall be provided for other instruments as well. Fifty (50) mm brass or plastic plates bearing respective circuit designation (which will be furnished during detailed design stage) etched in 30 mm letters and mounted suitably on the top of the front side and back side of each panel shall be supplied and fixed in such a way that these
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can be removed and refitted when desired.
5.2
Protection
Note: IED : Intelligent Electronic Device Feature Description / Configuration
5.2.1 Transmission Line Protection 5.2.1.1 Main Protection IED Distance Protection One IED for each Line.
(Type-II)
5.2.1.2 Backup Protection IED One combined Directional O/C and E/F Protection IED for
(Type-IV) each Line of make other than the Main Protection IED.
5.2.1.3 General Description (For all IEDs)

Type-II Numerical, fully discriminative, 3 phase, 3 steps directional distance protection, non-switched IED with 6 independent impedance measuring loops, for phase to phase, 3 Phase, double phase to Ground faults and single phase to ground faults. Type-IV Numerical, fully discriminative, 3 phase directional over current and earth fault protection IED. Both the types shall have necessary inbuilt hardware/feature to derive internally the open delta voltage if any required for E/F protection.
5.2.1.4
1 2 3
General Requirement (For all IED Types) The features described under this section shall conform by all the IEDs. Construction Modular Mounting Type Flush Mounted Back connected draw out type or plug in type modular cases, suitable for rack/panel mounting. For Draw out type, the provision of CT shorting shall be available when the IED is drawn out. Shall be able to measure true RMS values up to 10th harmonic with an accuracy of 0.1% under normal conditions. The metering accuracy shall be well within 0.2% for direct measurement. Measurement functions shall comprise of power system measurement, supervision and reporting to the local HMI, monitoring software and to station level (i.e. IEC 61850). Continuous monitoring of active power, reactive power, currents, voltages, frequency, power factor, detailed fault data etc. shall be present. Accuracy class of the measuring unit should be equal to or better than of class 0.5.
Measuring Unit
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Feature 5 Test Block/Test Plug/Test Handle
Description / Configuration Test Blocks/Test Plugs/Test Handle for in-situ testing of the IEDs shall be incorporated in the IEDs. Insertion of the Test Plug shall cause : 1) Shorting of CT Circuit 2) Opening of VT Circuit 3) Opening of Tripping Path Adequate number of inputs/outputs (I/O) to complete the scheme. These I/O shall be freely configurable. Shall be provided with at least one extra isolated I/O module, exclusively for Purchasers use. Auxiliary Supply : 250 V 20% D.C Current Coil : 1A/5A depending on relevant CT secondary current . The permissive thermal withstand(rms) on the current inputs shall be a) 2 times of rated current continuous. b) 100 times of rated current for 1 second. 1) Rear Ethernet port for station level communication (IEC 61850). 2) RS232 / RS485 / LAN port in the IED front for communication with Base computer/Laptop IEC-61850 compliant in all respect and interoperable with IEDs of other manufacturers. Shall comprise of Self Monitoring Feature. Shall facilitate displaying of the system parameters without the need for any deciphering and changing the required parameters through its front panel. However, such changes should have a password access control. Fixed and User configurable to allocate it for any critical fault / event at site. Indications for Relay Healthy and Relay Faulty shall be present. Number of User configurable LEDs shall be such that to accommodate at least the following eventsFor Type-II 1) R-Phase Trip 2) 3) 4) 5) 6) 7) 8) 9) 10) Y-Phase Trip B-Phase Trip Z1 operated Z2 operated Z3 operated Backup Directional Protection operated Backup Non Directional Protection operated LBB operated VT fuse Fail
I/O Device
Rating
Communication Port
IEC 61850 Compatibility
10 Self Monitoring 11 Display
12 IED Front Panel LED
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Feature 11) 12) 13) 14)
Description / Configuration Power Swing Block operated Carrier Protection operated SOTF operated Auto Reclose
For Type-IV 1) R-Phase Trip 2) Y-Phase Trip 3) B-Phase Trip 4) Backup Non Directional Protection operated 5) LBB operated 6) VT fuse Fail 7) Power Swing Block operated 8) Carrier Received 9) Carrier Protection operated 10) SOTF operated All the above configuration may change during detailed engineering stage depending upon the site requirement. 13 Fault Data Download Downloaded fault data shall be possible to save in COMTRADE format from a remote location with playback facility of the downloaded waveform. 14 Distance to Fault Locator i) The fault locater shall be microprocessor based On-line type. ii) It shall be suitable for breaker operating time of 2 cycles. iii) It shall have built-in display unit. The display shall be directly in percent of line length or kilometers with out requiring any further calculations with an accuracy of 3% or better for all type of faults and fault levels. The above accuracy shall not be impaired under the following conditions a) presence of remote end in feed b) predominant D.C. component in fault current c) high fault ARC resistance d) severe CVT transients. iv) It shall have facility for remote data transmission. v) It shall have mutual zero sequence compensation unit if fault locater is to be used on double circuit transmission line. 15 IRIG-B / equivalent Input 16 IED Case Shall be provided with time synchronising inputs (IRIG-B or equivalent) for receiving GPS UTC signal. Case of the IEDs shall be so constructed and arranged that any non-permanent deformation cannot prevent satisfactory operation of the IEDs.
5.2.1.5
Specific Requirement 5.2.1.5-A Main IED

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Feature 1 Distance Protection
Description / Configuration Type-II Shall have Polygonal and circular characteristics (offset mho type).It should cover at least line sections completely with 20% in hand margin. The Characteristic should be compatible to the line length with provision for independent reactance setting, phase to phase fault and phase to earth fault resistance setting. The circular characteristic shall have the provision for Arc Resistance Compensation. i) The IED shall operate at maximum fault current of 40 KA and a minimum fault current of 20% of rated current.
ii) Shall have residual compensation variable from 30150%. iii) Adjustable Forward & Reverse Offset feature shall be provided in Zone-3 setting. iv) The measuring unit shall not become inoperative even under very severe close in system fault conditions where the potential may collapse to zero. Sound phase polarization and directional voltage memory should provide dynamically unlimited directional sensitivity. v) The protective IEDs shall be suitable for use with electromagnetic Instrument Transformers. 2 Zone Switching Zone switching to extend the reach of the measuring elements is not allowed. The reach of each zone shall be independently and individually adjustable and shall have setting in steps of 1% . Selection shall be so that the first zone of the IED can be set to about 80% - 90% of the protected line without any risk of non-selective tripping. Two independent continuously variable time setting range of 0 3 seconds for zone 2 and 0 5 seconds for zone 3. Shall have adjustment upto 20 % of Zone 3 setting. Shall have Residual compensation variable from 30 150%. Memory circuits with defined characteristics shall be provided in all three phases to ensure correct operation during close in 3 phase faults and other adverse conditions. Power Swing Blocking feature having suitable setting range to encircle the distance protection zones with an inbuilt timer having continuously adjustable time delay on pick up .The IED shall block tripping during power swing
Zone selection
4 5 6 7
Zone Timer Offset Feature Residual Compensation Memory Circuit
Power Swing Blocking
14
Feature conditions. 9 VT Fuse Fail
Description / Configuration
Shall have the provision to detect Single phase/Two Phase/Three Phase VT fuse failure. In case of VT fuse fail, the Main and Backup IEDs shall inhibit tripping. The IED shall be configured in such a fashion that , i) If a single set of VT fuse is used for supplying potential to Main and Backup IEDs, the protection shall automatically switched to Non directional protection for both the IEDs. ii) If separate set of VT fuses are used for Main and Backup Protection, then a) In case of VT fuse fail of only Main Protection, tripping by Main Protection IED shall inhibit and the IED shall not switch over to non directional protection . b) In case of VT fuse fail of only Backup Protection, tripping by Backup Protection IED shall inhibit and the IED shall not switch over to non directional protection. Single and Three Pole High Speed Auto Reclosing feature selectable by external ARCO switch. Configuration : Three Pole High Speed Auto reclosing in the event of tripping by Zone-1 distance protection. a) Configuration of the IED shall be such that, Autoreclose shall not operate in case of tripping through i) Zone-2 and Zone-3 Distance Protection. ii) Backup Directional Over Current and E/F Protection. iii) Backup Non-Directional Over Current and E/F Protection iv) Switch On to Fault Protection (SOTF) v) Local Breaker Backup Protection (LBB) b) Variable Dead time range of 0.1- 60 seconds (minimum) with maximum step size of 0.01 sec. c) Variable Reclaim Time of 1-600 seconds (minimum) with maximum step size of 1.0 sec. d) In case of PLCC Out of Service, the IED shall be able for Auto Reclose. e) IED shall have multi shot auto reclose feature but shall be configured with single shot auto reclose.
10 Auto Reclose
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Feature 11 Switch on to Fault (SOTF)
Description / Configuration The IED shall comprise SOTF feature with an internal timer having variable time delay. For configuration of SOTF feature, contact of the TNC switch shall be used in such a fashion that at the time of closing the circuit breaker the feature shall initiate and remain active for the set time delay. Any further close pulse/holding the TNC switch in Close position for more than the Set time of the feature, shall not affect the feature. In case of any fault irrespective of Zone during the set time of SOTF, the IED shall trip in Zone-1 time. Selection of the feature shall be done by external CCO switch. The IED shall be configured in accordance with the principle of Directional Comparison Carrier Blocking Scheme. The IED shall block tripping in case of fault in the backward line. Zone-1 extension facility shall be available in case of PLCC is out of service. The IED shall be able to discriminate between Carrier Channel Fail and Carrier Out of Service. The protection shall deal with a situation where a circuit breaker fails to trip following receipt of trip command from associated tripping relays. All the protections that trip directly or indirectly the circuit breaker shall initiate the local breaker back up protection which after a suitable time delay shall initiate busbar clearance. The protection would trip all circuit breakers connected to the bus to which circuit with failed breaker is connected through the associated protection DC trip bus wires and the isolator auxiliary switches / switching relay contacts. Suitable arrangement shall be provided to short the bus bar protection check relay contact at negative side of the bus bar protection scheme. The protection shall not operate during the single-phase auto reclosing period. Separate alarm and indication from the local back up protection shall be provided for each circuit. The protective scheme shall include the necessary auxiliary relays etc. required for the above tripping functions. The LBB protection function for each circuit breaker shall be connected through the communication LAN and also with the bus bar protection at the bay level. Shall have Four(4) setting group having individual group setting of parameters for protection. The setting group shall be selectable by external Setting Group Selection Switch.
12 Carrier Protection
13 Local Breaker Back Up / Circuit Breaker Failure Protection
14 Setting Group Selection
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Feature 15 Check Synchronising / Dead Line Charging
Description / Configuration Check-synchronising and Deadline Charging Feature shall be selectable by external selection switch. The check synchronising feature along with a timer having variable time range shall be inbuilt in the Main and Backup IEDs. Shall consist of back-up Directional O/C and E/F feature having IEC Definite Time, Normal Inverse, Very Inverse, Extremely Inverse Characteristics selectable by software. Provision of keeping the feature OFF shall also be present. Shall consist of back-up Non Directional O/C and E/F feature having IEC Definite Time, Normal Inverse, Very Inverse, Extremely Inverse Characteristics selectable by software. Provision of keeping the feature OFF shall also be present. The feature shall be activated automatically in the event of VT fuse failure of the Main IED(Type-II) and Back Up IED (if one set of VT fuse is used for both the IEDs)
16 Inbuilt Directional O/C and E/F Protection
17 Inbuilt Non Directional O/C and E/F Protection
5.2.1.5-B Backup Protection IED All features detailed above for the Main IED except the features under section 5.2.1.5-A(1)(6),(15),(16) shall be available in the Backup protection IED. Additional Guideline The maximum fault current could be as high as 40 KA but the minimum fault current could be as low as 20% of rated current. The starting and measuring IEDs characteristics should be satisfactory under these extremely varying conditions. The protective IEDs shall be suitable for use with electromagnetic Voltage Transformers. Insulation barriers shall be provided to ensure that transient present in CT and VT connections due to extraneous sources do not cause damage to IED circuits. The circuits must comply with IEC recommendation for impulse withstand values. Adequate measures shall be taken to ensure that equipment is protected against voltage spikes occurring in Aux. DC supply. Disturbance Recorder, Fault Locator and Event Logger function may be an integral part of line protection IED, provided these meet specification requirements of the respective clauses of these equipments.
5.2.2 Protection of Bus Coupler

IED Type-IV shall be used in Bus Coupler Panel. All features indicated above for Type-IV relay shall be applicable for Bus Coupler Panel relay also. All the above indicated configuration of the IEDs are indicated and subject to change during detailed engineering stage/commissioning depending on the site requirement.
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5.2.3 Auxiliary Relays and Tripping Relays 5.2.3.1 Tripping Relay

Trip function shall be through a high speed tripping relay of the instantaneous type (operating time not to exceed 10 ms) and shall reset within 20 ms. It shall be D.C. operated and have adequate contacts to meet the requirement of scheme, other function like auto-reclose relay, LBB relay as well as cater to associated equipment like event logger, disturbance recorder, fault locater etc. It shall be provided with operation indications for each element coil.
5.2.3.2
Trip Circuit Supervision
The relay shall be capable of monitoring the healthiness of trip-coils and associated circuit of circuit breaker during ON and OFF conditions. The relay shall h ave adequate contacts for providing connection to alarm and event logger. The relay shall have time delay on drop-off not less than 200 ms and be provided with operation indications for each phase.
5.2.3.3
DC Supply Supervision
The relay shall be capable of monitoring the failure of D.C. supply to which, it is connected. It shall have adequate potential free contacts to meet the scheme requirement. The relay shall have a time delay on drop-off of not less than 100 ms and be provided with operation indicator / flag.
5.2.3.4
Auxiliary relays
Auxiliary relays may be electro-mechanical or static as deemed appropriate. The auxiliary relays shall be designed for continuous operation at 250 V 20% D.C. These shall generally be used for inter-locking and contact multiplication.
5.2.3.5
Communication accessories
At least two numbers of compatible communication cables for communication of the respective IEDs with Laptop/Base Computer, all necessary software for communication, configuration, setting calculation(with setting calculation guide) of the IEDs shall be provided without any additional cost implication to the purchaser .
Additional Equipment
In addition to the requirements stated herein the following shall be an integral part of the protection system.
6.1 Time Synchronisation

One time synchronisation equipment shall be supplied which shall be located in the control room and shall receive Coordinated Universal Time (UTC) transmitted through GPS for time synchronisation of DRs, static energy meters, numerical protections and master clock. Shall be complete in all respects including antenna, all cables, processing equipment, etc. All auxiliary systems and special cables required for synchronisation of the various equipment shall work from the plant UPS system or from substation 250 V 20% D.C supplies only and the bidder shall clarify if any built in battery backup is provided in which case same shall be of long life lithium batteries.
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It shall be compatible for synchronisation of Event Loggers, Disturbance recorders and SCADA at a substation. The synchronisation equipment shall have 2 micro-second accuracy. Equipment shall give real time corresponding to IST (taking into consideration all factors like voltage, temperature variations, propagation and processing delays etc). Shall be immune to hostile electrical environment. Suitable protections are to be provided against lightning surges and over voltages in power supply systems. The system shall be fully tested to the relevant international standards such as IEC:60255. One copy of all the test reports shall be enclosed with the bid. The synchronisation shall have one millisec accuracy. Shall give real time corresponding to IST (taking into consideration all factors like voltage, temperature variations, propagation and processing delays, etc.). The system should be able to track the satellites to ensure no interruptions of synchronisation signals. The output signal from each port shall be programmable at site for either hour, half hour, minute or second pulse as per requirements. The equipment offered shall have 6 output ports. Various combinations of output ports shall be from the following: voltage signal: 3-5V continuously variable with 50ms minimum pulse duration. potential free contact (minimum pulse duration of 50ms) and voltage rating of the contact shall be 250 V 20% D.C / 240 VAC max. IRIG-B RS232C/RS485 These output ports shall be compatible with the requirement of the equipment to be synchronised i.e. IEDs. The master clock in the control room shall also be synchronised with the time synchronisation system. The equipment should have a periodic time correction facility of one second periodicity. The equipment shall also have real time display in hour, minute, second (24 hour mode) and have a separate time display unit to be mounted on top of control panel having display size of approx 100mm height.
7
7.1
Tests
Type Tests
Complete Type Test Reports as per SCC shall be submitted with the offer. The tests shall be carried out as prescribed in the indicated standards. The following type tests shall be conducted on the Protective relays(IEDs). 1. i) ii) iii) High Voltage Withstand As per IEC-60255-5 Dielectric Withstand Impulse withstand Insulation resistance
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2. i)
Electrical environment Auxiliary supply test, dc interruption- as per IEC 60255-11.The relay or its associated power supply is required to operate satisfactorily with a DC supply voltage range of 250 V 20%. The performance shall not be affected due to - an interruption to the DC auxiliary supply of duration up to 10ms. - AC component (ripple) in the DC auxiliary supply up to 5% of rated value.,
ii) iii) iv) v) vi) vii) viii) ix) x) 3. i)
High frequency disturbance as per IEC 60255-22-1 Fast Transients as per IEC 60255-22-4 Conducted electromagnetic field disturbance as per IEC 60255-22-6 Radiated electromagnetic field disturbance - as per IEC 60255-22-3 Radiated emission as per IEC 60255-25 Conducted emission - as per IEC 60255-25 Electrostatic discharge as per IEC 60255-22-2, (Class III and IV) Surge immunity as per relevant IEC Power frequency magnetic field as per IEC 61000-4-8 Atmospheric EnvironmentTemperature as per IEC 60068-2-1-cold IEC 60068-2-2- dry heat Humidity as per IEC 60068-2-3,IEC 60068-2-30 Enclosure protection as per IEC 60529 Mechanical environmentVibration as per IEC 60255-21-1 Shock and bump- as per IEC 60255-21-2 Seismic as per IEC 60255-21-3 Relay characteristics, performance and accuracy test as per IEC 60255 Steady state Characteristics and operating time. Dynamic Characteristics and operating time for distance protection relays and current differential protection relays.
ii) iii) 4. i) ii) iii) 5.
6. 7.
Tests for rated burden as per IEC 60255-6 Conformance Testing as per IEC 61850-10
7.2
Routine Tests
Complete Routine Test Reports as per SCC shall be submitted with the offer. During fabrication, the panels shall be subject to inspection by the Purchaser to assess the progress of work as well as to ascertain that only quality raw material is used. Minimum three
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weeks notice shall be given to the Purchaser for witnessing the final testing of the complete equipment. The manufacturer shall furnish all necessary information concerning the supply to the inspectors. Routine test as per indicated IS/IEC shall be carried out on each equipment, wiring in the presence of Purchasers representative if so desired by the Purchaser. All test reports shall be submitted for approval. Testing and commissioning of the panels at site shall be carried out by the manufacturer at no extra cost.
7.3
Acceptance Test
Acceptance Tests as per SCC shall be Carried out. Acceptance Test includes: 1) Functional Check of all equipments and scheme of Control and Relay Panels with all equipments placed in its proper position.
Co-ordination
The Bidder shall co-ordinate with the manufacturer/supplier of transformer, circuit breaker, disconnecting switches and PLCC equipment for coordinating the control, protection and interlocking scheme of these equipments at no extra cost.
Documentation
The manufacturer shall develop the necessary general arrangement and schematic drawings adding necessary auxiliary devices, accessories, components etc which are required for safe, efficient and proper operation. The contract drawings shall cover but not be restricted to the following: 1. 2. Dimensioned detail drawings of the panels showing front view, rear view and side view. Template for foundation and details of cable trench and cable holes in the foundation platform. Elementary diagrams of all control, metering, protection, annunciation and other circuits. All devices shall be numbered according to international usage, which shall be separately coded. Cabling and wiring diagram of the front and rear cubicles and interconnections between them, ferrule number, device numbers, grouping for cable take off etc. shall be distinctly shown. Inter-connection diagram between switchboard and gear equipment, power transformers, instrument transformers etc. showing clearly the connection between the terminal blocks of the switchgear and control panel. Dimensional outline, drilling diagram and special mounting arrangement, if any, of each type of various devices on the switchboard. Internal wiring diagram of all devices and elementary wiring of relay where internal wiring is intricate. Construction details of control switches, terminal block, test blocks etc.
3.
4.
5.
6.
7.
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8. 9.
Dimensioned details of each unit cubicle complete assembly of panel. Dimensioned front and rear view of the panels with instrument and device position marked. List of all equipments and devices. Pictorial views of control switches, indicating instruments, test blocks, terminal blocks and exploded views of draw out type instruments and fuse blocks. Schematic and wiring diagram of the protection scheme, synchronising circuit, annunciator circuit. All drawings shall also be submitted in reproducible format (preferably in AUTOCAD) without any additional cost implication to the purchaser. Illustrative and descriptive literature, general technical data and specifications of each and every type of relays, meters, instruments and other devices offered. Literature describing construction, operation adjustment and rating specifications of all the protection IEDs and auxiliary relays, recording instruments, metering instrument, control switches etc. List of spare parts, identification number of renewable parts of relays, instruments and switches to enable the Purchaser to procure spare parts correctly at a later date.
10. 11.
12.
13.
14.
15.
16.
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Packing and Forwarding
The control panels shall be shipped to site packed in wooden crates. All equipment shall be divided, if required, into several sections for protection and ease of handling during transportation. They shall be wrapped with polythene sheets before being placed in the crates to prevent damage to finish. Crates shall have skid bottom for handling. Special notations giving details regarding the Purchase Order, weight and handling symbols shall be marked on the package. PTO for specific requirements.
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11 Specific Requirements
DUPLEX PANEL FOR 132 KV LINES Sl. Instrument Quantity (For each Bay) 3
CONTROL PART 1 Strip Mimic 2
1 set
36 way microprocessor based annunciator with repeat alarm contact and 1 set auxiliary relay 1 no. 1 no. as per scheme as per scheme as per scheme 3 nos. 1 no. 1 no. 1 no. 1 no. 1 no. I no. 1 no.
3 Semaphore indicators for earth switch 4 Control switch for circuit breaker 5 Control switches for isolators 6 Indicating lamps 7 Push buttons 8 Analog Ammeter 9 Analog Line voltmeter (from 1-ph CVT) 10 Analog Wattmeter 11 Anaog Varmeter 12 Synchronising switch (lockable key type) 13 Synchronising socket 14 Auto-reclose selector switch(lockable key type) 15 Carrier selector switch(lockable key type) RELAY PART 1
Main Protection : Type-II, Multifunction Distance Protection IED (IEC 1 set. 61850 compliant) complete with test blocks, trip relays, auxiliary relays, selector switches to complete the scheme as per specification Backup Protection : Type-IV, 3 phase combined directional overcurrent and earth fault protection IED (IEC 61850 compliant) with high set instantaneous unit complete with test blocks, trip relays, auxiliary relays to complete the scheme as per specification Trip circuit supervision relay for Circuit Breaker High speed trip relay with manual reset Trip relay circuit supervision for above
1 set.
3 4 5
2 nos. 1 no. 1 no.
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DUPLEX PANEL FOR 132 KV BUS COUPLER Sl. 1 Instrument 2 Quantity 3
CONTROL PART 1 Strip Mimic to include Bus Section Isolators, Bus PT and PT isolator 2 3 4 5 6 7 8 9 10 11 12 13
1 set
36 way microprocessor based annunciator with repeat alarm contact and 1 set auxiliary relay 1 no. as per scheme 3 nos. 3 nos. 1 no. 1 no. 1 no. 1 no. as per scheme as per scheme 1 no.
Control switch for circuit breaker Control switches for isolators Analog Voltmeter Analog Ammeter Analog Wattmeter Analog Varmeter Frequency meter with transducer Control switch if any required by the synchronisation scheme Indicating lamps Push buttons Synchronising socket RELAY PART 1 2 3 4 Type-IV, 3 phase directional over-current and earth fault protection IED with high set instantaneous unit complete with test blocks, trip relays, auxiliary relays to complete the scheme as per specification Trip circuit supervision relay for Circuit Breaker High speed trip relay with manual reset Trip relay supervision for above
1 set. 2 nos. as per scheme 1 no.
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SPECIFICATION FOR CIRCUIT BREAKERS

Scope
This specification covers design, manufacture, assembly, testing at manufac turers works, packing and delivery at site of 145 KV SF6 Circuit Breakers with all accessories, auxiliaries, galvanised supporting structures and spares for 132 KV Chandil Substation.
Standards
The Circuit Breakers shall comply in all respect with the requirements of latest issue of following: IEC 62271-100 : High voltage alternating current circuit breakers. IEC 62271-1 IS 13118 : Common specifications. : Specification for High-Voltage Alternating-Current Circuit-Breakers
Function
Circuit breaker shall be totally restrike free under all duty conditions and shall be capable of performing these duties without the use of an opening resistance. The breaker shall withstand high stresses during fault clearing, load rejection and reenergisation of lines with trapped charges. The circuit breaker shall be capable of auto-reclose operations. The breaker shall be capable of interrupting rated power with recovery voltage equal to the rated maximum line to line service voltage at rated frequency and at a power factor not exceeding 0.15. The breaker shall be capable of satisfactory operation ever under condition of phase opposition that may arise due to faulty synchronising. The maximum power, which the Breakers can satisfactorily interrupt under phase opposition, shall be stated in the tender. The circuit breaker shall be capable of interrupting line charging currents without undue rise in the voltage on supply side and without any re-strike and without showing signs of undue strains. Rated line charging breaking current shall not be less than 50 Amps. The guaranteed over voltage caused while interrupting the above charging current shall be as per the relevant IEC Standards. The breaker shall be capable of interrupting small inductive current also such as those
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occurring while switching off unloaded transformer without restrikes as indicated in the relevant IEC Standards. The breaker shall be capable of interrupting (a) the rated power with restriking voltage having a frequency of not less than 400 c/s and (b) 50% of nominal breaking capacity with restriking voltage at freq. of 2000 c/s. Complete data for the frequency amplitude factor etc. for the rate of rise of restriking voltage shall be furnished. The maximum rating of single bank of shunt capacitors which can be switched by the Circuit breakers without re-strikes shall be as per IEC Standards. The interrupting capacity of the breakers for kilometric faults (short line faults) shall be equal to its interrupting capacity as earlier specified.
Operating Mechanism
Closing circuits - shall operate correctly at all values of supply voltage between 85% and 110% of the rated voltage. Trip circuits - 145 KV breakers shall be provided with two independent tripping circuits, valves, pressure switches and coils per operating mechanism. The circuits shall operate correctly under all operating conditions and at all values of supply voltage between 70% and 110% of rated value. There shall be provision for trip circuit supervision for both pre and post close positions. Operation - shall have both remote and local operation provision with each mode selectable with a remote/local selector switch. Pressure switch and Densimeter - contacts suitable for direct use as permissive in closing and tripping circuits to be provided. DC supply monitoring - to be provided for all auxiliary circuits. Provision for remote annunciation and back-up capacitor trip shall be provided. Operating mechanism - shall be pneumatic, electro-hydraulic or spring charged type or any combination of these.
4.1 Pneumatic
1. Shall operate at air pressure limits of 85% to 110% of rated pressure. At these limits the specified make/break times shall be met. 2. The compressor shall be automatic start-stop type. Manual control shall also be provided. Pressure lockout device to be provided with remote alarm indication for trip lockout for both coils, close lockout and auto reclose lockout. 3. On failure of power supply, at least 2 CO operations should be possible at the lowest for auto reclose duty without refilling.
4.2 Hydraulic
1. On failure of power supply and pressure equal to the lowest pressure of auto reclose duty, at least two CO operations should be possible. Also complete duty cycle of breaker to be
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possible when oil is at its lowest permissible pressure before make up. 2. Provision for monitoring pressures of oil, nitrogen, reservoir to be kept both at local and remote ends.
4.3 Spring Charging

1. Motor shall be rated to fully charge the closing springs in less than 30 seconds and shall have adequate thermal rating for repeated sequence of closing and opening operations of breaker. 2. In the event of failure of power supply, at least one CO operation should be possible. Breaker operation should not be possible when spring is in partially charged condition.
Construction
Outdoor Type - The circuit breakers shall be of outdoor SF6 gas single pressure type mounted on steel structures. Operating Mechanism - The circuit breakers shall have three separate but identical single pole units operated through a common shaft (gang operated) with single motor operating mechanism / unit compressor pneumatic mechanism/ Electro hydraulic mechanism. The 145 KV CB shall also be suitable for three phase rapid auto-reclose operation in the rated operating duty cycles as specified in respective clause where applicable. Gas Leakage The design and construction of the Circuit Breaker shall be such that the gas leakage will be limited to 1% per year. No condensation of SF6 gas shall take place on internal insulating surface. Interrupting Chambers - Inside the interrupting chambers, there shall be an absorbent to eliminate SF6 gas decomposition products and moisture. The Breaker poles should be so arranged that individual breaker poles can be removed without leakage of SF6 gas. Gas Density Monitor - A suitable gas density-monitoring unit (temperature compensated) shall be provided to automatically block the operation of the circuit breaker on the loss of gas pressure. Upon loss of pressure the gas between open contacts shall be suitable to withstand at least the rated voltage at zero gauge pressure of gas. Special Seal - Special seal shall be provided to restrict the SF6 gas inside the insulator column. The position of vents, diaphragms and pressure relief devices, if required, shall be so arranged as to minimize danger to the operator in the event of gas or vapor escaping under pressure. Main Contacts - The main contacts shall have ample area and contact surface for carrying the rated current and the short time rated current of the circuit breakers without any excessive temperature rise. The main and arcing contacts shall be adjustable to allow for wear and shall be easily replaceable. Arc-Quenching - The arc-quenching device shall be of robust construction and shall not require any critical adjustment. The device shall be easily removable for access to the Breaker contacts. It shall be so designed as to satisfactorily interrupt low value, low power factor inductive and capacitive currents at the rated voltage plus ten percent. If multi-break interrupter are used they shall be so designed and augmented as to ensure a fairly uniform voltage distribution across them.
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Anti Pumping Device Shall be provided with anti pumping device. Capacitor Trip Device Shall be provided with capacitor trip device. Mechanism Housing - The operating mechanism and all accessories shall be enclosed in a weather proof sheet steel mechanism cabinet. Hinged door shall provide access at least from the front. The mechanism housing shall be padlocked and lock with duplicate keys has to be furnished. Suitable space heaters with automatic thermostatic control shall be mounted in the housing to prevent condensation. Terminal Blocks - Terminal blocks shall be furnished inside the mechanism housing or in a separate enclosure. A minimum of 10% spare terminals for control wiring shall by provided. All wiring in the housing shall be flame proof and vermin proof. All terminals and end connectors shall tinned. Suitably rated switch shall be provided to enable the control supply of the Breaker to be cut off from the mechanism housing. Local and Remote Operation - There shall be provision for both local and remote electrical operation. Safety Precaution - There shall be suitable protection to prevent breaker operation under low gas pressure. Cable Glands - Requisite number of cable glands shall be provided at the bottom of the operating cabinet to receive the Purchasers control cables. The number and sizes of the cable glands will be intimated to the successful Bidder. Illumination - A suitable lighting point with its associated control switches and socket pin plug outlet shall be provided inside the mechanism housing or enclosure for use in emergency. Auxiliary Contacts - An adequate number of breaker auxiliary contacts shall be provided to suit control, interlock and auto-reclose schemes. There shall be at least 8 nos. of spare auxiliary contacts of each type (NO and NC) for 145 KV breakers to incorporate, if so required, additional features in the control schemes. The contacts may be called upon to break the opening and closing inductive coil current rated 2 Amp at 250 V DC. At least two limit switches for each spring charging mechanism shall be provided. All Breaker auxiliary contacts and limit switch contacts should be terminated in terminal blocks. At least ten spare terminals should be provided per pole. Meters and Gauges - The operating mechanism box shall be provided with adequate number of gauges and meters for monitoring the pressure density of SF6 gas. Interlock - Electrical and mechanical interlock shall be provided. The circuit breakers shall be suitable for interlocking with their associated isolators. Low gas pressure alarm and indication shall be provided. Very low gas pressure lockout with alarm and indication shall also be provided. Electrical Clearance - The clearance between the live parts and grounded structure shall not be less than those specified in the relevant International or Indian Standards. Quality and Storage of Gas - The SF6 gas used shall conform to IEC 60376, ed-2. Bidder should indicate the method of storing of the CB and SF6 in stores till erected and commissioned. Support Structure - The circuit breakers shall be supplied with steel supporting structures.
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These shall be galvanised and shall be designed to allow a minimum factor of safety of 2.5 with respect to the yield point under conditions for maximum loading, allowing for wind pressure of 200kg/sq.cm on 1.25 times the projected area of such member of one face and taking into account the dead and the stock loads of the circuit breaker. Marshalling Kiosk Shall be made of 3 mm(min.) thick sheet steel and properly illuminated. Earthing - Each Circuit Breaker pole and Control Cabinet shall be provided with a minimum of two grounding pads/ terminals and clamps for grounding connections. Paint - All interiors and exteriors of mechanism housing and enclosure cabinet/marshalling kiosk and other metal parts shall be thoroughly cleaned to remove all rusts, scales, corrosion, grease or other adhering foreign material. All steel surfaces in contact with insulating oil as far as accessible shall be painted with not less than two coats of heat resistant, oils insoluble insulating varnish. Steel surfaces exposed to the weather shall be given a primer coat of zinc chromate and two coasts of weather resistant paint. All metal parts not accessible for painting shall be made of a corrosion resistant material. All machines finished or bright surface shall be coated with suitable preventive compound and suitably wrapped or otherwise protected. All paints shall be carefully selected to withstand tropical heat and extremes of weather. The paint shall not scale off or crinkle or be removed by abrasion due to normal handling. Adequate quantity of spare paint for retouching at site shall be furnished. Erection & Maintenance Tools - Any special tools required for SF6 Circuit Breakers for initial erection and subsequent maintenance of the Circuit Breakers shall be indicated.
Fittings and Accessories

1. SF6 gas pressure gauge and gas density temperature compensated pressure switch. 2. Provision for replenishing SF6 gas 3. Lockout Device. 4. Mechanically operated tripping and closing Device. 5. Local/ remote/ off Changeover Switch. 6. Local electrical closing and tripping push buttons/knobs. 7. Operation counter. 8. Interlocking device. 9. Supporting frame. 10.Earthing terminals. 11.Name Plate. 12.Foundation bolts. 13.Mechanical ON and OFF position indicator.
The following fittings and accessories shall form a part of each circuit breaker:
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14.Capacitor tripping device along with a circuitry for testing its health. 15.Anti-pumping device. 16.Handle for manual charging of Closing Springs. 17.Isolating Switches/MCB to cut-off control power supply (250 V 20% DC) 18.Fuses. 19.Space heater 20.Operating mechanism either pneumatic or hydraulic or motor operated spring. 21.Arc quenching devices and contacts, completely sealed into the insulated interrupting chamber. 22. All erection and maintenance tools for breakers and also for compressor of pneumatically operated breaker.
Design Rating
The rating of the Circuit Breakers covered by this specification is detailed in the section Specific Requirements.
Insulation
The insulation to ground, insulation between open contacts and the insulation between phase of the completely assembled Circuit Breaker shall be capable of withstanding satisfactorily dielectric test voltages corresponding to BIL specified herein. The clearances in air viz. minimum clearance between phases and that between live parts and grounded objects on the basis of the BIL specified shall be specifically mentioned in the tender in case the apparatus is not impulse tested after complete assembly. The clearances shall be in line with the indicated standard. The external insulator supports shall be designed for BIL as indicated above and shall be suitable for installation in contaminated atmosphere. Bushing shall conform to IS 2099 or equivalent. The porcelain used shall be homogeneous and free from cavities and other flaws. They shall be designed to have ample insulation, mechanical strength and rigidity for satisfactory operation. All bushing of identical ratings shall be interchangeable. The insulation of the bushings shall be coordinated with that of the Circuit Breakers. The puncture strength of the bushing shall be greater than the dry flash over value. When operating at normal rated voltage there shall be no electric discharge between the conductors and bushings, which would cause corrosion or injury to conductors, insulators, or supports. The bushings shall be free from radio disturbance when operating at a voltage upto 10% above rated voltage and shall also be free from external and internal corona. All iron live parts shall be hot dip galvanised. All joints shall be the SF6 gas tight. The surface of the joints shall be properly finished. The design of the bushing shall be such as to ensure a uniform compressive pressure on the joints.
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Table: Insulation Level for Bushings (Withstand Values). 1. Voltage level 145 KV Insulation classification : 145KV 275 KV 275 KV 650 KVp 3625 mm 50C
Power Frequency withstand voltage, 1 min. dry (KV RMS) : Power Frequency withstand voltage, 1 min. wet (KV RMS) : Impulse voltage (1.2x50 microsec impulse) Creepage distance (minimum) Ambient Temperature : : :
Temperature Rise
The temperature rise and the maximum temperature attained by any part of the equipment other than coils but inclusive of contacts when in service at site under continuous full load conditions and exposed continuously to the direct rays of the sun shall not exceed the permissible limits fixed by indicated standards. When the standards specify the limits of temperature rise, these shall not exceed when corrected for the difference between ambient temperature at site and the ambient temperature specified in the approved standards.
10 Tests
10.1 Type Test
Complete Type Test Reports as per SCC on similar Circuit Breakers shall be submitted with the offer. The tests shall be carried out as prescribed in the indicated standards. The following constitute the type tests: 1. Dielectric Test (a) Power Frequency Voltage Test (Dry and Wet) (b) Lightning Impulse Voltage Test (c) Partial Discharge Test (d) Dielectric Tests on Auxiliary and Control Circuits (e) Voltage Test as a condition check 2. Radio Interference Voltage (RIV) Tests 3. Measurement of the resistance of Circuits 4. Temperature Rise Test 5. Short Time Withstand Current and Peak Withstand Current Test 6. Verification of the degree of protection
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(a) Verification of the IP coding 7. Tightness Test 8. Electromagnetic Compatibility Tests (EMC) 9. Mechanical and Environment Tests 10. Basic Short Circuit Test Duties 11. Single-phase and double-earth fault tests 12. Short-line fault tests 13. Out-of-phase making and breaking tests 14. Capacitive current switching tests 15. Type Test of operating motors as per relevant IS/IEC
10.2
Routine Tests
Complete Routine Test Reports shall be submitted as per SCC. The tests shall be carried out as prescribed in the indicated standards. The following constitute the Routine tests: 1. Dielectric test on the main circuit 2. Tests on auxiliary and control circuits 3. Measurement of the resistance of the main circuit 4. Tightness test 5. Design and visual checks 6. Mechanical operating tests (a) At maximum supply voltage of operating devices and of auxiliary and control circuits and maximum pressure for operation : Five closing operations; Five opening operations. (b) At specified minimum supply voltage of operating devices and of auxiliary and control circuits and minimum functional pressure for operation : Five closing operations; Five opening operations. (c) At rated supply voltage of operating devices and of auxiliary and control circuits and rated pressure for operation : Five close-open operating cycles with the tripping mechanism energised by the closing of the main contacts
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Five open-close operating cycles O - t - C where t shall be not more than the time interval specified for the rated operating sequence. Mechanical operating tests should be made on the complete circuit-breaker. For all required operating sequences the following shall be performed and records made of the closing and opening operations: (a) measurement of operating times (b) where applicable, measurement of fluid consumption during operations, for example pressure difference. Proof shall be given that the mechanical behaviour conforms to that of the test specimen used for type testing. The mechanical travel characteristics can be recorded directly, using a travel transducer or similar device on the circuit-breaker contact system or at other convenient locations on the drive to the contact system where there is a direct connection, and a representative image of the contact stroke can be achieved. The mechanical travel characteristics shall be preferably a continuous curve. 7. After completion of the required operating sequences, the following tests and inspections shall be performed : connections shall be checked the control and/or auxiliary switches shall correctly indicate the open and closed positions of the circuit-breaker all auxiliary equipment shall operate correctly at the limits of supply voltage of operating devices and of auxiliary and control circuits and/or pressures for operation. 8. Furthermore the following tests and inspections shall be made measurement of the resistance of heaters and of the control coils inspections of the wiring of the control, heater and auxiliary equipment circuits and checking of the number of auxiliary contacts, in accordance with the order specification inspection of control cubicle (electrical, mechanical, pneumatic and hydraulic systems) recharging duration(s) (Test of stored energy system) functional performance of pressure relief valve operation of electrical, mechanical, pneumatic or hydraulic interlocks and signalling devices operation of anti-pumping device operation of capacitor trip device general performance of equipment within the required tolerance of the supply voltage inspection of earthing terminals of the circuit-breaker.
10.3
Acceptance Test
All tests indicated in the list of routine tests shall constitute the acceptance tests. The tests shall be carried out in the presence of Purchasers representative if so desired by t he
33
Purchaser.
11 Spares
Manufacturer shall guarantee that he will supply spare parts if and when required on agreed basis for the life of the supplied items. The agreed basis shall be the published catalogue prices at the time of supply of the Spare Parts. The manufacturer shall provide adequate advance notice before phasing out any spare part from their product line. The Bidder shall guarantee that before going out of production of the spare parts , he will give prints,drawings of spare parts and specification of materials at no cost to the purchaser,if and when required to enable the purchaser to fabricate or procure spare parts from other source.
12 Drawings & Documentation

The manufacturer shall provide the following drawings and manuals along with the circuit breakers. The number of copies required and mode of submission is covered on the SCC. 1. General outline drawings showing dimensions, clearance and other details, net weight and shipping/ transportation weight etc. Sectional views showing general constructional features of the Breaker and operating mechanism.
2. Foundation drawings of all component parts of the equipment including structure mounting and structural drawing clearly showing details of the foundation required for these parts foundation loads and details of all ducts, trenches etc. required for pipes cables and other accessories. 3. Type test reports of similar rated Circuit Breaker conforming to the indicated standard to be submitted along with the offer. 4. Any other relevant drawings and/or literature which the Bidder might decide to be necessary for explaining the constructional and operational features of the Circuit Breakers. 5. General outline drawing. 6. Assembly and sub-assembly drawings of the Breaker. All parts shall be labeled and numbered to enable the Purchaser to order for spare parts if necessary. 7. Detailed dimensions and assembly of Bushings. 8. Detailed dimension and assembly of important auxiliaries. 9. Wiring and control schematics diagram with ferrule numbers, kiosk terminal numbers and interlock system. 10. Interlock system. 11. General outline drawing of piping. 12. Bill of Materials with make,rating and quantity of each component. 13. Details of Terminal Pad. 14. Nameplate 15. Sectional Views showing general constructional features of the breaker and operating
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mechanism. 16. Interrupter assembly drawing. 17. Details of spare contacts of different relays/contactors/sensors with Circuit Breaker kiosk terminal numbers. 18. Wiring/interconnection diagram for each equipment and terminal block. 19. Erection, operation and maintenance manual of the equipment before effecting delivery of the Breakers. The instruction Manual shall include a list of spare parts.
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Sl. 1 Description 2 Parameter 3
145KV CIRCUIT BREAKER 1. Rated voltage 2. Interrupting medium 3. Type 4. No. of Poles 5. Rated normal current in Amps 6. Rated Frequency (Hz) 7. Symmetrical Breaking Capacity in MVA - 1st Break 8. 9. 10. 11. Symmetrical Breaking Capacity in MVA - 2nd Break after auto reclose Rated short-time withstand current (KArms) Rated Peak Withstand Current (KAp) Short time current (3 sec)
145 KV SF6 Restrike free, without PIR 3 2000 50 10000 10000 40 100 Not less than rated symmetrical breaking current. (O - 0.3 sec - CO - 3min - CO) 12 - 20 cycles adjustable Trip free operation Less than 4 cycles 50C
12. 13. 14. 15. 16. 17.
Operating duty Auto-reclose time (cycle from instant of trip coil energisation to the instant of contact fully closed) Latching requirement Interrupting time (cycles) Ambient Temperature
Temperature rise above ambient under continuous full load operation - For current carrying parts in SF6 As per indicated standards o including contacts (in C) Temperature rise above ambient under continuous full load operation - For all other parts in direct contact with As per indicated standards o insulation other than SF6 gas (in C) Over voltage factor consequent to low inductive current switching Basic Insulation level (KVp) Insulation level - 1 min power freq withstand voltage (KVrms) Insulation level - 1.2 / 50 micro-sec Impulse withstand (KVp) Not less than 2 650 275 650 Motor operated Spring or pneumatic or hydraulic with anti-pumping and trip free features
18. 19. 20. 21. 22.
23.
Operating Mechanism
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Sl. 1
Description 2
Parameter 3 Single phase AC, 240V 50Hz / 3-phase AC, 415V 50Hz < 2500 As per IEC As per IEC 3625 250 V DC Two One 1.3 10A, 250V DC 2A at 250 V DC with time constant not less than 20ms
24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.
Power supply for operating mechanism Radio interference voltage at 92 KVrms (V) Restriking Voltage Rate of rise of restriking voltage Minimum creepage distance in mm Closing and trip coil voltage Number of trip coils Number of closing coil First pole to clear factor Rating of auxiliary circuit(Continuous) Breaking capacity of auxiliary contact
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SPECIFICATION FOR ISOLATORS

DAMODAR VALLEY CORPORATION ELECTRICITY DEPARTMENT VIP ROAD KOLKATA 700054
Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of motor operated isolators of the following types for 132 KV Chandil Substation : 145 KV, 650 KVp BIL, triple pole, central post rotating, double break, normal, outdoor type, motor operated isolator suitable for horizontal upright mounting with all accessories, motor driven mechanism, electrical and mechanical interlocks, 2 unit solid core post insulator stack : i) ii) iii) High Level Normal Isolator without Earth Switch (2000 A) Low Level Normal Isolator without Earth Switch (1250 A) Low Level Normal Isolator with Earth Switch (1250 A)
Standards
Equipment covered by this specification shall conform to latest edition/revision the following Standards: IS 9921(Part-I to Part-V) IS 2544 : Specification for Alternating Current disconnectors (Isolators) and Earthing Switches for voltages above 1100V. : Porcelain post insulators for systems with nominal voltage greater than 1000 Volts.
Construction
3.1 General
There shall be no sharp corners or points on the live parts. Shields shall be furnished wherever necessary. The fixed and moving contacts shall be made of hard drawn electrolytic copper. The terminal pads shall be made of copper with tin plating. All ferrous parts shall be corrosion protected by hot dip galvanizing to conform to IS : 2633. All fasteners shall be locked in position. The design of mechanism shall be such as to prevent over travel of contacts when operated manually or electrically. The operating rods or pipes shall preferably be provided with universal coupling to account for angular misalignment. No moving parts shall require lubrication at intervals of less than one year.
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The equipment shall be designed to withstand the electrical and mechanical stresses imposed by system fault conditions. There shall be no harmful rise in temperature due to flow of short circuit current for time period indicated in the rating requirements.
3.2 Support Structure

The isolators shall be mounted on a supporting structure. The details of the supporting structure shall be obtained from the Purchaser. All design data in cluding base channels mounting holes are to be matched with the above structure.
3.3 Operating Mechanism for 145 KV Isolator

145 KV normal isolator shall be 3 pole mechanically ganged with motor operating mechanism. All bearings shall be heavy duty, lubricated for high life and sealed against dust and moisture. Suitable guides shall be provided for operating drive of earthing switch. The mechanism shall ensure simultaneous and identical operation of the speed of the blade during make and break will be such that there should not be any perceptible vibration of the stack. The whole mechanism of Make/ Break shall conform to stringent quality control of production. The rated peak withstand current and the rated short time withstand current, carried by an isolator in the closed position during the rated duration of short circuit, shall not causei) ii) Material mechanical damage to any part of the isolator. Separation of the contacts
iii) A temperature rise that added to the maximum temperature obtained when carrying the rated normal current continuously, is likely to damage the insulation. After the passage of these currents, the isolator shall be able to carry its rated normal current without its temperature rise exceeding the values specified in IS:9921.
3.4 Motors
Operating motors shall be totally enclosed, weather proof, outdoor type insulated for tropical service and suitable for continuous operation on 415 10%, 3 phase, 50 Hz, A.C. supply. Motor starters shall be automatic contactor, direct-on line type fitted with magnetic/thermal overload trip devices and HRC fuses. The motors should be electrically reversible type with high starting torque. Motor space heaters at 240 10% single phase, 50 Hz are also to be provided.
3.5 Contacts
Contacts shall be high-pressure self-aligning, self-cleaning adjustable type made of corrosion resistant hard drawn electrolytic copper. Full contact and current carrying capacity shall be secured with a lateral travel allowance. The high pressure type contacts shall wipe the contact surface while opening and closing. The contacts shall be so designed that wiping action shall not cause scouring and abrasion on the contact surfaces. The wiping action shall be sufficient to remove any film of oxide which may be formed during the operation of the switches.
3.6 Switch blade & Jaws

The switch blades shall be corrosion resistant of hard drawn electrolytic copper and capable of withstanding all conditions of operation including specified short circuits without distortion. Fixed guides wherever necessary should be provided.
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The switch contacts shall be capable of isolating power transformers generators and overhead lines at no load from the system and also be capable of interrupting charging current mentioned earlier. All movable parts in the current path shall be shunted by flexible copper conductors of sufficient length to prevent breaking due to repeated closing.
3.7 Operating kiosk

Shall be made of sheet steel of thickness not less than 2 mm. Weather and dust protected control cabinet shall be provided for housing the operating motor control equipment and interlocks for the mechanism. The degree of protection shall be IP - 55. All wiring for the motor and associated controls shall be terminated in this cabinet. It shall be complete with hinged door and padlock with duplicated keys, thermostat controlled space heaters, cubicle light switch, utility outlets and cable terminal glands for the Purchasers cables. The equipment to be supplied with the control cabinet shall include the following : 1. Supply cut-off switch backed up by air circuit breakers. 2. Push button reversible starters with magnetic thermal over load tripping device for the motors. 3. Local/ remote change over switches. 4. Auxiliary switch contacts. 5. One utility outlet for hand lamps. 6. Necessary terminal blocks with ten percent spare terminals. 7. Cable glands for PVC armoured cables. The wiring in the control cabinet near the isolators shall be made with 1100V grade, PVC insulated copper conductors. It shall be grouped, cleated and finished at numbered terminal blocks with cable lug type terminals and numbered terminal ferrules the space heater connections shall be insulated with porcelain beads over a safe distance.
3.8 Auxiliary switches

Sixteen, single pole, auxiliary contacts, which can be adjusted to be in the normally close or normally open position as required shall be furnished in the case 145 KV isolators. For earthing switch, six auxiliary contacts are to be supplied. The contact rating shall be at least 10 Amps as per IS:9921(Part-III).
3.9 Interlocks
Interlock shall be provided to prevent the isolator the being operated on load i.e. opening and closing of isolator can be done only when the circuit breaker is open. Manual operation of isolator shall only be possible when the breaker is open and the supply to control circuit for isolator operation is off (handle interlock). Interlock shall also be provided so that electrical operation of the isolator from local/ remote is only possible when the operating handle for manual operation is not in use. The isolator should be manually operable in case of aux. supply failure. Pole discrepancy shall provided for a 145 KV isolators with single units operated as one unit for 3phase operation. Earth switches wherever provided shall be mechanically and electrically interlocked so that they can be operated only when the isolator is opened or vice versa.
3.10 Insulators
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Solid core insulators are to be used for 145 KV isolators. The details are indicated in the respective specifications for solid core insulators.
3.11 Arching Horn

Suitable adjustable arcing horns made of tinned electrolytic copper or G.I. shall be provided on the contacts where required.
3.12 Protective Coatings

All ferrous parts shall be corrosion protected by hot dip galvanized to conform to IS:2633 or equivalent. All non-ferrous fasteners should be heavily tinned.
Operational Requirements
Isolators and earth switches shall be capable of withstanding the dynamic and thermal effects of the maximum possible short circuit of the system in the closed position. The earth switches wherever provided shall be interlocked so that they can be operated only when the isolator is open. The earthing switch shall be capable of discharging trapped charges of the associated lines. Isolators and earth switches shall have provision to prevent their electrical and manual operation unless the associated interlocking conditions with other equipment in the bay are met. All these interlocks shall be of fail safe type. The isolators and earth switches shall be able to bear on the terminals the total forces on the attached conductor without impairing reliability or current carrying capacity.
Material & Workmanship
All materials used in the manufacture of the equipment shall be new and shall conform to requisite design features like strength durability etc. Liberal factors of safety shall be used throughout the design and specially in the design of all parts subject to alternating stresses or shocks. Casting shall be free from blowholes, flaws, cracks or other defects and shall be smooth close grained and of true forms and dimensions. No plugged or filled up holes or other defects will be normally allowed.
Tests
Operation of the isolators shall be tested at manufacturers works. Demonstration at site also is to be carried out by suppliers representative. Tests shall be made in accordance with the indicated standards. The following are the minimum tests required to be carried out on the offered isolators.
6.1
Type Tests
Complete Type Test Reports as per SCC on similar Isolators shall be submitted with the offer. The tests shall be carried out as prescribed in the indicated standards. The following constitute the type tests: 1. Lightning Impulse voltage dry tests. 2. Power frequency voltage dry tests on main circuits.
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3. Power frequency voltage wet tests on main circuits. 4. Power frequency voltage on auxiliary equipment. 5. Temperature rise on main circuits and auxiliary equipment. 6. Test to prove the capability of carrying the rated peak short circuit current and rated short time current. 7. Satisfactory Operation and Mechanical endurance test.
6.2 Routine Tests

Complete Routine Test Reports shall be submitted as per SCC. The tests shall be carried out as prescribed in the indicated standards. The following constitute the routine tests: 1. Power Frequency voltage dry tests of the main circuit 2. Voltage test on the control and auxiliary circuit 3. Measurement of resistance of the main circuit 4. Mechanical operation test 5. Temperature rise test on main circuit.
6.3 Acceptance Tests

Each completely assembled unit shall be operated at least fifty times and all adjustments made before dispatch. All routine tests constitute the acceptance tests also.
Documentation
The following shall constitute the documentation required for the specified equipment. The submission and approval procedure is indicated in the SCC. 1 2 3 4 5 6 7 8 9 10 11 12 General outline and dimensioned drawings depicting the net and shipping weights. Detailed drawings of the operating mechanism, auxiliary switches, earthing switches etc. Detailed drawings of the contact assembly. Detailed drawings of terminal pad where the connector is to be mounted. Detailed diagrams of the interlock schemes. Details of mounting for the isolators. Schematic and detailed wiring diagrams for the motor control circuit. Arrangement drawing of the operating kiosk. Fixing details of the base on structure. Earth operating mechanism and foundation details. Foundation details of operating mechanism. Fixing details of earth operating mechanism with base channels.
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13
Instruction manual for erection, operation and maintenance.
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8
Sl. 1
Specific Requirements
Parameter 2 Value 3
145 KV ISOLATOR 1) 2) 3) 4) a) b) 5) 6) 7) 8) 9) a) b) 10) a) b) 11) Rated voltage Number of poles Type Rated continuous current For terminal height 5.3M & phase spacing 2.7M For stringing height 9M & phase spacing 2.7M Rated frequency Rated short time current Rated peak withstand current Type of Break Basic Insulation level 1.2/50 microsec Impulse test voltage (KVp) To earth and between poles Across isolating distance One minute power frequency withstand voltage (KVrms) To earth and between poles Across isolating distance Operating Mechanism 275 315 Motor operated, 3 phases mechanically ganged, Control voltage 415 V, AC, 50Hz Electrical As per IS:9921 As per IS:9921 Independent manual drive mechanically interlocked with main blades. Horizontal upright with horizontal break. 1472 mm 2 Amps Solid core post type as per specification 650 750 145 KV Three As per specification 1250 A 2000 A 50 Hz 40 KA for 3 secs. 100 KA Double, horizontal
a)
Normal type
12) 13) 14) 15)
Interlock Temperature rise of current carrying parts Short time rating Earthing Switch
16) 17) 18) 19)
Mounting Minimum clearance for isolator between phase and earth Maximum charging current to be interrupted Insulators
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SPECIFICATION FOR INSTRUMENT TRANSFORMERS

Scope
This specification covers design, manufacture, assembly, testing at manufac turers works, packing and delivery at site of 132 KV outdoor type current transformers and 132KV/3 / 110V/3 outdoor type, electromagnetic potential transformers for relaying and metering purposes in 132KV solidly grounded system at 132 KV Chandil Substation. The Current and Potential transformers shall be complete with all accessories including secondary terminal boxes. Current transformer shall hereinafter be referred to as CT and potential transformer as PT.
Standards
The equipment covered by this specification shall conform in all respect to the latest version of the following standards: IEC : 60044-1 IS : 2705(Part I, II, III, IV) IS : 5621-Specification of Hollow Insulators for Use in Electrical Equipment. IEC : 60044-2 IS : 3156 (Parts I,II,III) Wherever the stipulation in this specification are at variance with the standard, the stipulations made herein shall be binding.
System Data
132 KV system is effectively earthed. The system frequency is 50 Hz. The three-phase unit vector rotates anti-clockwise in the order Red - Yellow - Blue - Red.
Construction
The outdoor type single phase current transformers shall be of dead tank design for 132 KV CT. The design and construction shall be such as to enable ease of handling during repair and maintenance at site. The CT shall be structurally stable. The common features shall be as follows:
4.1 Tank and Fittings

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All 132KV instrument transformers shall be hermetically sealed. Nitrogen may be used for hermetic sealing. The tank as well as other metallics exposed to the atmosphere may be hot dip galvanized or painted and shall be designed to withstand internal pressures developed due to symmetrical short circuit values stated elsewhere in this document. The tank shall be hydraulically tested for oil tightness and all cover seals flanges joints, threaded connections and pipe- fittings shall be properly machined and provided with gaskets where necessary to ensure oil tight fitting. Compensation arrangements for oil volume variation in tank shall be ensured. The tank shall be fitted with oil sight gauges and cocks for convenient filling and draining of oil. Pressure relieving device capable of releasing abnormal internal pressures should also be provided. The bushing shall be of oil filled porcelain type suitable for outdoor use and mounted upright on Steel Structure. The porcelain shall be made by wet process, and shall be homogeneous thoroughly vitrified and impervious to moisture. The glazing shall be uniform brown color, free from blisters, burns and other similar defects. The oil filled bushing shall have ample insulation and mechanical strength for the duty involved and shall be designed to prevent accumulation of explosive gases and to provide adequate oil circulation to remove internal heat. There shall be no undue stressing due to temperature changes and adequate means shall be provided to accommodate conductor expansion. The Bushing should conform IS 5621. The insulation of the bushing shall be co-ordinated with that of the current transformer such that the flash-over will occur externally.
4.2 Mounting
The Instrument Transformers shall preferably have universal base for mounting on steel structures.
4.3 Connectors for earthing

Suitable connectors for earthing connections of the equipments to ground bus shall have to be supplied with the equipment. Each current transformer shall have two grounding pads.
4.4 Secondary Terminal Box

The secondary terminals shall be housed in a weather proof chamber for receiving Purchasers PVC insulated, PVC sheathed, armored power/control cables. The number of opening in the tank for bringing out tapping should be kept to a minimum. The secondary terminal compartment shall have a removable cover. The terminal box, with the cover closed and tightened and the cable/conduit in position when supplied shall have degree of protection conforming to IP 55 of IS :2147.The secondary terminals of CT shall be suitable for lugs of 6 sq.mm. Copper for 1A secondary and 10 sq.mm. for 5A secondary. In the case of 132 KV CTs, the primary winding power factor tap shall also be terminated in the secondary terminal box through proper bushing.
4.5 Terminals
CT primary and secondary shall be made of Copper. PT primary terminals shall be made of non-ferrous corrosion resistant material.
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4.6 Painting
All interiors or exteriors of tanks, secondary box and other metal Parts shall be thoroughly cleaned to remove all rust, scales, corrosion, grease or other adhering foreign matters. All steel surfaces in contact with insulating oil as far as accessible shall be painted with not less than two coats of heat resistant oil insoluble insulating varnish. Steel surface exposed to the atmosphere if not hot dip galvanized shall be given a priming coat of Zinc Chromate and two coats of light grey paint. All metal parts not accessible for painting shall be made of a corrosion resisting material. All machine finished or bright surfaces shall be coated with a protective compound and suitably wrapped or otherwise protected. All points shall be carefully selected to withstand tropical heat and extreme weather conditions. The paint shall not scale off or crinkle or be removed by abrasion due to normal handling and for a reasonable period of life.
4.7 Name Plate and Markings

Each current transformer shall carry rating and diagram plate giving particulars as per IS 2705. The terminal markings shall also be in according with the specification mentioned above.
4.8 Oil
The oil shall be un-inhibited conforming to IS-335.
Instrument Specific Features
Apart from the above constructional requirements each type of instrument transformer shall comply with the following additional features:
5.1
Current transformer
The current transformers shall have a ring type or hair pin type primary designed in such a manner as to bring of the secondary terminals in a weather proof terminal box at the bottom. The secondary terminals shall be terminated to stud type terminals inside the terminal box. Primary terminal shall be made of copper only.
5.1.1 Temperature Rise

The temperature rise of current transformer winding when carrying continuous thermal current at rated frequency with rated output shall not exceed the following values above the specified ambient: 40 C in all parts by thermometer o 45 C in the winding by resistance
o
5.1.2 Core Construction

The core shall be of high grade, non-aging, electrical silicon laminated steel of low hysteresis loss and high permeability to ensure high accuracy at both normal and over-current. The core shall be mechanically strong and all core-clamping bolts shall be effectively insulated. The core to be used for metering and instrumentation shall be of accuracy class specified. The saturation factor of the core shall be low enough not to cause any damage to measuring instruments in the event maximum short circuit current. Tariff metering cores shall be made of mumetal. Cores to be used for protective relaying purpose shall be of accuracy class specified.
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5.1.3 Windings
Primary and secondary shall be made of Copper only. Cross-section of the winding shall be chosen to suit the specified continuous and short-time current carrying capacity .The different ratios specified shall be achieved by secondary taps only and primary reconnection shall not be accepted in any case. The rating of the secondary windings shall be as indicated in the design requirements. The secondary terminals shall be provided with short circuiting arrangements. The secondary taps shall be adequately reinforced to withstand normal handling without damage.
5.1.4 Protective device

Secondary protective device shall be provided, if necessary.
5.1.5 Insulation
The current transformer shall withstand satisfactory the dielectric test voltages corresponding to basic insulation level of 650 KVp for 132 KV CT.
5.2
Potential transformers
The potential transformer shall be outdoor porcelain type, oil immersed self cooled, single pole, single phase, electromagnetic type for 132KV effectively earthed system. PT shall conform to IS : 3156 in all respect. PT shall be used as potential source to protective relays, indicating instruments, tariff metering equipment and for obtaining voltage reference for synchronizing purpose.
5.2.1 Temperature Rise

The temperature rise of voltage transformer at the specified voltage, rated frequency and rated burden at any power factor between 0.8 lagging and unity shall not exceed the following values above the specified ambient: 40 in oil by thermometer 45 in winding by resistance 55 in winding at rated Voltage factor by resistance The voltage transformer shall be designed to prevent accumulation of explosive gases and to provide adequate oil circulation to remove internal heat. There shall be no undue stressing due to temperature changes and adequate means shall be provided to accommodate conductor expansion. The bushing should conform to IS : 5621.
o o o
5.2.2 Core Construction

The core shall be of non-ageing silicon laminated steel of the highest quality. Laminations shall be coated on one side with approved insulating materials and shall be inter-leaved. The core shall be mechanically strong and all core clamping bolts shall be effectively insulated. The core shall be so designed that no saturation takes place when 1.73 times normal voltage is applied to the windings for a period of 15 minutes.
5.2.3 Winding
Secondary winding shall be made of Copper. The Primary VA capacity should be sufficient to deliver the summation of rated burdens of all secondary windings.
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The Potential Transformer Core to be used for metering and instrumentation shall be of specified accuracy class as per IS : 3156. The PT core to be used for protective relaying purpose shall be of specified accuracy class as per above mentioned IS.
5.2.4 Insulation
The PT shall withstand satisfactorily the dielectric test voltage corresponding to basic insulation level of 650 KVp for 132 KV voltage level.
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6.1
6.1.1
Tests
Current Transformers
Type Tests
Complete Type Test Reports as per SCC on similar Current Transformers shall be submitted with the offer. The tests shall be carried out as prescribed in the indicated standards. The following constitutes the Type Tests : 1. Short time current test. 2. Temperature Rise test. 3. Lightning Impulse test. 4. High voltage power frequency wet withstand voltage test. 5. Determination of errors and other characteristics specific to a particular accuracy class.
6.1.2
Routine Tests
Complete Routine Test Reports shall be submitted as per SCC. The tests shall be carried out as prescribed in the indicated standards. The following constitutes the routine tests: 1. Verification of terminal markings and polarity. 2. Power frequency dry withstand tests on primary winding. 3. Power frequency dry withstand tests on secondary windings. 4. Over-voltage inter turn test. 5. Partial discharge tests as per IS 11322/IEC 60270. 6. Determination of errors and other characteristics specific to a particular accuracy class.
6.1.3
Acceptance Tests
All tests indicated in the list of routine tests shall constitute the acceptance tests. In addition to the above, Temperature Rise Test shall be carried out on one CT of each lot offered for inspection. The tests shall be carried out in the presence of Purchasers representative if so desired by the Purchaser.
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6.2
6.2.1
Potential Transformer
Type Tests
Complete Type Test Reports as per SCC on similar Potential Transformers shall be submitted with the offer. The tests shall be carried out as prescribed in the indicated standards. The following constitutes the Type Tests : 1. Temperature-rise test 2. Short-circuit withstand capability test as per IEC 60044-2 3. Lightning impulse test 4. High voltage power frequency wet withstand test.
5. Determination of errors and other characteristics specific to a particular accuracy class.
6.2.2
Routine Tests
Complete Routine Test Reports shall be submitted as per SCC. The tests shall be carried out as prescribed in the indicated standards. The following constitutes the routine tests: 1. 2. 3. 4. 5. 6. Verification of terminal markings and polarity. Power frequency dry withstand tests on primary winding. Power frequency dry withstand tests on secondary windings. Over-voltage inter turn test. Partial discharge tests as per IS 11322/IEC 60270 Determination of errors and other characteristics specific to a particular accuracy class.
6.2.3
Acceptance Tests
All tests indicated in the list of routine tests shall constitute the acceptance tests in the presence of Purchasers representative if so desired by the Purchaser.
Documentation
The number of copies required and procedure for submission are indicated in the SCC. The following shall be submitted: 1. Detailed dimensional drawings and drilling plan, list of fittings and details of terminal pads, net weight of the instrument transformer complete with oil and fittings and weight and volume of oil. 2. Diagram of connections, name plate and rating plate. 3. Sectional view showing internal arrangement of Core and Windings and connections. 4. Magnetisation curve and other electrical data. 5. Manuals if any.
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132 KV Current Transformer Value Type 2 3 Type 3 4 132 145 650 275 50 40 100 800 960 3625 A 3 10pC max Dead tank 120% (for Core-1)
Sl. 1 1 2 3 4 5 6 7 8 9 10
Parameter 2
Nominal System Voltage in KVrms 132 Highest System Voltage in KVrms 145 Lightning Impulse withstand voltage in KVp 650 One minute power frequency wet withstand 275 voltage in KVrms Rated frequency in Hz Rated short time current for 1 sec in KA Rated dynamic current in KAp Rated Primary Current in Amps. Rated continuous thermal current in Amps. 50 40 100 800 960 3625 A
Minimum creepage distance (phase to ground) in mm 11 Class of insulation
One minute power frequency withstand 12 voltage between secondary terminal and 3 earth in KVrms 13 Partial discharge level 14 Type 15 Extended current rating 16 16a) 16b) 16c) 16d) 16e) Core-1 Ratio Class Burden ISF Minimum knee point voltage (Vkp) 10pC max Dead tank 120% (for Core-3)
800-400/5A PS 1000V/500V 100/200 mA at Vkp 800-400/5A PS 1000V/500V 100/200 mA at Vkp 800-400/5A 0.2 30/15 VA 5
800-400/5 A 0.2 30/15 VA 5 -
16f) Excitation Current (Iex) 17 17a) 17b) 17c) 17d) 18 18a) 18b) 18c) 18d) Core-2 Ratio Class Minimum knee point voltage (Vkp) Excitation Current (Iex) Core-3 Ratio Class Burden ISF
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132 KV Electromagnetic Potential Transformer Sl. 1 1 2 3 4 5 6 7 8 9 10 11 Parameter 2 Nominal System Voltage in KVrms Highest System Voltage in KVrms Lightning Impulse withstand voltage in KVp One minute power frequency wet withstand voltage in KVrms Rated frequency in Hz Rated voltage factor Minimum creepage distance (phase to ground) in mm Class of insulation Type Earth fault factor Winding 3 132 145 650 275 50 1.2 continuous 1.5 for 30 secs 3625 A Dead tank < 1.4 1 132KV/3 110V/3 3P 75 2 132KV/3 110V/3 0.2 75 Value Type 1
11a Ratio 11b Class 11c Burden in VA 12 Winding 12a Ratio 12b Class 12c Burden in VA
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SPECIFICATION FOR LIGHTNING ARRESTERS

1 Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of 120 KV heavy duty station class Zinc Oxide gapless Lightning Arresters for 132 KV AC neutral grounded system complete with insulating base, surge monitors, surge counters, current meters and other connecting accessories for 132 KV Chandil Substation.
2 Standards
The equipment shall conform to the latest edition of the following standards: 1. 2. IEC 60099-4, Metal-oxide surge arresters without gaps for A. C. systems. IS : 3070(Part-III) - Metal-oxide surge arresters without gaps
Wherever the stipulations in this specification are at variance with the standards, the stipulation made herein shall be binding.
3 System Data
Nominal System Voltage (KV rms) Highest system voltage (KV rms) No. of Phases Operating frequency (Hz) System neutral connection Isocraunic level Shielding Shield angle - 132 KV. - 145 KV. - 3. - 50. - 132 KV - solidly earthed - 70. - Overhead ground wires provided. - 30.
B.I.L. of the equipment to be protected (KVp) - 650 KVp for 145 KV system
4 Construction
Construction requirements shall conform to indicated IEC/IS. All cemented and detachable ferrous hardware shall be hot dip galvanised. Galvanising shall conform to IS:2629. Each Lightning Arrestor shall be complete with all fittings and accessories like grading rings, discharge counter, leakage current detector, connecting conductor, clamp type terminal
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connectors, porcelain base, two (2) clamp type ground terminal connectors suitable for G.I. Strip (50mm x 6mm) and necessary hardware such as nuts, bolts, spring washers etc. with 20% spare hardware.
5 Tests
Type Test Complete Type Test Reports as per SCC on similar Lightning Arresters shall be submitted with the offer. All tests prescribed in the indicated standards shall be carried out. The design test shall include Radio interference on the complete arrester. Routine Test Complete Routine Test Reports shall be submitted as per SCC. The tests shall be carried out as prescribed in IEC 60099-4 by the manufacturer on all complete arrestors and also on each section as per their standard practice. The resistive current drawn by the arrestor at rated voltage shall be indicated in the routine test report. A schedule of the standard tests carried out by the manufacturers shall be submitted along with the tender. Acceptance Test - All acceptance tests stipulated in IEC 60099-4 shall be performed.
6 Documentation
Documentation shall include the following: 1. Dimensioned drawing of complete arrester and fixing details. 2. Sectional view of the arrester. 3. Diagram of minimum clearances in relation to adjacent grounded metallic structures. 4. Dimensioned drawing of terminal and ground connector giving details of materials used. 5. Dimensioned drawing of the surge monitor and counter and current meter. 6. Dimensioned drawing of the insulating base.
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Sl. Instrument 120 KV LA 1 2 3 4 5 6 7 Outdoor, pedestal mounted Metal oxide, heavy duty, gapless, single Arrester type and class column, single phase, station class Rated arrester voltage in KV 120 o Maximum continuous operating voltage at 50 C 102 KV (MCOV) discharge current in KA with 8/20 sec Nominal 10 wave Insulation withstand voltage (Dry, Wet and Test as per IEC 60099-4 Impulse) Steep current impulse residual voltage at 10 KA Test as per IEC 60099-4 of 1 sec front time Lightning Impulse residual Voltage (KVp) (8x20 sec wave) 8 i) 5000 A Test as per IEC 60099-4 ii) 10000 A iii) 20000 A 9 10 11 Long duration discharge class Switching impulse withstand voltage of arrester housing High current impulse withstand value (4x10 sec) Pressure relief rated current i) High Current ii) Low Current BIL (KVp) Minimum creepage distance(mm) Class 3 Test as per IEC 60099-4 100 KA peak Type of installation LIGHTNING ARRESTERS Value
12 13 14
As per IEC 60099-4 650 3625
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SPECIFICATION FOR LT (FRLS) CABLES

1 Scope
This specification covers design, manufacture, assembly, testing at manufac turers works, packing and delivery at site of the following for 132 KV Chandil Substation: 1. LT POWER CABLE (FRLS TYPE) - AL. CONDUCTOR: 1.1 KV (E) circular/shaped stranded Aluminium conductor, extruded PVC insulated, extruded PVC innersheated, GI. round/flat armoured, overall served with PVC suitably compounded to ensure specified fire retardant low smoke properties, heavy duty power cable conform to IS:1554(Pt.I) and meeting type and special test requirements detailed herein. LT POWER CABLE (FRLS TYPE) - CU CONDUCTOR: 1.1 KV (E) circular/shaped stranded Copper conductor, extruded PVC insulated, extruded PVC innersheathed, GI. round/flat armoured, overall served with PVC suitably compounded to ensure specified fire retardant low smoke properties, heavy duty power cable conform to IS:1554(Pt.I) and meeting type and special test requirements detailed herein. LT CONTROL CABLE (FRLS TYPE) - CU. CONDUCTOR : 1.1 KV (E) stranded plain (untinned) annealed high conductivity copper conductor, extruded PVC insulated, extruded PVC innersheathed, Single layer GI round/ flat armoured, overall served with PVC suitably compounded to ensure specified fire retardant low smoke properties, heavy duty control cable conform to IS : 1554 (Pt. I) and also meeting type and special test requirements detailed herein.
2.
3.
2 Standards
Cables specified in this specification shall conform to latest version of the following International/Indian standards. 1. IS :3961 Recommended current ratings for cables. PVC insulated (heavy duty) electric cables for working voltages upto and including 1100 V. PVC insulation and Sheath of electric cables. Conductors for insulated electric cables and flexible cords. Mild steel wires, strips and tapes for armouring of cables. Methods of test for cables (All relevant Parts) Common test methods for insulating and sheathing materials of electric cables and optical cables Tests on electric and optical fibre cables under fire conditions (all relevant parts)
2. IS :1554 (Pt. I) 3. IS :5831 4. IS :8130 5. IS :3975 6. IS :10810 7. IEC 60811 8. IEC 60332 -
56
9.
IEC 60331
Tests for electric cables under fire conditions (all relevant parts) . Test on gases evolved during combustion of materials from cables Part 1: Determination of the amount of halogen acid gas Part 2: Determination of degree of acidity of gases evolved during the combustion of materials taken from electric cables by measuring pH and conductivity.
10. IEC 60754
If any better standards other than those specified above are adopted than the same shall be stated and latest revision of the English version of the same shall be submitted. The performance and operation of the equipment in such case shall be equal to or better than the specified standards.
3 Operating Conditions
Cables shall be used for rated system voltages 415 V / 240 V (neutral solidly grounded), 50 Hz, AC and 250 V DC. Voltage variation shall be 20%. Frequency variation shall be 5%. Combined voltage and frequency variation shall be 10%. For purpose of this specification ambient temperature shall be 50 oC peak and 45 oC average.
4 Design Requirements
4.1 Aluminium Conductor, PVC Insulated, LT Power Cables (FRLS)
1. Designation : 1100 V (E) grade, multi-core, Aluminium conductor, PVC insulated, GI flat/round armoured overall served with PVC suitably compounded to ensure specified fire retardant low smoke properties heavy duty power cable.
2. Reference : IS 1554 (Pt. - I), IS 8130, IS 5831, IS 3975,IS 10810 other applicable standard and test requirements as subsequently specified. 3. Conductor : Compact circular/sector shaped stranded H2 or H4 Aluminium conductor Class 2 Table 2 of IS:5831. 4. Insulation : PVC Type-A conforming to IS 5831. 5. Innersheath & filler : PVC Type ST-1 conforming to IS 5831. Inner sheath shall be extruded. 6. Armouring : GI Wires/Strips conforming to IS 3975 and IS 1554 (Pt. - I). 7. Outer sheath : PVC type ST-1 to IS 5831 suitably compounded for FRLS properties and with suitable additives to prevent attack by rodents and termites and passing test requirements specified here in after. 8. Factory test : As specified hereinafter.
4.2 Copper Conductor,PVC Insulated, LT Power and Control Cables (FRLS)

1. Designation : 1100 V (E) grade, multi-core copper conductor, PVC insulated GI flat/round armoured, overall served with PVC suitably compounded to ensure specified fire retardant low smoke properties heavy duty control cable.
57
2. 3. 4. 5. 6.
Reference : IS 1554 (Pt. I); IS 8130; IS 5831; IS 3975, other applicable Standard and test requirement as subsequently specified. Conductor : Standard plain (untinned) annealed high conductivity copper conductor Class 2 table 2 of IS 8130. Insulation : PVC Type-A of IS 5831. Innersheath and filler : PVC Type ST-1 of IS 5831. Inner sheath shall be extruded. Outer sheath : PVC type ST-1 of IS 5831 suitably compounded for FRLS properties and with suitable additives to prevent attack by rodents and passing test requirements specified hereinafter. Armouring : GI Wire/strips to IS 3975 and IS 1554 (Pt. I). Factory test : As specified hereinafter.
7. 8.
Identification Marks
Throughout the length, cables served with FRLS PVC outer sheath shall be identified by surface marking by embossing/ machine printing giving : 1. Name of manufacturing and year of manufacture: 2. Cable description e.g. 1100 V 4C x 10.0 Sq. mm Cu PVC FRLS Type cable etc. 3. Name of customer e.g. CUSTOMER: DVC 4. Embossed length measure in Meters at every meter interval. 5. Core identification shall be done by colours as per IS 1554 (Pt. I).
6 Drumming, Reeling & Marking

The cables shall be supplied in non-returnable wooden drums in 500M 5% reel lengths for power cables and 1000M 5% for control cables unless otherwise specified. The cable drums shall be suitable for taking round spindle and shall be suitably logged with strong 5cm thick wooden battens so as to prevent damage to the cable. A minimum clearance of 15cm shall be allowed between the outer layer and the inside of logging. Cable ends shall be properly sealed and made water tight so as to prevent ingress of moisture during transit/storage in the open cable yard. The drums shall be suitably reinforced with hoop iron to withstand transit hazards. Each drum shall have a distinguishing number. On outside of the flange particulars of the cable viz. voltage class, length, cable description, project reference and order details, finished gross weight and net weight and direction of reeling shall be clearly stated on the flange of the drum. The wooden drum shall conform to latest IS. Non-standard lengths are not acceptable.
7 Tests
Following type tests including special tests, acceptance and routine tests as per requirements of relevant standards mentioned shall be carried out on conductors, cores and finished cables in the works premises of the manufacturer.
7.1
Type tests
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Complete Type Test Reports shall be submitted with the offer as per the indicated standards from NABL accredited laboratory / Equivalent laboratory aboard. The test of one drum out of every 10 drums or less on each type and size of the cable shall be conducted as per IS:10418. A) Test on Conductor 1. Tensile test (for Aluminium) 2. Annealing test (for Copper) 3. Wrapping test (for Aluminium) : As per IS 8130. : As per IS 8130. : As per IS 8130. As per IS 8130. As per IS 3975. As per IS 1554(Pt.I) As per IS 5831
4. Conductor resistant test (for Aluminium and Copper) : B) C) D) Test for armouring wires Test for thickness of insulation and sheath Physical test for insulation and outer sheath a) Tensile strength and elongation at break b) Ageing in air oven c) Shrinkage Test d) Hot deformation e) Loss of mass in air oven f) Heat Shock Test g) Thermal Stability h) Cold Bend Test (for diameter 12.5 mm) i) Cold Impact Test (for diameter > 12.5 mm) E) F) G) H) Insulation resistance test High voltage test (water immersion test ) High voltage test at room temperature Flammability Test : : : : : :
As per IS 5831 As per IS 1554(Pt.I) As per IS 1554(Pt.I)
: As per IS 1554(Pt.I)
7.2
Special Tests
These tests will be conducted on any two drums of each group as per Purchasers choice. 1. Water absorption test for insulation as per IS 5831 2. Oxygen Index test as per ASTMD-2863. Minimum guaranteed value shall be 29. 3. Temperature Index test to ASTMD-2863. Minimum guarantee value shall be 250.0. 4. Acid gas generation test as per IEC 60754. Maximum guaranteed value should be 20 5. Smoke density test as per UTTD test method F4 of ASTM-D2843.
7.3
Acceptance Tests
1. Tensile test (for aluminium) 2. Annealing test (for copper) 3. Wrapping test (for Aluminium) 4. Conductor resistance test
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5. Test for thickness of insulation and sheath 6. Insulation resistance test 7. High voltage test at room temperature 8. Dimensional check.
7.4
Routine Tests
These tests will be conducted on each drum of FRLS cable. 1. Conductor resistance test 2. High voltage test at room temperature Existence of facilities for carrying out all the routine tests in manufacturers works shall be specifically confirmed. Dates of installation and commissioning and details of make, year of manufacture etc. for machines/test apparatus for carrying out special tests shall be furnished. The purchaser at his discretion may call for additional tests not included here, as may be required to ensure that all materials are satisfactory and in accordance with the specifications. All tests shall be carried out be the manufacturer expeditiously free of cost. Report for Type tests including special tests shall be furnished with the Routine test certificates for the first lot of each type/group of cable in the event of order. Reports for Acceptance tests shall similarly be furnished along with the Routine Test Certificates for all individual lots beginning with the first batch. Routine test certificates for all drums shall be furnished. Special tests shall be carried out on any two drum length of Power and control Cables at Purchasers choice. All test certificates shall be submitted to the Purchaser for approval before despatch. Approval of test certificates by the Purchaser must precede despatch of the cables. The Purchaser reserves the right to witness all tests, for which at least 3 weeks advance intimation for inspection, will be required. Under armour and overall diameters of cables (average values) shall be recorded on each Routine test certificates.
Documentation
As part of the offer, the tender shall furnish relevant descriptive and illustrative literatures on cable and also the drawings and technical data for the following besides other : 1. Descriptive literature/manufacturers leaflets giving construction details cross-section dimensions and characteristics of different type of cables offered. 2. Current rating of cable including derating factors due to grouping, ambient temperature and type of various installations. 3. Table for short circuit withstand capacity of cable and armour material indicating time duration. 4. Write-up, sketches, other details illustrating manufacturers recommendation for splicing jointing and termination. 5. Table of voltage drop per ampere meter duty considering impedance at 50 Hz at maximum conductor operating temperature. 6. Tables giving mechanical constructional details including weight, diameter etc.
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CABLES Sl. Description 2 LT Power Cable 1.1KV grade, FRLS, LT power cable (Al) 1.1KV grade, FRLS, LT power cable (Al) 1.1KV grade, FRLS, LT power cable (Al) 1.1KV grade, FRLS, LT power cable (Cu) LT Control Cable 1.1KV grade, FRLS, LT control cable (Cu) 1.1KV grade, FRLS, LT control cable (Cu) 1.1KV grade, FRLS, LT control cable (Cu) Type 3
1. 2. 3. 4. 1. 2. 3.
3.5C x 25 sq.mm 4C x 16 sq.mm 2C x 10 sq.mm 4C x 10 sq.mm 4C x 2.5 sq.mm 7C x 2.5 sq.mm 19C x 2.5 sq.mm
61
SPECIFICATION FOR ALUMINIUM TUBES

Scope
This specification covers design, manufacture, assembly, testing at manufac turers works, packing and delivery at site of seamless extruded Aluminium tubes of different lengths for use as busbars in 132 KV, 3-Phase AC, outdoor switchyards of 132 KV Chandil Substation.
Standards
The Aluminium tubes covered by this specification shall conform to the latest edition of IS : 5082. In the event of the Bidder offering the equipment conforming to specifications other than the above mentioned standards, an English translation of the specification shall be submitted with the tender stating the relevant advantages. The Aluminium tubes shall have ISI standard mark. Grade of Aluminium material is 63401 - WP. In the event of a conflict between the above standards and the stipulations laid down in this specification, the decision of the purchaser shall be final and binding.
Operating Conditions
Nominal System Voltage (KV rms) Highest system voltage (KV rms) No. of Phases Operating frequency (Hz) System neutral connection Clearance between phases 132 KV. 145 KV. 3. 50. 132 KV - solidly earthed 132 KV System - 2743 mm
Guarantee
The performance and test figures given with the tender shall be guaranteed and the tolerance applicable shall be stated. The items not conforming to the guaranteed figures shall be liable to rejection by the Purchaser. Any item found not satisfying the above performance characteristics or not conforming to the specification shall be replaced at site, free of the cost within a reasonable time but not later than three months from the date of reporting the defect to the supplier. The Purchaser reserves the right to call for samples if considered necessary and the same shall be submitted by the Bidder free of cost without any obligation.
Completeness of Offer
The materials offered, shall be complete with all components and accessories which are necessary or usual for their efficient performance and satisfactory maintenance. Such parts shall be deemed to be within the scope of the contract whether specifically included or not, in this
62
specification and tender schedule. The contractor shall not be eligible for any extras in respect of such accessories etc.
Tests
The Bidder shall also submit full particulars of testing facility available at the manufacturing plant or the manufacturing quality plan. The following tests shall be carried out in presence of the Purchasers representative on the required number of samples of Aluminium tubes as stipulated in this or any other approved standard : 1. Chemical composition of Aluminium. 2. Ultimate shearing strength. 3. Ultimate tensile strength. 4. Electrical resistivity or conductivity.
Packing
The Aluminium tubes shall be packed in such a manner that they do not suffer cut marks or bend during transit.
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2.5 inch inch AL. TUBES
Aluminium tubes shall have the following parameters:
Sl. 1 1 2 3 4 5 6 7 8 9
Parameter 2 Outside dia (mm) Wall thickness (mm) Unit length (meter) Weight/Meter in (Kg) Min. ultimate tensile strength (Kg/sq mm) 0.2% Proof stress Yield strength (Kg/sq mm) Modulus of Elasticity (Kg/mm) Minimum Elongation on 50.8 mm (%) Max. DC resistance/meter run at 20C (microohm)
Value 3 73.03 5.17 As per unit length specified in price schedule 3.002% 20.4 17.34 6700 10 26.08
10 Temperature coefficient of resistance/C 0.00364 11 Minimum electrical conductivity at 20C(% IACS) 55 12 Current carrying capacity outdoors at 50 Hz continuous (Amps) Electrical resistivity (Max) at 20C (ohm2 mm/mm ) 1950 35 0.03135 Cu - 0.05 max, Mg - 0.4 - 0.9, Si - 0.3 0.7, Fe - 0.5 max, Al -Remainder 0.52 shall conform to IS 2673 (latest edition)
13 Temp. rise over an ambient of 50C (C) 14
15 Chemical Composition (in %) 16 Thermal conductivity (Cal./Sec./Sq.cm/cm/C) at 100C
17 Tolerance on wall thickness and diameter
64
SPECIFICATION FOR CONDUCTOR

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of the following conductors for 132 KV transmission lines and Substations: AAAC PANTHER conductor (size - 37/3.15 mm) ACSR MOOSE conductor (size - Al-54/3.53 mm, St-7/3.53 mm)
Hereafter the abbreviation AAAC shall mean All Aluminium Alloy Conductor and ACSR shall mean Aluminium Conductor Steel Reinforced .
Standards
AAAC and ACSR conductor shall conform to the latest edition of IS - 398 (PART- 4) and IS - 398 (PART-2 ) respectively. The conductor shall have ISI standard mark. If the materials conform to a standard other than the Indian Standard specification then an English version of the standard in addition to the original standard if written in a language other than English, should be submitted indicating clearly the advantage, if any, that would be obtained by the purchaser by adopting this standard instead of the said Indian Standard. The standard proposed to be adopted shall clearly be stated in the tender papers. Any deviations from this specification will be considered provided they are necessary either to improve the utility, performance, efficiency and / or durability of the equipment or to secure an overall economy consistent with the purchasers requirements hereinafter specified.
Manufacturing Requirements
The AAAC shall consist of strands of heat treated aluminium alloy strands containing approximately 0.5% magnesium and approximately 0.5% silicon. The ACSR conductors shall consist of hard drawn aluminium strands and galvanised steel strands. The aluminium strands of the ACSR conductor shall be drawn from electrolytic aluminium rod having purity of not less than 99.5%. The steel strands of the ACSR conductor shall be drawn from steel produced by either acid or basic open-hearth process or by the electric furnace or basic oxygen process. No steel produced by the Bessemer process shall be used for drawing wires. All strands of both AAAC and ACSR conductors shall be reasonably uniform and shall be free from all defects, die marks and scratches after drawing and also after stranding. The length of any piece of finished conductor shall not vary from the standard length guaranteed in
65
the Schedule of Technical Particulars. Galvanising shall be uniform, free from blisters and shall not peel off due to abrasion. Zinc coating shall be thick and uniform enough to withstand the requirements stated in the indicated standards.The zinc used for galvanizing shall be electrolytic high grade zinc not less than 99.95% purity.
Tests
All the tests shall be carried out on the required number of samples as stipulated in the IS-398 (Part - IV) and IS-398 (Part - II) or any other approved standard, in presence of purchasers representative. Selection of samples, conditions of repetitive tests and rejection of materials if any shall strictly be in accordance with the requirements of the approved standard or as per the standard practice of the manufacturers and in the later case full details of the standard practice shall be stated in the tender. The relevant test reports for the repetitive tests including the results of the tests in which the equipment failed to satisfy the requirements of the approved standard, shall also be submitted in triplicate. All costs for tests / retests shall be borne by the manufacturer. The manufacturer shall submit full particulars of the testing facilities available at its laboratory and shall confirm that the laboratory will be readily available, when required, for testing of all the equipment offered by it. The Purchaser may choose to conduct any or all of the tests stipulated in the indicated standard be carried out in an accredited laboratory. Accreditation should be from the national accreditation body of the country in which the laboratory is located. The manufacturer shall arrange to carry out such tests expeditiously and at its own cost. Test reports in triplicate for such tests shall be submitted to the Purchaser for approval.
Packing
All cable reels shall conform to relevant IS and be of dimensions approved by the purchaser and made of seasoned wood sufficiently strong to ensure arrival at site intact, withstanding normal handling and hazards inland and ocean transit. The reels shall be of such size as to provide at least 0.5 (half inch) clearance at all points from the cable to the inner surface of the lagging. All reels shall have two coats of aluminium paint on both inside and outside surface and shall be fitted with malleable iron hub-bushings each having a 2.75 (inch.) diameter hole. All reels shall have a layer of waterproof paper around the hub under the cable and another layer over the outermost layer of the cable, that is, next to the lagging. The reels shall be properly reinforced with galvanised steel wires or iron strips over the lagging in two places in an approved manner. The wooden drums shall preferably be given protective coating of a reliable organic wood preservative before painting with Aluminium paint and the lagging shall also be given a similar treatment before being fixed on the drum. There shall be one specified length of conductor in each drum.
Marking of Drums
Each drum shall be marked on the sides as follows:

66
1. Name or designation of the consignee to be furnished by the Purchaser. 2. Ultimate destination and / or the port of discharge as required by the Purchaser. 3. The items and the respective quantities contained in it e.g size and type of conductor, length of conductor in meter etc. 4. The net and gross weights of the materials. The markings shall be stenciled in indelible ink on each drum.
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ACSR MOOSE
Conductors shall satisfy the following parameters:
Sl. 1 1. a) b) c) d) 2. a) b) 3. a) b) 4. 5. 6. 7. 8. 9. 10. a) b) c) d) 11. 12. 13. 14. a) b) c) d)
Parameter 2 Physical constants for hard drawn Aluminium wires shall be as follows: Maximum Resistivity of Al wire Density of Al. wire(at 20C) Coefficient of linear expansion Wires Physical constants for galvanised steel wire shall be as follows: Density(at 20C) Coefficient of linear expansion Stranding and wire diameter Aluminium Steel Nominal Sectional area of conductor Approximate total mass Calculated equivalent Al area Overall diameter of the conductor Calculated resistance at 20 C (corrected to standard weight) Ultimate tensile strength of conductor Lay Ratio Steel core Outside Aluminium layer (24 wire layer) Intermediate Aluminium layer (18 wire layer) Intermost Aluminium layer (12 wire layer) Final modulus of elasticity Final Coefficient of linear expansion Normal length without joint, weld Diameter of each strand : Standard - Steel Standard - Aluminium Maximum - Steel Maximum - Aluminium
o
Value 3
0.028264 Ohm-mm /m 3 2.703 g/cm -6 23.0 X 10 /C EC grade Aluminium of purity 99.5%
7.80 gm/cm -6 11.5 X 10 /C 54/3.53 mm 7/3.53 mm 2 597.0 mm 1999 Kg/KM 2 528.5 mm 31.77 mm 0.0555 Ohm/KM 161.20 kN Max : 28 Min : 13 Max : 14 Min : 10 Max : 16 Min : 10 Max : 17 Min : 10 2 69 GN/m -6 19.3 X 10 /C 1200 Mtrs. 3.53 mm 3.53 mm 3.60 mm 3.57 mm
68
Sl. 1 e) f) 15. a) b) 16. a) b) 17. a) b) 18. a) b) 19. a) b)
Parameter 2 Minimum - Steel Minimum - Aluminium Sectional area of each strand: Steel Aluminium Weight of each strand Steel Aluminium Minimum ultimate tensile stress Steel Aluminium Minimum breaking load of each wire before stranding after stranding Zinc coating No. and duration of Dips Minimum weight of Zinc coating AAAC PANTHER
Value 3 3.46 mm 3.49 mm 9.787 mm 2 9.787 mm 76.34 Kg/Km 26.45 Kg./Km 134 Kg/mm 16.59 Kg/mm Steel : 12.86 kN Aluminium : 1.57 kN Steel : 12.22 kN Aluminium : 1.49 kN 1 min. 3 dips 250 gm/m
2
Sl. 1 1. a) b) c)
Parameter 2 Physical constants for Aluminium wires shall be as follows: Maximum Resistivity of Al wire Density of Al. wire(at 20C) Coefficient of linear expansion
Value 3
0.0325 Ohm-mm /m 3 2.70 g/cm -6 23.0 X 10 /C Heat treated aluminium, magnesium, silicon alloy containing appx. 0.5% magnesium,0.5% silicon and rest aluminium 37/3.15 mm 2 288 mm 794.05 Kg/KM 22.05 mm 0.1182 Ohm/KM 84.71 KN
d)
Wires
2. 3. 4. 5. 6. 7. 8.
Stranding and wire diameter Nominal Sectional area of conductor Approximate total mass Overall diameter of the conductor Calculated resistance at 20 C (corrected to standard weight) Ultimate tensile strength of conductor Lay Ratio
o
69
Sl. 1
Parameter 2 a) 6 wire layers
Value 3 Max : 17 Min : 10 Max : 16 Min : 10 Max : 14 Min : 10 6 2 0.5814 X 10 Kg/cm -6 23 X 10 /C 1400 Mtrs. 5% Standard : 3.15 Max : 3.18 Min :3.12 2 7.793 mm 21.04 Kg/KM 2.41 KN 2.29 KN 4.29 ohms/Km
b) 12 wire layers c) 18 wire layers 9. 10. 11. 12. Final modulus of elasticity Final Coefficient of linear expansion Normal length without joint, weld Diameter of wire (mm)
13. 14. 15. a) b) 16.
Cross sectional area of nominal diameter wire Weight of each strand Minimum breaking load before stranding Minimum breaking load after stranding Resistance of wire (at 20C)
70
SPECIFICATION FOR CONNECTOR

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of Clamps and Connectors for 132 KV Chandil Substation.
Standards
The Clamps and Connectors under this specification shall conform to the latest version of the following standards as amended except where specified otherwise: 1. IS-5561 2. IS-10162 : Electrical Power Connectors. : Spacers and spacer dampers for twin horizontal bundle conductors.
3. IS-617 : Aluminium and Aluminium Alloy ingots and castings for general engineering purposes. 4. IS-5082 : Wrought aluminium and aluminium alloy bars, rods, tubes and sections for electrical purposes. 5. IS-1285 6. IS-2629 7. IS-2633 : Wrought Aluminium and Aluminium Alloys - Extruded Round Tube and Hollow Sections for General Engineering Purposes Specification : : Recommended practice for Hot Dip Galvanising of Iron and Steel. Method of testing uniformity of coating on Zinc coated articles.
The materials conforming to any other standards will also be acceptable if 1. the salient points of these standards and points of differences between these and the above standards can be clearly brought out. and 2. it can be proved to the satisfaction of the Purchaser that adoption of the proposed standard would ensure equal or better performance.
Functional Requirements
The functional requirements may be enumerated as follows:
3.1 Electrical Rating

Short time rating for 132KV connector shall be 40 KA for 1 second. The rated current of the connectors shall be governed by the item description of connectors indicated herein.
3.2 Temperature Rise

71
The limits of temperature rise shall be as indicated in Clause 6 in IS: 5561.
Construction
The connectors shall be of best quality and workmanship and in line with all the requirements laid out in the adopted standards. The thickness and contact surface should be maintained in such a way that the connector conforms to IS: 5561. All bolts, nuts and washers should have a bright finish. The holes of plain washers shall be reasonably concentric with the outer periphery. All sharp edges should be rounded off. Spring washers shall be supplied in natural finish and conforming to relevant IS specification and shall be Electro galvanised. Suitable size Aluminium braids are to be provided at each bolt points between upper and lower half of the connector to by-pass the bolt. Whenever copper to aluminium joints are required, 2 mm thick cold rolled aluminium copper bi-metallic strips shall be used between aluminium connector and copper terminal of the equipment as a sandwich plate between flat surfaces or as a sleeve around the circular studs to prevent galvanic corrosion. The current carrying parts shall be so designed, manufactured that contact resistance is reduced to the minimum. The resistance shall be as specified in IS: 5561. All connectors should be so designed and manufactured so as to offer ease of installation as these are to be used in overhead installations. Design should be such that full tightening of nuts and bolts is possible with the ordinary tools. The connectors shall be designed so as to avoid local corona, sound and visible discharge. Corresponding parts for each type of connector should be made to gauge or jig and should be interchangeable in every respect. The connectors should be legibly and indelibly marked with trademark of the manufacturer.
4.1 Materials
1. For connecting equipment terminal and conductors: Extruded Aluminium Alloy grade 63400 of IS 1285 2. For connecting equipment terminal of copper or brass : Extruded Al. alloy grade 63400 of IS 1285 with 2 mm thick bimetallic liner 3. Strain and PG clamps for GI shield wire : Dip forged steel 4. Earth clamps, earth strip supporting clamps, cleat clamps on wall and structures : MS hot dip galvanised 5. For bolts, nuts and plain washers of all clamps and connectors and spacers : Hot dip galvanised mild steel for size M12 and above. Electro galvanised mild steel for size below M12 6. Springs : Electro galvanised
Tests
There must be adequate testing facilities at the Works to conduct all acceptance and routine tests referred to in the above standards. A sample of each type of clamp and connector selected at random by the Purchaser shall be tested for Aluminium purity from any Govt. recognised Test
72
House and the report submitted to the Purchaser prior to despatch of materials. The following acceptance and routine tests shall be carried out on the connectors as per IS: 5561 and IS: 2633

1. Verification of dimensions. 2. Tensile Test. 3. Resistance Test. 4. Galvanising Test (when applicable).
5.2 Routine Test

1. Visual inspection. 2. Verification of dimensions.
5.3 Type Tests

The following tests shall be constitute type tests for clamps and connectors: 1. Tensile test. 2. Resistance test. 3. Temperature rise test. 4. Short time current test. The following tests shall be constitute type tests for spacers: 1. Resilience test. 2. Vibration test. 3. Short circuit current test. 4. Magnetic power loss test.
Documentation
1. Dimensional drawings of each item with mention of tentative weight and material of each item. 2. Tests reports.
The following shall constitute the documentation for the specified items:
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7
Sl. 1
Type Description 2 Terminal connector Expansion type, Bus post Insulator to 2.5 IPS Al Tube ,Horizontal take off Terminal connector Rigid type, Bus post Insulator to 2.5 IPS Al Tube, Horizontal take off Terminal connector Free type, Bus post Insulator to 2.5 IPS Al Tube, Horizontal take off Continuous Current Rating 3
132 KV BAY (2 BUS SYSTEM) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1250A 1250A 1250A
Terminal connector Expansion type, Circuit Breaker Al flat to 2.5 1250A IPS Al tube ,Horizontal take off Rigid Type Connectors tinned copper CT Stud to 2.5 IPS Al Tube Clamp Type CT Connectors suitable for Single AAAC Panther Conductor for Line bays Rigid Type suitable from CT Stud to ACSR Moose Conductor Clamp Type suitable from CT stud to ACSR Moose Conductor Expansion Type suitable for CT stud to 2.5 IPS Al. Tube Rigid Type PT Connectors suitable 2.5 IPS Al Tube Rigid Type Connector for Normal Isolator to 2.5 IPS Al Tube Expansion Type Connector for Normal Isolator to 2.5 IPS Al Tube 1250A 1250A 1250 A 1250 A 1250 A 1250A 1250A
Clamp Type Connector for High level Isolator to twin ACSR Moose 2000A Conductor Tee connector for 2.5 IPS Al Tube to Single ACSR Moose Tee connector for 2.5 IPS Al Tube to Twin ACSR Moose Tee connector for 2.5 IPS Al Tube to AAAC Panther Tee Connector for ACSR Moose to ACSR Moose Conductor Tee Connector for ACSR Moose to AAAC Panther Tee Connector for ACSR Moose to AAAC Panther Guide pipe support clamp on 127 PCD solid core post insulator suitable for 2.5 Al tube Guide pipe support clamp on 127 PCD solid core post insulator suitable for 3 Al tube 1250A 1250A 1250A 1250A 1250A 1250A -
22 End Plug suitable for 2.5 Al tube
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SPECIFICATION FOR HARDWARE AND ACCESSORIES

Scope
This specification covers design, manufacture, assembly, testing at manufac turers works, packing and delivery at site of Hardware and accessories for 132KV Substation.
Standards
The materials covered under this specification shall comply with the requirements of the latest edition of the following standards. 1. IS 2486 2. IS 2629 3. IS 2633 4. IS 6745 5. IS 5561 : : : : : Metal fittings for Insulator for overhead power lines with nominal voltage greater than 1,000V. Recommended practice for hot dip galvanising of iron and steel. Method of testing uniformity of coating of zinc coated articles. Method for determination of mass of zinc coating on zinc coated iron and steel articles Specification for Electric power connectors.
The materials conforming to any other national standards which ensure equal or better performance shall also be acceptable. The salient point of these specification and points of difference between these and the above specification shall clearly brought out in the bid and English version of the standard shall be submitted.
Construction
The material offered shall be of best quality, workmanship, well finished and of approved design. All casting shall be free from blow-holes, flaws, cracks or other defects and shall be smooth, close grained and of true forms and dimension. All mechanical surface shall be true, smooth and finished. Metal fittings of specified materials for string hardware are required to have excellent mechanical properties such as strength, toughness and high corrosion resistance and free from corona formation. All current carrying parts shall be so designed and manufactured that contact resistance is reduced to the minimum.
Compression areas shall be clearly marked on each accessories designed for continuous die compression shall bear the word COMPRESS FIRST near the point of each Accessory where
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the compression begin. Accessories designed for intermittent die compression shall bear the identification marks COMPRESSION ZONE and NON COMPRESSION ZONE distinctly of compression. The letters, numerals and other marking on finished accessories shall be distinct and legible. All bolts, nuts, bolt-heads shall be white worth standard thread. Bolts heads and nuts shall be locked in an approved manner. The threads in nuts and tapped holes shall be cut after galvanising shall be well lubricated or greased. All other threads shall undercut to take care of increase in diameter due to galvanising. Bolts and nuts should be of approved make. 2.5% extra bolts, nuts, washers shall be supplied. The general design of Hardware and Accessories shall be such as to ensure uniformity, high strength, free from corona formation and high resistance against corrosion even in high level of atmosphere, pollution. All hooks, eyes pins, bolts, suspension clamps and other fittings for attaching insulator to the tower or to the line conductor, shall be so designed as to reduce damage to the conductor, insulator or the fitting arising from the conductor vibration. Special attention must be paid to ensure smooth finished surface throughout. Adequate bearing area between fittings shall be provided and point or line contacts shall be avoided. All fittings shall be free from cracks, shrinks, slender, air holes, burrs or rough edges. All current carrying parts shall be designed to have minimum contact resistance. The design of the fittings shall be such as to avoid local corona formation or discharges that likely to cause interference to tele-transmission of signals of any kind. The tenderer shall offer tinned copper bonding pieces for connecting the ground wire suspension and tension clamp with tower body suitable for earthing. Each bond pieces shall have suitable compression type connecting leg or thimble on either side for making connections to clamps and tower body. The connecting socket should be made of tinned copper.
3.1 Galvanisation
All ferrous parts of hardware shall be galvanization in accordance with the latest edition of IS2629 or any other equivalent authoritative standards. The weight of zinc coating shall be determined as uniformity of coating of hot dip galvanized articles or any other equivalent authoritative standard. The zinc used for galvanization shall conform to grade Zn 99.95% of IS209. The galvanized parts shall withstand six(6) dip for 1 minute each time while testing uniform of Zinc coating as per IS-2633. Spring washers shall be electro galvanized.
Hardware Requirement
Materials for the various components of the Hardware shall be as follows:
4.1 Single tension set for conductor

1. Anchor Shackle. 2. Ball eye, ball link (H.H). 3. Tower side arcing horn (for line hardware only). 4. Socket clevis, socket eye with R type security clips.
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5. Line side arcing horn (for line hardware only). 6. Compression type dead end clamp with jumper for 132KV. 7. Bolts, nuts, washers, spring washer and split pin for the above.
4.2 Single suspension set for conductor

1. Ball hook. 2. Tower side arcing horn. 3. Socket clevis, socket eye with R type security clips. 4. Line side arcing horn (for line hardware only). 5. Anchor shackle. 6. Armour grip suspension clamp with armour rods. 7. Compression type dead end clamp with jumper for 132KV. 8. Bolts, nuts, washers, spring washer and split pin for the above.
4.3 Suspension set for earthwire

1. Eye hook. 2. Suspension clamp. 3. Flexible copper bond. 4. Bolts, nuts, washers, spring washer and split pin for the above.
4.4 Tension set for earthwire

1. Anchor Shackle. 2. Compression type dead end clamp with jumper sleeve with Aluminium casing. 3. Bolts, nuts, washers, spring washer and split pin for the above.
4.5 String set details

1. 132KV single suspension set Number of discs per string Electro-mechanical strength Ball diameter Spacing between discs 2. 132KV single tension set Number of discs per string Electro-mechanical strength Ball diameter Spacing between discs : : : : 10 120 KN 20 mm 145 mm : : : : 9 70 KN 16 mm 145 mm
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Above nos. of disc in the string are for Lines. One extra disc shall be provided (both for tension and suspension) when the string is used inside sub-station switchyard.
4.6 Mechanical Strength

The ultimate mechanical strength of the hardware should in no case be lower than the following: 1. 132KV suspension set for AAAC Panther 2. 132KV tension set for AAAC Panther 3. 132KV tension set for twin Panther / ACSR Moose : : : 70 KN 120 KN 120 KN
4.7 Material
1. Anchor Shackle 2. Chain Link 3. Ball hook or ball hook (HH) 4. Socket eye (HH) 5. Ball clevis 6. Socket clevis 7. Yoke plate 8. Arching horn 9. Suspension clamp 10. Dead end/cross-arm strap 11. Tension clamp (compression) 12. Tension clamp (bolted type) 13. Tension clamps and sleeves for earthwire : Forged steel : Forged steel : Forged steel : Forged steel : Forged steel : Forged steel : Mild steel : Mild steel : Aluminium alloy : MS Flat : Aluminium alloy (steel for ACSR) : Aluminium alloy : HDG steel with Aluminium encasing
Dimensions
1. Single Suspension set for AAAC Panther 2. Single tension set for ACSR Moose : 1600 mm for 132 KV : 1800 mm for 132 KV
The minimum length of the different hardware string sets shall be as detailed below :
3. Single tension set for ACSR twin Moose with turn-buckle - length variation from : 2000mm to 2500mm for 132 KV. 4. PG clamp for ACSR conductor (3 bolted Type): (180 X 95 X 54)mm for 132 KV
Suspension assembly
6.1 Tension clamps

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Compression type tension clamps shall be made of high strength extruded Aluminium alloy and suitable for ACSR Moose / Panther conductor in 132 KV system. The clamps shall also be designed, manufactured and finished to have a suitable shape without sharp angles at the end and to hold the respective conductor properly. It should however have sufficient contact surface to minimise damage due to fault current. The clamp shall have slipping strength of not less than 95% UTS of respective conductors. Compression type tension clamps shall be made of high strength aluminium alloy and suitable for respective conductor. The tension clamps shall not permit slipping of or damage to or failure of the complete conductor at any part thereof at a load less than 95% of the ultimate strength of the conductor. The electrical conductivity of tension clamps shall have the same value as the conductor and shall be of such design as will ensure unrestricted flow of current without use of parallel groove clamps.
6.2 Suspension Clamps for conductor

Suspension clamps for 132KV system shall be suitable for supporting the respective conductor wrapped with armour rods. The clamp body and keeper shall be high strength aluminium alloy. The suspension clamp shall consist of neoprene insert for armour grip. The suspension clamp shall be provided with galvanised steel U bolt, nut, washer etc. The suspension clamp shall be so designed manufactured and finished to have a suitable shape without sharp angles at the end and to hold the respective conductor properly. It should however have sufficient contact surface to minimise damage due to fault current. The suspension clamp shall permit the conductor to slip before failure of the conductor occurs and shall have sufficient slipping strength to resist the conductor tension under broken wire condition. The conductor should not slip at a load of 8% of the breaking load of the conductor. The slip strength shall not exceed 15% of breaking load of the conductor.
6.3 Suspension clamp for ground wire

Suspension clamps of suitable size are required for holding the galvanised stranded steel wire at suspension points. The suspension set shall be suspended from tower hanger. The clamp shall be so designed that the effect of vibration both on ground wire and the fitting is minimum. The clamp shall permit the ground wire to slip before the failure of ground wire occurs. One leg of the U-bolt holding the keeper piece of clamps shall be kept sufficiently long and shall be provided with threaded nuts and locking nut for fixing the flexible earthing bond between the suspension clamp and the tower structure.
Dead end assembly
7.1 Dead end assembly for conductor

Compression type dead-end assemblies for galvanised stranded steel wire shall be required for use on tension towers. The dead end assemblies shall be supplied complete with jumper terminals, nuts, bolts, suitable bind pieces between the steel clevis and tower strain plates so as to provide sufficient flexibility to the attachment. Dead end assembly shall have conductivity not less than GSS ground wire and tensile strength not less than 90% that of the UTS of the ground wire. The tension clamp should be made of forged steel with Aluminium encasement over it.
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One of the bolt holding jumper terminal of dead end assemblies shall be kept sufficiently long and threaded and shall be provided with washers, nuts and locking nuts for fixing the flexible earthing bond between the dead end assembly and tower structure. The earthing bond shall be made of tinned copper having at least 500 mm length and should be compressed with two sockets made of tinned copper at both ends. All ferrous parts shall be hot dip galvanised.
7.2 Dead end assembly for earthwire

All tension towers shall be fitted with suitable compression type tension clamps to support 7/3.15 mm earthwire. Anchor shackle shall be supplied which shall be suitable for attaching the tension clamp to strain plates. The clamps shall have adequate area of bearing surface to ensure positive electrical and mechanical contact and shall not permit any slip to the earthwire under working tension and vibration conditions. The angle of jumper terminal to be mounted should be 30 deg from the vertical. The complete assembly shall be so designed as to avoid undue bending in any part of the clamp and shall not produce any hindrance to the movements of the clamps in the horizontal or vertical directions. The slip strength of the assembly shall not be less than 95% of the ultimate strength of the earthwire. The clamps shall be complete with all the components including anchor shackle, bolts, nuts, washers, split pin, jumper arrangement etc.
Requirement of accessories
8.1 Mid-span straight joint

Material : Aluminium alloy for AAAC conductor, Mild steel for steel wire in ACSR conductor, HDG steel with Aluminium encasing for earthwire. Minimum failing load: 95% of UTS of conductor or earthwire. Electrical resistance at 20C : 75% of measured resistance of the equivalent length of conductor or earthwire. The mid span joints for conductor and earthwire shall be of compression type. The mid span joints for ACSR shall comprise of outer Aluminium sleeve made of Aluminium (99.5% purity), inner sleeve of HDG steel and two filler plugs. The mid span joints for AAAC shall comprise of Aluminium sleeve made of Aluminium alloy. The ground wire mid span joints shall be of HDG steel with aluminium encasement over it. The sleeves shall be of circular shape suitable for compression into hexagonal shape. The inner and outer diameters and lengths of these joints before and after compression shall be clearly shown on the drawing.
8.2 Repair sleeve

Material : Aluminium alloy for conductor and HDG steel with Aluminium casing for earthwire. : 95% of UTS of conductor or earthwire.
Minimum failing load
The repair sleeve of conductor shall be in two halves (one body and one keeper) and this should be extruded Aluminium (99.5%) purity. The repair sleeve of ground wire shall be of HDG steel with Aluminium encasing. The repair sleeve shall be of curcular shape suitable for compression into hexagonal shape.
8.3 Vibration damper

Clamp shall be made from gravity die cast Aluminium alloy, messenger cable from high strength galvanised stranded steel wire and weight from galvanised cast iron. The 4R (4 frequency) type vibration dampers shall effectively damp out the vibrations of the
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conductors and galvanised stranded steel wire. The tenderers shall give full details of damping characteristics and energy dissipation curves of the dampers and guarantee their effectiveness. The number of vibration dampers required to damp out the conductor vibration effectively and their points of fixation shall be indicated. The clamp of vibration dampers shall be made of Aluminium alloy. The clamp shall have sufficient grip to maintain the damper in position on the conductor without damaging the strands, premature fatigue of the clamp body and clamp cap shall be smooth, free of projection, grit or other material which could cause damage to the conductor when the clamp is installed. The messenger cable shall be made of high strength steel galvanised strands and preformed in order to prevent subsequent drop in weights in service. Clamping bolts shall be provided with self locking nuts designed to prevent corrosion of the threads or loosening durin service, ensuring that no slippage occurs. All ferrous parts shall be hot dip galvanised. The spring washers should be electro galvanised. The ends of the messenger cable shall be effectively sealed to prevent corrosion and also to ensure that the balancing weights of the damper can stand mechanical fly off pull of 500 kgs. The vibration damper shall be capable of being installed and removed from energised line by means of hot line tools without completely separating components. In addition, the clamp shall be capable of being removed and reinstalled on the line of the design torque without shearing or damaging bolts, nuts or capscrews. The damper assembly shall be electrically conductive.
Tests
The bidder shall have sufficient testing facilities at his works to conduct all acceptance and routine tests stipulated in the indicated standards. Complete Type Test Reports stipulated in the indicated standards as per SCC on similar hardware and accessories shall be submitted with the offer.
10 Packing and Marking

All accessories shall be supplied in strong wooden boxes or crates of approved design with steel loop and band for strength and durability to withstand rough handling during storage. Each package shall be marked on the sides as follows: 1. Name or designation of the consignee to be furnished by the Purchaser. 2. Ultimate destination as required by the purchaser. 3. The items and the respective quantities contained in it (packing list in weatherproof envelope). 4. The net and gross weights of the materials. The marking shall be stenciled indelible ink on each package.
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Sl. 1 1 2 3 4 5 6 7 8 9 10 11 Type Description 2 Single Suspension Hardware set ,Envelop Type with suspension clamp suitable for Single ACSR MOOSE conductor Single Suspension Hardware set ,Envelop Type with suspension clamp suitable for Single AAAC Panther conductor Single Tension Hardware set with compression type tension clamp for single ACSR Moose Conductor without Turn Buckle Single Tension Hardware set with compression type tension clamp for single ACSR Moose Conductor without Turn Buckle Single Tension Hardware set with compression type tension clamp for Twin ACSR Moose Conductor with Turn Buckle Single Tension Hardware set with compression type tension clamp for Twin ACSR Moose Conductor without Turn Buckle PG Clamp suitable for AAAC Panther conductor (Extruded Al) PG Clamp suitable for ACSR MOOSE conductor (Extruded Al) U-bolt 20 Dia X 76 mm for 132 KV Gantry side U-bolt 132 KV Swing Bus 18 Dia X 76 mm Spacer for Twin ACSR Moose Conductor EMS 3 70 KN 70 KN 120 KN 120 KN 120 KN 120 KN -
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SPECIFICATION FOR SOLID CORE POST INSULATORS

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of solid core post insulators for use in 132 KV systems of 132 KV Chandil Substation.
Standards
The Insulator covered by this specification should conform to the latest Indian Standard specification IS:2544, IEC-60168,IEC 60273 and IEC-60815. The Standard adopted should be clearly stated in the tender. Where the equipment offered conforms to any other standard, the salient points of difference between the standards adopted and IEC recommendation shall be clearly indicated and the English version of the proposed standard shall be furnished.
Solid core post type insulators shall consist of a porcelain part permanently secured in a metal base to be mounted on supporting structures. They shall be capable of being mounted upright. They shall be designed to withstand any shocks to which they may be subjected to by operation of the associated equipment. The design of the insulators shall be such that stresses due to expansion and contraction in any part of the insulators shall not lead to deterioration.
3.1 Porcelain
The porcelain shall be of the best electrical quality, homogeneous, free from any laminations, cavities, flaws or imperfections and shall be vitreous and impervious to moisture. Glazing shall be uniform brown colour, smooth surface, free from any blisters, burns or other defects. Its coefficient of thermal expansion shall be identical with the porcelain body. The glaze shall not crack or chip due to aging under weather conditions or while handling during shipment and creation. The insulator shall have alternate long and short sheds with aerodynamic profile. The shed profile shall also meet the requirements of IEC 60815 for the specified pollution level.
3.2 Cementing
The quality of cement and cementing shall ensure exact spacing, alignment and free from cracks and deterioration due to chemical action. The co-efficient of expansion shall be very near that of porcelain.
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3.3 Galvanising
All ferrous parts shall be hot dip galvanised in accordance with the latest edition of IS: 2633 and IS: 4579. Zinc should be of quality Zn - 99.95 and shall conform to the latest edition of IS - 209. Zinc coating over galvanising surface should not be less than 610 gm/Sq.m and the minimum thickness of coating shall be 85 microns for all items thicker than 6mm. After galvanizing no drilling or welding shall be performed on the galvanised parts. Sodium dichromate treatment shall be provided to avoid formation of white rust after hot dip galvanization.
3.4 Casting
All castings shall be true to pattern, free from defects and of uniform quality and condition. The surface of castings, which do not undergo machining, shall be free from foundry irregularities. The casting shall be tested for NDT, chemical, mechanical and metallographical tests. Iron casting material shall be in accordance with ASTM A 126 class B.
3.5 Nuts, bolts

Every bolt shall be provided with a steel washer under the nut so that part of the threaded portion of the bolts is within the thickness of the parts bolted together. Flat washer shall be circular and of diameter 3.5 times that of bolt and of suitable thickness. Where bolt heads / nuts bear upon the beveled surfaces they shall be provided with square tapered washers of suitable thickness of the parts bolted together. All bolts and nuts shall be of steel with well formed hexagonal heads forged from the solid and shall be hot dip galvanised. The nuts shall be a good fit on the bolt and two clear threads shall show through the nut when it has been finally tightened up.
Tests
Quality control of the insulators supplied shall be as per the latest edition of IS:2544, IEC 60168 or any other equivalent International/Indian standard with regard to selection of samples, numbers to be tested, and the tests to be carried out. The tests on individual Unit and also Stack including potential distribution test with the hardware fitting shall have to be carried out. The extent of tests, which will be made shall be stated in the Schedule of Technical Particulars and no departure from this shall be made. Ten(10) copies of certified test certificates that the full supply conforms in materials and workmanship to the specimen tested shall be furnished. Purchasers written approval of tests made shall be obtained prior to dispatch. The purchaser may at any time call for optional tests so specified in the standards. The contractor shall arrange such optional tests such as partial discharge test, expeditiously at his own cost. Test reports for such tests shall also be submitted. High frequency electrical routine test on all insulator shells and assembled units shall be performed as per relevant IS or IEC.
4.1 Type Tests

Complete Type Test Reports as per SCC shall be submitted with the offer. The tests shall be carried out as prescribed in the indicated standards. The following constitute the type tests :
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1 Visual examination 2 Verification of dimension 3 Visible discharge test 4 Impulse voltage withstand test(dry). 5 Wet and dry power frequency voltage withstand test 6 Temperature cycle test 7 Test for mechanical strength 8 Puncture test 9 Porosity Test 10 Galvanising test
4.2 Routine Tests

Complete Routine Test Reports shall be submitted as per SCC. The tests shall be carried out as prescribed in the indicated standards. The following constitute the Routine tests : 1 Visual examination 2 Mechanical routine test (for Unit and Stack) 3 Electrical routine test.

The following constitute the acceptance test : 1 Verification of dimensions 2 Temperature cycle test 3 Mechanical strength test 4 Puncture test (for Stack and Unit) 5 Porosity Test 6 Galvanising test
Documentation
1 Submission and approval procedure is detailed in the SCC. Test reports. 2 Guaranteed technical particulars. 3 Dimensional drawings.
The following constitute the documentation.
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6
Sl. 1
Parameter 2 Values 3 145 275 650 105 6 80 4.5 1500 127 184/200/254 M16 18 Heavy (III) 3625
132KV SOLID CORE 1 Voltage class in KV 2 3 4 5 6 7 8 9 10 11 12 13 14 Dry and wet one minute power frequency withstand voltage in KVp Dry impulse withstand positive and negative (KVp) Minimum visible discharge voltage in KVrms Total minimum cantilever strength in KN Minimum tensile strength KN Minimum torsional moment in KN-m Total height of insulator in mm PCD - top in mm PCD - bottom in mm Diameter of holes - top in mm Diameter of holes - bottom in mm Pollution level as per IEC-60815 Minimum creepage distance in mm
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SPECIFICATION FOR DISC INSULATORS

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of line insulators for 132 KV lines/bays for 132 KV Chandil Substation.
Standard
The insulator strings and its components shall conform to the latest edition of the following lndian/International Standards. Where the equipment offered conforms to any other standard, the salient points of difference between the standards adopted and IS/IEC recommendation shall be clearly indicated and the English version of the proposed standard shall be furnished. Sl. No. 1. Indian Standard IS:731 Title Porcelain insulators for overhead Power lines with a nominal voltage greater than 1000 V Specification for Insulator fittings for Overhead Power Lines with a nominal voltage greater than 1000V General Requirements and Tests Dimensional Requirements Locking Devices Tests for Locking Device Recommended Practice for Hot, Dip Galvanising of iron and steel Methods for testing uniformity of coating of zinc coated articles Thermal Mechanical Performance test and mechanical performance test on string insulator units Residual Strength of String Insulator Units of Glass or Ceramic Material for Overhead Lines after Mechanical Damage of the Dielectric American National Standard for Insulators wet process porcelain and toughened glass suspension type Methods of RI Test of HV insulators International Standard IEC:60383
2.
IS:2486
3. 4. 5.
Part- I Part- II Part-III Part-IV IS:2629 IS:2633
IEC:60120 IEC:60372
6.
7.
ANSI C29.2
8.
IS:8263
IEC:60437
String Insulator Requirements

132 KV : Insulator string suitable for 132 KV voltage shall consist of standard (255 mm
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x 145 mm) discs & (255 mm x 145 mm) discs ball and socket type, for suspension & tension string respectively. The exposed porcelain parts shall be glazed brown. Unless otherwise specified in the case of special assemblies, 10 Units shall be used on all 132 KV tension string and 9 Units for suspension having ultimate tensile strength of 160 KN, 120 KN for tension string and 70 KN for suspension string. Strain insulator discs shall have suitable differentiating marks from suspension discs to facilitate easy identification and to ensure against wrong use. Such marks shall be permanent and either glazed or stamped on insulator discs or embossed on cemented hardware. To ensure against spot loading cap-sockets shall be machined properly for correct ball stud seats. W or R shaped security clip for locking the ball head of the stud in the socket of the cap conforming to relevant IEC/ IS specification shall be supplied. Ball and socket parts refer to 20 mm designation conforming to specification IS-2486 (Part II)(Fig. No. 10 to 19) or IEC-60120.
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Type
Design Ratings
: Conventional ball and socket type. : 255 mm (for 70 KN Disc) for 132 KV 255 mm (for 120 KN disc) for 132 KV
Diameter
Spacing
: 145 mm (for 70 KN Disc) for 132 KV 145 mm (for 120 KN disc) for 132 KV
Colour Surface
: Brown : Glaze.
String arrangement
No of Discs (for 132 KV) Suspension Strings for normal suspension locations suitable for 16 mm B & S dia. Tension Strings for normal tension locations suitable for 20 mm B & S dia. Double suspension for special location (crossing) suitable for 16 mm B & S dia. Electro-mechanical Strength (for 132 KV)
a)
9*
70 KN
b)
10 *
120 KN
c)
2x9
70 KN
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No of Discs (for 132 KV) d) e) Double tension for special location (crossing) suitable for 20 mm B & S dia. Minimum failing load 2 x 10
Electro-mechanical Strength (for 132 KV) 120 KN
Shall be equal to electromechanical strength as stated above * Above nos. of disc in the string are for Lines. One extra disc shall be provided (both for tension and suspension) when the string is used inside sub-station switchyard
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a. b. c. d. e. f.
Electrical System Data

Nominal Voltage Maximum system voltage BIL (Impulse) Power frequency withstand voltage (Wet) Corona extinction voltage at 50 Hz AC system under dry condition Radio interference voltage : : : : : : 132 KV 145 KV 650 KV (Peak) 275 KV (rms) 105 KV(rms) Phase to earth. 500 Micro volts
Detailed design requirements
Only porcelain insulator will be acceptable.
7.1 Porcelain
The porcelain shall be of the best electrical quality made by wet process, homogeneous, free from any laminations cavities, flaws or imperfections and shall be vitreous and impervious to moisture. Glazing shall be uniform brown colour, smooth surface, free from any blisters, burns or other defects. Its co-efficient of Thermal expansion shall be identical with the porcelain body. The glaze shall not crack or chip due to ageing under weather conditions or while handling during shipment and erection.
7.2 Cementing
The quality of cement and cementing shall ensure exact spacing, alignment and free from cracks and deterioration due to chemical action. The co-efficient of expansion shall be very near that of porcelain/steel.
7.3 Galvanizing
All ferrous parts shall be hot dip galvanized to conform to IS-2633.
Tests
Quality control of the insulators supplied shall be as per the latest edition of IEC 60383 / IS-731 or any other equivalent authoritative standard with regard to selection of samples, numbers to be tested, and the tests to be carried out. The test on individual disc and also string including potential distribution test with the hardware fitting shall have to be carried out. The extent of tests to be conducted, shall be stated in the schedule of Technical particulars and no departure from this shall be made.
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The purchaser may at any time call for any optional tests so specified in the standards. The contractor shall arrange such tests expeditiously for which payment will be made. Test reports for such tests shall also be submitted to the purchaser for approval. High frequency electrical routine test on all insulator shells and assembled units shall be performed as per relevant IEC/IS . The bidder shall submit full particulars of the testing facilities available to him. Complete Type Test Reports as per SCC shall be submitted with the offer. The tests shall be carried out as prescribed in the indicated standards. The following constitute the Type Test : i) On unit disc Insulators
a) b) c) d) e) f) g) h) i)
Verification of dimensions Thermal mechanical performance test Power frequency voltage withstand and flashover test under (i) dry & (ii) wet condition Impulse voltage withstand and flashover test (dry) Visible Discharge test (dry) RIV test (dry) Residual strength Test Steep wave front Test Impact Test
: As per IEC :60383 : As per Annexure-A : As per IEC : 60383 : As per IEC : 60383 : As per IS:731 : As per IEC:60437 : As per Annexure-A : As per Annexure-A : As per Annexure-A
ii) On the complete Disc Insulator String with Hardware Fittings
a) b) c) d) e) f)
Power frequency voltage withstand test with arcing horns under wet condition Impulse voltage withstand test under dry condition Impulse voltage flash over test under dry condition Voltage distribution test Mechanical Strength test Vibration test
: As per IEC : 60383 : As per IEC: 60383 : As per IEC : 60383 : As per Annexure-A : As per Annexure-A : As per Annexure-A
For Type Tests which involves the tests on the complete insulator string with hardware fitting, the bidder shall supply the necessary number of sets of hardware fittings at the place of testing free of cost. In case of failure in any type test the bidder is either required to modify the design of the material and successfully carryout all the type tests or to repeat that particular type test at least three times successfully at his own expenses.
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The following constitute the Acceptance Test :
a) b) c) d) e) f) g) h) i) j) k)
Visual examination Verification of dimensions Temperature cycle test Galvanising test Mechanical performance test Test on locking device for ball and socket coupling Eccentricity test IR Measurement Electro-mechanical strength test Porosity test Puncture test
: As per IEC : 60383 : As per IEC : 60383 : As per IEC : 60383 : As per IEC : 60383 : As per IEC: 60383 : As per IEC:60372 : As per IEC:60383 : As per Annexure-A : As per Annexure-A : As per IEC : 60383 : As per IEC : 60383
The following constitute the Routine Test : a) Visual Examination b) Mechanical routine test c) Electrical routine test : As per IS: 731 : As per IS: 731 : As per IS: 731
Documentation
1) Detailed dimensioned drawings and 2) Guaranteed technical particulars shall constitute the documentation for the specified material.
10 Marking
Each Disc Insulator shall be legibly and indelibly marked with the name of the manufacturer, name of the purchaser i.e DVC and month and year of manufacturer. The guaranteed Electromechanical strength shall be indicated in Kilo Newton followed by the word KN to facilitate easy identification and to ensure proper use.
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ANNEXURE-A 132 KV 1. 1.1 Tests on Complete Strings with Hardware Fittings: Voltage Distribution Test The voltage across each insulator unit shall be measured by sphere gap method. The result obtained shall be converted into percentage. The voltage across any disc shall not exceed 20% for suspension insulator strings and tension insulator strings. 1.2 Mechanical Strength Test The complete insulator string along with its hardware fitting excluding arcing horn, corona control ring, grading ring and suspension assembly/dead end assembly shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string components shall not show any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to, remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded. 1.3 Vibration Test The suspension string shall be tested in suspension mode, and tension string in tension mode itself in laboratory span of minimum 30 metres. In the case of suspension string a load equal to 600 kg shall be applied along the axis of the suspension string by means of turn buckle. The insulator string along with hardware fittings and conductor tensioned at 1850 kg in case of ACSR Panther conductor shall be secured with clamps. The system shall be suitable to maintain constant tension conductor throughout the duration of the test. Vibration dampers shall not be used on the test span. The conductor shall be vertically vibrated simultaneously at one of the resonance frequencies of the insulators string (more than 10 Hz) by means of vibration inducing equipment. The peak to peak displacement in mm of vibration at the antinode point, nearest to the string, shall be measured and the same shall not be less than 1000/f1.8 where f is the frequency of vibration in cycles/sec. The insulator string shall be vibrated for not less than 10 million cycles without any failure. After the test the insulators shall be examined for looseness of pins and cap or any crack in the cement. The hardware shall be examined for looseness, fatigue failure and mechanical strength test. There shall be no deterioration of properties of hardware components and insulators after the vibration test. The insulators shall be subjected to the following tests as per relevant standards :
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a) b) 2. 2.1
Tests Percentage of Temperature cycle test followed by mechanical performance test
Percentage of units to be tested 60 40
Puncture test/steep wave front test On Disc Insulator Units Steep Wave Front Test
Test following test shall be performed on 10 insulator units in case of disc insulators selected at random from the lot offered for selection of sample for type test. a) Each insulator unit shall be subjected to five successive positive and negative impulse flashovers with a wave having minimum effective rate of rise of 2500 KV per microseconds. b) Each unit shall then be subjected to three dry power frequency voltage flashovers. Acceptance Criteria An insulator shall be deemed to have met the requirement of this test if, having been successfully subjected to the ten impulse flashovers, the arithmetic mean of the three subsequent dry/power frequency voltage flashover values equals or exceeds 95% of the rated dry power frequency flashover voltage. An insulator shall be deemed to have failed to meet the requirement of above testing if, (a) It has not flash over when the oscillogram or peak voltage indicator shows a marked reduction in voltage. or (b) Any one of the subsequent three dry power frequency voltage flashover value is less than 80% of the value specified. Failure of any one unit either in the steep wave front or subsequent low frequency voltage test shall cause for testing on double number of units. 2.2 Thermal Mechanical Performance Test Thermal Mechanical Performance Test shall be performed in accordance with IEC-60383-1 Clause 20 with the following modifications : (1) The applied mechanical load during this test shall be 70% of the rated electromechanical or mechanical value. (2) The acceptance criteria shall be (a) X greater than or equal to R + 3S. Where X = Mean value of the individual mechanical failing load.
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R = Rated electro-mechanical / mechanical failing load. S = Standard deviation. (b) The minimum sample size shall be taken as 20 for disc insulator units. (c) The individual electromechanical failing load shall be at least equal to the rated value. Also puncture shall not occur before the ultimate fracture. 2.3 Electromechanical/Mechanical Failing Load Test This test shall be performed in accordance with clause 18 and 19 of IEC 60383 with the following acceptance (i) X greater than or equal to R + 3S Where X = Mean value of the electro-mechanical/mechanical/ failing load. R = Rated electro-mechanical / mechanical failing load. S = Standard deviation. (ii) The minimum sample size shall be taken as 20 for disc insulators units. However, for larger lot size, IEC 60591 shall be applicable. (iii) The individual electro-mechanical/mechanical failing load shall be at least equal to the rated value. Also electrical puncture shall not occur before the ultimate fracture. 2.4 Residual Strength Test The above test shall be performed as per clause 4.4 and 4.5 of IEC 60797 preceded by the temperature cycle test, on both glass and porcelain disc insulators. The Sample size shall be 25 and the evaluation of the results and acceptance criteria shall be as per clause No. 4.6 of IEC 60797. 2.5 IR Measurements IR measurement shall be carried out by the instrument operating at 1 KV DC. IR value when measured under fair weather condition, shall not be less than 1000 M-ohm. 2.6 Impact Test The Impact Test shall be carried out in accordance with ANSI-C-29.2 Clause 8.2.8 with the following modification. The breaking point of the pendulum shall be so adjusted that, when released the copper nose will strike the outer rim of the shell or the most protruded rim of the shell squarely in a direction parallel to the axis of the unit and towards the cap. The test specimen shall receive an impact of 7 N-m for 70 KN and 120 KN Disc by releasing the pendulum.
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The disc insulators shall have the following parameters: Sl. 1 Description 2 Parameter 3 Ball and socket
1 2 a
Type 1 String 2arrangements for 132KV No. of discs in 132KV suspension strings for normal suspension locations suitable for 16mm ball and socket a diameter
b c d 3 a b 4 a b 5 a b 6 a b 7 a b 8 i) a b ii) a b iii) a
Electro mechanical strength of discs in 132KV suspension strings for normal suspension locations suitable for 16mm ball 70 kN and socket diameter No. of discs in 132KV tension strings for normal tension locations suitable for 20mm ball and socket diameter Electro- mechanical strength of discs in 132KV tension strings for normal tension locations suitable for 20mm ball and socket diameter Diameter for 70 KN disc for 120 KN disc Spacing for 70 KN disc for 120 KN disc Total creepage distance for 70 KN disc for 120 KN disc Protected creepage distance for 70 KN disc for 120 KN disc Visible discharge voltage for 70 KN disc for 120 KN disc Flashover / withstand test voltage Power frequency (dry) withstand for 70 KN disc for 120 KN disc Power frequency (wet) withstand for 70 KN disc for 120 KN disc Power frequency dry flashover voltage for 70 KN disc 75 KV 40 KV 40 KV 70 KV 70 KV 10
120 kN
255 mm 255 mm 145 mm 145 mm 320 mm 320 mm 160 mm 160 mm 9 KV 18 KV
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Sl. 1
Description 2 for 120 KN disc Power frequency wet flashover voltage for 70 KN disc for 120 KN disc Power frequency puncture voltage for 70 KN disc for 120 KN disc Impulse withstand voltage +ve for 70 KN disc for 120 KN disc Impulse flashover voltage +ve for 70 KN disc for 120 KN disc
Parameter 3 75 KV 45 KV 45 KV
b iv) a b v) a b vi) a b vii) a b
110 KV 120 KV 110 KV 110 KV
115 KV 115 KV
120 KN disc Minimum failing load shall be equal to electro-mechanical strength stated.
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SPECIFICATION FOR LIGHTING

1 Scope
This specification covers manufacture, assembly, testing at manufacturers works, packing and delivery at site of the equipment required for lighting of substations switch yard area for both general and emergency use. The equipment covered under this scope includes: 1. The light fittings and accessories includes but not limited to the following: (a) (b) (c) (d) (e) (f) (g) Weather proof - Lighting Distribution Board (LDB) for Lighting of the Switchyard Clamps, fixtures etc. required for holding conduits/light fittings/cables for complete wiring. Light fittings as required by this specification provided with water-tight conduit wiring boxes. Mounting and suspension attachment for switchboard etc. Switches Plugs and Sockets. Safety earthing materials. Water-tight Junction boxes etc.
2 Standards
The design, manufacture, testing and performance of the equipment offered and the illumination system shall in general comply with the latest issues including amendments of the following Indian (or equivalent IEC) Standards: IS:1913, Part-I - General and safety requirement for luminaries:Tubular Fluorescent lamps. IS:1777 - Industrial luminaries with metal reflectors. IS:4012 Specification for Dust proof electric lighting fittings. IS:4013 - Dust tight electric lighting fittings. IS:5077 - Decorative lighting outfits. IS:3287 - Industrial lighting fittings with plastic reflectors. IS:3528 - Water proof electric lighting fittings. IS:2418(all relevant parts) Specification for Tubular fluorescent lamps for General lighting
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service. IS:1258 - Bayonet lamp holders. IS:3323 - Bi-pin lamp holders for tubular fluorescent lamp. IS:1534 - Ballasts for fluorescent lamps-(Part-I)-For switch start circuit. IS:1569 - Capacitors for use in tubular fluorescent high pressure mercury and low pressure sodium vapour discharge lamp circuit IS:2215 Specification for Starters for fluorescent lamps. IS:3324 - Holders for starters for tubular fluorescent lamps. IS:10322(all relevant parts)- Specification for Luminaries Conduits, Junction Boxes IS:9537(Part 2) Conduits for electrical installations, Part 2- Rigid steel conduits IS:3480 - Flexible steel conduit for electrical wiring. IS:2667 - Fittings for rigid steel conduits for electrical wiring. IS:3837 - Accessories for rigid steel conduits for electrical wiring. IS:4649 - Adapters for flexible steel conduits. IS:14772 General requirements for enclosures for accessories for household and similar fixed electrical installations-Specifications Lighting Panels IS:13947 Specification for low voltage switchgear and control gear (all relevant parts). IS:13703(all relevant parts)-LV fuses for voltages not exceeding 1000 V AC or 1500 V DC. IS:5082 - Wrought aluminium and Al. alloys, bars, rods, tubes and sections for electrical purposes. IS:8828 Electrical accessories :Circuit Breakers for over current protection for household and similar installations. Cables IS:694 - PVC insulated cables for working voltages upto and including 1100 V. Electrical IS:1293 Plugs and Socket- Outlets of rated voltage upto and including 250 volts and rated current upto and including 16 Amps-Specification. IS:3854 - Switches for domestic and similar purposes. IS:5216(Part I and II) Recommendations on safety procedures and practices in electrical work.
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IS:732 - Code of practice for Electrical wiring installations . IS:3646 - Code of practice for interior illumination (Part I, II & III). IS:800 - Code of practice for general construction in steel. IS:1944 - Code of practice for lighting of public thoroughfares. IS:2633 - Methods for testing uniformity of coating of zinc coated articles. IS:6005 - Code of practice for phosphating iron and steel. IS:3043 - Code of practice for earthing. IS:6665 - Code of practice for Industrial lighting.
3 Completeness of Supply
All items shall be offered complete with all parts, mountings, fixtures and standard accessories etc., which are necessary for efficient and proper illumination. Any structure of fittings specially required shall also be included in the scope. Such parts shall be deemed to be within the scope of this specification whether specially mentioned or not.
4 Materials and Workmanship

All equipment and accessories to be supplied under this specification shall conform to relevant IS specification and free from defects and imperfection and of approved grade and classification. The makes of all the equipment and accessories shall clearly be indicated in the tender. All equipment shall be guaranteed by the Tenderer to be free from any defect due to faulty design, materials and/or workmanship.
5 Erection Tools & Tackles

All erection tools and tackles as may be required for the complete installation work shall be supplied by the contractor.
6 Supply System
1. AC System : 3 phase, 4 wire AC supply. (a) AC Supply for auxiliaries - 3 phase, 4 wire, 415 Volts + 10%, Fault MVA - 25 MVA at 415 Volts. (b) System frequency - 50 cycles per second + 3%. (c) System grounding - Effectively grounded. (d) The lighting distribution boards shall be fed from 415 Volts board through MCCBs located within the misc. board room. (e) Fault level - 25 KA.
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7 Tender Drawings
The Tenderer shall furnish a design and drawings (along with the tender) indicating therein the location and type of light fittings and also locations of Main Distribution Boards, Sub-distribution Boards, Lighting Panels, Power Plugs, Lighting Plugs etc. Panels details shall also be stated clearly. The final design and quantity, however, will be finished and approved during execution of contract on the basis of approved Switchyard layout and control room building. Standard literature of all type of fittings, switches, power receptacles, MCCBs, MCBs, Lamps and all other materials offered, shall also be submitted a long with the tender.
8 Power Receptacle Connections

The 3-phase power supply shall be provided for each power receptacle from main distribution boards. Each main distribution board shall have at least 1 No. 63 Amps power receptacle connections. There shall be total 4 Nos. such receptacles suitably distributed over the switchyard.
9 PVC Wires in Conduits

This should be as per IS 694 but more than 40% of the inside space of the conduit should not be covered by the wires drawn through it. The contractor must furnish calculations for voltage drop in different sub-mains and sub-circuits. The contractor should indicate the derating factor used for higher temperature (50 oC) and on a single line diagram should indicate the size of the wires used and voltage drop in each submains and sub-circuits (load line diagram).
10 Luminaries
Following type of luminaries shall be used in the switchyard : 1. Location: Switchyard area. Type of luminaries for general lighting: Flood light luminaires suitable for 2 x 400W HPSV lamp complete with C.G.Box and lamps. Note : Make and type of all the luminaries and lamps to be used in different area both for general lighting along with detailed literature must be submitted along with the tender.
11 Lamp
All tungsten filament lamps shall be rated for 240 Volts, gas filled clear. The filament shall be designed such that the lamps can be fitted in any position though normally these will be fitted in base up position. All fluorescent tubes shall be of 240 Volts. The accessories shall be housed in the lighting fixture. The colour of the lamp shall be cool white. All lamps shall be able to withstand 20% variation of the rated voltage and + 3% of the rated frequency. The performance shall not be affected for such variation. Make and type of the lamps for different areas should be clearly stated in the tender without whom the tender is liable for rejection.
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12 Wiring Materials & Accessories

The PVC wires and cables shall be of 1100 volts grade. The wiring should be of open conduit type with G.I. conduits of suitable size. For the battery room, the conduits and other accessories, which are liable to corrosion, should be painted with acid proof painting before erection. The exhaust fans should be of fairly quiet type. AC and DC wires should never run through the same conduit.The galvanised steel conduits of 14 SWG and the weather proof accessories shall be of first class quality subject to the approval of purchaser and should bear ISI mark. All mounting and suspension attachments, clamps, fixtures and accessories etc. should be supplied by the contractor and should be suitable for G.L. conduit wiring (ET). The Tenderer shall assess the quantity of all wiring materials and accessories required for complete illumination system and quote accordingly.
13 Boards & Panels

Outdoor Type LDB/Lighting Boards
Shall be suitable for outdoor installation (Protection of Panel IP 55) i.e. with suitable canopy, door with watertight gasket etc. Cable entry from bottom only and the panels shall be fabricated from 3mm thick sheet steel. 1. Incomer isolator. 2. Outgoing MCBs. 3. Caution board. 4. Detachable blank circuit label to be inscribed at site. The equipment shall be housed inside a sheet steel cubicle with hinged front access door and the board should be complete with Aluminium bus bar of size not less than 25x3 mm, in an enclosed bus chamber. The board should also be provided with fixtures and nuts, bolts, washers etc. for either wall or column mounting to be decided later.
14 General Consideration
If desired by the purchaser, the Tenderer shall be prepared to supply an install additional luminaries and other equipment complete with all accessories at the quoted unit prices. Suppliers should therefore indicate unit prices for all materials and installation charges over and above as has been indicated in the schedule of prices, if required.
15 Maintenance Factor
Dust proof fittings and water tight fittings shall be provided wherever the layout shall call for the same and the general type fittings shall not be acceptable in those special areas. The type of fittings at different areas of the complex shall clearly be indicated in the relevant schedules along with detailed literature of the same.
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16 Earthing of the Installation

Two main earth-wires of suitable size shall be laid from the purchasers earthing bus provided in the control room/switchyard to each distribution boards by the contractor. To those earthing leads iron-clad switches, bus bar chambers etc. would be connected. The earth pin of all socket outlets shall be connected to the general earthing system by means of an earth continuity conductor of suitable size either running inside the conduit or over the surface. G.I. shall ground outdoor lighting/junction boxes flat to the nearest ground grid.
17 Contract Drawings & Literature

The contractor shall submit 4 (four) copies of the following drawings and liter ature for Purchasers approval : 1. Detail drawing showing arrangement of luminaries, conduit wiring, mounting and suspension arrangement of all luminaries and boards. 2. Details drawing of all accessories, fittings and boards. 3. Standard literature of all luminaries and lamps. 4. Any other drawing/literature as will be required by the purchaser. 5. After final erection and testing, the contractor shall supply ten (10) copies of each of the approved drawing along with a set of reproducible. 6. Ten (10) copies of erection and maintenance manual shall also be submitted.
18 Tests
18.1 Tests of Equipment and Materials
All the LDBs and other equipment will be tested as per relevant IS. Polar distribution curves and other type tests reports of different type of luminaries shall be submitted. Test certificate for lumen output and characteristic curves of different lamps are also to be submitted. Four (4) copies of all the test reports shall be submitted before despatch of materials.
18.2 Testing of the Installation

The following tests shall be done on the installation and test reports in triplicate shall be submitted after completion of the installation. The wiring of the LDBs and lighting panels shall withstand an applied voltage test of 2500 volts for 1 minute. Insulation resistance test : As per IE Rule No. 60. Earth resistance tests : The final earth resistance as measured by a suitable earth tester between the earth electrodes and any point on earth continuity system shall not exceed 1 (one) Ohm. Earth continuity and mains conductors : The tests shall be in accordance with IE Rule No. 61. Testing of polarity of single pole switches : The contractor shall ensure that all single pole nonEQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT
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linked switches and single phase breakers are connected to the live wire of the system.
19 Handing Over
After completion of installation , illumination measurement of Lux shall be done by Lux level meter (Lux level meter to be arranged by the contractor at his cost) at each decided point in presence of purchasers Engineer and to be noted. If the Lux levels are found to be less than what was guaranteed in tender, additional light fittings along with all accessories are to be supplied and installed by the contractor without any additional cost to DVC. The illumination system will only be taken over after desired lux level mentioned in finally approved designs attained.
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SPECIFICATION FOR JUNCTION BOXES & OUTDOOR PANELS

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of outdoor type weather proof panels and junction boxes (JB).
Standards
The item shall conform to the latest edition of the following lndian/International Standards. Where the equipment offered conforms to any other standard, the salient points of difference between the standards adopted and IS/IEC recommendation shall be clearly indicated and the English version of the proposed standard shall be furnished. IS 13947 IS 8623 : : Specification for Low voltage switchgear and control gear Specification for low voltage switchgear and control gear assemblies. IS 5039 : Distribution feeder pillars for voltages not exceeding 1000V AC / 1200V DC. IEC 60439 (all relevant parts) : IS 13703 (All parts) : Low voltage switchgear and control gear assemblies. Specification for low voltage fuses for voltages not exceeding 1000 V AC and 1500 V DC
Outdoor weather proof panel/ box shall be of sheet steel enclosure and shall be dust, water and vermin proof. The thickness of sheet steel shall be 2 mm cold rolled or 2.5 mm hot rolled. The box shall be properly braced to prevent wobbling. There shall be sufficient reinforcement to provide level surfaces, resistance to vibrations and rigidity during transportation and installation. All enclosures shall provide a degree of protection of not less than IP 55 as per IS 13947. The panel shall be free standing floor mount type and the junction box shall be pedestal mount type. They shall have hinged doors with padlocking arrangement. All doors, removable covers and plates shall be gasketed all round with suitable profiled EPDM gaskets. The distance between two hinges shall be adequate to ensure uniform sealing pressure against atmosphere. All gas-keted surfaces shall be smooth, straight and reinforced if necessary to minimize distortion and to make a tight seal. The quality of gaskets shall be such that it does not get cracked during ten years of operation of the
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equipment or its major overhaul whichever is earlier. Ventilating louvers, if provided, shall be with screens and filters. The screen shall be fine wire mesh made of brass. All panels/ boxes shall be designed for the entry of cables from the bottom by means of weatherproof and dust proof connections. Panels/ boxes shall be designed with generous clearance to avoid interference between the wiring entering from below and any terminal blocks or accessories mounted within the housing. A suitable undrilled cable gland plate projecting at least 150 mm above the base of the housing shall be provided for this purpose. The gland shall project at least 25 mm above the gland plate to prevent entry of moisture in the cable trench. Each panels/ boxes shall be provided with two earthing pads to receive 75mm x 12mm or 50mm x 6mm GS flat. The connection shall be bolted type with 2 bolts per pad. The hinged door shall be provided with danger plate and internal wiring diagram pasted on the inside of the door. The front label shall be on a 3 mm thick plastic plate with white letters engraved on black background.
Terminal Blocks
Terminal blocks shall be 1100V grade and have continuous rating to carry the maximum expected current on the terminals. These shall be moulded, complete with insulating barriers, stud type terminals, complete with washers, nuts and lock nuts. 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 terminal clamp unless it is done intentionally. The conducting part in contact with the cable shall preferably be tinned or silver plated. However, nickel plated copper or zinc plated steel shall also be acceptable. The terminal blocks shall be of extensible design. The terminal blocks shall have locking arrangement to prevent its escape from the mounting rails. Terminal block design shall include a white fiber marking strip. Markings on terminal strips shall correspond to numbers on wiring diagrams. The terminal blocks shall be fully enclosed with removable covers of transparent, nondeteriorating type plastic material. Insulating barriers shall be provided between the terminal blocks. There barriers shall not hinder the operator from carrying out the wiring without removing barriers. The arrangement shall be such that it is possible to safely connect or disconnect terminals on the live circuits and replace fuse links when the cabinet is live. Space shall be provided for mounting 20% spare terminal blocks on each junction box. There shall be a minimum clearance of 250 mm between the first/bottom row of terminal blocks and the associated cable gland plate. Clearance between adjacent rows of terminal blocks shall be a minimum of 150 mm.
Tests
5.1 Type Tests

Complete Type Test Reports as per SCC shall be submitted with the offer. The tests shall be carried out as prescribed in the indicated standards. The panels/ boxes shall have been type tested for IP 55 degree of protection as per IS : 13947. The following tests shall also be performed on the junction boxes: 1. 2.5 KV withstand for one minute. 2. Insulation Resistance.
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3. Functional tests.
5.2 Routine Tests

The Junction Boxes shall be subjected to the following routine tests as per IS : 5039 1. 2.5KV withstand for one minute. 2. Check for wiring. 3. Visual and dimensional check. 4. Check for paint.
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6
Sl. 1 1 2 3 4
Description 2 Installation Design ambient air temperature Thickness of sheet steel Degree of protection Parameter 3 Outdoors 50C At least 2.5 mm hot rolled or 2 mm cold rolled IP 55 as per IS 13947 6 sq.mm for 1A secondary CT terminations, 10 sq.mm for 5A secondary CT terminations, 25 and 10 sq.mm for power cable terminations, 2.5 sq.mm for other control cable terminations stranded copper/ aluminium Of approved make As required
Size of terminating wires
6 7 8
Wire type Terminal blocks Earthlinks
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SPECIFICATION FOR BATTERY

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of Heavy duty Lead acid battery bank with accessories.
Standard
In general the equipment covered by this specification shall, unless otherwise specified, conform to the requirements of any of the latest applicable standards such as: IS :1652 - Stationary lead acid Plante positive plate type battery.
Wherever the requirements in this specification are in conflict with any of the above Standards, the requirements under this specification shall be binding.
Battery Bank
The battery banks shall be suitable for 250 V DC and 48 V DC systems . Each set of battery banks shall comprise of a number of cells indicated in Specific Requirement of this specification. Each set of the battery bank shall consist of a heavy duty lead-acid Plante Cell meeting the following requirements:
3.1 Performance
The output voltage shall be limited to 107.5% of nominal battery voltage when batteries are float charged while feeding the load. Battery bank voltage at end of duty cycle shall not be less than 90% of nominal battery voltage. The cells shall be designed for operation under constant potential float or trickle charge conditions, not involving regular deep cycles of charge and discharge. The cells shall be particularly suitable for circuit breaker tripping and closing duties together with diesel generator starting operations.
3.2 Construction
Each cell shall contain positive plates cast from pure lead and consist of numerous thin vertical laminations, strengthened by a series of horizontal cross-ribs. The plates shall be hung from ledges moulded in the container. The cells shall have negative plates of interlocking design to ensure active material retention and provide balance with the positive plate to give maximum performance and life. The negative group shall always have one more plate than its matching positive group, so that when the groups are interleaved. Each positive plate will be located between two negative plates to
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ensure that both surfaces are worked equally. Separator made of micro porous PVC shall be provided in each cell. This will provide a complete diaphragm between the plates, give maximum electrolyte utilisation together with high mechanical and electrical strength. To provide the ampere-hour capacity specified, each respective group of positive and negative plates are to be joined together by group bars made of lead. The cell containers shall be injection moulded from transparent plastic material and stressrelieved. The maximum and minimum levels are to be marked on the sides of the cell to facilitate maintenance. The cell lids shall be moulded in an easily cleaned form from opaque plastic material and bonded to the container to prevent leakage of gas or electrolyte. The lids will carry vent plugs and terminal pillars. Two polystyrene filling plugs shall also be fitted to each lid. The vent plugs shall be designed to effectively return all acid spray to the cell but allow free exit of oxygen and hydrogen which are generated toward the end of boost charging. Terminal pillars shall consist of high conductivity corrosion free material. The holes through which the terminal pillars are to be brought out shall be sealed to prevent escape of electrolyte or gas at all times during the working life of the cell. All cells shall be pressure tested prior to despatch, to check the integrity of the seals. Similar to the terminal pillars, single, twin and triple intercell connectors shall be provided depending on the cell capacity. These connectors will be made from lead plated high conductivity copper. Bolt sets provided with each cell will be cadmium plated. A + (plus) sign shall be moulded into the lid in a minimum of two positions adjacent to the positive pillar which shall also be identified by a marking (usually red) and negative pillars shall be similarly identified with a marking (usually blue) with the - (minus) sign moulded into the lid. The cells will be provided with pure sulphuric acid having a specific gravity of 1.207 at 20 C when fully charged and with the electrolyte at maximum level. The cell will be placed of stands of high quality knot-free timber and finished with three coats of acid resisting paint.
3.3 Wooden Stand and Accessories

The supply of each set of indoor storage battery bank shall in addition to the number of cells of Ampere-hour capacity specified in Design Consideration, consist of wooden stand and all accessories and devices including but not limited to the following: 1 2 3 4 5 6 7 Battery stand made of first class C.P. teak wood. Rubber cell pads, if required, for each cell. Supporting porcelain insulators. Set of vinilyte (or equivalent) cell number plates. Set of inter cell and inter-row connectors and inter-bank connectors for the battery. Three connector bolt wrenches/spanners One center Zero 5-0-5 Volt D.C. Voltmeter(portable) complete with leads for measuring cell voltage.
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8 9
Three hydrometer syringes suitable for vent holes provided in the cells. Three vent plug thermometers to be permanently mounted should in any three cells. Each cell will have suitable clamps for holding the thermometers in position.
10 11 12 13 14 15 16
Three pocket thermometers with 0 - 150C scale. Two rubbers aprons. Four sets of rubber gloves. Two Nos. acid mixing jars. Electrolyte required for first filling + 10% extra. Two Nos. rubbers syringes. Sufficient quantity of petroleum jelly for covering exposed metal parts of the battery plus 10% extra.
17 18
One no. Nylon brush with stout bristles for cleaning connections. Suitable tapping and terminals arrangements in the battery for incoming supply to D.C. Board.
19
Cable lugs suitable for accommodating single core PVC cable for each end of the bank and tapping point.
20 21 22
Vent plugs. Acid level indicator for each cell. Other special tools and tackles, if required.
Tests
Type Test :
Complete Type Test Reports as per SCC shall be submitted with the offer. The tests shall be carried out as prescribed in the indicated standards. The following constitutes the Type Tests : 1) 2) 3) 4) 5) 6) 7) Verification of constructional requirements Verification of marking Verification of dimensions Test for capacity-Test for voltage during discharge Ampere-hour and watt-hour efficiency test Test for retention of charge Endurance test
The manufacturer shall allow physical verification of the offered cell at their works. A capacity test must also be conducted to demonstrate the rated capacity of the cells.
Acceptance Test :
The following shall constitute the acceptance tests : 1) 2) Verification of marking Verification of dimensions
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3) 4)
Test for capacity Test for voltage during discharge
5
Sl. 1
Description 2 Parameter 3
For Substation equipment(along with accessories as per specification) 1. 2. 3. Battery voltage Number of cells in a set Type 250 Volts 125 Stationary, Lead acid, Plante, high discharge, closed top, indoors type
4. Capacity 400 Ah 5. Nominal discharge voltage per cell 2.0 V 6. Float voltage 2.2 V per cell For Communication Equipment (along with accessories as per specification and AutoFill system) 1. 2. 3. 4. 5. Voltage Number of cells in a set Capacity Nominal discharge voltage per cell Float voltage 48 V 24 300 Ah 2.0 V 2.2 V per cell
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SPECIFICATION FOR BATTERY CHARGERS

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of battery chargers as per the following details.
Design Criteria
The battery chargers shall be compatible with the heavy duty Lead-acid cells specified herein. The requirements are detailed as follows: There shall be two AC sources - one main and the other stand by, only one of which will be in service at any time. The charger output voltage shall be automatically maintained within 1% of the voltage setting when operating under any combination of the following conditions: Load between 0 to 100%. variation of 10% in nominal input voltage. variation of 5% in nominal input frequency. The equipment enclosure shall provide a degree of protection equivalent to IP41. The float charger output shall be automatic SCR controlled with change over facility to manual control. The boost charger shall be manual SCR controlled. The float charger shall be capable of floating the battery cells to 2.23 Volts/cell (or as recommended by the battery manufacture) and the boost charger shall be capable of charging the battery cells up to 2.75 Volt/cell (or as recommended by battery manufacturer). There shall be provision for two output feeders controlled by two nos. isolators for connecting to DC board. Each float charger when in float mode shall be capable of supplying the specified DC load, over and above the normal trickle charge current. The arrangement and capacity of the charger shall be such that when the boost charger has been put to service, the float charger can be simultaneously put to service to cater to the DC load. During boost charging condition, 80 (eighty) per cent of the battery voltage would be made available at the positive terminal of the load through a series parallel combination bank of blocking diodes (each of 100% capacity) to ensure uninterrupted DC supply to the load in the event of failure of the Float Charger/AC supply fail. The control circuit shall be such that any one charger unit can be placed in Float mode and the other can be placed in Boost mode without affecting each other.
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Construction
The chargers shall be housed in a single continuous board but in separate detachable sections so that any section can be disconnected and removed for maintenance purpose. Each section shall be made from sheet steel of minimum thickness 2mm. The front plates should be of formed construction with minimum 25 mm turned back edges. The front plates shall also be hinged making breakers accessible and removable from the front. The panel shall be free standing, fitted with louvers for proper ventilation and must be suitable for use in tropical climate. Instruments : shall be switchboard type, back connected, flush mounted type, dust and moisture resistant. Marking on scales shall be black on white background. The accuracy class shall be 1.0 or better. Instruments to show the following minimum parameters shall be provided: float charger output voltage. float charge and boost charge currents. battery charge and discharge current. trickle charge current. Wiring : shall be of single core, multi conductor, tinned, PVC insulated annealed copper wire suitable for 660 Volts grade and shall be flame proof. Terminal ends of all wires shall be provided with numbered plastic ferrules. Ends shall be fitted with terminals, cable and sockets wherever applicable. MCCB : All chargers shall have AC input and DC output MCCBs with suitable overload setting of air break, single throw, load break and fault make type. The switches shall be rated for 120% of the maximum continious load. Control switches : shall be of rotary stay-put type with plates showing function and position. The contact ratings shall be such as to make and carry continuously 10A, breaking a current of 0.5A inductive at 250V DC and break current of 5A at 0.3 p.f. at 240V AC. Fuses : shall be HRC cartridge fuse link type. Fuses shall be mounted on fuse carriers which are mounted on fuse bases. Indicating lamps : Shall be of bright LED type capable of clear status indication under normal room illumination. Annunciation system : annunciation facia if used shall be as per EEUA-45D. Rectifiers : shall be of the full wave bridge type, employing thyristors. Junction temperature of the thyristors must be limited by employing heat sinks rated to carry 200% of the load current continiously and temperature of the heat sink shall not be permitted to exceed 85 oC absolute taking into account the maximum temperature inside the panel. Individual thyristor fuses shall be fitted for protection against thyristor failure. Protection against voltage surges shall be ensured with the help of surge supression circuits. Transformers, chokes : shall be of naturally air-cooled type. There shall be means of input voltage adjustment to permit voltage variation of 5%. Electronic circuits : all current free metallic parts shall be earthed with soft drawn PVC insulated standard copper conductor. Colour of the insulation shall be invariably green. The main earth connection shall be brought out to the terminals for connections to station earthing
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system.
Protection & Monitoring
Overvoltage protection : The chargers shall be provided with voltage sensing circuit capable of shutting down the charger if the voltage at the charger output terminals rise significantly. This circuit must be disabled when operating in boost charge mode. Low voltage detection : to be provided for warning about load failure due to insufficient voltage. Battery circuit monitoring : battery continuity monitoring device to be provided warning in the case of an open circuit. Alarms : 1 2 3 4 5 6 7 8 the following minimum annunciation shall be provided -
Loss of AC supply. Charger shutdown on DC system failure. Rectifier fuse failure. Surge circuit fuse failure. Over temperature. Battery open circuit. Battery earth fault. Battery voltage low.
Tests
5.1 Type Tests

Complete Type Test Reports as per SCC shall be submitted with the offer. The following constitutes the Type Tests : 1. 2. 3. 4. 5. 6. 7. 8. 9. Power losses in rectifier assemblies. Power consumption of auxiliaries. Equipment reactance. Test for transformers, phase shifters, regulating equipment, transducers, reactors. Connection checking. Measurement of voltage regulation. Automatic voltage regulator operation. Efficiency measurement. Measurement of power factor.
10. Temperature rise. 11. Insulation test.
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12. Inspection. 13. Auxiliary devices. 14. Alternating current measurement. 15. Ripple content test. 16. Load limiter operation test and DC short circuit test. 17. Input and output surge withstand capability test. 18. Environment tests. 19. PCB type tests.
5.2 Routine Tests

The following shall constitute the routine tests. 1. Connection checks. 2. Measurement of voltage regulation. 3. Insulation test. 4. Inspection. 5. Auxiliary devices. 6. Alternating current. 7. Temperature rise test at full load. 8. Ripple content test. 9. Load limiter operation test and DC short circuit test. 10. Environmental tests on PCBs.

The following shall constitute the acceptance tests. 1. Visual examination. 2. Heat run with a limited number of thermocouples attached to hot spots determined during the type tests. 3. Check on smoothing, insulation, accuracy of instruments, correct functioning of switches, indications and alarm contacts. 4. Insulation resistance of the complete equipment. 5. Applied high voltage test, followed by a further insulation test to detect any breakdown that may have occured.
Documentation
Drawings and manuals required with each charger are enumerated below. The document
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submission and approval procedure is indicated in the SCC. 1. 2. 3. 4. 5. OGA drawings of the panels showing front, rear and side views with dimensions. Panel mounting details. Schematic diagrams. Internal wiring details of the complete charger. Manual detailing design, construction, operation and maintenance of the equipment.
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Sl. 1
Description 2 Parameter 3
250 V Battery Charger 1 2 3 Input source Rated current capacity Rated DC output 415V, 3-phase, freq-50 Hz 100 A 250 V Battery Charger Board shall comprise of two Float cum Boost chargers and one Boost charger for two separate battery banks. 1% 1% 10% to 100% of rated current capacity 20 kA 10 kA 250 V to 285 V 250 V to 345 V Plante type, 125 cells, 400Ah as per specification
Configuration
5 6 7 8 9 10 11 12
Voltage regulation in float mode Voltage regulation in boost mode Rated current variation in boost mode AC short circuit level DC short circuit level Voltage setting range in float mode Voltage setting range in boost mode Battery data
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SPECIFICATION FOR LTAC AND DC, DISTRIBUTION BOARD

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of Low Tension (LT) AC and DC, switch board and distribution board of approved shape, size and colour.
Standards
The equipment covered by this specification shall, unless otherwise specified, be built to conform to the Indian Electricity Rules, 1956, wherever applicable and any of the following standards: 1. 2. IS: 13947 IS: 5082 : Specification for Low Voltage Switchgear and Control gear-(Part-I-Part3,Part-5) : Wrought Aluminium and Aluminium alloy bars, rods, tubes and sections for electrical purposes. : Code of practice of phosphating of iron and steel. : Specification for factory built switchgear and control gear assemblies. : Specification for degrees of protection provided by enclosures (IP code) : Guide for marking of insulated conductors : Guide for Uniform System of Marking and Identification of Conductors and Apparatus Terminals
3. 4. 5. 6. 7.
IS: 6005 IS: 8623 IEC 60529 IS: 5578 IS: 11353
If standards other than those specified above are adopted, then English version of the same accompanied with comparative statement with the above standards shall be enclosed.
3
A) B) C)
System Details
The frequency of supply is 50 Hz Fault level of the 415 Volt A.C. system shall be 25 KArms symmetrical. All fault interrupting devices shall have adequate breaking capacity to suit the fault level of the system as specified above. The making capacity of the breakers at the above condition shall not be less than 25 KA. All incoming breakers, shall be suitable for 25 KArms symmetrical breaking capacity and
The following arrangements for the AC station service supply would be adopted :
D)
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shall be absolutely interchangeable. E) The DC system will be 2 wire, unearthed type. The system voltage shall be 250 VDC and the fault level will be 15 KA.
Construction
The switchboards covered by this specification i.e. AC and DC and distribution boards shall be of the vertical front, sheet metal enclosed, finished in Grey enamel, floor mounted, free standing type for indoor use. The switch boards shall be self-supporting and wherever inherent structural construction may require strengthening, inconspicuous bracing, gusseting, welding etc. shall be utilised. There should be arrangements for earth connections. The insulation at any point of all the switchboards shall be suitable for 1100-Volt service grade.
4.1 General Details

The switch boards frames shall be fabricated with leveled steel plate at least 2 mm thick or light sections of structural steel. All panel edges shall shall be reinforced against distortion by rolling, bending or by the addition of welded reinforcement members. The complete structure shall be rigid, self-supporting, free from flaws, twists and bends. All cut-outs shall be standard equipment sizes, without sharp edges. All boards shall be of dust and vermin proof and with a degree of protection of IP-52 as per indicated standard and shall be easily extensible on either side for addition of extra vertical sections if required. Board height shall not exceed 2450mm. Boards shall be supplied with base frames of structural steel sections and necessary mounting hardware. All boards shall have distinct compartments as detailed below: 1. Completely enclosed bus bar compartment for running horizontal and vertical bus bars. Bolted covers shall be provided for access to these compartments for repair and maintenance work without disturbing other compartments. 2. Completely enclosed switchgear/ feeder compartment for incoming or outgoing feeders. Circuit breakers or MCCBs to be mounted as applicable. The front of the compartment shall be provided with a hinged single leaf door with captive screws for positive closure. 3. A compartment or alley for running power and control cables. Cable alley door shall preferably be hinged. Cable alley shall have no exposed live parts, and shall have no communication with the bus bar chamber. It shall be of at least 175mm width. Cable terminations located in cable alley shall be suitably shrouded to prevent accidental contact with tools etc. 4. Other compartments for relays, energy meters etc. as may be necessary. All equipments associated with a single circuit shall be housed in a separate compartment of the vertical section. The compartment front shall have a hinged single leaf door with locking facilities. It should be possible to carry out maintenance work in a compartment after isolating all power and control circuit connections. The minimum clearance in air between phases and between phase and earth for the horizontal and vertical busbars shall be 25mm. For all other components, the clearance between live
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parts and live part and earth shall be at least 10mm throughout. The temperature rise of busbars when carrying rated current along its full run shall in no case o o exceed 55 C over an ambient of 50 C. All disconnecting contacts for power circuits shall be of robust design and self aligned. Fixed and moving contacts of drawout type contact system shall be replacable and silver plated. The connections from busbars to the main switch shall be fully insulated and securely bolted. The partition between the feeder compartment and cable alley may be non-metallic and of such design as to allow cables with lugs to be easily terminated in the feeder compartments. The power and control cable entries shall be from the bottom unless otherwise stated during the detailed engineering stage. Each switchboard shall be provided with undrilled, removable type gland plate, which will cover the entire cable alley. For single core cables, gland plate shall be of non-magnetic material. All sheet work shall be pre-treated in line with IS:6005. Degreasing to be done by alkaline cleaning. Rust and scale shall be removed by pickling with acid. Class C phosphate coating is to be applied as per IS:6005. The phosphated surfaces shall be rinsed and passivated prior to application of lead oxide primer. Two coats of synthetic enamel paint shall then be applied. The final paint on panels shall be shade 692 of IS:5 unless otherwise specified.
4.2 Busbars & Insulators

All AC switch and distribution boards shall be provided with a neutral bus bar in addition to the three phase busbars. All busbars shall be of high conductivity aluminium/ copper of adequate size. The busbar size calculation shall be submitted for approval. The bus bar for DC distribution board shall be rated for 400 Amp continuous current carrying capacity and shall satisfactorily withstand the fault current as specified above. The bus bars for AC distribution board shall be rated for 1000 Amp continuous current carrying capacity and shall satisfactorily withstand the fault currents as specified above. If ratings offered are other than the above, the manufacturer shall provide calculations to justify the adequacy of the busbar size offered. The busbar sections shall be uniform throughout the length of the panel and shall be supported and braced adequately to withstand stresses due to the specified short circuit currents. All busbars joints shall be provided with high tensile steel bolts, spring washers and nuts to ensure good contacts at the joints. All busbars shall be colour coded as per indicated standard.
4.3 Earth-bus & Earthing

A copper earthing busbar of adequate dimension shall be provided at the bottom of each panel and shall extend throughout the length of the switchboard. It shall be bolted to the frame work of each panel and earthing contact vertical bus of each bus. The earth-bus cross-section shall be sufficient to carry the short circuit and short time fault currents indicated in this specification without exceeding the allowable temperature rise. Arrangement shall be provided at each end the earth-bus for connecting to Purchasers earthing conductors. The arrangement shall be in the form of projections out of panel ends with
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pre-drilled holes. All non-current metal work of the panels shall be effectively bonded to the earth bus. Breaker truck and frame shall be earthed while the truck is being inserted into the panel and earthing of the truck and breaker frame shall be maintained in all positions. All hinged doors shall be earthed by means of flexible earthing braid. All metallic cases of relays, instruments and other mounted equipment shall be connected to the earth-bus by independent stranded copper wires of size not less than 2.5 sq.mm. Earthing wires shall be connected to terminals with suitable clamp connectors only. Looping of connections that might lead to a loss of connectivity on removal of a device will not be allowed. Looping to provide alternative paths is allowed. VT and CT secondary neutral point earthing shall be at one place only through links so that earthing of one secondary circuit can be removed without disturbing the earthing of other circuits.
4.4 Circuit Breakers

Circuit breakers shall be three-pole horizontal draw-out type. These shall be mounted with its operating mechanism on a wheeled carriage with suitable guides. The breakers shall have Service, Test and Withdrawn positions. At least 4NO and 4NC potential free auxiliary contacts shall be provided. These contacts will be in addition to those provided for functional necessities of the breaker. Limit switches shall also be provided in Service and Test positions. All contacts shall be rated for carrying 10A, 240V AC. Suitable mechanical indications shall be provided for Open, Close and Spring charged positions. Closing of a circuit breaker shall not be possible unless it is in Service, Test or Withdrawn position. The breaker operating mechanism shall be such that the following sequence of operation : open-close-open. This shall be ensured even during loss of AC power supply. There shall be provision for manual spring charging. The co-ordination of the overload and short circuit tripping of the circuit breakers with downstream MCCBs and fuses shall be the responsibility of the manufacturer.
4.5 MCCB & MCB

Moulded Case Circuit Breaker (MCCB) shall conform to IS:13947, Part-2 and of duty type AC4. Miniature Circuit Breakers (MCB) shall conform to IS: 8828. MCCBs shall be provided with over-current and short circuit protection. All the AC MCCBs shall have interrupting capacity of 25 KA. All the DC MCCB shall have interrupting capacity of 15 KA.
4.6 Panel Wiring

All switch boards and control boards shall be supplied completely wired and dressed internally upto the terminal blocks.
4.7 Cable Termination

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Cable termination compartment and arrangement shall be suitable for stranded aluminium conductor, armoured, XLPE / PVC insulated, single or three core, 1100V grade, power cables. All necessary cable terminating accessories such as gland plates, supporting clamps and brackets, power cable lugs, etc. shall be provided to suit the cable sizes indicated elsewhere in this document.
4.8 Protective Relays

Protection Scheme : Each incoming circuit to the L.T. switchboard shall be protected by two over-current and one earth-fault relay unit. The relays shall have IDMT characteristics with instantaneous element having range (5-20) times of relay plug setting. The relays shall be draw out type for easy replacement form the front. The breakers shall also be provided with under voltage release for tripping out in case of supply failure. Selected transformer faults such as Buchholz trip, too high winding temperature trip and too high oil temperature trip shall also cause immediate tripping of the relevant circuit breakers. The auto trip of the breaker shall operate an annunciator.
4.9 Instruments and Meters

All indicating and integrating meters shall be flush mounted on panel front. The instruments shall be of at least 96 mm square size and 90 degree linear scale. The class of accuracy will be 2.0 or better. The covers and cases of the instruments shall be rust and vermin proof. All instruments shall be compensated for temperature errors and factory calibrated to directly read the primary quantities. Means shall be provided for zero adjustment. Each incoming circuits shall be provided with an Ammeter and energy meter. Detailed requirement of energy meter is stipulated in the Specification for LT Metering Equipment
4.10 Instrument Transformers

All current transformers shall be completely encapsulated, cast resin insulated type suitable for continuous operation at the temperature prevailing inside the switchgear enclosure, when the switchboard is operating at its rated condition and the specified ambient temperature. The class of insulation shall be F or better. All instrument transformers shall be able to withstand the thermal and mechanical stresses resulting from the maximum RMS short circuit breaking and peak making current ratings of the associated switchgear. All instrument transformers shall have clear indelible polarity markings. All secondary terminals shall be wired to separate terminals on an accessible terminal block where star point formation and earthing shall be done. All CTs shall be provided with supports independent of busbar supports. The current transformers to be provided in the incoming circuits for protection, instrumentation and metering shall be generally according to IS 2705 with subsequent amendment if any. The accuracy class for protection CTs shall be 5P20 and 0.5 for metering CTs. The corresponding burdens shall be adequate to suit the applications specified.
Tests
5.1 Type Tests

Complete Type Test Reports as per SCC shall be submitted with the offer.
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The following constitutes the Type Tests :
5.1.1 Busducts
The following type test certificates on each rating of busduct shall be submitted. (a) Heat run test on an assembly of representative sections and fittings (b) Short circuit test for a duration and current as covered in the specification on an assembly of representative section. (c) One minute high potential power frequency voltage withstand test. (d) Degree of protection tests.
5.1.2 L. T. Switchgear
The following type test certificates on each type & rating of L.T. Switchgear, MCC panel and distribution boards shall be submitted. (a) Short time withstand test with circuit breaker mounted inside the switchgear panel. (b) Temperature rise test. (c) Degree of protection test (d) High Voltage test
5.2 Routine Tests

The following shall constitute the routine tests: 1. 2. 3. Inspection of the assembly including inspection of wiring and electrical operation test. Dielectric test. Checking of protective measures and of the electrical continuity of the protective circuit.

All tests indicated as routine tests shall constitute the acceptance tests.
Documentation
Documentation required for each equipment is detailed below. The procedure for submission and approval is indicated in the SCC: 1. 2. 3. 4. 5. 6. Front and rear view of the switchboards with instrument and device position marked complete with dimensions. Load on floor and arrangement drawings. Detail drawings of the LTAC panel and DC board showing front, rear and side views with dimensions. Template for foundation and details of cable trench and cable slot in the foundation platform. Dimensional outline, drilling diagram and special mounting arrangement, if any, each type of various devices on switchboard. Internal wiring diagram of all devices and elementary wiring relays.
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7. 8. 9. 10. 11. 12.
Erection and maintenance instructions. Schematic wiring diagrams for switchboards. Literatures on each type of circuit breakers, meters, relays and other components offered. Hard bound literatures describing design construction, operation, maintenance, and adjustment and rating specifications of all the equipment. List of spare parts, identification number, renewable parts of all equipment mounted on the switchboard to procure spare parts correctly at a later date. Complete bill of materials indicating type, make, rating, and specification of all the components.
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Sl. 1
Description 2 Quantity 3
DC Distribution Board 1 2 3 4 5 6 7 8 9 10 Incomer section with double pole 400 Amps MCCB with necessary protection Bus coupler section with 400 Amp MCCB Feeder section with double pole, 50 Amps, MCCB with thermal overload and magnetic short circuit release AC/DC automatic changeover contactor switch, double pole, 50 amps rating for switching on DC supply to emergency DC lighting DC over voltage relay with timers for tripping two nos. incomer MCCB in case of over voltage of the DC Bus. Ground alarm relays. Pilot indicating lamps with white lens for ground indication. Flush mounted moving coil voltmeter with fuses to read the load bus voltage. Flush mounted type ammeter with shunt to read the load current. 2 nos. 1 no. 16 nos. 2 nos. 2 nos. 2 nos. 2 nos. 1 no. 1 no.
Indicating lamp for ON/OFF indication of all MCCBs AND Switch fuse as indicated units herein
AC Distribution Board Incomer with air circuit breakers, draw out type, four pole, 415 Volts, 800 Amps, 25kA sym. breaking capacity. The breaker shall be 1 2 nos. complete with cable glands suitable for two numbers 1100 Volt grade 1 300 sq.mm, 3 2 core Aluminium cable. 2 3 4 5 6 7 8 9 10 Bus coupler section with air circuit breaker, draw out type, four pole, 415 volt, 800A, 25kA sym. breaking capacity Feeder sections with 100 Amps. MCCB Feeder sections with 63 Amps. TPN switch fuse unit Feeder sections with 32 Amps. TPN switch fuse unit Feeder sections with 32 Amps. SPN switch fuse unit Feeder sections with 16 Amps. SPN switch fuse unit Indication lamps for close, open and trip condition of circuit breakers AC ammeter with range 0-800A for each incomer AC voltmeter with range 0-500V for each incomer 1 no. 8 nos. 12 nos. 8 nos. 4 nos. 3 nos. as per reqmt. 2 nos. 2 nos. 6 nos
Resin cast CTs of 400-200/5A ratio, continuous thermal rating 520A, insulation level 600V/3KV, short time thermal rating 14kA for 3 sec, 11 dynamic current rating 35kA peak, accuracy class 0.5, ISF 5, insulation class F, for each incomer Resin cast CTs of 400-200/5A ratio, continuous thermal rating 520A, insulation level 600V/3KV, short time thermal rating 14kA for 3 sec, 12 dynamic current rating 35kA peak, accuracy class 5P20, burden 20VA, insulation class F, for each incomer
6 nos
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Sl. 1
Description 2
Quantity 3 2 nos.
3 pole, relay unit with two over-current elements having current setting range of 2.5 - 10 Amps. and one earth fault element having current 13 setting range of 0.5 - 2.0 Amps. Each element shall also have an instantaneous unit having range (5-20) times plug setting current and an operation indicator with manual reset
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SPECIFICATION FOR SAFETY EQUIPMENT

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of safety equipment like fire extinguishers and insulating mats.
Standard
The equipment covered by this specification shall, unless otherwise specified, conform to the latest edition of the following: 1. IS 2171 2. IS 2878 3. IS 2584 4. IS 8437 - Specification for portable fire extinguishers, dry powder (cartridge type) - Fire Extinguisher, Carbon Dioxide Type (Portable and Trolley Mounted) Specification - Method of test for electric strength of solid insulating materials at power frequencies - Guide on effects of currents passing through human body
5. IS 15652 - Insulating Mats for Electrical Purposes - Specification 6. Guidelines of the Tariff Advisory Committee. Wherever the requirements in these specifications are in conflict with any of the above document, the requirements under this specification shall be binding.
3
1 2 3 4 5 6 7
Extinguishers
For electrical equipment, only extinguishers expelling dry powder or carbon dioxide (without metal horn) shall be used. The extinguishers will be portable and freestanding type. Portable extinguishers shall be provided with suitable clamps for mounting on walls else they shall be provided with rollers. They shall be capable of discharging freely and completely in upright position. Instructions for operation shall be on the body of the equipment. All extinguishers shall be painted with durable enamel paint of a colour conforming to the above standards. All extinguishers shall be ISI marked.
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Insulating Mats
4.1 General Requirements

4.1.1
1) 2)
Composition :
The mat shall be made from the material- Elastomer, free from any insertions leading to deterioration of insulating properties. Upper surface of insulating mat should have small aberration (rough surface) without edges. The lower surface should be plain.
4.1.2
1) 2) 3)
Dimension
The thickness of the mat shall be 2.0 mm Tolerance(10%). The length of the mat shall be a multiple of 5000 mm Tolerance (20 mm). The Width of the mat shall be 1000 mm Tolerance (20 mm).
4.1.3
Colour
The colour shall be mutually decided between purchaser and manufacturer during design engineering stage. However no colour with metallic derivatives shall be used.
4.1.4
Workmanship and Finish
Mats shall be free on both surfaces from harmful physical irregularities. Harmful physical irregularities shall be defined as any feature that disrupts the uniform, smooth surface contour, such as pinholes, cracks, blisters, cuts, conductive embedded foreign matter, creases, pinch marks, voids (entrapped air),prominent ripples.
4.2 Physical Properties

4.2.1 Tensile Strength and Elongation at break
The tensile strength and elongation of the mat at break shall be as follows :a) b) c) Tensile strength Elongation : : 15 N / mm (Min) 250% (Min) (-)10 to 55
2
Ambient Temperature Range (C) : Dielectric Properties Insulation Resistance with water
4.2.2 1)
Minimum Insulation resistance of the mat in wet condition will be 100000 M when measured with 5 KV Megger or 1000000 M with 500 volt Megger.
2)
Leakage Current
To meet the requirements of IS 8437 (Part-I), the leakage current of the mat, measured as per C-3.2 of IS 15652 shall not be more than 10 A.
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3)
AC Dielectric Strength
Minimum dielectric strength of the mat measured as per IS: 2584, shall not be less than 30 KVrms AC.
4)
AC Proof Voltage
The mat shall withstand proof voltage of 10 KVrms AC, when using electrodes and applying the voltage as per C-3.4 of IS 15652 .The test is deemed successful, if the specified test voltage is reached and maintained for 3 min for the Type and Sampling Test and 1 min for the Routine Test without become appreciably warm at any spot.
4.2.3
Ageing properties
Tensile Strength and elongation at break, when measured after subjecting the mat to aging for 168 Hrs at 70C1C as described in C-4 of IS 15652 shall not be less than 75% of the corresponding values obtained for unaged test pieces from the same lot.
4.2.4 1)
Thermal Properties Flame Retardance
Fire should extinguish within 5s after removal of blue flame, when tested as described in C-5.1 of IS 15652.
2)
Low Temperature Resistance
The mat will not show any visible break or crack when folded after placing for one hour at a temperature of (-)103C as described in C-5.2 of IS 15652.These shall also pass ac proof voltage as per relevant clause of IS 15652.
4.2.5
Acid, Alkalis and Oil Resistance
Following the conditioning in acids, alkalis and oil as described in C-6 of IS 15652,the resulting mechanical deterioration and chemical damage on the mats shall be determined by measuring tensile strength and elongation. The values obtained for these shall not be less than 80% of the corresponding values obtained in tests carried out on samples from same batch without conditioning.
4.2.6
Sample
The Contractor shall arrange to submit one set of sample of the item offered for Purchasers approval prior to taking up of the manufacturing work. However, such submission of sample shall be without any cost implication or any other obligation.
4.3 Marking
4.3.1
Every Flat/roll will be marked with the following : (a) (b) (c) (d) Class Lot No. Roll No. Manufacturers identity
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4.3.2
BIS Certification Marking
The product may also be marked with Standard Mark.
4.4 Packing
The material should be rolled smoothly on hollow Mandrel either made of hard cardboard or waste plastic, of diameter 50 mm or higher. The material should be wound tightly and the edges of top most layer should not shift from the edge of 1st bottom layer by more than 75 mm. The roll should be clamped at two places with the help of plastic unidirectional tape & clamps. Gunny / jute material should be used for packing covered by proper plastic bag having lining of suitable fabrics to avoid any kind of damage to the material.
4.5 Tests
4.5.1 Type Tests
Complete Type Test Reports as per SCC shall be submitted with the offer. The tests shall be conducted as per the latest edition of IS 15652. The following shall constitute the Type Tests : 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) Shape Dimension Thickness Workmanship and Finish Marking Packaging Tensile strength and elongation Insulation resistance Leakage current AC di-electric strength AC Proof Voltage Ageing Flame Retardance test Low Temperature Acid and Oil resistance
4.5.2
Routine Test
The following shall constitute the routine tests: 1) 2) 3) Shape Dimension Thickness
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4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15)
Workmanship and Finish Marking Packaging Tensile strength and elongation Insulation resistance Leakage current AC di-electric strength AC Proof Voltage Ageing Flame Retardance test Low Temperature Acid and Oil resistance
4.5.3
Acceptance Tests
All tests indicated as routine tests shall constitute the acceptance tests.
4.6 Documents
The following drawings and documents shall form part of the offer: 1) Dimensional drawing of the mat and packing mandrel. 2) Notes and instructions for installation.
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SAFETY EQUIPMENT
Sl. 1
Description 2
Type 3
Fire Extinguishers 1 9 Ltrs Carbon dioxide, as per IS:2878 2 22.5 kg, Carbon dioxide as per IS:2878 3 2 kg, Dry powder as per IS:2171 4 10kg, Dry powder as per IS:2171 Insulating Mat 1 Class 2 Material 3 Length 4 Width 5 Thickness 6 Ambient temperature range 2 7 Tensile strength in N/mm 8 Elongation at break 9 Leakage Current
Trolley Trolley Portable Trolley A Elastomer Multiple of 5000 mmTolerance(20mm) 1000 mm Tolerance(20mm) 2 mmTolerance(10%) o o -10 C to 55 C 15 (Min) 250 % (min) < 10 A
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SPECIFICATION FOR EARTHWIRE

Scope
This specification covers design, manufacture, assembly, testing at manufac turers works, packing and delivery at site of Galvanised Earthwire.
Standards
The equipment covered by this specification shall, unless otherwise specified, conform to the latest edition/revision of the following: 1) 2) 3) 4) 5) IS 2363 IS 2629 IS 2633 IS 4826 : Glossary of terms relating to wire ropes : Recommended Practice for Hot-Dip Galvanizing of Iron and Steel : Methods for testing uniformity of coating of zinc coated articles : Specification for Hot-Dipped Galvanized Coatings on Round Steel Wires
IS 12776 : Galvanised Strand For Earthing Specification
3
3.1
Technical Particulars
Material
The conductors shall be Galvanised stranded Steel Wire for Ground wires. The material of steel wire shall conform to IS 12776.
3.2
Construction
2
The conductors shall be of the size 7/3.15 mm galvanised stranded steel wire of 1100N/mm quality.
All steel galvanised steel earth strand shall be smooth, uniform and free from all imperfections such as spills, die-marks, scratches, abrasion and kinks after drawing and also after stranding. Standard length of each coil shall be 1.5 KM.
Dimension and Tolerances
The dimension and manufacturing tolerances in diameter of individual wires and lay length of galvanised steel earth strand has been indicated in the Specific Requirement of this specification.
Standard Length
Standard length of each coil without joint or weld shall be 1.5 KM.
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Galvanising
The wires shall be galvanised in accordance with IS 2629. Galvanising shall be uniform, free from blisters and shall not peel off due to abrasion. Uniformity of Zinc coating shall be determined as per IS 2633. Number of dips shall be in accordance with Annexure-A of IS 12776 and as indicated in the Specific Requirement of this specification..
Tests
The following tests shall be conducted on the complete strand.
7.1 Breaking Force

Shall be as per IS 12776 .
7.2 Elongation
The elongation of individual wires when measured on a gauge length of 200 mm after breakage shall meet the requirements as given in Annexure-A of IS 12776 .
7.3 d.c. Resistance Test

The galvanised steel earth strand shall be tested according to clause 8.3.2 of IS 12776.The value of d.c. resistance shall be as per Annexure-A of IS 12776.
7.4 Wrapping Test

The test shall be conducted by wrapping the wire around a mandrel of diameter equal to four times the wire diameter to form a close helix of eight turns. Six turns then be unwrapped and finally closely wrapped again, in the same direction as before. The wire shall not break during the test(applicable for wires before stranding).
7.5 Galvanising Test

The zinc coating on the individual wires shall be tested as per IS 2633 and shall meet the requirement of IS 12776.
7.6 Torsion Test

Torsion value of the individual wires shall meet the requirements as given in Annexure-A of IS 12776.
Sampling
The sampling plan shall be in accordance with the standard practice of the manufacturers who shall clearly certify that the full sample or samples tested. No dispatch shall be effected prior to the Purchasers written approval of the test certificates. The purchaser may, at any time, call for any tests, that are laid down in the specification as optional test. The Contractor shall arrange to carry out such tests expeditiously at extra cost. Test reports for such optional tests, shall also be submitted to the purchaser, in triplicate for approval.
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Selection of sample, conditions of respective tests and rejection of materials if any, shall strictly be in accordance with the requirements of the approved standard or as per the standard practice of the manufactures and in the latter case, full details of the standard practice shall be stated in the tender. The relevant test reports for the repetitive tests including the results of the tests in which the equipment failed to satisfy the requirements of the approved standards shall also be submitted in triplicate. All cost for tests / retests shall be borne by the contractor. The bidder shall submit full particulars of the testing facilities available in Govt./approved laboratory and shall confirm that the laboratory will be readily available when required, for testing of all the material offered by him.
Packing
All reels shall be of dimension approved by the Purchaser and made of seasoned wood sufficiently strong to ensure safe arrival at site, withstanding normal handing and hazards inland transit. The reels shall be such size as to proved at least clearance at all points from the cable to the inner surface of the laggings. It shall conform to IS 1778. All reels shall have two coats of aluminum paint on both inside and outside surfaces and shall be seated with malleable iron Hub-bushings each having a 90 mm diameter hole. All reels shall have a layer of waterproof paper around the hub under the cable and another layer over the outermost layer of the cable, that is, next to the lagging. The reels shall be properly reinforced with galvanised steel wires or iron straps, over the laggings in two places, in an approved manner. The wooden drum shall preferably be given a protective coating of a reliable organic wood preservative before painting with aluminum paint and the laggings shall also be given a similar treatment before, being fixed on the drum.
10 Marking of Drums & Packages

Each drum / package shall be marked on the sides as follows : a) b) c) d) e) f) Name or designation of the consignee to be furnished by the Purchaser. Ultimate destination as required by the Purchaser. Size of galvanised steel earth strand Length of galvanised steel earth strand The net and gross weights of the materials. Arrow Marking for unwinding
The markings shall be stenciled in indelible ink on each package / drum.
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Sl. 1 1 2 3 (a) (b) (c) 4 (a) 5 (a) 6 7 (a) 8 (a) (i) (b) (i) 9 10 11 12 13 14 15 16 Description 2 Material Construction Wire diameter (mm) Nominal Maximum Minimum 2 Minimum Tensile Strangth(N/mm ) After Stranding Torsion of wire on 100 X D After Stranding Wrap Test on wire as per Sec 8.4 of IS 12776 Elongation of wire(on 200 mm gauge length) After Stranding Zn-coating on wires 2 Amount of coating (g/m ) After Stranding Uniformity of coating After Stranding Lay and lay length of galvanized steel earth wire (mm) Minimum breaking force of galvanised steel earth strand (KN) Mass per KM of galvanized steel earth strand(Kg) Density of galvanised steel wire at 20C Coefficient of Linear Expansion Equivalent Modulus of Elasticity of galvanized 2 steel earth strand (Kg/mm ) Maximum d.c resistance in ohm per KM of the galvanized steel earth strand at 20C Nominal Length without joint or weld Type 3 Carbon Steel as per IS 12776 7 X 3.15 3.15 3.25 3.07 1050 18 (Min) No wire breakage during the test 3.5% (Min)
228 (Min) Minimum 2 dips of 1 minute and 1 dip of minute RH 54.0 426 3 7.8 gm/cm -6 11.5 X 10 /C 19 X 10 3.41 1500 Meters
3
Min : 123 Max : 252
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SPECIFICATION FOR TOWERS

1
A)
Scope of Supply
Fabrication, galvanization and supply of steel structural members for all types of complete set of 132 KV Transmission towers, Gantry Towers, Gantry Trusses, Other Tower parts (i.e., Stub-setting templates, Muff-boxes, Hangers, Extn. Links, MS clamp plates, Shackles for conductor & ground wire, Bird-guard etc.) Tower accessories (i.e., Anticlimbing devices including spikes, Danger plates, Number plates, Phase plates, Circuit plates, Earthing materials for pipe and counterpoise earthing etc. complete) Bolts and Nuts, Spring washers, Pack washers, Step-bolts, U-Bolts etc. and delivery F.O.R. destination. Muff boxes, i.e. steel form boxes to be used as shuttering of tower foundations shall not be galvanized; instead they will be painted with red-oxide paint. Preparation of Bill of Materials on the basis of detailed Structural / assembly drawings. Assembly drawings will be supplied by DVC to the successful tenderer.
B)
C)
Detailed Technical Data are furnished in the Appendixes attach to this Section.
2
2.1
Transmission Towers
General Description
The towers are fully galvanized lattice steel structures using bolted connections capable to be used as self supporting structures and designed to carry the line conductors with necessary insulators, earth wires and all fittings under all loading conditions. The 132 kV towers has been designed as per the latest edition of IS:802 to suit conductor temperature of 75C for AAAC Panther (37/2.88mm).
2.2
Type of Towers
The towers shall be classified as given below :
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a)
A 2 Type Tangent Towers: This type of tower shall be provided with suspension strings and are angles up to 2 degree deviation at the normal ruling span. designed for
b)
S 150 Type Angle and Section Towers: This type of tower shall be provided with tension strings and shall be used for angle of deviation in the line up to 15 with normal ruling span and also for longer spans with smaller angles. These towers may also be used for section towers.
c)
B 300 Type Angle and Section Towers: This type of tower will be similar to above S-15 type except for angle of deviation up to 30 in the line with normal ruling spans and also for longer spans with smaller angles.
d)
C 600 Type Angle and Dead-end Towers: This type of tower shall be provided with tension string and shall be used for angles of deviation in the lines up to 60 with normal ruling span and also for longer spans with smaller angles. These towers will also be used as terminal or dead-end towers. Only a common structure and common Cross-arm are designed both for dead-end condition and 60 deviation. For dead-end condition, towers are designed for no angle of deviation of the tower on line side and there will be up to 15 angles on slack span (Gantry) side.
e)
D 900 Type Deviation and Dead-end Towers: This type of tower will be similar to above C-type except for angle deviation up to 90 when used as angle tower and 30 angles on slack span (Gantry) side when used as dead-end.
f)
Line X-ing Towers: These towers shall be used for crossing another Transmission Line and they are designed for angle upto 5. Note: The above towers can also be used for longer span with smaller angle of deviations without infringement of ground clearance.
g)
Special Towers : The towers which will be specially designed for very long spans, which can not be crossed by normal tower with extensions like Major River crossings etc. .
2.3
Tower Extensions
The above towers are designed so as to be suitable for extension at the base without reducing the specific factor of safety in any manner. The extension leg will have butt joints with normal towers. Such extension shall be needed where ground clearances are found to be inadequate or for power line / railway / river-crossing etc. The foundations of towers are so designed as to be suitable for towers with or without extensions.
2.4
Stub-Setting Templates
Stub-setting templates shall be supplied by the Contractor for all types of towers. Stub-setting
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templates for towers with extensions are of adjustable type. The stub-setting templates shall be fully galvanized.
3
3.1
Development of Drawing / BOM

General
The relevant drawings for all the towers and their extensions which will be furnished to the Contractor by DVC shall include Structural / assembly drawings with required fabrication details, Tower accessories, Muff-boxes, Foundation working drawings in duplicate. The contractor should prepare their own bill of materials on the basis of Structural / assembly / erection drawings of various types of towers and extension portion to be supplied by DVC to the successful tenderer. The types of steel sections to be used for different types of towers / extensions are indicated in Structural Steel Requirement
3.2
Design and Drawings
The Structural / assembly drawings with required fabrication details for all the towers and their extensions will be given to the Contractor in two copies. The tower members can be directly fabricated from the Structural / assembly drawings. However, if the contractor is required to prepare the shop fabrication drawings in addition to the Structural / assembly drawings with required fabrication details, they have to prepare the same without any additional financial implication to DVC. Before taking up the mass fabrication, the Contractor shall arrange for one number protoassembly for each type of towers and extensions which shall be inspected by DVC Engineer. The Contractor shall submit BOM and it will approved by DVC before carrying out the Proto Inspection.
3.3
Shop Drawings
Shop drawings should clearly indicate the member sizes, length and marks, hole positions, gauge lines, bend lines, edge distances, amount of chipping, notching etc. For Gusset, separate individual item wise templates shall be made to facilitate fabrication as well as inspection. In case of members to be bent, shop drawings should indicate the provisions for variation in length. At the fabrication stage, care should be taken to see that the degree of bend given in any member is such that neither flange width nor thickness shall vary beyond permissible limits for the section. Items requiring steep bends can be cut and welded as per approved welding procedure.
3.4
Bill of Materials
Bill of material for each type of tower should be prepared separately. This should indicate grade of steel, mark numbers, sections sizes, member lengths, their unit & calculated weights, number of bolts, nut and washers and their sizes, total quantities required and structural drawing numbers. No reduction in weight due to drilling, punching of bolt holes, skew cuts, chipping, notching, chamfering etc., should be made while computing calculated weights of the members. All steel sections used should have dimensions as per IS:808.
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Bolts, Nuts and Washers
All tower members shall be joined together with Bolts and nuts. All hexagonal bolts and nuts shall conform to IS-12427. They shall have hexagonal head and nuts, the heads being forged out of the solid, truly concentric, and square with the shank, which must be perfectly straight. All bolts and nuts shall be galvanised as per IS:1367 (Part-13)/IS:2629 . The bolt shall be of 16/20/24 mm diameter and of property class 5.6 as specified in IS:1367 (Part-III) and matching nut of property class 5.0 as specified in IS:1367 (Part-VI). Bolts up to M16 and having length up to 10 times the diameter of the bolt should be manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. The shear strength of bolts for 5.6 grade should be 310 MPa (minimum) as per IS:12427.Bolts should be provided with washer face in accordance with IS:1363 (Part-III) to ensure proper bearing. Nuts for hexagonal bolts should be double chamfered as per the requirement of IS:1363 PartIII. It should be ensured by the manufacturer that nuts should not be over tapped beyond 0.4mm oversize on effective diameter for size up to M16. Fully threaded bolts shall not be used. The length of bolts shall be such that the threaded portion will not extend into the place of contact of the members. All bolts shall be threaded to take the full depth of the nuts and threaded for enough to permit firm gripping of the members, but not further. It shall be ensured that the threaded portion of each bolt protrudes not less than 3mm and not more than 8mm when fully tightened. All nuts shall fit tight to the point where the shank of the bolt connects to the head. M/s. BI (Simplex) / ASP make bolts & nuts shall be used. Flat and tapered washers shall be provided wherever necessary. All pack washers shall be made of steel conforming to IS : 2062 Gr. A. (latest). The plain washers & heavy washers shall conform to IS : 2016 & IS : 6610 (latest) respectively. Spring washers shall be provided for insertion under all nuts. These washers shall be steel electrogalvanised, positive lock type and 3.5mm in thickness for 16mm dia bolt and 4.5mm for 24mm bolt. To avoid bending stress in bolts or to reduce it to minimum, no bolt shall connect aggregate thickness of members more than three (3) times its diameter. Bolts at the joints shall be so staggered such that nuts may be tightened with spanners without fouling. It may be necessary to tack weld bolts & nuts upto bottom cross-arm level as a precaution against theft & sabotage. Contractor shall supply 2.5% extra of all sizes of bolts, nuts and washers to take care of losses during erection. No payment shall be admissible for these extra supplies.
Details of Fabrication
The fabrication of towers shall be in conformity with the following: a) Except where hereinafter modified, details of fabrication shall conform to IS:802 (PartII).The tower structures shall be accurately fabricated to connect together easily at site without any undue strain on the bolts. b) No angle member shall have the two leg flanges brought together by closing the angle. c) The diameter of the hole shall be equal to the diameter of bolt plus 1.5mm. All parts shall be accessible for inspection and cleaning. Drain holes shall be provided at all points where
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pockets of depression are likely to hold water.
6
6.1
Operations in Fabrication
General
Workmanship & finish shall correspond to the best modern transmission line practice. All similar parts shall be made interchangeable. All steel sections before any work is done on them shall be carefully leveled, straightened and made true by methods which shall not injure the material so that when assembled, the adjacent surface are in close contact throughout. No rough edges shall be permitted any where throughout the work.
6.2
Straightening
All material should be reasonably straight and, if necessary, before being worked, be straightened and/or flattened by pressure and be free from twists. Straightening should not damage the material. Adjacent surfaces of the parts when assembled should be in close contact throughout keeping in view the tolerances specified. Machines used for straightening are :(1) For angle sections upto 110x110x10mm Roller Straightening Machine; (2) For higher sections Beam bending machine and Hydraulic Press.
6.3
Cutting
Cutting may be effected by shearing, cropping, flame cutting or sawing. The surfaces so cut should be clean, smooth and reasonably square and free from any distortion.
6.4
Bending
Mild steel angles sections (IS:2062-Grade A) up to 75x75mm (thickness upto 6mm) shall be bent cold upto and including bend angles of 10 degree; angles above 75x75mm (thickness upto 6mm) and upto and including 100x100mm (thickness upto 8mm) may also be bent cold upto the bend angle of 5 degree. All other angle sections not covered above should be bent hot. All plates upto 12mm thickness should be bent cold up to bend angle of 15 degree. Greater bends and/or other thicknesses should be bent hot.
6.5
Punching and Drilling
Transmission line towers demand accurate drilling or punching of holes with high standard of workmanship and finish. Before any cutting work is started, all steel sections shall be carefully straightened and trued by pressure and not by hammering. They shall again be trued after being punched and drilled. Holes for bolts shall be drilled or punched with a jig but drilled holes shall be preferred. The punching may be adopted for thickness up to 16mm. For thicker sections, drilling should be done. Tolerances regarding punch holes are as follows:a) b) Holes must be perfectly circular and no tolerances in this respect are permissible. The maximum allowable difference in diameter of the holes on the two sides of plates or angle is 0.8mm. i.e. the allowable taper in a punched holes should not exceed 0.8mm on diameter. Holes must be square with the plates or angles and have their walls parallel.
c)
All burns left by drills or punch shall be removed completely. When the tower members are in
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position the holes shall be truly opposite to each other. Drilling or reaming to enlarge holes shall not be permitted. The edge security and bolt gauges should be maintained in all cases.
6.6
Marking of Members
Each individual tower member shall carry a stamped mark (number) assigned to in the approved drawings. These stamping shall be done by a metal die of 16 mm size before galvanizing and on optimum depth so as to clearly legible after galvanizing. Further more, the mark No. should be stenciled in indelible ink on each tower member after galvanizing. Erection Mark shall be AA-BB-C-DDD AA BB C = = = Contractors Mark-a-Numeric ( maximum 4) DVCs code assigned to the Contractors- Alphabet Tower Type Alphabet. Number mark to be assigned by Contractor - Numerical.
DDD =
Erection mark for high tensile steel members shall be prefixed by the letter H
6.7
Shop Erection/Proto-Type Tower Assembly
Before starting mass fabrication, one each of the different types of tower complete with maximum extensions, cross arms and stubs or part thereof shall be assembled horizontally in the shop to check the assembly, details and fabrication defects, if any, so that any modifications necessary in approved drawing can be incorporated and a fresh assembly presented to the Corporations Engineer or Inspector for inspection and approval. Mass fabrication shall only start after receipt of final approval of the check assembly. The prices quoted for the tower shall include all modifications to be carried out in the fabrication and assembly as a result of check assembly. The contractor shall give, at least two weeks notice to the Corporation for him to arrange for his Engineer or Inspector to check the assembly.
6.8
Tower Finish
Contractor shall quote rates for supply of fully galvanized fabricated materials for towers/ structures including extensions, stubs and stub-setting templates etc. All bolts and nuts, washers, step bolts and attachments like hangers, shackles, earth wire, binding clamp, M.S. strip and pipe for earthing shall also be fully galvanized.
7
7.1
Tolerance
Tolerance in Holes
Holes for bolting should be cylindrical. The diameter of hole is equal to diameter of bolt + 1.5mm for bolts up to 20mm in diameters. For 24 mm dia bolts, the clearance between bolt shank and hole is 2.0 mm. While deciding the diameter of the hole whether drilled or punched, care should be taken in making allowance for thickness of galvanizing coat on bolts as well as in the holes and for the tolerances in bolt shank diameter. It has been observed after series of measurements on bolt shanks that their diameter varies up to 0.3 mm above the nominal diameter. Thus, the final diameter of the holes to be punched/drilled at Black stage will be
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1.5mm + bolt diameter + 0.3 mm for bolts up to 20mm in diameter. For 24 mm diameter bolts, the final diameter of the hole at Black stage will be equal to bolt diameter + 2.0 mm + 0.4 mm. Blocking of mis-punched/excess holes: Mispunched or excess holes not more than one on any one cross-sectional area should be blocked by proper welding technique by qualified welders.Total number of such blockings by welding may be limited to three holes in a member.No new holes should be permitted overlapping the plugged hole. The welding must be of proper quality and specification to ensure that strength of the welded member shall be not less than that of the normal member.
7.2
(a)
Tolerance in Fabrication
On straightness (camber) 0.4% of the length of sections of sizes up to 100x100mm. 0.2% of the length of sections of sizes over 100x100mm.
(b)
The maximum allowable difference in diameter of the holes on the two sides of plate or angle shall be 0.8mm; i.e., the allowable taper in a punched hole shall not exceed 0.8mm on diameter. On overall length of angle members On consecutive holes On first hole to last hole in member On gauge distances : : : : 2mm 1 mm 2 mm 1mm 0.3 mm / -0.0 mm
(c) (d) (e) (f) (g)
On specified hole diameters on the punch side : (in black) or where drilled
The fabrication tolerances in general shall conform to IS: 7215. In case of deviation beyond prescribed tolerance, the assembly of the members may be made as per Structural Drawings and if the overall dimensions of the structure are within limits, such items can be accepted. For leg member joint holes, a manufactured cleat may be taken at random and placed over the member. The bolt should pass at right-angle to the surface of member. For corner cuts, notches, flanged cuts etc., a tolerance of 2.0 mm is allowed.
8
8.1
Tower Accessories
Anti climbing Device:
Barbed wire type anti climbing device, as per DVCs drawing shall be provided and installed by the Contractor for all towers. The barbed wire shall conform to IS-278 (size designation A1). The barbed wires shall be given chromating dip as per procedure laid down in IS:1340.
8.2
Danger, Number, Circuit and Phase plates :
Danger Plates, Number plates, circuit plates (for double circuit line only) and phase plates as per DVCs drawing shall be provided and installed by the Contractor. a) Each tower shall be fitted with a danger plate, number plate and two sets of phase plates for double circuit tower. Circuit plates shall also be provided on all the Double Circuit towers. The letters, figures and the conventional skull and bones of danger plates shall conform
b)
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to IS-2551 and shall be in a signal red on the front of the plate. The number plate, phase plate and circuit plate shall conform to IS 5613. c) d) e) The corners of the danger, number and circuit plates shall be rounded off to remove sharp edges. The letters of number and circuit plates shall be red enameled with white enameled background One set Phase plate consists of 3 plates having red, blue and yellow colours. One set Circuit plate consists of 2 plates with marking I & II for double circuit tower.
9
9.1
Inspection
General
All standard tests, including quality control tests, in accordance with appropriate Standard, shall be carried out unless otherwise specified. a) The Contractor shall keep DVC informed in advance about the time of starting and of the progress of manufacture and fabrication of various tower parts at various stages, so that arrangements could be made for inspection. The acceptance of any part of items shall in no way relieve the Contractor of any part of his responsibility for meeting all the requirements of the Specification.
b)
DVC representative shall have free access at all reasonable times to those parts of the Contractors works which are concerned with the fabrication of the DVCs material for satisfying himself that the fabrication is being done in accordance with the provisions of the Specification. Unless specified otherwise, inspection shall be made at the place of manufacture prior to dispatch and shall be concluded so as not to interfere unnecessarily with the operation of the work. If any member of the structure is found not to comply with the supplied design, it shall be liable to rejection. No member once rejected shall be resubmitted for inspection, except in cases where the DVCs authorized representative considers that the defects can be rectified. Defect which may appear during fabrication shall be made good with the consent of, and according to the procedure proposed by the Contractor and approved by DVC. All gauges and templates necessary to satisfy DVCs authorised representative shall be supplied by the contractor. The specified grade and quality of steel shall be used by the Contractor. To ascertain the quality of steel used, the inspector may at his discretion get the material tested at an approved laboratory. In general, all measurements are done with steel winding tapes in accordance with IS: 1270 For inspection of galvanized material, the manufacturer should provide galvanized coupons enabling the Inspector to carry out tests on the coupons. The coupons should be taken from the batches corresponding to the fabricated material under inspection. However, galvanizing test will also be carried out on samples drawn from the finished material.
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10 Structural Steelwork
10.1 Material
a) Steel :
IS Steel Sections of tested quality of conformity with IS:2062 (Designated Y.S. 250 MPa) or / and IS:8500 grade 490 (Designated Y.S. 350 MPa) are to be used in towers, extensions and stub setting templates. The chequered plates shall conform to the latest edition of IS : 3502. The material shall be of tested quality, recent manufacture & free from scales, slag intrusions, pitting, flake, rusts etc. Steel sections produced by main producers like SAIL / IISCO / TISCO / RINL shall be used in general. However, steel sections from the DVC approved re-rollers may also be used. Procurement of all steel materials required for fabrication of towers, such as angles, plates, rounds etc. shall be arranged by the contractor himself at his cost. The rate quoted for supply of towers shall include the cost of steel.
b)
Zinc
The Contractor shall arrange for procurement of Zinc required for galvanizing the structure by himself. The rate of fabrication shall be inclusive of the cost of Zinc and galvanization. The Zinc required for galvanizing shall be of quality Zn 99.99 and shall conform to the latest edition of IS: 209 .
c)
Bolts and Nuts
All M.S. Bolts & Nuts shall conform to IS: 6639 (latest) & IS: 12427 (latest). The step bolts should conform to IS: 10238 (latest). The bolts shall be of property class 5.6 as specified in IS : 1367 (Pt.-III)(latest) & nuts shall be of property class 5 as specified in IS : 1367 (Pt.-VI)(latest).. All bolts & nuts shall be galvanised & tested in accordance with IS : 2633 (latest) & shall have hexagonal heads & nuts, the heads being forged out of the solid, truly concentric & square with the shank which must be perfectly straight. Fully threaded bolts shall not be used. The length of bolts shall be such that the threaded portion will not extend into the plane of contact of the member. Diameter of bolt shall be 16/20/24 mm. unless noted otherwise.
d)
Washers
All pack washers shall be made of steel conforming to IS : 2062 Grade-A( latest ). The plain washers & heavy washers shall conform to IS : 2016 & IS : 6610 ( latest ) respectively. Spring washers shall be steel electrogalvanised, positive lock type and 3.5mm in thickness for 16mm dia bolt and 4.5mm for 24mm bolt. It shall conform to IS : 3063 ( latest ). Spring washers shall be Electro-galvanized in accordance with Service Condition IV of IS : 1573 ( latest ). . Contractor shall supply 2.5% extra of all sizes of bolts, nuts and washers to take care of losses during erection. No payment shall be admissible for these extra supplies
e)
Step Bolts and Ladders
Each tower shall be provided with step bolts conforming to IS : 10238 of not less than 16mm diameter and 175mm long, spaced not more than 450mm apart and extending from 2.5 meters above the ground level to the top of the tower. For double circuit tower, the step bolts may be
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fixed on two diagonally opposite legs up to top of the towers if shown in the drawing. Each step bolt shall be provided with two nuts on one end to fasten the bolt securely to the tower and button head at the other end to prevent the feet from slipping away. The step bolts shall be capable of withstanding a vertical load not less than 1.5 KN. For special towers, where the height of the super structure exceeds 50 meters, ladders along with protection rings as per DVC approved design shall be provided in continuation of the step bolts on one face of the tower from 30 meters above ground level to the top of the special structure. From 2.5m to 30m height of super structure step bolts shall be provided. Suitable platform using 6mm thick perforated chequered plates along with suitable railing for access from step bolts to the ladder and from the ladder to each cross-arm tip and the ground wire support shall also to be provided. The platform shall be fixed on tower by using counter-sunk bolts.
10.2 Procurement of Raw Materials

The contractor must procure the materials from the manufacturers mentioned in the approved vendor list. The contractor shall not obtain without written permission of the Corporation any material for the purpose of this contract from manufacturers other than those approved by the purchaser. All raw materials required for fabrication, galvanizing etc and for complete execution of work shall be stocked in adequate quantities by the contractor to ensure that the progress of work is not hampered. While designing the towers, rationalized steel sections has been used. During execution of the project, if any particular section is not available, the same shall be substituted by higher section at no extra cost to DVC and the same shall be borne by the Contractor. However, design approval for such substitution shall be obtained from DVC before any substitution.
11 Testing of Materials
11.1 Structural Steel
Original copies of the test certificates of steel should be sent to the office of the Chief Engineer(PSR), DVC Towers, VIP Road, Kolkata 700 054. Steel collected should be properly stacked to avoid corrosion and kept for physical verification of the Corporation s Engineer. Contractor shall offer all assistance in regard to the Corporations inspection and proper care shall be taken so that steel collected for Corporations work is not mixed up with the steel for other agencies works. Samples from fabricated and / or raw steel for each type should be tested if required by the Corporation at Govt. Test house or any DVC approved Testing Laboratory free of cost to the Corporation. Such samples will be collected by the authorized representative of the Corporation. Test should be made in accordance with provisions of concerned ISS (latest). The various testing to be performed are as follows : 1. Material Specification as per IS-2062(Grade-A) and tolerances as per IS-1852. 2. Sampling shall be as per IS-2500. 3. Physical properties : i) Verification of Mill Test Certificate. ii) Actual Test Certificate from Laboratory.
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4. Dimensional and visual inspection shall be in accordance to IS-808 and IS-1852. 5. Chemical Property in accordance to IS-2062 (Grade-A)
11.2
Bolts and Nuts
Producers routine test certificates for bolts, nuts, washers etc. as laid down in relevant ISI code approved by the Corporation, shall be submitted by the contractor. In addition, minimum ten numbers of random sample tests for bolts and nuts for proto-type test tower and bulk supply shall be performed by the contractor either in Governmental Test House or any approved Test Laboratory, free of cost to the Corporation. Sample bolts and nuts will be collected by the Engineer or its authorized agent. The various Testing to be performed are as follows: 1. Materials Specification: IS-6639 / IS-1363 / IS-1367(Part III) 2. Sampling shall be as per IS-1367(Part XVII) 3. Visual Inspection. 4. Dimensional Checking for Bolts & Nuts in accordance to IS-6639 and IS-1363 respectively. 5. Physical Test : i) Bolts To property class 5.6 as per IS-1367(Part III) ii) Nuts To property class 5 as per IS-1367(Part VI) 6. Galvanising Test in accordance to IS-1367(Part XIII)
11.3
Spring Washers
Producers routine test for spring washers shall be submitted by the contractor. In addition minimum ten numbers of random sample tests shall be performed by the contractor as directed by the Corporation. Sample spring washers will be collected by the Engineer or its authorized agent. The various Testing to be performed are as follows : 1. Materials Specification : IS-3063. 2. Sampling shall be as per IS-1367(Part XVII) 3. Visual Inspection. 4. Dimensional Checking. 5. Permanent Set Test. 6. Twist Test . 7. Hardness Test. 8. Galvanising Test in accordance to IS-1573 Service condition IV.
11.4
Galvanising
Fabricated Tower Parts & Stubs

The tower parts, stubs and pack washers shall be hot dip galvanized .The galvanization shall be done as per requirements of IS 4759 after all fabrication work is completed. The contractor shall also take guidelines from the recommended practices for hot dip galvanizing laid down in IS 2629 while deciding and implementing galvanizing procedure. The mandatory requirements however, are specified herein.
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The zinc coating shall be adherent, reasonably uniform, smooth, continuous and free from imperfections such as black/ bare spots, ash rust strains, bulky white deposits / wet storage strains and blisters. The surface preparation for fabricated tower parts and stubs for hot dip galvanizing shall be carried out as indicated herein below: (i) Degreasing & Cleaning of Surface: Degreasing and cleaning of surface, wherever required, shall be carried out in accordance with clause 4.1 of the latest edition of IS 2629.After degreasing the article shall be thoroughly rinsed. However, if acidic degreasers are used rinsing is not required. (ii) Pickling: Pickling shall be done using either hydrochloric or sulphuric acid as recommended at clause 4.3 of the latest edition IS 2629. The actual concentration of the acids and the time duration of immersion shall be determined by the Contractor depending on the nature of material to be pickled. Suitable inhibitors also shall be used with the acids to avoid over pickling. The acid concentration, inhibitors used, and maximum allowable iron content shall form part of plant standard to be formulated and submitted to Purchaser along with Quality Assurance Program. (iii) Rinsing: After pickling, the material shall be rinsed, preferably in running water to remove acid traces, iron particles or any other impurities from the surface. Two rinse tanks are preferable, with water cascading from the second tank to the first to ensure thorough cleaning. Wherever single tank is employed, the water shall be periodically changed to avoid acid contamination, and removal of other residue from the tank. (iv) Fluxing: The rinsed article shall be dipped in a solution of Zinc ammonium chloride. The concentration and temperature of the flux solution shall be standardized by the contractor depending on the article to be galvanized and individual circumstances. These shall form part of plant standard to be formulated and submitted to Purchaser along with Quality Assurance Program. The specific gravity of the flux solution shall be periodically monitored and controlled by adding required quantity of flux crystals to compensate for drag-out losses. Free acid content of the flux solution also shall be periodically checked and when it is more than two (2) grams of free acid per litre of the solution, it shall be neutralized. Alternatively, ph value should be monitored periodically and maintained between 5.0 to 5.5. (v) Drying: When dry galvanizing is adopted the article shall be thoroughly dried after fluxing. For the purpose of drying, the contractor may use hot plate, air oven or any other proven method ensuring complete drying of the article after fluxing and prior to dipping in the molten zinc bath. The drying process shall be such that the article shall not attain a temperature at which the flux shall get decomposed. The article thus dried shall be galvanized before the flux coating picks up moisture from the atmosphere or the flux layer gets damaged or removed from the surface. The drying procedure, time duration, temperature limits, time lag between fluxing, drying, galvanizing etc shall form part of plant standard to be formulated and submitted to Purchaser along with Quality Assurance Program. (vi) Quality of Zinc: Any one or combination of the grades of zinc specified in IS 209 or IS 13229 or other comparable international standard shall be used for galvanizing. The contractor shall declare the grade(s) of zinc proposed to be used by them for galvanizing.
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The molten metal in the zinc bath shall contain minimum 99.5 % zinc by mass. It shall be periodically measured and recorded. Zinc aluminum alloy shall be added as per IS 2629. (vii) Dipping Process: The temperature of the galvanizing bath shall be continuously monitored and controlled. The working temperature of the galvanizing bath shall be maintained at 450+/ - 10 degree C .The article should be immersed in the bath as rapidly as possible without compromising on safety aspects. The galvanizing bath temperature, immersion angle & time, time duration of immersion, rate of withdrawal etc shall be monitored and controlled depending upon the size , shape, thickness and chemical composition of the article such that the mass of zinc coating and its uniformity meets the specified requirements and the galvanized surface is free from imperfections and galvanizing defects. (viii) Post Treatment: The article shall be quenched in water. The quench water is to be changed / drained periodically to prevent corrosive salts from accumulating in it. If water quenching is not done then necessary cooling arrangements should be made. The galvanized articles shall be dipped in chromating solution containing sodium dichromate and sulphuric acid or chromic acid base additive at a predetermined concentration and kept at room temperature to retard white rust attack. The temperature of the chromate solution shall not exceed 65 degree C. The articles shall not be stacked immediately after quenching and dichromating. It shall be ensured that the articles are dry before any further handling operation. (ix) Storing, Packing and Handling: In order to prevent white rust formation sufficient care should be exercised while storing handling and transporting galvanized products. The articles shall be stored in an adequately ventilated area. The articles shall be stored with spacers in between them and kept at an inclination to facilitate easy drainage of any water collected on the articles. Similar care is to be taken while transporting and storing the articles at site. The Contractor shall prepare a detailed galvanizing procedure including Flow Chart with control parameters and all plant standards as required above and submit to DVC for approval as part of Quality Assurance Plan. The various testing to be performed on the finished galvanized materials : 1. Visual Inspection in accordance to IS-2629. 2. Uniformity of coating ( Preece Test) as per IS-2633 3. Magnetic Gauge Test (Elcometre). 4. Stripping Test. 5. Adhesion of coating as per IS-2629. Contractor shall perform routine test at least three samples from each Batch of production and record the result in separate registered book. Engineer or its authorized agent will be present at the time of test. Contractor should submit regularly the result of all the tests performed to the Corporation for approval. Fasteners: For fasteners, the galvanizing shall conform to IS-1367(Part-13). The galvanizing shall be done with centrifuging arrangement after all mechanical operations are completed. The nuts, may
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however be tapped (threaded) or rerun after galvanizing and the threads oiled .The threads of bolts & nuts shall have a neat fit and shall be such that they can be turned with finger throughout the length of the threads of bolts and they shall be capable of developing full strength of bolts. Spring washers shall be electro galvanized as per Grade-IV of IS-1573.
11.5
Optional Tests
DVC may like to send samples of smelter drawn from the galvanizing bath to the National Test House, Kolkata or similar Test Laboratories for Chemical analysis as per samples drawn in accordance to IS : 209, in which case the contractor shall furnish the samples to the Corporation as desired by the latter. The cost of one such test shall be borne by the contractor and that of any additional test by the Corporation.
12 Calculation of weight for Payment

The weight of tower shall mean the weight of tower calculated by using the black sectional (i.e. ungalvanised) weights of all steel members of the sizes indicated in the Structural / assembly / erection drawings and bill of materials without taking into consideration the reduction in weight due to drilling of bolt holes, notches, skew cuts, chamfering, etc. or increase in weight due to galvanizing, but taking into consideration the weight of the Bird guard, D shackles, hangers, strain plates, extension links, pack plates, gusset plates etc. The weight of stub and cleats also shall be calculated in similar manner. For bolts and nuts along with spring washers, Pack washers, U-bolts and step bolts, the weight per tower shall be calculated from the bolt schedule applicable to each type of towers and body extensions as approved by DVC. The contractor is permitted to get inspected and supply upto 2.5% extra fasteners to take care of losses during erection. No payment shall be admissible for these extra supplies.
13
Packing
The material shall be boxed or bundled for transport in the following manner : a) Angle shall be packed in bundles securely wrapped four times around at each end and over 900 mm with No. 9 SWG gauge wire with ends twisted tightly. Gross weight of any bundle shall not exceed approximately 450 Kg and length of any individual members 6000 mm. b) Cleat angles, brackets, fillet plates and similar small loose pieces shall be tested and bolted together in multiples, and securely wired together through holes wrapped round at least four times with No. 9 SWG steel wire and ends twisted tightly. Gross weight of each bundle shall not exceed approximately 70 Kg. c) The correct numbers of bolts, nuts and washers plus 2.5% extra for each tower shall constitute a packing unit and shall be dispatched packed in crates or wooden boxes strong enough to withstand the normal vigorous transit and handling. The various sizes of bolts, nuts and washers shall be kept in separate bags in side the main container. Each container shall carry a list of the bolts contained therein printed in water-proof ink, resistant to moisture. The weight of each container shall not exceed 70 Kg.
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14 Marking of Packages
Each bundle or package shall have the following details marked on it. a) The name, designation and address of the Consignee. b) Ultimate destination as required by the Corporation. c) The relevant marks and number of tower members or reference of bolts, nuts and small component like gusset plates, various attachments etc. for easy identification. The marking shall be stenciled in indelible ink on the top member 0f the bundle of tower steel and on wooden boxes or gunny bags containing smaller components. Details dispatch instructions shall be asked for by the contractor from the Corporation 4 weeks ahead of the Schedule date of dispatch. Corporation shall, in no case, be responsible for loss of any package or bundle during transit. It shall be the responsibility of the contractor to replace the lost items free of cost.
15 Standards
The design, manufacturing, fabrication, galvanising, testing, erection procedure and materials used for manufacture and erection of towers, design and construction of foundations shall conform to the latest revisions of following Indian Standards (IS).In the event of supply of material conforming to Standards other than specified, the Bidder shall confirm in his bid that these Standards are equivalent to those specified. In case of award, salient features of comparison between the Standards proposed by the Bidder and those specified in this document will be provided by the Contractor to establish their equivalence. Sl. No. 1. 2. 3. 4. Standard IS:209 IS:278 IS:800 IS:802(Part 1) Title Zinc Ingot - Specification Galvanised Steel Barbed wire for fencing Code of Practice for General Construction in Steel. Code of practice for use of structural steel in overhead transmission line towers, Part 1 Materials and Loads and permissible stresses Section 1 Materials and Loads Section 2 Permissible stress Code of practice for use of structural steel in Overhead Transmission Line : Fabrication, Galvanising, Inspection and Packing Code of practice for use of structural steel in Overhead Transmission Line Towers: Testing. Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle Sections Code of practice for design loads (other than earthquake) for buildings and structures Hexagon Head Bolts, Screws and Nuts of Product Grade `C' Technical Supply Conditions for Threaded Steel Fasteners
Sec 1 Sec 2 5. IS:802 (Part 2)
6. 7. 8. 9. 10.
IS:802 (Part 3) IS:808 IS:875 IS:1363 IS:1367
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Sl. No. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Standard IS:1573 IS:1852 IS:2016 IS:2062 IS:2074 IS:2551 IS:2629 IS:2633 IS:3757 IS:4759 IS:5369 IS:5613(Part-2)
Title Specification for Electroplated Coatings of Zinc on Iron and Steel Rolling and cutting tolerances for hot rolled steel products Specification for Plain Washers Steel for General Structural Purposes - Specification Ready Mixed Paint, Air Drying, Red Oxide Zinc Chrome, Priming - Specification Danger notice plates Recommended Practice for Hot-Dip Galvanizing of Iron and Steel Methods for testing uniformity of coating of zinc coated articles Specification for High Strength Structural Bolts Hot-dip zinc coatings on structural steel and other allied products General Requirements for Plain Washers and Lock Washers Code of practice for design, installation and maintenance of overhead power lines: Part 2 Lines above 11 kV and upto and including 220 kV, Section 1 : Design Section 2 Installation and maintenance Specification for Heavy Washers for Steel Structures High Strength Structural Nuts - Specification Hexagon Head Bolts for General Steel Structures Specification Fasteners - Threaded Steel Fastener - Step Bolts for Steel Structures Fasteners - Threaded Steel Fasteners - Hexagon Head Transmission Tower Bolts - Specification Indian Electricity Rules. Regulation for Electrical Crossing of Railway Tracks.
23. 24. 25. 26. 27. 28. 29.
IS:6610 IS:6623 IS:6639 IS:10238 IS:12427
Publication No. 19(N)/700
16 Structural Steel Requirement Schedule

16.1 The various steel sections to be used for fabrication of 132 KV D/C transmission towers
are given below :
Sl. No. 1 2 3 4
Section size ISA ISA ISA ISA 45 x 30 x 5 45 x 45 x 4 45 x 45 x 5 50 x 50 x 5
Sl. No. 23 24 25 26
Section size ISA ISA ISA ISA 110 x 110 x 10 130 x 130 x 10 130 x 130 x 12 150 x 150 x 12
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Sl. No. 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Section size ISA 50 x 50 x 6 ISA 55 x 55 x 5 ISA 60 x 60 x 5 ISA 65 x 65 x 5 ISA 65 x 65 x 6 ISA 70 x 70 x 5 ISA 75 x 75 x 5 ISA 75 x 75 x 6 ISA 80 x 80 x 6 ISA 80 x 80 x 8 ISA 90 x 90 x 6 ISA 90 x 90 x 7 ISA 90 x 90 x 8 ISA 100 x 100 x 6 ISA 100 x 100 x 7 ISA 100 x 100 x 8 ISA 100 x 100 x 10 ISA 110 x 110 x 8
Sl. No. 27 28 29 30 31 32 33 34 35 36 37 38
Section size ISA 150 x 150 x 16 ISA 150 x 150 x 20 PLATE 2MM PLATE 5MM PLATE 6MM PLATE 8MM PLATE 10MM PLATE 12MM PLATE 16MM PLATE 20MM PLATE 25MM PLATE 32MM
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SPECIFICATION FOR SIMPLEX METERING PANEL

Scope
This specification covers design, manufacture, assembly, testing at manufacturers works, packing and delivery at site of Simplex Metering Panels for 132 KV Chandil Substation. Each type of metering panel shall be supplied complete with all accessories and associated devices but excluding the tariff metering equipment.
2
2.1
Detailed Design Requirement

Type of Panel
Type-4 : Metering Panel for Four Bays : This type of panel shall have the provision of accommodating one (01) number of Meter for each bay. All the meters shall have its own Test Terminal Block, PT fuses, PT Indication lamps. The metering panel shall contain the items and accessories as indicated in the Specific Requirement under Section-5 of this specification.
2.2
Panel Construction
All the types of Metering Panels shall be of size 2200 mm (height), 700 mm (depth), 800 mm(width) fabricated from minimum 3(three) mm thick steel sheet(CRCA), totally enclosed , dust proof, weather proof and vermin proof, floor-mounted and self supported vertical front , indoor type cubicle provided with an access door in two halves at the back side with latch, locking and sealing arrangement . The bottom of the panel frame shall be about 100 mm high tie space all around, shall be erected by means of evenly spaced grout bolts projecting through base channel (MS) members of the frame, the panel shall be provided with suitable cable entry arrangement through bottom plates. Panel inside shall be painted with two coats of white enamel glossy paint and outside shall be painted with two coats of light grey shade-631 of IS:5 or equivalent international standards. The degree of protection of panel shall be IP 54. Ten (10) mm wide plastic plates bearing suitable identification marks shall be fixed in the interior of the panel to identify the fuse blocks, terminal blocks, switches, socket etc. Similar plates shall also be provided at the Panel front to identify the PT indication Lamps, Test Terminal Blocks etc. Glass Front panel with 19 rack is also acceptable.
2.3
i)
Small Wiring
All wiring shall be switchboard type, single core, multiconductor (minimum 7 strands) annealed copper wires insulated with PVC insulation.The wirings shall be flame-proof
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and vermin-proof. The wires shall be of 1100V grade and conductor sizes for current and potential circuits shall be of 2.5 sq. mm and 1.5 sq. mm respectively. Distinct colour scheme shall be followed for wiring of phases(R,Y,B) and Neutral/Earth circuits of instrument transformers, auxiliary circuits, etc. ii) All wirings shall be arranged flat and cleated. Bunching of wirings shall be avoided to the extent possible. Wirings connected to the space heaters in the cubicle shall have porcelain headed insulation over a safe length from the heater terminals. Each wire shall be continuous from end to end and shall not have any joint in its run. Individual wires shall be connected only at the terminal blocks, meters and other devices in the panel. Terminals shall also be provided with numbered ferrules (duplicate ferrules where a change of number is necessary) and shall be connected to stud etc. with lock nut and washers. Connection to terminals etc. shall be at right angles to stud axis. Nuts, washers, bolts, screws and numbered ferrules shall be supplied extra to the extent of 5% of the quantities actually used on the metering panels.
iii)
iv)
v)
2.4
i)
Terminal Block, Connector, Cable Gland

The terminal blocks shall be of rail mounted type, located so as to ensure easy access. Stud type terminal blocks shall be provided for all circuits. The terminal screws shall be of the Washer type and long enough for connecting following type conductor on each side : CT circuits PT circuits AC supply circuits 2 nos 10 mm sq. copper 2 nos 1.5 mm sq. copper 2 nos 1.5 mm sq. copper
ii)
All the terminal blocks shall be provided with a wire-marking strip and shall be shrouded by easily removable shrouds moulded of transparent dielectric material. Provision shall be made on each pillar for holding 20% extra connections both for incoming and outgoing. The terminal blocks shall be rated not less than 660V,10A There shall be a minimum clearance of 250 mm between the front row of terminal block and the associated cable gland plate on panel side wall. The clearance between two rows of terminals block edges shall be a minimum of 150 mm. All inter-panel wiring within each shipping section shall be the vendors responsibility. Wiring between panels shall be routed through PVC sleeves. For wiring between shipping section, vendor shall provide terminal blocks on adjacent shipping sections and supply suitable jumpering wires. Sufficient space for receiving the Power and Control cables inside the cubicle at the bottom and mounting arrangements for this terminal cable glands shall be provided. Power / Control cables and cable glands for external connections will be supplied by the purchaser.
iii)
iv)
v)
2.5
i) ii)
Earthing
Panel shall be provided with common earthing rail that shall be connected with flexible GI strips with existing substation/receiving station earthing. A continuous 25mm X 3mm copper (tinned) earth bus shall be provided along the full length of the panels.
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iii) iv)
The ground buses shall be bolted to the frame of the panel in such a way as to make good electrical contact with the panel. Each panel and the equipment mounted on each panel shall be securely connected to the grounding bus. For this purpose the ground wire shall be looped from equipment to equipment and both ends of the ground wire shall be connected to the ground bus. All doors and movable parts shall be connected to the ground bus with flexible copper connections. Current free metallic parts or metallic bodies of equipment shall be earthed with soft drawn single conductor bare copper. Tail connection shall have minimum area of 16 sq. mm and main connection 60 sq. mm. These wires shall be connected by Ross-Courtney terminals and clamp junctions. Soldered connections shall not be employed.
v)
2.6
i) ii)
Illumination & Space heaters

Fluorescent lamps working on 240 V AC, operated by door switches shall be provided for internal panel illumination. A 240V, single phase, 5/15A, 5 pin socket shall be provided in the panel corridor or interior of each cubicle with on-off switch.This socket shall be metal clad type with a spring loaded flap. Panel space heaters shall operate on 240 V10% AC and shall be supplied complete with on-off switch, fuse and thermostat. The thermostat shall maintain the internal temperature above the ambient temperature to prevent moisture condensation. The watt loss per unit surface of the heaters shall be low enough to keep surface temperature well below visible heat.
iii)
Contract Drawings and Literature
The manufacturer shall submit three (3) prints of each of the following drawings ,for each type of metering panels for approval of purchaser. The entire and ultimate responsibility of properly designing and manufacturing the right type of metering schemes with proper ratings and types of equipments and wiring shall rest with the supplier. Ten (10) sets of all final drawings with a permanent Velograph for each type of metering panels shall be supplied as contract drawings. The contract drawings & literatures shall cover but not be limited to the following : i) Dimensioned front elevation, plan and sectional views of each type of metering panel showing all the equipments and other devices in position. A complete list of all equipments and devices mounted on the panel shall be furnished on the drawing indicating type, make and quantity of each item. The drawing shall also indicate a floor drilling plan for grounting bolts and cable entry. Complete panel wiring diagram incorporating all devices, equipments. Terminal Nos. ferrule Nos. grouping of cables etc. Internal connection diagram, literature etc. describing all the equipments and devices. List of spare parts, identification number of renewable parts to enable purchaser to procure the same at a later date. One copy of complete schematic wiring diagram showing all equipment and fuses, duly sealed in water proof packets shall be furnished inside each type of metering panel
ii) iii) iv) v)
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supplied.
4
i)
Inspection and Testing

The purchaser and / or his authorised representative reserves the right to visit the manufacturers works and inspect the equipment at any stage of manufacture for the purpose of ascertaining the quality of workmanship and materials, checking of drawings, witnessing of tests etc. All facilities and co-operation shall be extended to the purchaser and / or his authorised representative during his visit to the manufacturers work for inspection of equipments and witness of tests. All routine tests as per the standard specification of manufacture shall be conducted at the manufacturers works on various supplied equipment and accessories as well as on the completely assembled metering panels. The details of routine tests to be performed by the manufacturer shall be stated in the tender indicating the specification reference as per which the tests will be carried out. The routine tests shall include the following amongst others : a) b) c) Checking correctness of wiring of circuits and continuity. One minute applied voltage test. All equipments on panel and small wiring shall be tested for a withstand voltage of 2 KV r.m.s. to earth for one minute. Insulation resistance of the complete wiring, with all equipments mounted on the panel. At least three (03) weeks advance intimation shall be sent to the purchaser for witnessing the tests. Six (6) sets of certified tests reports of all tests carried out on the equipments at the manufacturers works shall be submitted to the purchaser before dispatch of equipments. No. equipments shall be dispatched unless tests have been witnessed and / or test reports approved by the purchaser and / or his authorised representative. Type test report of panel having protection I.P. 54 is to be submitted along with tender without which tender will not be considered.
ii)
iii)
iv)
157
5
Sl.
Instrument Quantity/Type Type-4 3 Bays For Four As per requirement plus 20% extra 4 Nos 4 Nos As per requirement to complete the scheme plus 20% extra 12 Nos. 12 Nos. 1 Fuse+1 Carrier Link
1 2 3 4 5 6
Provision 1 of Number of Tariff Meters in Panel (Tariff Meters are not under the scope of supply) Test Terminal Block (3 Phase,4 Wire) Stud 0 Type Terminal Block as per Specification PT 0 Supply complete fuse assembly, HRC 2A rating. PT supply indication lamp(110 V AC) Panel LTAC incoming single phase 240 V, 50 HZ supply complete fuse assembly, HRC 16A rating Panel i Space Heater supply single phase 240 V, 50 HZ supply complete fuse assembly, HRC 2A rating Panel illumination single phase 240 V, 50 HZ supply complete fuse assembly, 2 nos HRC 2A rating Panel i socket single phase 240 V, 50 HZ supply complete fuse assembly, HRC 6A rating Panel 0 space Heater,240V, 50 Hz, 100 W, of any reputed make Thermostat 0 (30 - 110 C), of any reputed make Piano 0 type switches , 240 V, 50 Hz , 6/16A Power 0 supply socket(5 pin type) , 240 V , 50 Hz, 5/15A Panel florescent type illumination fittings, 240 V, 50 Hz, 40 W Door limit switch. 240 V, 50 Hz, of reputed make FRLS, PVC insulated, annealed Cu flexible panel wires, minimum 7 strands (2.5 sq.mm for CT and 1.5 sq.mm for PT,Other circuit) as per specification Lugs, nuts, bolts, washers, spring washers, channels, rails, and PVC type perforated Cable dressing enclosures etc as per requirement 25mm 1 X 3mm copper (tinned) earth bus as per specification
1 Fuse+1 Carrier Link
1 Fuse+1 Carrier Link
9 10 11 12 13 14 15 16
1 Fuse+1 Carrier Link 1 No 1 No As per scheme 1 No 1 Set. 1 No
1 Lot
17
1 Lot
18
As per requirement
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SPECIFICATION FOR AIR CONDITIONING EQUIPMENT

Scope
This specification covers design, manufacture, assembly, testing at manufac turers works, packing ,delivery at site and installation of Split Type Air Conditioners for 132 KV Chandil Substation.
Standards
Equipment covered by this specification shall conform to the latest edition/revision of the following Standards: IS 1391 (Part-2) : Room air conditioners: Part 2 Split air conditioners
IS 10617 (Part-1) : Specification for Hermetic Compressors - Part 1 : High Temperature Application Group IS 11338 : Specification for Thermostats Conditioners, Water Coolers and Beverage Coolers for Use in Refrigerators, Air
3
1) 2) 3) 4)
General Technical Particulars

The Air Conditioning Equipment shall be suitable for working at an ambient temperature of 50C(Max.). The Air Conditioning Equipment shall be suitable for 230V , 50 Hz single phase AC supply, capable of performing the functions as Cooling, Dehumidifying, Air circulating and Filtering. The Air Conditioning Equipment shall have Star Rating of 2 Star or better as per Bureau of Energy Efficiency Specification. The Air Conditioning Equipment shall be fitted with hermetically sealed type suction cooled reciprocating or discharge cooled rotary compressor (as applicable), compressor unit operating on Refrigerant R-22 with suitable rated capacitor start electric motor. The Air Conditioning Equipment shall be equipped with overload protection. The Air Conditioning Equipment shall be mounted on resilient mountings for quiet operation. The compressor shall conform to the latest edition incorporating the amendments of IS 10617-Part (1) . Rotary compressor shall be of Matshutisha / Hitachi / Toshiba / Carrier / SIAM / LG make and shall be covered by manufacturers test certificate and TTC to JISS or ASHRAE. The Air Conditioning Equipment shall be complete with automatic temperature control and
5) 6) 7)
8)
159
cut - in and cut-out etc. for temperature range 16 degrees to 30 deg. C. The differential of the thermostat for cut-in and cut-out shall not be greater than +/- 1.75 deg. C. The Air conditioners may either be provided with adjustable step less type mechanical thermostat or electronic thermostat as per IS:11338. 9) 10) The filter pads provided shall be washable. The cabinet of the evaporator unit and condensing unit shall be made from galvanised steel sheet of 1.0mm thick with galvanised coating thickness of 120 gm / sq. mtr and shall be provided with stiffness for robust construction and shall have rounded corners, steel parts/front panel etc. shall have stove-enamelled finish preceded by undercoat of anticorrosive primer paint phosphating and through cleaning of the surface. Alternate methods of corrosion protection like plastic powder coating, electrostatic paintings are also acceptable in lieu of stove enamelled finish. Overall power factor of the unit shall be at least 0.85 at capacity rating test conditions. Maximum power consumption of the split air conditioners shall be measured at capacity rating test conditions. Standard evaluation of cooling capacity shall be done by connecting indoor and outdoor units with piping of 5 mtrs. length with six bends of standard radius. Connecting copper tubing shall have dimensions suitable for the compressors offered with model. Refrigerant used shall be Freon-22. The indoor units shall be of flame retardant and impact resistant life. Indoor unit cabinet shall pass inflamablity test requirement for Grade V-O as per UL-94. For impact resistance the unit duly packed, when dropped from a height of 1 Mtr. shall show no damage. Remote control (Cordless) with LCD Display shall be provided with one On/Off timer, selecting Fan speed(minimum three speeds) and setting up of temperature. Suction line copper pipe shall be of 0.70 mm thickness. Liquid line copper pipe shall be of 0.70 mm thickness. Suction line copper pipe shall have expanded polyethylene foam insulation tubing. Drain pipe shall be of 15mm diameter flexible PVC pipe. The drain pipe to be routed to suit site and to be terminated in the defined drain point Indoor and outdoor unit shall be electrically connected by suitable capacity 1100V, FRLS, 2 core, PVC insulated, armoured , minimum 2.5 sq. mm copper wire. Input power to each Air Conditioning Equipment shall be supplied through MCB of proper rating. The Outdoor Units shall be placed at the roof of the Control Room or at a place indicated by the purchaser during detailed engineering stage. The indoor units shall be placed in a fashion to maintain uniform cooling inside the control room. Minor Civil Work, MS Angle/Channel required for installation of the indoor and outdoor units shall be done by the bidder.
11) 12) 13)
14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26)
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27)
Labels shall be designed and placed on units .Colour Scheme and Marking shall be as per BEE Specifications
Power Point for Air Conditioning Equipment
A separate board with 15 Amp plug point with MCB(32 A) and fuses shall be provided with each unit.
5
1) 2)
Documentation
Detailed design, make & model of all components, lay out drawing, constructional details duly certified and signed by BEE. Star rating approval Certificate from BEE.
6
5.1 5.2 5.3
Tests
Type Test Routine Test Acceptance Test
Complete Type Test Reports as per SCC shall be submitted with the offer.
Complete Routine Test as per SCC shall be carried out on the Air Conditioning Equipments.
The tests shall be carried out in the presence of Purchasers representative if so desired by the Purchaser.
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7
Sl. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11)
Instrument Type of Air Conditioning Equipment Type of Compressor Suitable for working at an ambient temperature Material of Body of Cooling Unit Nominal Cooling Capacity Star Rating Temperature Control Temperature Range Remote Control Unit Display Timer Fan Speed Feature Split Type Wall Mounted Indoor Unit complete with power supply board, MCB, fuses Rotary / Reciprocating 50C(Max.) ABS / HIPS 6000 Kcal/ Hr 2 Star or Better Automatic 16C to 30C LCD ON and OFF Timer Minimum Three Speed
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SPECIFICATION FOR LT METERING EQUIPMENT

Scope
This specification covers i) Microprocessor-based CT operated, 3-phase, 4-wire unbalanced load,0.5S Class LT metering equipment for single-station auxiliary / grounding transformer feeder having energy audit feature. ii) Test terminal blocks for in-situ testing of the meters. The LT metering equipment shall be the integral part of the LTAC Panel.
Standards
1. IS 14697 : AC static Transformer operated Watt-hour and VAR-hour meters, class 0.2S and 0.5S 2. IS 9000 : Basic environmental testing procedures for Electronic and Electrical Items. 3. IEC 62052-11 : Electricity Metering Equipments (a.c)-General requirements, tests and test condition. 4. IEC 62053-22 : Static meters for active energy (classes 0.2S and 0.5S) 5. CBIP Technical Report : 88 - Specification for AC static electrical Energy Meters. 6. CBIP Technical Report :111 - Specification for common meter reading Instrument. 7. CBIP Technical Report: 93 - Study on tamper-proof methods for Energy meters. 8. CEA Regulation : 2006 - Installations and Operations of Energy meters. 9. IPC-A-610 : Acceptability of Electronic Assemblies Meters conforming to other international Standards which ensure better performance than the standards mentioned above shall also be considered. Salient points of difference between standards adopted and standards specified in this specification shall be clearly indicated in the relevant schedule and copy of such standards along with their English translation shall be furnished with the offer.
Equipment covered by this specification shall conform to latest issues the following Standards:
Function
The metering equipment shall have at least the following functional features: The energy accounting and audit meters shall also have the facility to measure, record and display with date and time at least the following parameters. All electrical parameters shall also
163
be stored in a non volatile memory. (a) Serial Number of the Meter(Display only) (b) PT ratio (For HT Meter only) (c) Cummulative Active Energy (d) Cummulative Reactive Energy (e) Cummulative Apparent Energy (f) Phase wise active power at peak KVA (g) Phase wise reactive power at peak KVA (h) Phase wise voltage at peak KVA (i) Power down time (j) Average power factor (l) Line currents (m) Phase voltages (n) Date and time (o) Tamper events 2. The energy accounting and audit meter shall have data storage capacity for at least 35 days in a non-volatile memory. 3. Energy accounting and audit meters shall have facility to allow download of parameters to Laptop/Desktop by suitable password protect software as well as transmission of data over communication network to a local and remote computer. 4. The meters shall be totally sealed and tamper-proof, of any adjustment at site, except for a restricted clock correction. with no possibility
4
Sl. 1
General Requirement
Requirement Type LT Meter CT operated 3 phase, 4 wire static energy meter with measurement (active, reactive, apparent energies),calculation, recording, printing, communication, tamper recorder modules in a single unit. 0.5S The Meter shall start and continue to register the Energy flow at current value of 0.01 (1.0%) In and unity power factor. When the voltage is applied with no current flowing in the current circuit, the test output of the Meter shall not produce more than one pulse. 5A 1.2 In Pressure Coil Voltage: 415V AC (4 wire directly fed) /240 V AC (Single phase directly fed) Dual supply. DC supply : 250 V 20% AC supply : From Pressure supply 415V / 240V. For AC supply, auxiliary power shall be drawn from the three phases equally and the meter shall be able to remain powered up with availability of any two phases. As per indicated IEC Shall be present for running internal calendar, clock and other important functions, whose life shall be at least 3 years. There shall
Accuracy Class
3 4
Rated Current(In) Rated Maximum Current Reference Voltage(Vref) Auxiliary Supply
7 8
Power Consumption Internal Battery
164
Sl.
Requirement
LT Meter be provision to indicate the health of the Battery. As per indicated IEC
Influence of supply voltage Voltage dips and short interruptions Influence of Short Time Over current Influence of self heating Influence of heating Immunity to Electromagnetic disturbance Radio Interference suppression Insulation Temperature range Clearance and creepage distances Starting and running with no load condition Accuracy Requirements Limits of error due to variation of current Limits of error due to other influencing quantities Limits of error due to ambient temperature variation Data Storage
10
As per indicated IEC
11
12
13 14
As per indicated IEC As per indicated IEC
15
16 17 18
As per indicated IEC As per indicated IEC As per indicated IEC
19
20
21
Non volatile memory having a minimum retention time not less than 5 years.
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Sl. 22
Requirement CT Ratio User programmable.
LT Meter
(For calculation Minimum Available Range : purpose, use of any 50/5, 100/5, 150/5, 200/5, 300/5, 400/5, 600/5, 750/5,800/5, multiplication factor is 1000/5, 1500/5,1800/5 and 2000/5 not permissible)
23
PT Ratio (For calculation purpose, use of any multiplication factor is not permissible)
Not Applicable
24
Communication port
a) Galvanic/ Optical Isolated Communication Port for connecting the Laptop/Desktop for data transfer. b) Pulse Output Front Port (for Active and Reactive) for calibration purpose c) Remote communication port both for Meter programming Data collection. and
25
Method of calculation TVM method of Apparent Power/ Energy Integration period Billing Period CT/PT error compensation Display 15/30 minutes-user programmable. Not Applicable Shall have the facility to compensate CT Ratio and phase angle errors at different load points. The Meter shall have at least 8 digit LED/LCD display. The different parameters shall be cycled by a Push Button. Push Button operation shall have the higher priority over the Auto Display. The display shall revert back to Auto Mode after a certain time after the last push button operation. The display shall contain at least the parameters as stated in Section(3) .The display shall have adequate resolution depending upon the load. For a lower value of CT ratio and/or low load, the unit of active reactive / apparent energy shall be selectable accordingly ,e.g for a low CT ratio the measurement unit for active energy shall be in KWh and for a moderate to high CT ration the same shall be in MWh.
26 27 28
29
30
Billing report generation
Not Applicable
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Sl. 31
Requirement
LT Meter
Software and security All software shall be compatible with latest version of Windows Operating System and shall be password protected. Provision for of software change of password by purchaser shall be available. The software shall be considered as integral part of the metering equipment. The software shall be considered as integral part of the metering equipment. Details of software packages to be supplied is detailed as follows : 1.Reading Software This Package shall consist of all necessary Software to perform the following functions: [A] Load Survey Data, information from the Meter after identifying the make of the Meter and Meter Sl. No. and store all the above data against each Meter Sl. No. and Make. Display any of the above data collected on its screen.
[B]
Load Survey Curve, Load Survey Chart (with Numerical Value), and Calculation of Average Power Factor etc. Load Survey Curve, Load Survey Chart (with Numerical Values) etc. that has been processed in (C) above. This Package shall also consist of Operating System Software, AntiVirus Software, Self-monitoring Software and driver Software necessary to install in the Base Computer/ Laptop. 2.Configuration Software This Package shall consist of all necessary software to configure the Meter to perform the following functions : [A] To programme the Meter Unit to act as Energy accounting and Audit meter as per CEA regulation: 2006. [B] To change the Integration Period. [C] To change the CT ratio. [D] To incorporate any change of the Name of the consumer against Sl. No. of the Meter (if this facility is available). [E] To adjust the time of Internal Clock in case of drifting. [F] To perform any other special task, if any, available in the offered meter. 3.Remote Communication API (Application Programming Interface) to ensure that the meter data is compatible with the software for Energy accounting/Audit and MIS report generation installed at a remote server. Meter shall support IEC 62056-21/DLMS protocol. The softwares shall be the integral part of the LT Metering Equipment. 32 Meter Sealing Provision to seal the meter with all individual modules in their working position shall be available, so that it is not possible to draw out any of the modules without breaking the seal (s). [C]
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Sl. 33
Requirement Front Cover
LT Meter Preferably transparent with sealing facility. No internal part of the meter shall be accessible without breaking the seal. Case of the meter shall be so constructed and arranged that any non-permanent deformation cannot prevent satisfactory operation of the meter. The meter shall conform to the degree of protection IP 51. The Terminal Block of Meter shall be provided with a separate cover that can be sealed independently. This cover shall enclose the actual terminals, Conductor fixing Screws, a suitable length of the external conductors and their insulation and access to the terminals shall not be possible without breaking the seal(s) of Terminal Cover. The cover shall not, in any way, touch the Terminal fixing screws or bare portion of external conductors. Material of the terminal block shall comply IS:11731, Part-I. As per indicated IEC
34
Meter Case
35
Terminal Block
36
Clearance and Creepage Distances Connection Diagram
37
The connection diagram shall be marked on each Meter in an indelible and durable manner. The diagram shall indicate the marking of Meter Terminals as well as phase sequence for which the Meter is intended. Following information shall be printed in an indelible and durable manner: 1. Manufacturers Name and Type designation 2. Place and Year of manufacture. 3. Serial Number of Meter 4. Rated Voltage 5. Rated Current 6. Rated Frequency 7. Number of Phases and Number of Wires for which the Meter is designed. 8. Meter Constant and Transformation Ratios of CT, PT if included in Meter Constant. 9. Accuracy Class. 10. Auxiliary Supply Voltage
38
Nameplate
39
Time Synchronisation Synchronisation of time shall be possible from an external source like GPS receiver/Central computer. The Internal Clock Shall feature 24 hours display with all consideration of a perpetual calendar.
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Sl. 40
Requirement Self Diagnostic feature
LT Meter The meter shall be capable of performing complete self-diagnostic check to monitor the circuits for any malfunctioning to ensures integrity of data memory location at all time. The meter shall have indication for unsatisfactory/nonsatisfactory/malfunctioning of the following: [A] Time and date on meter display. [B] All display segments on meter display [C] Real time clock (RTC) status in meter reading prints out at the Central computer station in management information system. [D] Non volatile memory (NVM) status in meter reading prints out at the Central computer station in management information system. [E] The meter shall have self diagnostic feature to indicate healthiness or any disorder of different modules. Configurable pulse outputs shall be provided for operation during any abnormal system condition or abnormal device condition causing alarm. Such alarm events shall be indicated on front panel by LEDs and shall also be recorded and stored in nonvolatile memory for retrieval through local or remote communication.
41
Tamper Recording Device
Not Applicable
Inspection & Testing
The equipment shall be tested at original manufacturers works in accordance with the relevant Indian, International standards in presence of Purchasers representative(s). The Supplier shall give Purchaser at least fifteen days notice of the equipment being ready at works for inspection. Routine test reports for all the equipment shall be submitted before inspection. Additional Tests which are felt necessary by the Purchasers representative(s) for checking of satisfactory operation/ functioning of the meter under different system/site conditions, but not included in the relevant standards may also be carried out during inspection. In case, inspection / test is carried out abroad at OEM works, then to and fro journey etc for at least two engineers shall be borne by the contractor.
6
6.1
Documentation
Proof
The Bidder shall furnish proof of being the original manufacturer of the metering equipment.
6.2
Type Test Reports
Complete Type Test Reports as per SCC shall be submitted with the offer for the offered type of meter : a) Standard Electrical Values as per IEC 62052-11/ IS 14697 b) Accuracy requirements as per IEC 62053-22/ IS 14697
169
c) Electrical requirements as per IEC 62052-11/ IS 14697 d) Climatic Influences as per IS 14697. e) Mechanical requirement and tests including Vibration Test, as per IEC 62052-11/ IS 14697 f) Type test certificate of remote communication standards. The above type test reports shall be complete in nature including drawings and diagrams of the test meter.
6.3
Drawings, Literature
The manufacturer shall provide the following drawings and manuals along with their equipment. The number of copies required and mode of submission are covered in the SCC. All the routine and acceptance test reports shall be submitted to the appropriate authority for scrutiny and approval before issuance of dispatch clearance. Detailed dimensional drawings showing overall dimensions of each unit along with their mounting arrangement, layout and panel cut-out details. Schematic wiring diagrams showing in detail the connections to be made between different units. Instruction manuals of each of the equipment(s) and supplied software shall be provided by the bidder.
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METERING EQUIPMENT PANEL
Sl.
Instrument
Quantity
TYPE - 1 01 Microprocessor based static CT/PT operated, 3 phase 3 wire unAs per quantities balanced loaded, HT Energy meters, class 0.2S with associated given in price test terminal blocks installed in the front side and mounting of the schedule meters and TTB shall be panel flush type. Terminal Boards, CATD M4 (disconnecting type) or equivalent for CT/ PT circuit. As per requirement plus 20% extra
02
03
Terminal Boards stud type CATM6 or equivalent for other circuits As per requirement except CT/PT. plus 20% extra Potential supply complete fuse assembly, (3 fuses + 1 link) HRC 2A 4 nos for each meter rating. Complete fuse assembly : Panel LTAC incoming single phase 240 V, 50 HZ supply complete fuse assembly, 2 nos (1 fuses + 1 link). HRC 16A rating. Panel Space Heater supply single phase 240 V, 50 HZ supply complete fuse assembly, 2 nos (1 fuses + 1 link). HRC 2A rating. Panel illumination single phase 240 V, 50 HZ supply complete fuse assembly, 2 nos (1 fuses + 1 link). HRC 2A rating. Panel socket single phase 240 V, 50 HZ supply complete fuse assembly, 2 nos (1 fuses + 1 link). HRC 6A rating. Panel space Heater: 240V, 50 Hz, 100 W, of any reputed make. Thermostat (30 - 110 C), of any reputed make. Piano type switches , 240 V, 50 Hz , 6A Power supply socket(3 pin type) , 240 V , 50 Hz, 6A Panel florescent type illumination fittings, 240 V, 50 Hz, 20 W. Door limit switch. 240 V, 50 Hz, of reputed make. 02 nos.
04
05 i)
ii)
02 nos.
iii) iv) 06 07 08 09 10 11 12
02 nos. 02 nos. 01 no. 01 no. As per scheme 01 no. 01 set. 01 no.
FRLS, PVC insulated, annealed Cu flexible panel wires, minimum 1(one) lot 7 strands (2.5 sq.mm for CT and 1.5 sq.mm for PT circuit) as per requirement. Lugs, nuts, bolts, washers, spring washers, channels, rails, and PVC type perforated Cable dressing enclosures etc as per requirement. Panel Earthing Rail and flexible GI strips for substation earthing connection. 1(one) lot
13
14
1(one) set.
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Sl.
Instrument
Quantity
TYPE - 2 01 Microprocessor based Static CT operated, 3 phase 4 wire, Direct potential supply fed, LT Energy meters, class 0.5S with associated test terminal blocks installed in the front side and mounting of the meters and TTB shall be panel flush type. 02 03
As per quantities given in price schedule
Data concentration unit, desktop/Laptop computer, power supply 1 set units and networking equipment if any Terminal Boards, CATD M4 (disconnecting type) or equivalent for As per requirement CT/PT circuit. plus 20% extra Terminal Boards stud type CATM6 or equivalent for other circuits As per requirement except CT/PT. plus 20% extra Potential supply complete fuse assembly, (3 fuses + 1 link) for each meter. HRC 2A rating. Complete fuse assembly : Panel LTAC incoming single phase 240 V, 50 HZ supply complete fuse assembly, (1 fuse + 1 link). HRC 16A rating. Panel Space Heater supply single phase 240 V, 50 HZ supply complete fuse assembly, (1 fuse + 1 link). HRC 2A rating. Panel illumination single phase 240 V, 50 HZ supply complete fuse assembly, (1 fuse + 1 link). HRC 2A rating. Panel socket single phase 240 V, 50 HZ supply complete fuse assembly, (1 fuse + 1 link), HRC 6A rating Panel space Heater: 240V, 50 Hz, 100 W, of any reputed make. Thermostat (30 - 110 0C), of any reputed make. Piano type switches , 240 V, 50 Hz , 6A Power supply socket(3 pin type) , 240 V , 50 Hz, 6A Panel florescent type illumination fittings, 240 V, 50 Hz, 20W Door limit switch. 240 V, 50 Hz, from Siemens or reputed make FRLS, PVC insulated, annealed Cu flexible panel wires, minimum 7 strands (2.5 sq.mm for CT and 1.5 sq.mm for pressure circuit) as per requirement. Lugs, nuts, bolts, washers, spring washers, channels, rails, and PVC type perforated Cable dressing enclosures etc as per requirement. Panel Earthing Rail and flexible GI strips for substation earthing connection. 4 nos for each meter
04
05 06 i) ii) iii) iv) 07 08 09 10 11 12 13
02 nos. 02 nos. 02 nos. 02 nos 01 no. 01 no. As per scheme 01 no. 01 set. 01 no. 1(one) lot
14
1(one) lot
15
1(one) set.

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DAMODAR VALLEY CORPORATION

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

SPECIFICATION FOR CONTROL AND RELAY PANELS

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

IEC 60255-25 IEC 61850

4.1 Component mounting

3) Other Circuit including Control wires

4.4 Illumination & Space heaters

132 KV - Signal Red to shade 537 of IS : 5. Earth Black

Name and identity Plates

can be removed and refitted when desired.

Note: IED : Intelligent Electronic Device Feature Description / Configuration

5.2.1.3 General Description (For all IEDs)

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

Feature 5 Test Block/Test Plug/Test Handle

IEC 61850 Compatibility

10 Self Monitoring 11 Display

12 IED Front Panel LED

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

Feature 11) 12) 13) 14)

Specific Requirement 5.2.1.5-A Main IED

Feature 1 Distance Protection

Zone Timer Offset Feature Residual Compensation Memory Circuit

Power Swing Blocking

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

Feature conditions. 9 VT Fuse Fail

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

Feature 11 Switch on to Fault (SOTF)

13 Local Breaker Back Up / Circuit Breaker Failure Protection

14 Setting Group Selection

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

Feature 15 Check Synchronising / Dead Line Charging

16 Inbuilt Directional O/C and E/F Protection

17 Inbuilt Non Directional O/C and E/F Protection

5.2.2 Protection of Bus Coupler

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

5.2.3 Auxiliary Relays and Tripping Relays 5.2.3.1 Tripping Relay

Trip Circuit Supervision

6.1 Time Synchronisation

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

ii) iii) iv) v) vi) vii) viii) ix) x) 3. i)

ii) iii) 4. i) ii) iii) 5.

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

Packing and Forwarding

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

CONTROL PART 1 Strip Mimic 2

2 nos. 1 no. 1 no.

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

DUPLEX PANEL FOR 132 KV BUS COUPLER Sl. 1 Instrument 2 Quantity 3

1 set. 2 nos. as per scheme 1 no.

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

SPECIFICATION FOR CIRCUIT BREAKERS

4.3 Spring Charging

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

Fittings and Accessories

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

12 Drawings & Documentation

EQUIPMENT SPECIFICATION, PSR SECTION, ELECTRICITY DEPARTMENT

12. 13. 14. 15. 16. 17.