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KARNATAKA SOLAR POWER DEVELOPMENT CORPORATION LIMITED

KSPDCL/SP/F-29/2015-16/02 dated 09-12-2015

BIDDING DOCUMENTS FOR

Establishing 4 nos of 2 x 150 MVA, 220/66kV stations at Nagalamadike Hobli in Pavagada Taluk, Tumkur District along with connected Transmission lines and Terminal Bays on Total Turnkey Basis,in two lots ( Lot1 & Lot 2 ) in respect of the proposed 2000 MW Pavagada Solar Park in Tumkur District, Karnataka including supply of all Materials,Erection (including Civil Works ),Testing and commissionig.

BID DOCUMENTS CONSIST OF THE FOLLOWING VOLUMES

VOLUME- I CONDITIONS OF CONTRACT

VOLUME-IIA (Part 1 of 3) ↔ | (Part 2 of 3) ↔ | TECHNICAL SPECIFICATIONS

(Part 3 of 3) ↔ |

DRAWINGS

VOLUME- IIIA TECHNO-COMMERCIAL SHEETS AND PRICE SHEETS

(BID PROPOSAL SHEETS)

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KSPDCL/SP/F-29/2015-16/02 dated 09-12-2015

BIDDING DOCUMENTS FOR

Establishing 4 nos of 2 x 150 MVA, 220/66kV stations at Nagalamadike Hobli in Pavagada Taluk, Tumkur District along with connected Transmission lines and Terminal Bays on Total Turnkey Basis,in two lots ( Lot1 & Lot 2 ) in respect of the proposed 2000 MW Pavagada Solar Park in Tumkur District, Karnataka including supply of all Materials,Erection (including Civil Works ),Testing and commissionig.

VOLUME - IIA(PART 3 OF 3)

TECHNICAL SPECIFICATION

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ISSUED BY

The Chief Executive Officer, KSPDCL

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BANGALORE-560 001THIS BID DOCUMENT CONTAINS FOLLOWING VOLUMES:

VOLUME - IlA TECHNICAL SPECIFICATIONS (Part 3 of 3)

OTHER VOLUMES CONTAIN THE FOLLOWING:

VOLUME - I CONDITIONS OF CONTRACT

VOLUME-IIA TECHNICAL SPECIFICATIONS(Part 1 of 3)

VOLUME-IIA TECHNICAL SPECIFICATIONS(Part 2 of 3)

VOLUME- III TECHNO-COMMERCIAL SHEETS AND PRICE SHEETS

(BID PROPOSAL SHEETS)

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VOLUME IIA (PART 3 OF 3)TECHNICAL SPECIFICATION

SECTION DESCRIPTION

5.1 1.1KV GRADE POWER AND CONTROL CABLE5.2 415 / 240 VOLTS PANEL 5.3 AC OUT DOOR DISTRIBUTION BOX5.4 BATTERY5.5 BATTERY CHARGER5.6 LT TRANSFORMER5.7 FIRE FIGHTING5.8 DG SET5.9 11KV UG CABLE5.10 SWITCH YARD ERECTION5.11 STRUCTURES5.12 CIVIL WORKS5.13 RELAY & PROTECTION PANELS5.14 PLCC EQUIPMENTS5.15 FURNITURE5.16 EARTH MATERIAL5.17 11KV SWITCH GEAR5.18 CAPACITOR BANK5.19 11KV SPECIAL GOS5.20 TESTING AND COMMISSIONING

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SECTION-5.1

1.1 kV GRADE POWER & CONTROL CABLE

VOLUME - IIASection 5. 1 (1. 1 KV Grade Power & Control Cables)

1. REQUIREMENTS FOR 1.1 KV GRADE CABLES:

1.0 Qualifying Requirement :

Please refer Volume - 1 Section IFB Clause 11.0

1.1 GENERAL:

The bidder shall quote for cables for entire scope of work. Following are the preferred sizes of cables to be used in the project and the cable vis a vis the purpose f or which to be used in indicated in part I of 3 of volume - II i.e., Technical specifications.

PVC POWER CABLES (ALUMINUM CABLES):

4C x 95mm²4C x 25 mm²2C x 10mm²

PVC CONTROL CABLES (STANDARD COPPER CABLES):

2C x 2.5 mm²10C x 2.5 mm²19C x 2.5 mm²4C x 6 mm²4C x 10 mm²4C x 25 mm²

1.2 Successful bidder shall prepare entire laying and termination schedules in accordance with criteria stipulated at Clause 1.3 below along with final cable quantities required and the same shall be submitted in advance for Owner's approval.

1.3 CRITERIA FOR SELECTION OF POWER & CONTROL CABLES:

1.3.1 Aluminum conductor P V C insulated armoured power cables shall be used for main power supply purpose from L T Aux. Transformers to control room.

1.3-2 Aluminum conductor P V C insulated armoured power cables shall be used for various other applications in switchyard area / control room except for control / protection purposes.

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1.3.3 For all control / protection instrumentation purposes P V C insulated armoured control cables of minimum 2.5 sq. mm. size with stranded copper conductors shall be used.

1.3.4 The size of the Power & Control and power cables for various purposes have been indicated in part 1 of 3 of Technical specifications. The bidder has to asses the quantities and indicate in the bid proposal sheets. In some cases tentative quantities have been indicated. These can be reassessed and indicated by bidder.

The Bidder may offer other than sizes specified, in such case and for other application where sizes of cables have not been indicated in the specification, sizing of power cables shall be done keeping in view continuous current, voltage drop and short circuit consideration of system. Relevant calculation shall be submitted by the bidder during detailed engineering for Purchaser approval.

The successful bidder has to finalize the cable schedules based on the site conditions and the schemes quoted, which are to be approved by owner payment for control and power cables will be made quantities of both power and control cables indicated in the bid proposal sheets and quantities finalized as per cable schedules WHICHEVER is LOWER

1.3.5 While preparing cables schedules for control / protection purposes following shall be ensured :

Separate cables shall be used for AC & DC

Separate cables shall be used for DC1 & DC2 (only for 220KV Station)

For different cores of CT, CVT, & VTs separate cables shall be used.

At least one (1) core shall be kept as spare in each copper control cables up to 9C size where as minimum no of spare cores shall be two (2) for control cables of 10 cores or higher size.

For control cabling, 2.5 sq. mm copper cables shall be used for connections. For CT & VT circuits 6 &10 sq. mm copper control cables shall be used, respectively.

2.0 TECHNICAL:

2.1.0 CODES & STANDARDS

The design manufacture testing and performance of cablescovered under this specification shall comply with latestedition of the following standards including amendments:

IS:7098 XLPE insulated PVC sheathed cables(Part-I)for working voltage up to & including 1100 Volts .

ISS130Conductors for insulated electrical cables & flexible cords.

IS:5831 PVC insulation & sheath of electrical cables.

IS:3975 Mild steel wires strips & tapes for arm armoring of cables . of 409

IS:10418 Specification of drums for electric cables

IS: 1554 PVC insulated (heavy duty) electric cables for working voltage (part-I) up to and including 1100 V.

ASTMD Measuring & minimum oxygen concentration to support 2683 candle like combustion of plastic(oxygen index).

2.1.2 Cables complying with other internationally accepted standards such as IEC, VDE, JPCEA etc., will also be considered if they ensure performance & constructional features equivalent or superior to standards listed above In such a case.The Bidder shall clearly indicate the standard / standards adopted and furnish a copy of English version of the latest revision of the standard(s) along with the tender & shall clearly bring out the salient features for comparison.

2.1.3 In case of any conflict between the referred specifications codes or standards & this technical specifications, the latter shall prevail to the extent of such difference.

2.1.4 1.1 KV grade power & control cables to be supplied under this package shall be ISI approved & marked as such. Non-compliance of above shall not be accepted.

2.1.5 However, if cables to be, supplied under this package are manufactured outside India confirm to other internationally accepted equivalent or superior standards the above specification not be applicable .

2.1.6 The Indian Standards mentioned in Clause 2.1 can beobtained from: - Bureau of Indian Standards

Manak Bhavan,9. Bahadur Shah Zafar Marg,NewDelhi - 110002.INDIA.

2.2.0 TECHNICAL REQUIREMENTS:

2.2.1 GENERAL

2.2.1.1 The cables shall be suitable for laying in racks, ducts, trenches, conduits & underground buried installation with uncontrolled back fill & chance of flooding by water.

2.2.1.2 They shall be designed to withstand all mechanical, electrical & thermal stress under steady & transient operating conditions.

2.2.1.3 The Aluminum / Copper wires used for manufacturing the cables shall be true circular in shape before stranding should be uniformly of good quality, free from defects . All aluminum used in the cable shall be of H2 grade.

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2.2.1.4 The fillers & inner sheath shall be of non-hygroscopic, & shall be softer than insulation The outer sheath must be fill reluctant suitable for the operating temperature of the cable.

2.2.1.5 Progressive sequential marketing of the length of the cable in meters. Every one-meter shall be provided on the outer sheath of all cables.

2.2.1.6 Only galvanized round steel wire armour shall be used for multicore cables. G.S.strip armour shall not be accepted for these cables.

2.2.1.7 The cables shall have outer sheath of a material with an oxygen index of not less than 29 & a temperature index of not less than 250º C.

2.2.1.8 All the cables shall pass fire resistance test as per IS:1554(part-1).

2.2.1.9 The P V C cables insulated cables shall be capable of withstand in a conductor temperature of 160º C during a short circuit.

2.2-1-10 Repaired cables shall not be accepted.

2.2-1-11 Allowable tolerance on the overall diameter of the cables shall be plus or minus 2 mm.

2.2-1-12 The normal current rating of PVC insulated cables shall be as per IS 3961.

2.3 L.T. PVC Power Cables.

The P V C ( 70ºC ) insulated 1100V grade power cables shall be of FR type clause category, conforming to IS:1554 (part-I ) its amendments, read along with this specification & shall be suitable for steady conductor temperature 70 º C. The conductor shall be stranded Aluminum. The insulation shall be extruded P V C to type-A of IS : 5831. A distinct inner sheath shall be provided in all multi-core cables. For multicore armored cables, the inner sheath shall be of extruded P V C. The, outer sheath shall be extruded PVC to type ST-1 of IS : 5831 for all cables . Where armouring is specified for single core cables the same shall be of aluminium wires /strips.

2.4 L.T. PVC Control Cables:

2-4. 1 The 1100 grade 70° C control cables shall be of FR type Clause category confirming to IS : 1554 ( Part-I ) & its amendments, read along with this specification The conductor shall be stranded copper. The insulation shall be extruded PVC to type A of IS:5831. A distinct extruded inner sheath shall be provided in all cables. The fire retardant over sheath shall be extruded P V C to type ST-1 of IS : 5831 & shall be grey in color except where specifically advised by the owner to be black.

2.4.2 Cores shall be identified as per IS:554 for the cables up to five (5) cores & for cables with more than five(5) cores the identification of cores shall done by printing legible Hindu Arabic Numerals on all cores as per clause 10.3 of IS :1554(Part-1).

2.6.0 CABLE DRUMS

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2.6.1 Cables shall be supplied non-returnable wooden or steel drums of heavy construction & drum shall be properly seasoned sound & free from defects. Wood preservative shall be applied to the entire drum.

2.6.2 Standard lengths for each size on power & control cables to be supplied by bidder shall be 500/1000 meters. The cable length per drum shall be subject to a tolerance of plus or minus 5% of the standard length. The owner shall have the option of rejecting cable drums with Shorter lengths. However, the total quantity of cables after taking into consideration of all cable drum of each size shall be within tolerance of 2%.

2.6.3 A layer of waterproof paper shall be applied to the surface of the drums over the outer most cable layer.

2.6.4 A clear space of atleast 40 mm shall be left between the cables & the lagging.

2.6.5 Each drum shall carry the manufacture's name, the owner's name, address, contract number & type, size & length of the cable, net & gross weight stenciled on both sides of drum. A tag containing the same information shall be attached to the leading end of the cable An arrow &. suitable accompanying wording shall be mark-ed on one end of the reel indicating the direction in which it should be rolled.

2.6.6 Packing shall be sturdy & adequate to protect the cables, from any injury due - to mishandling or other conditions encountered during transportation, handling & storage. Both cables ends shall be scaled with good quality heat shrinkable caps so as to eliminate ingress of water during transportation & erection.

2.7.0 TYPE TESTS

2.7.1 All cables shall conform to all type routine & acceptance tests listed in the relevant-IS.

2.7.2 The type tests on cables shall be conducted on each type and size of cables offered.

2.7.3 Following type tests as per IS:1554(Part-I)-1988 including its amendments and additional type tests shall be carried out on 1.1KV grade PVC insulated cables:

a. Tests on conductora. Annealing test (for copper)b. Tensile test (for aluminium)c. Wrapping test (for aluminium)d. Conductor Resistance test.

b. Test for armouring wires/stripsc. Test for thickness of insulation and sheath d. Physical tests for insulation and outer sheath.

i. Tensile strength and elongation at breakii. Ageing in air oveniii. Shrinkage testiv. Hot deformation, Loss of mass v. Heat shock testvi. Thermal stability.

e. Insulation resistancef. High voltage test (water immersion test only a.c. test as per clause No. 16.3.1)g. High voltage test at room temperature

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h. Flammability testi. Oxygen index and temperature index test on outer sheathj. Short time current test on power cables of sizes 240 Sq. mm and above.

i. On conductor(s)ii. On armours.

2.7.4 Following type tests as per IS:7098(Part-2)-1988 including its amendments and additional type tests shall be carried out on XLPE insulated HT cable up to 33KV earthed system:

a. Tests on conductori. Annealing test (for Copper)ii. Tensile test (for aluminium)iii. Wrapping test (for aluminium)iv. Resistance test.

b. Test for armouring wires/stripsc. Test for thickness of insulationd. Physical tests for insulatione. Physical tests for outer sheathf. Partial discharge testg. Bending test h. Dielectric power factor testi. Heating cycle testj. Impulse withstand testk. High voltage testl. Oxygen index temperature index test on outer sheath

2.7.5 Following type tests as per IS:7098 (part-3)-1993 including its amendments and additional type tests and additional type tests shall be carried out on XLPE insulated HT cable from 66KV up to and including 220KV:

a. Tests on conductor i. Annealing test(for copper)ii. Resistance testiii. Tensile test (for aluminim)iv. Wrapping test (for aluminium)

b. Physical tests for insulation i. Test for thickness and dimensions of insulationii. Tensile strength and elongation at breakiii. Hot set testiv. Shrinkage testv. Thermal ageing in air oven

c. Resistivity test for semi-conducting layersd. Test for concentric metallic screen:

i. Test for concentric copper wireii. Test for concentric copper tape

e. Thickness of metallic sheath f. Test for armouring material:

i. Dimensions.g. Physical tests for outer sheath:

1. Measurement of thickness of 409

2. PVC sheathi. Tensile strength and elongation at break ii. Ageing in air oveniii. Loss of mass in air oven only for PVC sheathiv. Heat shock testv. Hot deformation testvi. Shrinkage testvii. Thermal stability

3.PE sheath.

i. Carbon black contentii. Tensile strength and elongation at break before and after ageing.iii. Hot-deformation.

h. Flammability test (for PVC outer sheathed cables only)i. Water tightness testj. 1. Thermal ageing on complete cable sample.

2. Tensile strength and elongation at break for insulation and outer sheath. 3. Resistivity test for semi-conducting layer

k. Bending test followed by P.D. testl. Dielectric power factor and capacitance measurement at ambient temperature m. Dielectric power factor measurement at elevated temperature n. Impulse withstand test followed by HV test.o. Oxygen index temperature index test on outer sheath.

2.7.6 Contractor shall submit type test reports as per clause No. 9.2 of Technical Specification, Section: GTR for which test conducted once are acceptance (i.e. The requirement of test conducted within last five years shall not be applicable) for the following:

2.7.7 1.1KV grade PVC insulated cables

High voltage test (water immersion d.c. test as per clause No. 16.3.2 of IS: 1554 (Part-1)-1988)

2.7.8 1.1KV grade XLPE insulated cablesa. Water absorption (gravimetric) test as per IS: 7098 (part-1)-1988

2.7.9 XLPE insulated HT cable from 66KV upto and including 220KV a. Load cycle test followed by P.D. measurement as per IS:7098 (part-3)

2.7.10 Terminating/jointing accessories as per IEC 60840:1999a. Partial discharge test at ambient temperature;b. Heating cycle voltage testc. Partial discharge tests

-At ambient temperature-At high temperature

d. Impulse voltage test followed by power frequency test. e. Test of outer protection for buried joints.

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2.7.11 The owner reserves the right to witness any or all the tests, for which at least 30 days advance notice, shall be given- by the contractor.

2.7.11.1 Ten(10) copies of all routine & type test results shall be submitted for approval before dispatch of the cables from the works.

2.7.12 Bound copies of complete test reports, ten ( 10 ) in number, shall be furnished along with the cables. These shall include complete reports & results of the type tests, acceptance tests routine tests.

2.7.13 The owner reserves the light to get the cable Type tests at his own expense for any further tests to verify the compliance with the specifications & to reject the cables in case they are found not satisfying the qualifying requirements as per relevant standards.

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SECTION-5.2


415/240 VOLTS LTAC PANELS

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VOLUME - IIATECHNICAL SPECIFICATION

Section 5.2. 415/240 Volts LTAC Panels

Clause No. Particulars

1.0 Scope2.0 Completeness of supply3.0 Tropical Protection4.0 Interchangeability5.0 Technical particulars of LTAC Boards6.0 Ventilation7.0 Void8.0 Buses switching devices and connections9.0 Ground Bus10.0 current transformers11.0 Space headers and lighting outlets12.0 Wiring13.0 Terminal blocks14.0 Cable Entry15.0 Control and Indication16.0 Name and Identity plates17.0 Earthing18.0 Indicating 'instruments19.0 Alarms20.0 Power Interrupting devices21.0 Industrial Circuit Breakers22.0 Over load and earth fault protection of Air 23.0 Heavy duty switch and fuse units24.0 Neutral connection25.0 Schedule of equipotent of LTAC switch Board26.0 Panel27.0 Outgoing feeders28.0 Tests29.0 Test witness

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Volume - IIASection 5.2 (415/240 Volts LTAC Panels)

Technical Specification for 415/240 Volts LTAC Panels

1.0 Scope:

1.1 This specification covers the design manufacture, shop testing and supply of 415/240 volts indoor type L.T.AC panels for control of A.C. supply to various auxiliaries in 220 W stations with all materials and accessories for efficient and trouble free operation.

2.0 Completeness of Supply:

2.1 It is not the intent to specify completely herein all details of the equipment. Nevertheless, the equipment shall be complete and operative in all aspects and shall conform to highest standard of engineering and design and workmanship.

2.2 Any material or accessory which may not have been specifically mentioned but which is necessary for satisfactory and trouble free operation and maintenance of the equipment shall be supplied without extra charges.

2.3 The contractor shall supply all brand new equipment and accessories as specified herein with such modification and alteration as agreed upon in writing, after mutual discussion.

3.0 Tropical Protection:

3.1 All equipments, accessories and wiring shall have fungus, protection involving special treatment of insulation & material against fungus insects and corrosion, screens of corrosion resistant material shall be furnished- on all ventilating louvers to prevent the entrance of insects.

4.0 Interchangeability

4.1 All similar component parts supplied shall be interchangeable with one another physically and electrically.

5-0 Technical particulars of LTAC Boards:

5.1 The switchboard shall consist of completely enclosed self supporting cubicle - type sheet steel panels. the switch boards shall consists of the required number of sheet steel enclosures for mounting the circuit breakers, relays, instruments and other equipments.

5.2 Each panel assembly shall be provided with the back easily removable or shall be provided -with hinged doors at the back .to enable, easy access for inspection and maintenance work.

5.3 Cold Rolled Sheet Steel not less than 3 mm thick and structural steel having light sections shall be used and also 2 mm thick sheet shall be used for sides and doors. All fastening between the structural members shall preferably be bolted and not welded, to provide flexibility during installation. The base of switch gear frame shall be suitable for

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erecting on flush concrete floor by means of evenly spaced grounding bolts projecting through the base channel members of the frame.

5.4 The depth of the boards shall be of the order of 500 mm to 1000 mm. The height of the board shall preferably be about 2200 mm and equipment shall be so arranged as to reduce the length of the boards to the minimum possible. The working height shall be limited within 400 mm to 1800 mm from floor level.

5.5 The construction of the front of cubicle shall be such that heavy capacity breakers are isolated from, the adjacent breakers by means of suitable barriers. The design and construction shall be such as to allow extension at either end.

5.6 The breakers, fuses, bus bars and associated jumps etc, in the L.T.A.C. panel shall be capable of withstanding 31.5 KA for one second. The symmetrical breaking capacity of the breakers should be not less than 31.5 KA.

6.0 Ventilation: -

7.0 Ventilating louvers shall be provided.

7.1 All steel surfaces shall be sand blasted , grounded pickledas required to produce a smooth, clean surface free ofscale, grease and rust.

7.2 After cleaning, the surface shall be given a phosphate coating followed by two coats of high quality primer and stored after each coat.

7.3 The finishing coat on the exterior of the panels shall be opaline green corresponding to shade no. 275 of I.S.5 with two coats- of synthetic enamel paint- and colour to the interior surface shall be finished stoved enamel white.

8.0 Buses switching devices and connections:

8.1 All buses, switching device and connections shall be of sufficient size to limits the temperature rise to 45° C over ambient temperature of 45° C (peak) inside the enclosure while carrying full load current

8.2 The main buses and connections shall be of type conductivity electrolyte copper. All main bus joints and bus taps shall be silver plated and tightly clamped with through bolts to ensure maximum conductivity.

8 3 All buses wherever possible shall be of rigid type. They shall be liberally spaced and so mounted that their expansion and contraction do not subject either the bus bars or the insulating supports to any stresses and should withstand the stresses due to maximum short circuit current. Wherever required suitable expansion joints shall be provided.

8.4 All bus work and connection shall be accessible for inspection and maintenance purpose from ends and rear, after first removing the respective enclosing plates.

8.5 Bus bars and connections shall be fully insulated for working voltage with adequate phase to phase and phase to ground clearances. Insulating sleeves for bus bars and shrouds for joints

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shall be provided. Bus insulators shall be flame retardant, track-resistant type with high creepage surface.

8.6 Bus bars shall be colour coded for easy identification and so located that the sequence R-Y-B , shall be from left to right, top to bottom or front to rear when viewed from the front of the assembly.

9.0 Ground bus:

9.1 For ensuring the rigid connection, the minimum section ofthe ground bus shall not be less than 160 sq.mm.

9.2 The ground bus is to be earthed solidly and connected tothe station main earth in system, for which suitable provisions shall be made. The

ground bus shall be provided with two bolt drillings with G.I bolts and nuts at each and to receive 50 x 6 mm. G I. flat.

9.3 All stationery structures shall be directly connected to the ground bus for effective grounding. The frame of draw out type breakers shall be grounded at all

times except when the breaker disconnects are separated by a safe distance.

10.0 Current Transformers:

10.1 The current transformers shall be of cast resin type. Current transformers to be provided shall be mounted in the associated circuit breaker housing in a separate accessible compartment. The core lamination shall be of high grade low loss, silicon steel and the excitation current shall be as low as possible. The Current transformers shall be designed to withstand the thermal and electromagnetic stress- resulting from the maximum

expected short circuit current. Suitable arrangements shall be made so that secondary of CT shall not be open circuited with primary fully loaded. All secondary connections shall be brought out to terminal blocks where

star or delta connection shall be made. Suitable shorting links shall be provided for shorting the secondary- links shall be provided for shorting the secondary winding of C.T. if necessary. The particulars of C.T. i.e burden, accuracy class is detailed in the feeder wise requirement detailed else where in the specifications.

11.0 Space headers and lighting outlets:

11.1 Thermostat controlled space heaters shall be provided inside to prevent condensation of moisture. The cubicle heater shall be provided with individual switch fuse circuits . All switch boards, cubicles etc., shall be provided with suitably located lighting, outlets. The lighting switch shall be provided inside each entrance door at the back of the panels.

12.0 Wiring:

12-1 The LTAC panels shall be fully- wired at the factory to ensure proper functioning of control., protection and inter locking schemes.

12.2 Fuse and links shall be provided to permit individual circuit isolation from bus without disturbing other circuits. All spare contacts of relays, push buttons and other devices shall

be up to terminal blocks.

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12. 3 Wiring small done with flexible, 1100 V grade, PVC insulated switch board type super flexible multi-slandered tinned annealed copper conductors of 2.5 sq. mm. for control and current circuits and 1.5 sq. mm , for voltage circuits.

12.4 Each wire shall be identified at both ends with permanent markers or ferrules bearing wires numbers as per contractors wiring diagrams.

12.5 Wire terminations shall be made with crimping type connector with insulating sleeves. Wires shall not be spliced between terminals.

13.0 Terminal Blocks:

13.1 Terminal blocks shall be 1100 V grade box- clamp type with marking strips similar to ELMEX 10 sq. mm or equal. Terminals for C.T. secondary leads shall have provision for shirting.

13.2 Not more than two wires shall be connected to any terminal. Spare terminals to extent of 20% should be provided.

13.3 Terminals blocks shall be located to allow easy access. Wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals.

14.0 Cable entry:

14.1 Sufficient space provision shall be made for entry of the cable at bottom of cubicle and sufficient space shall be provided base of termination and connection. Suitable cable glands for lead sheathed cables for feeders of 100A and above and PVC cables for feeders of lower rating shall be provided.

14.2 All provisions and accessories shall be furnished for termination and connection of cables including, removable gland plates, cable supports, crimp type tinned copper lugs, brass compression glands with tapered washer (power cables only) and Terminal blocks.

14.3 Gland plates shall be minimum of 4 mm thick. The gland plate and supporting arrangement for single core power cables shall be such as to prevent flow of eddy current

15.0 Control and Indication:

15.1 Push button shall be heavy duty, oil tight, push to activate type with integral escutcheon plate marked with its function.

15.2 The circuit breaker shall be wired up for local operation. Each breaker cubicle shall be equipped with the following:

One (1) test-normal-trial selector switch stay put type with pistel grip handle and key interlock for breaker.

Two (2) heavy duty oil tight push buttons for trip and close. Four (4) indicating lights in front of compartment

Breaker open - Green

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Breaker closed - Red

Breaker Auto - tripped - Amber

Breaker spring charged - white

15.3 Lamps shall be low-watt filament type with series resistor and coloured lens. Lans and lamps shall be replaceable from the front suitable for connection to 220 volts D.C. shall be used.

15.4 The general scheme of connection for control, 'interlock and protection is shown in the enclosed drawings. Detailed requirements of individual circuits will be intimated later to the successful tenderer who shall develop and furnish the schemes accordingly

16.0 Name and identity plates:

16.1 12 mm wide plastic plates bearing suitable identification marks shall be fix-ed on the exterior of the switch board in a appropriate place to indicate the function of different electrical devices, measuring instruments etc., and circuit labels. All equipments shall be numbered according to ASA code numbers.

17.0 Earthing:

17.1 Earthing of dead metallic parts or metallic bodies of the equipment on the panel shall be connected with soft drawn single conductor bare copper, Tail connections shall have minimum area of 14.5 sq.mm. and the main earthing connections to the earthing bus bar 65 sq.mm . Those Wires shall be connected to suitable terminals and close junction. Soldered

connections shall not bee employed. The number of earthing terminals shall be two for the whole assembly of panels.

18.0. Indicating Instruments:

All instruments shall be of the square switchboard type, back connected, suitable for semi-flush mounting and provided with dust tight cases for tropical use with dull black enamel finish. The dials shall be made of such material as to ensure freedom from warping, fading and de colouring. Marking on scales shall be black on white background. All instruments all have easy laboratory means of adjustment to accuracy. The limits of error shall be those permissible for switchboard instruments as per relevant standards.

18.2 The instruments - shall be capable of indicating correctly when operated continuously at any temperatures from O°C to 50°C instruments shall be able to give correct indication at a temperature of 65 deg C for a period of 16 hours. Necessary test blocks shall be provided.

I8.3 Indicating instruments shall be of 96 x 96 mm, 90° Scale, antiglare glass and accuracy class of 2% full scale . Each meter shall have zero adjustment on front.

18.4 Kilo Watt hour meter class 1.5, accuracy shall be provided with built in test facilities. Alternatively, they may have test block to facilitate testing of meter without disturbing CT or VT secondary connections.

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19.1 The main incoming feeder circuits and inter connecting feeder shall have lamp indication and audible alarms for circuit breaker tripping indication.

20.0 Power Interrupting devices:

20.1 The 800A feeders (incomers) shall be provided with industrial type air circuit breaker. Circuits of a lower rating may be provided with rotary type Switch fuse units.

20.2 The fuses shall be of the high rupturing capacity type with rupturing capacity of not less than the maximum expected short circuit levels already indicated in the specifications.

20.3 All such equipments shall be back connected, equipped with completely fabricated buses and shall be rated as shown in the enclosed drawings for the various switch boards.

20.4 All breakers shall be suitable for operation at a voltage 10 % above and 20% below the normal rated voltage 220V D. C.

20.5 The blow out or suppression features shall minimize the arc and flame so that no damage will be done to other portions of the circuits breakers arc blow out or suppression features and contacts shall be rated to carry full load continuously.

21.0 Industrial Circuit Breakers:

21.1 The industrial type circuit breakers shall be electrically operated and equipped with a trip free and lock out device which shall prevent the interrupting device from re-closing after it has been tripped due to an overload or short circuit until the device has been reset manually.

21.2 Each circuit breaker shall be furnished complete with the necessary operating devices, alarm contacts and direct operated and direct switches as may be required.

21.3 Operating cubicle shall operate satisfactorily at 20% below normal operating voltage of 220 V D.C. Breakers shall be of robust design, trip free, shunt trip and on electrical closing, the over load relay coils shall trip all the poles simultaneously.

21.4 They shall be of draw out type having service , test and isolated position. Breaker housing shall be flush mounted on the panel, operating mechanism shall be arranged for emergency manual operation. Mechanical on / off indicators of the breakers, on operation counters and mechanism charge /discharge indicator shall be provided. The OFF and ON position of the breakers shall also be indicated by means of red and green indicating lamps.

21.5 The closing mechanism of the circuit breakers shall have motor operation, designed for 220V D.C. supply For motor wound mechanism spring changing shall take place automatically after each breaker closing operation. One open operation of the circuit breakers should be possible after failure of power supply to the motor.

21.6 Mechanical safety interlock shall be provided to prevent the circuit breakers from being racked in or out of the service position when the breaker is closed.

21.7 Automatic safety shutters shall be provided- to fully cover the female primary disconnects when the breaker is withdrawn and inter-phase barriers to prevent failures. Necessary carriages for drawing out the breakers for servicing should be supplied, As

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already indicated in clause 9.06 the breaker should have a symmetrical breaking capacity of 31.5 KA and making capacity as per relevant standards.

22.0 Over load and earth fault protection of air circuit breakers.

22.1 Under normal conditions, the breaker shall not be affected by, moderate or momentary over loads like those caused by initial in rush currents in the starting of an

appliance motor. However, when such over loads reach dangerous values, the circuits shall be opened by the action of the over current relay with adjustable time delay action. The earth fault relay shall be provided for protection against earth faults. The over current relays

shall be provided with instantaneous elements also.

23.0 Heavy duty switch and fuse units:

23.1 Heavy duty switch and fuse units shall be air break type, back of board mounting type and shall comprise of a heavy duty switch and high rupturing capacity fuses. The frame of these shall be suitable for mounting at the back of sheet steel cubicles.

23.2 Suitable interlocks shall be provided such that the doors can not be open until the appropriate switch operating handle is in the 'OFF' position. Similarly, the door opens. Each switch shall preferably be actuated by a powerful mechanism arranged to secure positive closing and quick break opening action, provision shall preferably be made for visibility of either OFF or ON position of operating mechanism. Thus handle shall have

provision for pad locking in ON and OFF position. Contacts shall make and break with a definite wiping action and have a high pressure line

contact of both heel and toe of the moving contacts. Arc chutes of insulating materials shall be provided forming an effective barrier between the poles preventing the arcing from pole to pole or to the body. High breaking capacity cartridge type fuse links shall be fitted throughout.

23.3 Feeders of capacity 200A and below shall consist of switch fuse units. The switch fuse units shall have the ratings indicated in the clause 26.05.

24.0 Neutral connection:

24.1 All feeders are of three phase four wire type. The switch shall make or break the individual phases. All incoming and outgoing feeders shall be provided with bolted disconnect link for isolation of neutral if necessary.

25.0 Schedule of equipments of LTAC switch board:

25.1 Refer drawing for 415V LTAC panel (Typical) for 220 K V stationauxiliaries. . There will be two independent incoming feeders feeding the two sections of

the bus bars as indicated in the drawing. There will be a bus section switch fuse unit of 800 A capacity connecting these two bus bars. The breakers of the two incoming feeders and the bus section switch fuse unit shall be interlocked so that no two sources are paralleled on to single bus section.

25.2 Each incoming feeder will normally be feeding its own Section of the bus bars and in the event of failure of supply on one of the incoming feeders, the bus section switch fuse unit shall close manually and ensure continuity of supply on this section of the bus bar al so.

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25.3 In addition one bus section shall be connected to 63 KVA D.G. set as shown in the single line diagram, from which priority load will be fed.

26.0 Panel:

26 1 The switch board shall consist of the following equipments. One set of LTAC switch board panels complete with all the equipments listed below with 3 panel copper bus bar system and neutral, cable compartments, self supporting free standing, all steel doors at front and rear, mimic diagram in front of the panel, individual compartments, completely wired

and printed, with power outlets, cubicle heating fuses, ON/OFF switch, current transformers, etc., as detailed in the drawing shall be supplied.

2 6. 2 Two Nos. of incoming feeders of 800 Amps 3 Phase each comprising of the following components:

a) one - air circuit breaker 800 Amps. 415 V AC equipped with shunt trip suitable for 220 V.D.C. auxiliary switches, power drive suitable for 220V.D.C. auxiliary with self interrupting device conforming to B.S.S. or equivalent standard, mounted on a carriage which can be drawn out horizontally.b) Four - Indicating lamps for ON/OFF, AUTO TRIP breakers spring

charge indications.c) Two - Push buttons ON/OFF.d) Three - current transformer cast resign in type ratio 400-200 /5-5 Amps. Double core, one core with accuracy class 1for metering

and another core with accuracy class 10P 10 for protection. TheVA burden shall be 15 VA each for metering and protection cores.

e) Three - Moving from ammeters size 96x96 mm flush mounting industrial grade conforming to BS 89/ISS 1248 or equivalent standard with suitable scale range of 0-200 Amps.f) One - KW meter suitable for CT ratio 400-200 / 5A, 415 volts AC

(flush mounting, size 96 x 96 mm industrial grade conforming toBS 89 / ISS 1248 or equivalent standards.

g) One -3 elements, KWHR meter accuracy class 1 .5 415 v suitablefor CT ratio 400-400/5A conforming to ISS 722 or equivalentstandards.

h) One - voltmeter, range 0-600 V with selector switch, size 96x96mm flush mounting, industrial grade conforming to ISS 1248 orequivalent standards.

i) Two - single pole over current relay, induction type with inversecharacteristics with three seconds minimum time at 10 times thePlug setting. The range of adjustments of induction elementshould be 50 - 200 of 5 Amps- The relay shall be mounted in adraw out type case with operational indicators conforming to IS:3231 or equivalent

standards The relay also shall have on instantaneous element of range 200-800%.j) One - Earth fault relay, similar to item (i) above but with

setting range of 20 -80%.k) Three - under voltage relay with fixed setting with pick up voltage

at 90 % and drop of voltage at 80% of the 415 7 L.T. supply.l) Seven - cable and boxes suitable for 3 ½ x 400 sq. mm. PILC

cables (the size and type of cable will however be conformed atthe time of ordering). Necessary test blocks for the instruments

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transformers for testing relays and meters shall be provided.

26.3 ) Bus isolator:

a) One - 3 phase switch fuse unit, 500V, 800A, conforming torelevant standards.

b) The purpose of the Bus isolator switch is to connect the two bus sections when one of the. incomers fails. Normally the two bus sections will be fed from the respective incomers and the bus switch fuse unit will be open.

26.4 Incomer from DG set:

Incoming from 63 KVA DG set on one bus section, with followingequipments shall be housed in bus coupler panel.

a) One - switch fuse unit of reputed make of 300 A at 415 v A.C.with HRC fuses etc.

b) One - 4 pole, 100A, 415 V AC change over switch, conforming torelevent standard.

c) One - Cables -land, for 75 sq. mm. 3 ½ core PVC cable.

26.0 Outgoing feeders:

1) Two outgoing feeders 200 A 3 phase each consisting ofa) One switch fuse unit of reputed make of 200A, at 415 V A-C.,

fitted with HRC fuses, etc.b) One cable gland suitable for 150 sq. mm 3 ½ core cable. One

feeder should be of each section of the bus.

2) Eight out going feeder 100 A, 3 phase each consisting of : a) One 100 A 415 Volts AC switch fuse unit of reputed make with

suitable HRC fuses.b) One cable gland suitable for 75 sq.mm. 3 1/2 core cable.

NOTE: Four feeders should be on each section of the bus.

3) Four-teen outgoing feeders of 63 A, 3 phase, each consisting ofa) One switch fuse unit 63 A, capacity at 415 V AC, with suitable

HRC fuses etc.,b) Cable gland suitable for 50 sq. mrn. 3 ½ core cable.

NOTE: Seven feeders should be on each section of the bus.

4) Twelve outgoing feeders 32 A, 3 phase each consisting ofa) One switch fuse unit 32 A, capacity at 415 V AC.b) One cable gland suitable for 25 sq. mm. 3 ½ core cable.

NOTE: Six feeders should be on each side of the bus.

NOTE:

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1) Necessary wiring, terminals, contacts, bus bars, foundation bolts, keys, control fuses, mimic bus, lighting, frame, plates, circuit labels, device identification numbers, carrier for cable termination and safety earthing shall be provided.2) One insulated fuse puller shall be 'included to take out HRC fuses from switch board.3) Louvers shall be provided 'in cable chamber deers at the rear for ventilation.4) The bus tars and other connection leads shall be of copper.5) One No. 15 A. multi pin power plug outlets shall be provided for each switch board.6) The fuses shall be of high rupturing capacity of not less than the expected short circuit levels already indicated 'in the specification.

27.0 The successful bidder shall furnish the following drawings in quanta duplication for purchaser's approval.

a) Details of construction of cubicles and the complete dimensionsdiagram cross section drawing of the switch boardindicating details of location of switches, indicating instrumentsrelays, bus bars, cable glands and bus supports.

b) Detailed floor plan and foundations diagram showing necessaryfloor openings.

c) Complete details of the air circuit breakers showing operatingmechanism, quenching arrangements, etc and otherconstructional details.

d) Consolidated Bill of materials.e) Schematic diagram.f) Wiring diagram.g) Instruction manual of LTAC panel and "individual equipment

The manual shall clearly indicate the installation method, checkup and tests to be carried out before commissioning of theequipment.

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SECTION – 5.3


A.C.OUTDOOR DISTRIBUTION BOX

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Section - 5.3 A. C. OUTDOOR DISTRIBUTION BOX

Clause No. Particulars1.0 Scope2.0 Standards3.0 General requirements4.0 Terminal Blocks5.0 Small Wiring6.0 Circuit labeling7.0 Rating Plate8.0 Equipment Details9.0 Tests

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Volume - IIASection 5.3 (A.C.Outdoor Distribution Box)

TECHNICAL SPECIFICATIONS FOR OUTDOOR DISTRIBUTIONBOX (A.C.) FOR POWER & LIGHTING CIRCUITS

1.0 SCOPE:

This specification covers the manufacture, testing at manufacturer' works, Supply & delivery of outdoor type distribution fuse boards for lighting & power circuits at 220 kV & 110 kV Receiving stations.

2.0 STANDARDS

2.01 The distribution boards shall generally conform to IS:2675/1966 (with latest amendments) - specification for enclosed distribution fuse boards & courts for voltages not exceeding 1000 Volts.

3.0 GENERAL REQUIREMENTS

3.01 Irrespective of anything said or omitted in this specification, the distribution box shall be suitable for the purpose they are intended be used. Each distribution box shall be complete with accessories such as bus-bars, fuses, lock & key etc.,

3.02 The distribution fuse boards are required for distribution of 415V±10%, 3Phase, 4 wire / 240V ± 10% single phase AC with phase AC neutral earthed, required for power supply to group operating switches, CB, lighting of - outdoor yard, cable duct fighting & emergency lighting.

3.03 The A. C. distribution fuse boards shall be 500 V grade. The distribution boxes shall be double front or single front type, as specified with provision for incomers & outgoing feeders in each section of the box as shown in the drawing The general arrangement of the AC/DC distribution boxes are shown in the following drawings

1. Drawing No.KF-B/TECIVSub-Station/220/168/9.9.92 - detailed arrangement of distribution box "Type - A" - Single front type.

2. Drawing No. KEB/TECIVSub-Station/220/168/9-9.92 - detailed arrangement of distribution box "Type - B" - Double front type.

3.04 The distribution fuse boards shall be fabricated out of 2.5mm thick- M.S.sheets of tested quality for body & shutters with 40x4Ox4mm M.S .and iron frame.

The shutters & body shall be suitably ribbed to give light but strong structure.

3.05 The A.C. distribution fuse boards shall have hinged double doors at front 7 at back for double front type. Each door shall have independent

type door lock & shall be capable of being opened & closed independently. The doors shall be so fitted as to provide the interior with maximum protection from atmospheric condition. The hinges shall be of such construction that the doors can swing

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open by not less than 150ºC and in addition binges shall permit doors being completely removed when necessary.

3.06 The distribution boxes shall be provided with suitable aprons/canopy as shown in the drawing enclosed. The un-drilled sides, bottom & top covers shall be detachable, The distribution fuse boards shall be designed in such a way that when closed they are ptrf6ctly water tight dust & vermin proof. Special arrangement to prevent ingress of moisture into the interior

of the distribution boxes shall be made. All bolts nuts & washers used shall be galvanized mild steel. All the doors of the distribution box shall be fitted with dust proof gaskets. The louver type ventilators shall be provided the front as shown in drawing & wire nets shall be provided on the back of the ventilator for prevention of entry of dust, insects etc., into the boxes.

3.07 The cable entry & exit are the sides through the extended box at the top on both sides & the design of the box must be such as to facilitate for housing of 100A, MCCB for incoming & 100 A HRC fuse link, for outgoing, The clearance inside the box must be such as to afford fair working facilities during erection & maintenance.

There shall be provision for easy removal of cable during erection & repairs, by suitably bolting -the box coven &preferably sliding the bottom plates. A front hinged door with lock arrangement shall be provided for each of the side box for operation of MCCB &HRC fuse links. However, the entry of the cable at the extended box is to be through a 50mm G.I.pipe & projecting.50mm inside the box through suitable gland. The extended box must be provided with suitable gland & clamp for fixing the cable rigidly. The box shall be suitably ribbed to give a light but strong structure.

3.08 The distribution boxes shall. be mounted on, a suitable angle iron mounting structure.2 Nos of rust proof grounding lugs shall be provided on the angle iron framework of box with terminals suitable for M.S.flat. The earthing ter1ruinal shall be identified by means of the sign marked legibly & indelibly adjacent to the earthing terminals.

3.09 FINISH:

All steel surface shall be sand blasted, grounded, pickled as required to produce a smooth, clean surface free of scale, grease 7 rust. After cleaning, the surfaces shall be given a phosphate coating followed by quality primer & stowed after each coat

The finishing coat on the exterior of the distribution' box shall be fight Grey corresponding to shade No. 631 of IS-5 with two coats of synthetic enamel paint &

colour to the interior surface shall be finished stowed enamel white. A small quantity of finishing paint shall be supplied with each consignment of distribution box to enable to restore at site any finish, which may get damaged during transit.

3-10 The distribution fuse boards shall be provided with high purity electrolytic aluminum bus bars. The side of aluminium, bus-bars phase to phase spacing should

be consistent with the currents & voltage rating of the incoming / outgoing feeders. The bus bars shall be fixed on the Hylam sheets 10mm thick & of suitable width using 30mm brass bolt & nuts. Exposed portion of the bus-bar shall b-. provided with insulated sleeves, red for top phase, yellow for the mid phase, blue for the bottom phase & black for the neutral. The overhung portion shall be suitably supported- AD current carrying parts shall be rigidly supported to withstand short circuit stresses. The fuse carrier shall be easily withdrawable. The short circuit will be about 20 KA at 400V.

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3.11 All the terminals used for 'interconnection shall be made out of solid drawn copper tubing having suitable conductivity. The interior & exterior surface of tubular sockets shall be tinned by electroplating or by hot dip tinning. After final connections of the bus bars, the bus-bars shall be completely insulated with the approved quality insulation tapes.

.3.12 In the A.C. distribution boxes there will be 2 independent circuits each with an incomer & outgoing is provided with removable HRC fuse links for positive isolation of the circuit & also from the point of high fault level on the sub-station. The general arrangement of the circuits is shown in the drawing referred earlier.

There should be insulated barrier of hylem sheets between the front & back portion of the distribution boxes carrying different circuits & it should be possible to work on one side of the box (say front ) with circuit in another side (back 'in energised condition The moulded case CB & HRC fuses shall be of stranded make, ISI mark. Suitable cable gland should be provided for the main incomer/outgoing to the distribution boxes.

3.13 The outgoing feeders should be provide with HRC fuses front connected type, & MCB of adequate rating. The MCB, MCC13 & the HRC fuse

links shall be rated for rupturing capacity of 25 KV at 400 V & they shallbe of reputed & standard make. The 'OFF& 'ON' position of the MCB& MCCB shall be clearly visible when the doors is open- MCB &MCCBs used shall be of ISI approved make. All the outgoing circuitsshould be brought to terminal blocks of adequate rating from whichoutgoing cables will be taken out . The inter connecting wires shall be ofcopper & suitable bimetallic connections for connections with the bus-barsshould be used. table cable glands should provided for the outgoingfeeders of the distribution box.

3. 14 The drawing of distribution box shows the typical arrangement. The current ratings etc., are also specified in the drawings.

3.15 All the fuse cutouts & cable terminals shall be so arranged that they shall be not cause them to come in contact with one-another or with the enclosure by the movement of the cable after insulation & the fixed connections shall be such that the necessary contact pressure is maintained under the conditions of service & operation. The terminal shall

be such that they shall not turn or get displaced when the connecting screws are tightened & such that the conductors shall not be displaced, while wiring inside the distribution fuse boards shall be arranged neatly by grouping the leads properly.

4.0 TERMINAL BLOCKS:

4.1 Terminal blocks shall be 600V grade box clamp type with marking stripssimilar to ENGLISH / ELECTRIC / JOHNSON / ELMEX type, of stud & bolttype, not more than two wires shall be connected to any terminal Terminals equal in number to 20% of active terminals shall be finishedas spares. Terminal block shall be located to allow easy access. Wiringshall be so arranged that individual wires of an external cable can be

connected to consecutive terminals.

5.0 SMALL WIRING:

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The AC distribution box shall be labeled wired at the factory to ensure proper functioning & control of protection scheme. Wiring shall be done, using 660VGrade PVC insulated with stranded famed annealed copper conductor. The size of the wire shall be 25 sq mm for 100 Amps circuits & 4sq mm for outgoing 15 Amps circuits. Each wire shall be identified at both ends with permanent markers bearing Wire numbers as per contractors wiring diagram. Wire terminals shall be made with crimping type lugs with insulating sleeves. Wires shall not be spliced between terminals. for each circuit the neutral wire to be connected from neutral bus to terminal block. The colour of the wires used shall be Red for phase. Yellow for 'Y' phase, blue for 'B' phase & black for neutral.

6.0 CIRCUIT LABELLING:

6.01 Each outgoing & incoming circuits shall be labeled both near the MCCBS / HRC fuse, MCB s and also near the terminal blocks, provision shall be made. by means of a label (which is preferably of the renewable type & protected by transparent material) for recording the circuit title, cable size etc.

7.0 RATING PLATE:

7.01 The following information shall be clearly &indelibly marked on all the distribution fuse boards

1. Rated Voltage.2. Total number/current rating of incoming fuse ways. going fuse ways.3. Total number/current of out'.4. Manufacture's name.5. P.O. reference & date.

8.0 EQUIPMENT DETAILS:

8.1 One set of AC distribution box complete with all the equipments listed below with 3 pole electrolyte aluminium bus-bar system & neutral,completely wired, painted, with MCB, MCCB, HRC fuse units, Circuitlabels as indicated in the drawing shall be supplied.

8.2 Single & double front AC distribution box shall comprise of the following equipments.

Sl No.

ITEM SINGLE FRONT DOUBLE FRONT

1 Free standing sheet steel clad outdoor type, MS cubicle of dimension

750 x 1350 x 300 mm

1200 x 1350 x 600 mm

2 Two independent circuitsa) incomer -415V, 3pole, 100

A MCCB with rupturing capacity of 20 KA for 1 sec with separate neutral line

b) outgoing 100 A, removable HRC fuse links with fuse base of rating 100A & rupturing capacity of 25KA

1 No.

3 No.

2 Nos.

6 Nos.

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for 1 sec, with separate neutral line

3 Outgoing feeders :a) 415V, 15/16A, 3 pole

MCBb) 10A, HRC fuse links ( for

3 phase ) with suitable base (rupturing capacity 25 KA for 1 sec)

6 Nos.

18 Nos.

24 Nos.

72 Nos.

4 a) 240V, 5/15 A, multi pin industries socket & plug

b) 240V, 15A, 2 pole, ON/OFF switch

c) 10A, HRC fuse link with suitable fuse base, of rupturing capacity 25 KA for 1 sec with separate neutral link.

1 No.

1 No.

1 No.

2 Nos.

2 Nos.

2 Nos.

5 Electrolytic aluminium bus-barsa) for phases & neutral 20 x 6 mm

As required As required

6 10 mm thick 100 grade HYLEM sheet for bus-bar mounting 7 installation


7 a) 50/70 sq. mm shrouded terminals for 100 A incoming & outgoing circuits

b) 4 sq. mm shrouded terminals for 10A outgoing feeders.

If required

As required

If required

As required

8 Indication lamp for hive bus indication

4 numbers ---------

9.0 Test:

Tests for rust protection: This shall be mad-, on a representative sampleof the material used for enclosure. The test shall be carried out cither on asample cut from a complete enclosure or metal identical in all respects tothe metal used for the enclosure & given an identical protective finish.The same shall be first cleared with a piece of wadding soaked inBenzons & then dried. Then it shall be totally immersed in a solutionprepared as detailed below:Solution for use in test for rust protection (13S 214-1973):Prepare a solution of 7.5 grams potassium femicyanide (K3PC Cns) & 2.5grams of ammonium per sulphate (NHS) 2 (S2013) in I liter of water. Adda quantity of about 1 gram of suitable wetting agent for instance a sodium salt of alkaline naphthalene sulphuric acid to each-liter of the solution. The solution & the sample being maintained. at a temperature of 20 ± 1º C. After immersion for 5 minutes, the sample shall be removed from the solution & left dry in air at room temperature. After the test the sample shall should, no more than two blue colour red spots in any area of 100 sq mm & no spot shall-have a

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dimension larger than 1.5 mm. Traces of rust on sharp edges & screw threads & any yellowish film removable by rubbing shall be ignored.

9.2 TESTS & TEST CERTIFICATES:

All the other type & routine tests prescribed in IS 2675/1966 shall be conducted on all complete distribution box assembled & completed in all respects & the copies of the certificates shall be submitted for approval before dispatch of the material. Copies of the latest Type test certificates from a cognized test house for having conducted such tests on a distribution box to prove the conformity of the equipment with the above ISS shall be submitted along with the tender.Copies of the type & routine test certificates for all components used in manufacture of the box from a recognized test house (to prove the conformity of the components to the relevant standards) shall be submitted along with the tender.

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SECTION-5.4


BATTERY

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Volume - IISection 5.4 (Battery)

TECHNICAL SPECIFICATIONS FOR BATTERY FOR 220 KVRECEIVING STATIONS 220 VOLTS, 300 AH CAPACITY

1.0 SCOPE:

1.1 This specification covers the supply of battery system to feed the protection equipments and emergency lights in the 220 KV Receiving station.

1.2 This specification covers manufacture, supply,assembly, shop testing at manufacturer’s works before despatch & delivery, for destination of lead acid batteries with plante type positive plates of capacity 220 Volts, 300AH Capacity.

1.3 This specification covers supply, erection & commissioning of the battery sets at the specified station.

2.0 SPECIFICATION FOR 1X 220 VOLTS, 300 AH BATTERY SETS:

2.1 As detailed in clause 1.0 above, the battery sets are required for 220KVReceiving station.

2.2 The batteries shall be complete in all respects.

2.3 The battery shall be of lead acid with plante type positive plates heavy durable, half pasted type negative plates confirming to IS : 1652 latest version. The positive plates shall resist the foaming action of the current during charge & discharge & retain its strength, rigidity, shape dimensions over the operating life of the plates. The Battery shall be suited for a long life under continuous float operation and occasional discharge.

2.4 TEMPERATURE CONDITION: The batteries are required to operate under the following temperature conditions.Maximum temperature 45 degree centigradeMinimum temperature 5 degree centigradeAverage rainfall varies from 1000mm to 2000mmHeight above M.S.L. Below 1000 mtrs.Relative humidity 95%

2.5 STANDARD: - The batteries shall fully conform to the latest edition of following standards or any other equivalent international Standard.

A LIST OF RELEVANT STANDARDS IS GIVEN BELOW:

i). IS-1652-1991 - Specification for stationery cells and batteries, lead

Acid type with Plante Positive Plates.

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ii). IS- 266 – 1993 - Specification for Sulphuric Acid

iii). IS- 6071 – 1986 - Specification for synthetic separators for lead acid batteries.iv) IS- 1069- 1993 - Specification for quality tolerances water for storage batteries v) IS- 1146 – 1981 - Specification for rubber and plastic containers for lead acid storage batteries.vi) IS- 8320- 2000 - General requirements and methods of tests for lead- acid storage batteries.vii) IS- 1885-Part-8/1996 - Electro technical vocabulary – stationary cells & batteries viii) IEEE- 485/1983 - IEEE recommended practice for sizing large lead storage batteries for generating stations and sub- stations.ix) IS- 3116 - Specification for sealing compound for lead acid batteries.x) IS- 1248 - Indicating instruments.xi) IEEE – 484 - Recommended design for installation.

2.6 CONTAINERS: - The Container material shall have Chemical & Electro- Chemical compatibility and shall be acid resistant. The material shall meet all the requirement of Plante type batteries and be consistent with the life of battery. The container shall be fire retardant and shall have an oxygen index of at least 28%. The Tensile strength of material of container shall be such as to handle the internal cell pressure of the cells in worst working conditions. Cell shall not show any deformity or bulge on the sides under all working conditions. The Container shall be capable of withstanding the rigours of transport, storage and handling. The containers shall conform to IS - 1146.

The containers shall be mounted on insulator blocks. Routine and Acceptance tests shall be as per the requirements of IS- 1146 – 1981. The lable attached to the containers shall be marked with the information as per requirements of Cl. No. 2.2 of the above standard. The supplier’s manufacturer’s test certificates shall be submitted by the tenderer for the scrutiny of the purchaser. In case the battery offered conforms to Standards other than IS -1652, a copy of the relevant standard should be enclosed to the tender.

2.7 Cell Covers: The covers shall be made of suitable material compatible with container

material, permanently fixed with the container & provided with vent plug. It shall be capable to withstand internal pressure without bulging or cracking. It shall also be fire retardant.

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2.8 Rating: The batteries are intended to supply power at 220V to the protection equipments in the receiving stations. Each battery set

shall contain 110 cells of normal voltage of 2 volts. The batteries are required to supply indicating lamps, the coils & control scheme of breakers and disconnectors of GIS, relays & station emergency lighting etc., Batteries shall normally remain under floating condition with the trickle charger supplying the continuous load.

The following particulars shall be noted:

a) Normal voltage 220V

b) Float charge voltage 198-280

c) Boost/Equalizing charge voltage 190-300

d) Amperes hour capacity 10 :300 AHhours discharge rate

2.9 END CELL TAPPING: -

The tenders should clarify as to whether it is preferable to have end cell tapping arrangement in the battery banks in order to control the voltage of the load side, when the battery banks are being boost charged or not. If end cell tapping is recommended to regulate the voltage across load, battery set supplier should agree to supply necessary switch to cut-in /cutout the cells as also end cells as loose item.

2.10 Terminal Posts: Both the +ve and –ve terminals of the cells shall be of proper termination and shall ensure its consistency with the life of the battery. The surface of the terminal post extending above the cell cover including bolt hole shall be coated with an acid resistant and corrosion retardant material. Terminal posts or any other metal part which is in contact with the electrolyte shall be made of the same alloy as that of the plates or of a proven material that does not have any harmful effect on cell performance. Both +ve and –ve posts shall be clearly and unambiguously identifiable.

2.11 Connectors, Nuts & Bolts, Heat shrinkable sleeves:Where it is not possible to bolt the cell terminals directly to assemble a battery, separate non-corroding lead or copper connectors of suitable size shall be provided to enable connection of the cells. Copper connections shall be suitably lead coated to withstand corrosion due to sulphuric acid at a very high rate of charge or discharge.

Nuts & Bolts for connecting the cells shall be made of copper, brass or stainless steel. Copper or brass nuts & bolts shall be effectively lead coated to prevent corrosion. Stainless steel bolts and nut can be used without lead coating.

The connectors shall be of suitable cross-section to withstand all the working conditions including 1 min. discharge rate as well as short circuit condition.

All inter cell connectors shall be protected with heat shrinkable silicon sleeves for reducing the environmental impact including a corrosive environment.

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2.12 SEPARATORS: The separators used in the manufacturing of battery cell, shall be of glass mat or synthetic material having high acid absorption capability, resistant to sulphuric acid and good insulating properties. The design of separator shall ensure that there is no misalignment during normal operation and handling. These shall permit free flow of electrolyte and would not be affected by chemical reaction inside the cell & shall last for indefinite time. The internal resistance factor of separators shall assure high discharge characteristics under all operating conditions.

2.13 HYDROMETERS. - Hydrometers suitable for floating in any Cell in the battery, & with a reasonably long scale permissible for the depth of the cell & capable of reading specific gravity 1100 to 300 with sub-divisions 0.022 shall be provided. A wall mounting type teak wood holder for the hydrometer shall also be supplied.

2.14 ELECTROLYTE: - The full quantity of electrolyte required for the first filling with 10% extra shall be included in the offer. The electrolyte shall be supplied in Non-returnable acid resisting jars. The electrolyte shall generally confirm to IS - 266 or equivalent international standards. The electrolyte shall have a specific gravity of 1.2 at 270C. Sufficient quantity of distilled water conforming to IS – 1069 – 1993 shall be supplied in non-returnable containers to correct the level of electrolyte during initial testing & commissioning. 2.15 SUPPORTING RACKS OR STILLAGE FOR BATTERY BANK:- All batteries shall be mounted on a suitable metallic stand/frame. The frame shall be properly painted with the acid resistant paint. The suitable insulation shall be provided between stand/frame and floor to avoid the grounding of the frame/stand.

The Battery layout arrangement is required to suit battery room dimensions of 7.4x5.7 mtr/existing battery room.

2.16 Capacity requirement: When the battery is discharged at 10 hour rate, it shall deliver 80% of C (Where C is rated capacity, corrected at 27 degree Celsius) before any of the cells in the battery bank reaches 1.85 V/cell.

The battery shall be capable of being recharged from the fully exhausted condition (1.75 V/cell) within 10 Hrs upto 90% state of charge. All the cells in a battery shall be designed for continuous float operation at the specified float voltage throughout the life.

The Capacity (corrected at 27 degree Celsius) shall also not be less than C and not more than 120% of C before any cell in the battery bank reaches 1.75 V/cell. The battery voltage shall not be less than the following values, when a fully charged battery is put to discharge at C/10 rate:

(a) After six minutes of discharge : 1.98 V/cell(b) After six hours of discharge : 1.92 V/cell(c) After 8 hours of discharge : 1.85 V/cell(d) After 10 hours of discharge : 1.75 V/cell

Loss in capacity during storage at an average ambient temperature of 35 degree Celsius for a period of 6 months shall not be more than 60% and the cell/battery shall achieve 85% of its rated capacity within 3 charge/discharge cycles and full rated capacity within 5 cycles, after the storage period of 6 months. Voltage of each cell in the battery set shall be within 0.05V of the average voltage throughout the storage period. Ampere hour efficiency shall be better than 90% and watt hour efficiency shall be better than 80%.

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2.17 Expected Battery Life: The battery shall be capable of giving 1200 or more charge/discharge cycles at 80% depth of discharge (DOD) at an average temperature of 27 degree Celsius. DOD (Depth of discharge) is defined as the ratio of the quantity of electricity (in ampere-hour) removed from a cell or battery on discharge to its rated capacity. The battery sets shall have a minimum expected life of 20 years at float operation.

2.18 ACCESSORIES: - The tenderer shall quote unit prices for the following battery accessories.

Item Quantity

a) Cell testing Voltmeter (range -3 -0- +3 volts) accuracy class 0.5 or better I No.b) Rubber apron 2 Nos.c) Rubber shoes (Knee height) 2 pairsd) Thermometer (mercury/ alcohol type)

(0º to 100 º C) with separate gravity correction chart 2 Nos.e) Glass funnels 2 Nos.f) Spanners 1 Setg) Acid resisting jars 2 Ltrs capacity 2 Nos.h) Rubber Gloves 2 pairsi) Rubber Siphon 2 Nos.j) Special tools required for connecting the terminals of batteries 2 Sets

2.19 MAXIMUM SHORT CIRCUIT CURRENT:-The Bidder shall state the maximum short circuit current of each battery along with the safe duration in seconds which it can withstand. Methods, proposed to be adopted for protecting batteries from the short circuit conditions should also be stated to avoid damage to the battery and loss to the associated equipment.

2.20 VENTILATION:-The bidder shall indicate in his bid the requirements of ventilation in the battery room. The battery shall operate satisfactorily over the entire range of the temperature and humidity indicated in this specification without affecting its normal life. If any special ventilation requirements are necessary the same shall be indicated.

2.21 CHARGING:-The bidders shall state whether an equalizing charge is recommended for the battery. If so, the equalizing charge voltage, current, duration and the interval between the equalizing charging shall be specified in the Data sheet. Bidder shall also indicate the requirements for boost charging

2.22 PACKING: - All materials shall be securely packed, crated & protected against mechanical damage in conformity 'With manufacturer's standard practice.

2.-23 INSTRUCTION MANUALS:Eight sets of instruction manuals for installation, commissioning, charging and maintenance instruction shall have to be furnished.

2.24 Routine maintenance of Battery system: For routine maintenance of battery system, the contractor shall supply 1 set of following tools:

(a) Torque wrench(b) Cell test voltmeter ( -3 - 0 - +3) volts with least count of 0.01 Volt.

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2.25 Type Test of Battery:-

2.25.1 Contractor shall submit type test reports of following tests as per IEC 60896-21 & IEC 60896-22, 2004. Tests having been conducted within last five years as mentioned therein shall not be applicable.

Sl. No. Description of test1. Gas emission2. High current tolerance3. Short circuit current and d.c. internal resistance.4. Protection against internal ignition from external spark sources5. Protection against ground short propensity6. Content & durability of required markings7. Material identification8. Valve operation9. Flammability rating of materials10. Intercell connector performance.11. Discharge Capacity12. Charge retention during storage13. Float service with daily discharges for reliable mains power.14. Recharge behaviour15. Service life at an operating temperature of 40 degree Celsius for brief

duration exposure time16. Impact of a stress temperature of 60 degree Celsius for brief duration

exposure time with 3 h rate discharge test17. Abusive over-discharge18. Thermal runaway sensitivity19. Low temperature sensitivity20. Dimensional sensitivity at elevated internal pressure and temperature21. Stability against mechanical abuse of units during installation

Tests shall be conducted in accordance with IEC 60896-21 & IEC 60896-22, 2004.

2.25.2 List of Factory & Site tests for Battery:-

Sl.No. Test Factory Tests

Site Tests

1. Physical verification Yes2. C/10 Capacity Test on the cell Yes3. 8 Hrs charge and 15 minutes discharge

test at full rated loadYes

2.26 Installation & Commissioning:

Manufacturer of Battery shall supervise the installation and commissioning and perform commissioning tests as recommended in O&M manual / or relevant standards. All necessary instruments, material, tools & tackles required for installation, testing at site and commissioning are to be arranged by Battery manufacturer/Contractor.

2.27 DRAWINGS AND OTHER DOCUMENTS:- of 409

The tenderer shall submit the following drawings/ documents along with his offer failing which the offer is liable for rejection.

a). General battery arrangement, proposed size of individual and over all dimensions along with sectional views showing all connections etc.

b). Pamphlets and technical literature giving detailed information of the batteries offered.

Contractor shall submit following documents for approval:(a) Data sheet / GTP as per Annexure-I(b) GA of cell and layout drawing(c) Discharge data for 10 Hour, 8 Hour, 3 Hour, 2 Hour, 1 Hour, 15 minutes and One

minute indicating capacity factors for end cell voltage of 1.75 V & 1.85 V.(d) Temperature correction factors.(e) Installation & Commissioning instructions.(f) O&M manual.

2.28 GUARANTEED TECHNCAL PARTICULARS:-

The Guaranteed technical particulars, as called for in the ‘Annexure – I & II shall be furnished along with the tender. Any tender lacking complete information in this respect is likely to be rejected.

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SECTION – 5.5


BATTERY CHARGER

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VOLUME - IIASECTION 5.5 - BATTERY CHARGER

TECHNICAL SPECIFICATIONS FOR BATTERY CHARGERS WITH D.C. DISTRIBUTION BOARDS FOR VARIOUS SUB-

STATIONS OF KPTCL - 220VOLTS, 300AH CAPACITY

1.0 Intent of Specification

This section of the specification covers design, manufacture, testing, supply and

supervision of erection and commissioning of battery charger and DC distribution

panel with all materials and accessories required for various Stations of KPTCL for

boost, float and trickle charging 220V, 300AH battery set and for distribution of DC

supply with efficient and trouble free operation to various equipments in receiving

stations of the owner

1.1 Scope

1.1.1 The brief requirement for each station is detailed below :

a) A Charger – 1 panel consisting of a separate boost charger and separate

float charger with trickle charging as detailed else where in the

specification.

b) A Charger – 2 panel exactly similar to (a) above consisting of a separate

boost charger and separate float charger with trickle charging as detailed

else where in the specification and both should be in service.

1.1.2 Two separate DC sources each with one battery charger together with the battery

bank and DC distribution board shall constitute a 220V DC source for supply to

Main-1 & Main-2 numerical relay for distance scheme of protection and various of 409

equipments in the main receiving stations. In addition to this, the charger shall be

capable of being used for initial charging, trickle charging and equalizing charge

as stipulated by battery manufacturer. The arrangement for end cell tapping, if

required will be provided, so that while boost charging, the battery AC supply

voltage fails or float charger feeding loads develops trouble, at least about 84 cells

(84 x 2.62 Volts = 220V) are connected across the load and part of battery

continue to meet the DC requirement till change over takes place and full battery is

put across the load. The detailed circuit arrangement is explained else where in the

specification.

1.2 CODES & STANDARDS:

All the equipments and materials shall be manufactured and tested in accordance

with the latest applicable standards.

1.3 COMPLETENESS OF SUPPLY:

It is not the intent to specify completely herein all details of equipments/

components. Nevertheless, the equipment shall be complete and operate in all

aspects and shall conform of highest standard of engineering design and

workmanship.

Any materials or accessories which may not have been specifically mentioned, but

which is necessary or used for satisfactory and trouble free operation and

maintenance of the equipment shall be furnished.

1.4 SERVICE CONDITION

The battery charger and its associated accessories shall be designed for operation

in the following climatic condition.

i. Maximum Temperature of Air in Shade 45°

ii. Minimum Temperature of Air in Shade 5°

iii. Average Daily Ambient Air Temperature in Degree C. 65°C

iv. Maximum Relative Humidity 10-100%

v. Altitude Less than 1000mm

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vi. Average rainfall 100-3000/5000mm

vii. No. of rainy days per annum 100 Days (Max.)

viii. Isoceraunic level days /year 46

ix. Siesmic Level (Horizontal Acceleration). 0.3

All the equipments, accessories and wiring shall have tropical protection involving

special treatment of metal and insulation against fungus, insects, and corrosion.

1.5 DESIGN CRITERIA

1.5.1 The Battery charger will constitute the DC power supply source for all stations

loads.

1.5.2 The equipment will be installed indoor in a clean but hot, humid and tropical

atmosphere.

1.5.1 The battery charger combination shall be such as to ensure continuity of DC

supply at load terminals at all times without even momentary interruption.

1.5.2 Further, the voltage at load terminals shall never exceed the limits of 10% and –

15% of nominal, system concept.

1.6 System Concept

1.6.1 The battery charger panels shall consists of the following

a) A Charger – 1 panel consisting of separate boost and float charger suitable

for charging, equalizing charging and trickle charging of 220V, 300AH

battery sets besides meeting continuous and emergency DC loads as

detailed else where in the specification.

The above modes of charging both automatically and manually shall be

through manually operated Auto / manual selection switch.

b) The boost charger shall be capable of initially charging of the 220V, 300AH

battery at quick rate after an emergency or after a discharge test or for

giving periodical curative charge once or twice a year as per battery

manufacturer’s recommendations.

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c) The float charger shall always be connected to the DC load and shall

maintain a steady voltage of 220V, plus or minus 0.5 % using a constant

potential controller.

1.6.2 During normal condition the float charger shall be on and working in parallel with

DC load and battery. The rating of the float charger shall be such as to meet the

float charge current requirement of the battery plus the continuous DC load, the

details of which is given else where in the specification. While boost charging the

battery set shall be across boost charger and float charger shall be across the load.

1.6.3 During the boost charging, if there is an AC supply failure, the battery should

automatically be connected to the load to maintain continuity of DC supply.

1.6.4 Further, to have battery supply across load even during short interval of change

over period and if float charger develops trouble, the 84th cell of the battery should

be capable of being connected through a blocker diode to the load so that under

boost charging condition the float charger, the continuous DC load and battery up

to 84th cell are in parallel. A charger – 2 panel exactly same as charger-1 panel is

required as 100% stand by. There should be an interlock in the circuitry such that

if charger No. 1 panel is in service, it should not be possible to put charger No. 2

panel into service and vice versa.

1.7 RATING :

The ratings for boost charger, trickle charger, float charger and emergency lighting

change over system shall be as detailed below :

Sl. No. Particulars Required valuea. Boost charger

i) Range of voltageii) Continuous current rating

220V, 300AH190 to 300V50 Amps

b. Trickle charger and float charger i) Range of voltageii) Continuous current rating – floatiii) Trickle charger current

200 to 280 V20 Amps200mA Min800mA Max

1.8 Detailed specification for charger panel.

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The battery charger shall be supplied complete with all devices including but not

limited to the following. If any device/components felt is required at the time of

approval of drawings, the same shall be provided without any extra cost.

1.8.1 Each charger panel shall consists of –

a) A Boost charger operating on AC input voltage of 415 volts

–30 % to +10%, three phase, 50hertz, + 5%, to give a DC output ranging

between 190V to 300V so as to quick charge a bank of 110cells each of 2V

from an end voltage of 1.75V to 2.65 / 2.7 V at a Max, continuous rate of

50 A and shall consist of the following components (boost charge current –

start – 50A, finish 25 Amps).

i) One No. triple pole and neutral pole ON / OFF AC input switch of

adequate rating.

ii) Required Nos. of HRC fuses with base, fittings etc. for DC output &

AC input.

iii) Three Nos. of pilot lamps for indicating availability of 3 phase

supply.

iv) One No. AC contactor triple pole with one normally open contact for

controlling DC contactor connecting battery to the DC bus with

overload release and one No. ON / OFF switch (for providing

interlock between charger – 1 and charger – 2).

v) One constant potential controller for error detection, load current

detection, amplification etc., so that the Boost charger output voltage

is maintained automatically to the required value, with input voltage

variation detailed above.

vi) One 3Ph naturally air cooled transformer liberally rated for the

rectifier rating specified with + 2.5% taps on input side for input

voltage correction by means of selection switch mounted on the

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front of the panel which can be operated on load for changing the

taping of the input transformer.

vii) Three Nos. ballast chokes, if required.

viii) a) One set of 3- phase full wave bridge connected silicon

rectifier, with zener type thyristor with simple smoothening circuits,

liberally rated to meet the continuous current rating specified with

stepless voltage control.

b) One set ripple filtering device to limit the ripple content to

less than 2%

ix) One double pole moulded case circuit breaker backed by HRC fuses

on DC output side.

x) A set of indicating lamps for DC on indication & A.C supply

indication

xi) One DC ammeter moving coil type with shunt etc., for measuring

DC output /charge / discharge current and one ammeter for

measuring load current.

xii) One moving coil voltmeter with selector switch to read boost charge

voltage, float charge voltage, battery tap and off and one volt meter

for AC input voltage.

b) A float charger operating on AC input voltage of 415 V –30% to + 10%,

three phase 50Hz + 5% to give a DC output ranging from 200V to 280V

separately controlled to give a continuous variable load max 20 A and to

give a trickle charge current of 200 to 800 mA the load current varying

from 0-100% and consisting of the following components.

i) One AC input triple pole & neutral pole ON/OFF switch of adequate

rating.

ii) Three Nos. of HRC fuses with fittings.

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iii) Three Nos. of pilot lamps.

iv) One No. AC input contactor with over –load releases and coil

/ON /OFF switch.

v) One constant potential controller for error detection, load current

detection, amplification etc., so that the float charger output is

adjusted automatically such that the battery voltage is around 220

volts with load current and input voltage variation detailed above

(both) occurring simultaneously.

vi) One auto manual change over switch.

vii) One raise / lower push button for manual operation.

viii) One main transformer, 3 phase, natural cooled, liberally rated for the

rectifier rating specified with

+ 2.5% taps on input side for input voltage correction by means of

selection switch mounted on the front of the panel which can be

operated on load for changing the tapping of the input transformer.

ix) a) One set of 3 phase full wave bridge connected silicon rectifier

with zener type thyristor with simple smoothening circuit liberally

rated to meet the continuous current rating specified with step less

voltage control.

b) One set of smoothing choke to limit the ripple content to less

than 2%.

x) One moulded case circuit breaker to control float charger DC output.

xi) Required Nos. of HRC fuses with base fittings etc for DC output and

AC input.

xii) One moving coil ammeter for float charger current.

xiii) One centrezero milli ammeter to measure trickle charging current to

the battery.

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[c) IMPORTANT NOTE :

1. For each station two charger panels each consisting of one boost charger

and one float charger detailed above shall be supplied.

2. a) Fuses for DC output and AC input shall be brought on the

front of the panel and cutouts provided.

b) Semi conductors devices, Power failure, relay alarms on Ac failure

and to disconnect all internal charger loads from battery to prevent

unnecessary discharging during power failure.

3. Printed circuit shall be accommodated in modules, plug in type, and similar

modules shall be interchangeable in standard socket chasis.

1.8.2 FOLLOWING COMMON EQUIPMENTS FOR CHARGER-1 &

CHARGER-2 ARE REQUIRED.

NOTE:

It may be noted that there are two banks of battery sets operating independently

i.e., 1 bank of 300AH battery set. Normally both the banks (300AH) will be in

service.

i) 2 Sets of single pole two way on and off suitably rated for each battery

charger.

ii) Two sets of single pole two way on and off, suitably rated change over

switch for selection of Battery Float/ Boost mode (one for each battery

bank).

iii) 2 MCCB (one for each battery bank), triple pole for connection of 110 th cell

and 84th cell positive and for first cell negative.

iv) 2 DC Contactors, (One for each battery bank), for connecting the battery

110th cell to bus positive through above MCCB.

v) Two silicon blocker diodes (one for each battery bank) for connecting 84 th

cell positive to positive of DC bus through the above MCCB.

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vi) Suitable no. of earth leakage circuits for annunciation both audible and

visual with push button for reset.

vii) Two sets of milli-ammeter (one set for each battery bank) to indicate the

leakage current when the mid point of the battery is earthed.

viii) A set of audible and visual alarm annunciation scheme with all necessary

accessories to acknowledge reset and test scheme as also other necessary

relays, with the following facia window.

i. AC Mains fail

ii. Float Charger DC Fail

iii. Boost Charger DC Fail

iv. DC Earth Fault

v. Rectifier fuse fail

vi. Filter fuse fail

vii. Blocking Diode fail

viii. Load Bus DC fail

ix. Boost charger over load

x. Float charger overload

xi. Under voltage of the battery

xii. Over voltage of the battery

xiii.

xiv. As required

xv.

NOTE :

All MCCB shall be of breaking capacity of 25 KA with over load and short circuit

protection.

1.8.3 A DC distribution board consisting of :

i) Electrolytic Copper insulated DC bus bars of adequate rating.

ii) Ten circuits of 60 Amps with switch fuse unit consisting of suitably rated

HRC fuses.

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iii) Ten circuits of 30 Amps with switch fuse unit consisting of suitably rated

HPC fuses.

ii) One set of automatic emergency light circuits of 10A rating with AC/DC

contactors etc.

1.8.4 The necessary internal wiring, space heater, terminal blocks, panel to mount the

equipments shall be provided.

1.8.5 The equipments not specifically covered in the above schedules but required for

the satisfactory working of schematic arrangements detailed else where in the

specification shall be provided by the supplier, giving all the details.

1.8.6 The makes of all equipments supplied shall be detailed. The equipments shall be

carefully be selected such that only proven components are used particularly the

diodes, thyristors etc., so as to give trouble free operation.

1.8.7 INTEREFRENCE AGAINST RE-CIRCUITS:

The equipment shall be efficiently screened against interference to radio as also

other communications equipment, which may be installed in the same building.

All the sources of noise shall be fitted with Re-suppressors generally in accordance

with relevant ISS/IEC.

1.9 DETAILS OF CHARGER / DC DISTRIBUTION PANELS :

1.9.1 The components detailed in clause 1.5.1 ie., of one boost charger and one float

charger shall be mounted in separate panel. The components common to two

charger panels detailed in clause. 1.5.2, shall be housed in common panel. The

common, panel shall be accommodated in between two charger panels.

1.9.2 The panels shall have maximum height of 2.5 mtrs. and depth around 1.0mtr. It

shall consist of completely enclosed self supporting cubicle type CRCA sheet steel

enclosures for mounting various equipments. Each panel assembly shall have

easily removable hinged door at the back with easy access for inspection and

maintenance. The sheet steel shall be of minimum 3mm thickness where

equipments are mounted on them and the side and back door sheets shall be of 409

mounted on structural steel of light but rigid sections. The bottom of the panel and

frame works shall be suitable for mounting on slush concreate floor using evenly

spaced ground bolts projecting through the base channel.

The equipment layout on the panel be such as to give neat appearance ease of

operation of various equipments keeping the over all width to the barest minimum.

1.9.3 The rear, side and front enclosing, steel sheet shall be such as to have good

ventilation particularly for the portion housing transformers etc.,

2.0 COOLING :

Natural air cooling shall be employed in all units. Suitable louvers with fine mesh

or perforations are to be provided in the panels for this purpose. The use of fans

etc., for including accelerated air flow is precluded. Oil cooled components are

not acceptable.

2.1 FINISH :

All unfinished surfaces of the steel panels and frame work shall be rust proofed

after fabrication and prior to painting and before applying the finishing coat, and

an under coat suitable to a serve as base and binder for the finishing coat shall be

given. The first coat on the exterior of panels shall be polished cellulose, enamel

or equivalent and of colour to be indicated by the purchaser at al later date. The

interior surface shall be finished stoved enamel white. A small quantity of

finishing paint shall be supplied with each consignment of panels to enable the

purchaser to restore at site any finish, which may get damaged during transit. The

exterior colour of the panel shall correspond to shade no. 275 of IS-5. The interior

of the panel shall be white enamel.

2.2 Buses, switching devices and connections :

All buses, switching devices and connections shall be of sufficient size to limit to

the temperature raised to 45° C (Peak) inside the enclosure while carrying full load

current. All main bus joints and bus to taps shall be silver plated and tightly

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clamped with through bolts to ensure maximum conductivity. All buses wherever

possible shall be of rigid type. They shall be liberally spaced and so mounted that

their expansion and contraction do not subject either the bars or the insulating

supports to any stresses. Wherever required, suitable expansion joints shall be

provided. All bus work and connections shall be accessibly for inspection and

maintenance purpose from end to end rare, after first removing respective

enclosing plates. All buses, AC & DC switches connections shall be designed to

carry 25 KA for 1 second.

2.3 Ground Bus :

For ensuring the rigid connection the minimum section of the ground bus shall not

be less than 160 Sq. mm. The ground bus shall be earthed solidly and connected to

the purchaser’s station main earthing system through 50 x 6 mm G.I flat with 2

bolts of M12 size.

2.4 SPACE HEATERS AND LIGHTING OUTLETS :

Space heaters shall be provided inside all cubicles and panels to prevent

condensation of moisture. Wiring connection to the space heaters in the cubicles

shall have suitable insulation over a safe length from the heater terminals. All

lightning outlets with the switches etc., shall be provided inside each entrance door

at the back of the panels.

2.5 WIRING

The internal power and control wiring of the charger shall be of adequate rating as

recommended by cable manufacturers and relevant IS.

The interconnecting cables or bus bars carrying load current from the main

transformers secondary onwards upto and including DC output bus bars shall be

copper. Interconnecting leads in the control circuits and leads of filter capacitors

shall also be of copper. Ends of all load current carrying cables shall be fitted with

copper lugs of adequate rating and shall be soldered or crimped effectively to the

conductor to ensure that the temperatures rise at the joints does not exceed that of

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the conductors. All cabling and wiring shall be neatly secured in position and

adequately supported. All cables and wire carrying AC supply shall be kept

separate from other cables. The colour scheme employed for the cabling and

wiring shall be shown in the suppliers instructions manual. The colour scheme

employed shall be as follows :

i. For AC Circuits - Grey

ii. For DC Circuit - “Positive” -Red

“Negative” -Black

“Earth” -Green

All outgoing wiring shall be brought out to terminals on terminal blocks provided

with 10% additional terminals. The terminal end shall be provided with suitable

identification marks. All the terminals shall be of nut and stud type of brass coated

with nickel, not less than 8mm and suitably rated to carrying the respective rated

current.

2.6 SPACE FOR CABLE AND CABLE GLANDS :

Sufficient space for receiving the cables inside the switch board on the bottom,

cable glands and mounting arrangements for the feeders shall be suitable for PVC

insulated cables. The size of the cables shall be intimated at later date.

Necessary cable glands for all cables shall be included in the supply.

2.7 MIMIC DIAGRAM :

The mimic diagram shall be incorporated with red and green lamps for indicating

air circuit breakers position. Switchboard purpose, built in resistor type lamps of

low watt consumption inter changeable and suitable for easy replacement shall be

provided. LED lamps are also acceptable.

2.8 NAME AND IDENTIFY PLATES :

Twelve mm (half inch) wide plastic plates bearing suitable identification marks

shall be fixed on the exterior of the switch board in appropriate places to indicate

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the function of different switches, electrical devices, measuring instruments etc.,

and circuit breakers. Also suitable designation plates with details shall be provided

for all equipments inside the panel.

2.9 EARTHING :

Earthing of a dead metallic part of bodies of the equipment on the panels shall be

done with a soft drawn single conductor bare copper. Main connection shall have

minimum area of 14.5 mm and the main earthing connection to the earthing bus

bar, 65 sq. mm these wires shall be connected to suitable terminals and clamp

junctions. Soldered connections shall not be employed. The no. of earthing

terminals shall be two for the whole assembly of panels.

3.0 INDICATING INSTRUMENTS :

All instruments shall be of the square switch board type, of 96 Sqmm. Size back

connected, suitable for semi flush mounting and provided with dust light cases for

tropical use with dull black enamel finish. The accuracy class shall be 1.5. The

dials shall be made of such materials as to ensure freedom from wrapping, fading

and discolouring. Marking on scales shall be black on white background. The

dials of the instruments shall be of 2400 scale. All instruments shall have

practicable laboratory means of adjustments to accuracy. The limits of error shall

be those permissible for switchboard instruments as per IS-1248 or BSS-87. The

instruments shall be capable of indicating correctly when operated continuously at

any temperature from 00C to 500 C. Instruments shall be able to give correct

indication at a temperature of 65 C a for period of 16 hours. Necessary test blocks

shall be provided.

3.1 Regulation :

The DC output shall be maintained at + 1% for input variation of + 10% from no

load to full load and input frequency variation from 47.5 Hz to 52.5 Hz. The

power factor shall not be less than 0.65.

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3.2 TESTS OF FACTORY :

The equipment and panels shall be tested in accordance with relevant ISS or BS or

equivalent standards.

3.2.1 ROUTINE TESTS :

During manufacture and on completion the equipment shall be subjected to routine

tests in accordance with latest relevant standards.

3.2.2 TYPE TESTS :

Type test certificates as per relevant standards shall be furnished by the tenderer.

a) Type tests of battery charger : Radio Frequency interference test.

b) Routine tests on Battery charger :-

i) Insulation resistance test

ii) Voltage regulation check from 0 to 100% load with + 10% voltage

variation.

iii) Ripple content measurement

iv) Heat run test on current limiting value

c) Routine tests on component parts and accessories as per relevant IS.

TEST WITNESS

Test shall be performed in the presence of Purchaser’s representatives.

3.2.3 TEST CERTIFICATES

Certified reports of all the tests carried out at the work shall be furnished in 3

copies for approval of the purchaser. The equipment shall be dispatched from

works only after the receipt of Purchaser’s written approval of test reports.

3.3 SPECIAL TOOLS & TACKLES:

A set of special tools and tackles which are necessary or convenient for erection,

commissioning, maintenance and overhauling of equipment shall be supplied.

3.4. SPARES:

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The Tenderer shall submit a list of recommended spare parts for three years &

satisfactory and trouble free operation indicating the itemized price item of spares.

3.5 TENDER DRAWINGS:

Duplicate copies of the relevant drawings shall be submitted along with the tender.

3.6 CONTRACT DRAWINGS:

The supplier shall submit four copies of the following drawings for approval.

i) Details of construction of cubicles and complete drawings of the switch

board indicating full details of the location switches, instruments, relays,

bus bars, cable glands, support etc.

ii) Wiring and cabling diagram for all the circuits. All devices shall be

numbered according to the international convention.

iii) Details of construction of boost and float charger.

3.6.1 SUPPLIER SHALL FORWARD

After the drawings are approved six copies of the drawing printed on 90 GSM

paper shall be supplied for immediate use. The supplier should forward the

drawings and literature as follows :

a) One set of reproducible originals and 12 sets of blue print copies of all

approved drawings along with 12 sets of literature, commissioning and

maintenance manuals to the office of the Chief Engineer, Electy., Tendering

and Procurement, KPTCL, Kaveri Bhavan, Bangalore – 560 009.

b) Four sets of blue print copies of all approved drawings along with four sets

of literature and manual to consignees in respect of each of the stations.

c) Non-supply or part supply of drawings, literature and manuals will be

deemed as incomplete supply of switchboard.

d) Foundation drawings indicating the details of foundation bolts cable entries

and trenches, etc.,

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e) Elementary diagrams of all controls, metering, protection, annunciation and

other circuits, panel wise. All devices shall be according to SA CODE.

f) Schematic diagram’s of PCB’s and charger.

g) Dimensional outline of charger drilling diagram and special mounting

arrangement if any of each type of various devices.

3.7 INSPECTION:

All the tests and inspection shall be made at the place of manufacture unless

otherwise specifically agreed upon by the manufacturer and the purchaser at the

time of purchase.

3.8 PACKING:

The supplier shall provide such packing of goods as is required to prevent damage

or deterioration during transport to their final destination. The packing shall be

sufficient to withstand, without limitation, rough handling during transport and

exposure to extreme temperature and open storage. The packing case, size, rates

shall be taken into consideration, where appropriate, the remoteness of goods final

destination and the absence of mechanized heavy handling facilities, at all points

in transport.

3.9 DEVIATION FROM TECHNICAL SPECIFICATION:

The tenderer shall furnish the details of deviation/modification proposed by him to

improve overall performance of the system. The deviation shall be brought in the

tender clause by clause as per annexure.

4.0 PERFORMANCE GUARANTEE:

The equipments offered shall be guaranteed for satisfactory performance for a

period of 60 months from the date of satisfactory commissioning of equipment.

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The equipment found defective / failed within the above guarantee period shall be

replaced or repaired by the supplier free of cost within one month from receipt of

intimation. If the defective / failed components of battery chargers are not replaced

/ repaired as per the above guarantee clause, the KPTCL shall recover an

equivalent amount plus 15% supervision charges from any of the supplier’s bills.

4.1 MINIMUM EXPERIENCE FOR QUALIFYING AS TENDERER :

4.1.1 The tenderer shall have a minimum experience of five years in the design,

manufacture, testing and commissioning of Battery charger similar to the type

specified in the present enquiry. At least 50% of the quantity of similar type of

battery charger called for in the present enquiry shall be in successful operation for

a minimum period of two years. The tenderer shall also furnish the details of

similar battery charger supplied by them so far giving order reference, name and

address of the customer etc., also indicating the date of commissioning. The

tenderer shall also furnish performance certificates for a period of minimum two

years of similar battery charger in proof of the satisfactory operation of battery

chargers.

4.1.2 Test reports for the test conducted in accordance with relevant ISS or BS or

equivalent standards shall be supplied. Three copies of test certificates shall be

furnished along with the tender without which offer is liable to be over looked.

Further the test certificates furnished shall pertain to test carried out not older than

five year from the date of notification of bid.

********

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Annexure - I

Schedule of guaranteed Technical particulars of 220V, 300AH Battery Chargers.

Sl. ParticularsNo.1. Manufacturer’s type of designation :

2. Type of Rectifier and rating as per :

IS – 3895 – 1966 with latest version.

3. Input AC supply.

a) Voltage :

b) Current :

c) No. of Phases :

d) Frequency :

e) Power Factor :

4. Percentage Tap provided on the

Transformer +/- & Voltage ratio of

Transformer & KVA rating. :

i. For Boost Charger :

ii. For Float Charger :

5. Boost/Quick charge current

Minimum :

Maximum :

6. Float Charge Current

Minimum :

Maximum :

7. Trickle Charge Current

Minimum :

Maximum :

8. Whether Auto/Manual feature is :

provided.

9. Whether voltage across load is

constant while boost/quick charging :

the battery. of 409

10. Whether Automatic change over from

boost charging mode to float charging is :

provided when AC failure takes place.

11. a) Allowable limits to voltage variation

on A.C. side for satisfactory charging :

of DC side.

b) Type of device on AC side :

12. Instantaneous forward voltage drop

versus instantaneous current at rated :

service (a graph to be enclosed)

13. Type of voltage control for Boost Charger,

Float charger & Trickle Charger :

14. Instantaneous reverse current

versus instantaneous reverse volts :

at rated service (a graph to be enclosed)

15. Range of variation of DC voltage :

and device used for the same.

16. Rated DC output for

a) Boost Charger :

b) Float Charger :

17. D.C. output voltage regulation from

no load to full load. :

18. Maximum ripple content in % :

19. Maximum permissible temperature

rise over an ambient temperature :

20. Whether the charger is tropicalised :

21. Over load capacity. :

22. Duration of overload. :

23. Efficiency at

a) 25% Load. :

b) 50% Load :

c) 75% Load :

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d) 100% Load :

24. Dimensions of the charger width x :

Height x depth in mm

25. Weight of the charger in Kgs. :

26. Recommended spares :

27. List of major accessories provided :

28. Other Details, if any :

29. Rating & make of Thyristor :

30. Meters

Ammeter / ltmeter

i) Type & Make

ii) Size

iii) Scale Range

iv) Accuracy

31. Heat Sink for Boost Charger & Float Charger

Whether provided :

Details of Components & Rating

I DC Distribution Board

i. Maker’s Name :

ii. Country of Manufacturer :

ii. Number of Circuits with rating :

II BUS BARS

i. Sectional Area :

ii. Material :

iii. Current Carrying Capacity :

iv Maximum Temperature rise over 45oC

ambient with continuous full load

condition :

v. Type of Supporting Insulator :

III Small Wiring

i. Type :

ii. Size :

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IV Moulded Case (OR Equivalent)

Air Break Switch & Fuse Units

i. Type :

ii. Make :

iii. Normal Voltage :

iv. Normal Current :

v. Interrupting Capacity :

vi. Fusing Factor for fuses :

vii. Temperature rise of contact under oC

continuous full load condition over 45o

ambient temperature :

viii. Material & Type of Contact :

V Dimensions of Battery Charging Panel

(Including DCDB) :

i. Width :

ii. Depth :

iii. Height :

VI Dimension of DC Distribution Panel

i. Width :

ii. Depth :

iii. Height :

VII i. Number of Crates for Shipment, Shipping

Dimensions of the largest crate :

ii. Whether equipments and the switchboards

are tropicalized or not :

iii. How is access provided to the

switchboard interior :

iv. Mounting Arrangements for cable

glands provided. :

Date :……………….. Signature :…………………………

Place :……………… Designation:……………………….

Company:…………………………. of 409

Annexure - II

Schedule of Tenderer’s Experience

1. Name of the Manufacturer :

2. Standing of the Firm as manufacturer of

Equipment:

3. Testing Facility at manufacturer’s work. :

4. If the Manufacturer is having collaboration With

another Firm, details regarding standing of

parent Firm, Period of collaboration

:

5. Description of equipment similar to that quoted,

supplied and installed during the last 5 years

with names of parties to whom the supplies are

made along with PO No., the names of persons

to whom a reference may be made by purchaser

in case the considers such a reference necessary

:Shall be furnished in the

Form indicated below

Sl.

No.

Description Value

of

Work

Place

Where

installed

Period of

Execution

& date

Client Persons to whom

reference can be

made

(a) (b) (c) (d) (e) (g) (h)

Date :……………….. Signature :…………………………


Company:………………………….

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Annexure - III

SCHEDULEOF

DEVIATIONS FROM SPECIFICATION

All deviation from this specification, shall be set out by the bidder, clause by clause, in

this schedule, unless specifically mentioned in this schedule the bidder shall be deemed to

conform to the owner’s specification.

Sl. No.

Specification Clause No.

Deviation By the Tenderer Justification for Deviation

Date :……………….. Signature :…………………………


Company:………………………….

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SECTION-5.4


LIGHTING SYSTEM

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VOLUME - IIA



1.0 Lighting System2.0 Schedule of quantities3.0 Codes and Standards4.0 Lighting Fixtures and Accessories5.0 Receptacles6.0 Switch and Switchboards7.0 Conduit and Conduit accessories8.0 Junction Boxes9.0 Terminal Blocks10.0 Pull out Boxes11.0 Void12.0 Emergency Portable Lighting Fixtures13.0 Lighting Poles14.0 Ceiling fans and Regulators15.0 Lighting wires16.0 Painting of shop made items17.0 Tests and Test reports18.0 Lighting system installation works19.0 System description

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VOLUME-IIA

SECTION 5.4: LIGHTING SYSTEM

1.0 LIGHTING SYSTEM:

1.1 General:

1.2 The scope of work comprises of design, engineering , Supply installation, testing &commissioning of various lighting fixtures complete with lamps, supports & accessories, ceiling fans complete with regulators and accessories, lighting poles complete with distribution boxes, galvanized rigid steel conduits, lighting wires, G.I Earth wire , receptacles, switchboards, switches, junction boxes , pull out boxes complete with accessories both in control room & outdoor yard. The bidder has to quote for ceiling quantities for various type of luminaries based on the area and level of illumination required payment will be made for the ceiling quantity vis-a-vis the actual quantity vis-à-vis at after the detailed Engineering, whichever is less.

1.3 The minimum lux levels to be maintained in the different areas shall be as per following

Sl No Area Average level Remark1 Control room 350 At floor level2 PLCC Room 300 At floor level3 LT Room 150 At floor level4 Battery Room 1005 Corridor & Landing 1506 DG Set Room 150 At floor level7 Tool Room 150 At floor level8 Toilet 50 At floor level9 Switchyard layout 50 50 lux on main equipments ( power

Tr., capacitor banks , isolators, circuit breakers, CT, CVT, VTs, surge Arrestors etc) at first level ( equipment connection level), 20 lux on balance areas of switchyard ground level.

10 Street / road At ground level

Bidder shall submit detailed calculation for reaching the above LUX levels. The contractor shall confirm the lux levels at different locations by measurement after execution of work . ( 2 locations in 220 KV / 110 KV/66KV switchyard & one in each of above place).

1.4 Scope of Work:

The equipment to be furnished & erected as covered in this volumeshall be designed, engineered, manufactured , type tested ,supplied received at site, unloaded , stored & erected , tested &commissioned as per requirement specified here under.

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1.6 Supply, Storage & Installation of :

i) Lighting fixtures complete with lamps & accessories.ii) Receptacles & switchboardsiii) Galvanized iron conduits for lighting system wiring &

fixture supports, complete with all accessories including junction boxes & pull out boxes & associated civil works.iv) Lighting cables & wires for wiring of all lighting fixtures, ceiling fan points,

receptacles etc, from lighting panels/ switch boards.v) Lighting poles including associated civil works.vi) Earth wires / rods / falls for all lighting fixtures, ceiling fan points, receptacles & GI conduit installation.vii) Battery operated portable the fluorescent lamps & fixtures.viii) 1400 mm sweep A.C.230 volts ceiling fan.

1. 7 Supply of aluminum ladders for the maintenance of lighting system.

1.8 The following specific areas are included in the scope of lighting.

i) 220K'V / 1 10KV/& 66KV switchyard Area.ii) Switchyard Control Room building.iii) DG Set room.iv) Street lighting inside substation premisesv) Any other area like 11KV switchyard, approach road etc

intimated to vendor during detail engineering.

1.9 The detailed drawing showing the lighting layout of these areas shall be prepared by the bidder & submitted for approval. The above layout drawings will include disposition & location of lighting fixtures, receptacles, switchboards, ceiling fan points etc-, The conduit layout for substation buildings, cable schedule for sub-station yard etc., for wiring of these

equipment shall also be prepared by the contractor & shall be submitted for approval

1.10 Associated minor civil works like fixing of anchor bolts, breaking of floors/walls for fixing conduits / pipes / earth conductors. Sealing of floor / wall openings after conduits, pipes, earth conductors have been put shall be carried out by the contractor. Further, Civil works associated with erection of lighting poles. Lighting panels etc, are also 'included in the scope of the contractor. Hardware's, in addition to conduit required, for fixing arrangement for various lighting fixtures are also included in the contractor's scope.1.11 The supply & erection of double compression glands & lugs required for termination of cables in receptacles & junction boxes, lighting , panels, sub-lighting panels, street lighting, junction boxes & any other area are in

contractor's scope.1.12 Power cables shall be laid through the available cable trenches to the maximum extent possible. Whether cable trench is not available, the cable shall be laid buried under ground. The contractor shall quote the unit price of cable laying & termination in the RCC trench & buried cable trench separately.1.13 Each cable & conduit run shall be tagged With number that appears in the cable & conduit schedules. Cables & Conduits shall be tagged at their entrance and/or exit from any piece from any piece of equipment, junction or pull box floor opening etc.,1.14 The tag shall be made-up of aluminum with the number punched on it & securely attacked to the cable by not less than two turns of G.l. wire. cable tags shall be rectangular in shape for power cables & circular shape for control cables.

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1.15 Location of cables laid directly under ground shall be indicated clearly by cable maker made of galvanized iron plate embedded in concrete block.1.16 The location of under ground cable joints if any, shall be indicated clearly with cable marker with an additional inscription "Cable joint.1.17 The marker, which is a concrete block, shall project 150mm. above ground & shall be spaced at an interval of 30 meters & at every change of direction . It shall also be located on both sides of the road or drain

crossing.1.18 The contractor shall furnish & install all tags & markers stated above. The rates for supply & erection of these tags & markers have to be included in the erection rates quoted for cable laying & termination.1.19 Any material, wire, conduits, accessories etc., not specially mentioned or specified but required for Installation of lighting fixtures are included in the scope of contractor.1.20 The successful bidder shall furnish a computer print out for illumination levels at intervals of every 10 metres in the sub-stations area and also within the buildings. .also after the installations the illumination at various points of switchyard will have to cheeked by suitable instrument for the illumination levels as per specifications.

2.0 SCHEDULE OF QUANTITIES:

The contractor shall supply & install the following equipment accessories in accordance with the specification.

2.1 VOID

2.2 VOID

2.3 LIGHTING FIXTURES & RECEPTACLES:

The fighting fixtures shall be of standard make only. The typical types are indicated infra. Sub item Type Description

FC

2 x 36 W fluorescent lamp in corrosion proof fixture consisting of a canopy made of fibre glass reinforced polyester (FRP) with gasket a gear tray made of sheet steel & a reeded acrylic cover fixed by toggle clips, similar to Philips Cat. No. TDC-10/240/bajaj Cat No.BJI-240 FG/Crompton Greaves.

SC

150 W SON-T Tubular Sodium – Vapour lamp in street lighting luminary. A special optical reflector clear acrylic cover, a single piece die cast aluminum housing made out of LM6 & corrosion resistance proof similar to Philips Cat No. SRP-51 & bajaj Cat No. BJMSC/150/Crompton Greaves.

F12 x 36W fluorescent lamps in industrial reflector type fixture, complete with accessories & suitable for pendent Mounting, similar to Philips Cat TKC 24/240 Bajaj cat No. BJIV – 240/ Crompton Greaves.

IF100W incandescent GLSD lamp in recessed black/anodized bowl, reflector with provisions fro lamp replacement from bottom, similar, to Philips Cat. No. BJDR-100/Crompton Greaves.

SF2 2 x 250 W, HP Sodium vapour lamps in high Flood lighting fixture suitable for outdoor mounting with aluminum enclosure: similar to Philiphs Cat. No. SNT001/Bajaj Cat. No. BJEF-22CA/Crompton

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Greaves.

SF1

Weather Proof integral Floor lighting with housing made of corrosion resistant die cast aluminum painted black. Grey powder coated outside suitable for 150 W SON-T lamp for termination with conduits/flexible Cat. No. SNT 100/Bajaj Cat No.BGEMF-150W/Crompton Greaves.

PF

1x11 CFL lamp emergency light with battery operated portable fixture with build in battery & battery charger suitable for a lighting period to six hours similar to alpha Deluxe of M/s.DELTA FLASH LITE/MICRO LITE of M/s. MICRO.

IB

9W CFL lamp in bulkhead fixtures with cast Aluminum alloy body, suitable for column, wall & ceiling mounting finished stove enameled silver gray outside white inside, to be supplied complete (priest, front glass, wire guard, tropicalised, gasket & E.S. Procelain, lamp holder taped ¾ E.T. for conduit entry) similar to Philips Cat.No. FXC 101/Bajaj Cat. No. BJBE-19/Crompton Greaves.

FF

2x36 fluorescent lamp with mirror optics in recseed mounting type decorative fluorescent fitting consisting of whit stove enameled sheet steel housing with accessories & reflector of aluminum sheet steel duty of aluminum sheet duty electro-chemically brightened & iodized fitted with aluminum lamellae white. Similar to Philiphs Cat No. TBS-285/236 & Bajaj Cat. No. 240/Crompton Greaves.

MP

125 W MV Lamp, in weather proof post top latern with case aluminum canopy, mounting piece, opal acrylic cover tripod gasket & all other accessories for mounting on pole top similar to Philips Cat.No. HRC-40/Crompton Greaves.

RECEPTACLES

RO 15 A, 240V, Outdoor Receptacle.RI 5/15A, 240V, Indoor Receptacle.RP 63A, 415V, Interlocked switch

Socket , Outdoor Receptacle.SWITCH BOARDSSWD1 Decorative type switch-board with

Nos.-5A switches & No-5A receptacle.

SWD2 Decorative type switch-board with Nos.-5A switches & No-5A receptacle.

CONDUITS & ACCESSORIESGalvanised Rigid Steel Conduits:

Sub – Item Description19 mm

25 mm

32 mm

40 mm

JUNCTION BOXES

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Sub – Item Description

Qty. in Nos.

Junction Box with 5 Nos.

Of terminal blocks

LIGHTING POLES


Qty. in Nos.

Type A1 poles

Type E1 poles

LIGHTING WIRES


Qty. in Nos.

2.5 Sq. mm Cu

4.0 Sq. mm Al

6.0 Sq. mm Al

10.0 Sq. mm Al

Sub – Item Description Qty in metres

15 SWG GI wire 50x6 thick M.s. Road 20mm Dia M.S. Road.

Ceiling fans (Nos.) 1400 mm Sweep with Electronic regulator

MAINTAINANCE EQUIPMENT (Nos.)

Cart wheel mounted aluminum Ladder vertical height 7.5 mtrs.CABLE LAYING IN RCC CABLE

TRENCHES & TERMINATION (Kms)

415V – 4C x 95 Sqmm. Al. PVC 415V – 2C x 25 Sqmm. Al. PVC 415V – 2C x 6 Sqmm. Al. PVC Armoured cable 415V – 2C x 70 Sqmm. Al. PVC Power cable

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CABLE LAYING IN BURRIED CABLE

TRENCHES & TERMINATION (Kms)

415V – 4C x 70 Sqmm. Al. PVC 415V – 2C x 25 Sqmm. Al. PVC 415V – 2C x 6 Sqmm. Al. PVC Armoured cable 415V – 2C x 70 Sqmm. Al. PVC Power cable

3.0 CODES AND STANDARDS

3. 1 The design, manufacture, performance of equipment shall comply with all currently applicable standards, regulations & safety codes in the locality where the applicable, will be installed. Nothing in this specification shall be constructed to relieve the Bidder of these responsibilities.

3 Unless other-wise specified equipment offered shall confirm to latest applicable Indian & IEC standards. Equipment complying, with any other authoritative standards such as 7-3r-1tish, U.S.A, VDE etc., will also be considered if it ensures performance equivalent be installed. Nothing in this application shall be constructed to relieve the bidder of these responsibilities.

LIGHTING FIXTURES & ACCESSORIES

i) IS: 19 13 General & safety requirements forelectric lighting fittings.

ii) IS:3528 Waterproof electric lighting fittings.

iii) IS:4012 Dust proof electric lighting fittings.

iv) IS:4013 Dust tight proof electric lightingfittings.

v) IS: 10322 Industrial' lighting fittings with metalreflectors.

vi) IS: 10322 Industrial lighting fittings with metalreflectors.

vii) IS:2206 Well glass lighting fittings for use under ground in mines(non-flame prooftype)

viii) IS: 10322 Specification for flood lights.

ix) IS: 10322 Specification for decorative lighting outfits.

x) IS: 10322 Luminaries for street lighting .

xi) IS:2418 Tubular fluorescent lamps.

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xii) IS:9900 High pressure mercury vapour lamps.

xiii) IS: 1258 Specification for Bayonet lampfluorescent lamps.

xjv) IS:3323 Bi-pin lamp holder tubular fluorescentlamps.

xv) IS: 1534 Ballasts for use in fluorescent lighting(Part-1) lamps.

xvi) IS: 1569 Capacitors for use in fluorescentlighting lamps.

xvii) IS:2215 Starters for fluorescent lamps.

xviii) IS:33324 Holders for starters for tubularfluorescent lamps.

xix) IS:418 GLS lamps.

xx) IS:3553 Water tight electric fittings.

xxi) IS:2713 Tubular steel poles.

xxii) IS:280 MS Wire for general engg. Purposes.

3.4 CONDUITS, ACCESSORIES & JUNCTION BOXES

i) IS:9537 Rigid steel conduits for electric wiring

ii) IS:3480 Flexble steel conduits for electricwiring.

iii) IS:2667 Fittings for rigid steel conduits forelectric wiring.

iv) IS:3837 Accessories for rigid steel conduits forelectric wiring

v) IS:4649 Adapters for flexible steel conduits.

vi) IS:5133 Steel & Cast Iron boxes.

vii) IS:2629 Hot dip galvanizing of Iron & Steel.

LIGHTING PANELS:

I) IS:13947 LV Switchgear & Control gear(Part- I to 5)

ii) IS: 8828 CB's for over current protection for of 409

house hold & similar installations.

iii) IS: 5 Ready mix paints

iv) IS:2551 Danger notice plates.

v) IS:2705 Current Transformers.

vi) IS:9224 HRC Catridre fuse links for voltage

vii) IS:5082 Wrought aluminum & Al. Alloys, bars.Rods, tubes & sections for electrical purposes.

viii) IS:8623 Factory built Assemblies of Switchgear & Control gear for

voltages upto, & including 1000V AC & 1200V DC.

ix) IS: 1248 Direct Acting indicating instruments.

CABLES:

IS: 694PVC insulated cables for workingvoltages upto & excluding 1100 volts.

IS: 1293 3 Pin plug.

IS: Two or three ceiling roses.

IS:3854 Switches for domestic & similarpurposes.

IS:5216 Guide for safety procedures & practicesin electrical work.

IS:732 Code of practice for- electrical vdringinstallation (System voltage notexceeding 650v.

IS:3043 Code of practice for earthing

IS:3646 Code of practice of interior alluminumpart 11 & 111.

IS: 1944 Code of practice for lighting of publicthrough fares. ,

IS:5571 Guide for select-ion of electricalequipment for hazardous areas.

IS:800 Code of practice for use of structuralsteel in general building, construction.

IS:2633 Methods of Testing uniformly of coating of 409

on zinc coated articles.

IS:6005 Code of practice for phosphate IronSteel

INDIAN ELECTRICITY ACT.

INDIAN ELECTRICTY RULES.

LIGHTING FIXTURFS & ACCESSORIES.

4.1 General:

All lighting fixtures & accessories shall be designed for continuous operation under atmospheric conditions existing at site, without reduction in the Life or without any deterioration of materials, internal wiring,

4.2 Temperature Rise:

All lighting fixtures & accessories shall be designed to have a lowtemperature rise according to the relevant Indian Standards. The design ambient temperature shall be taken as 50 degree C.

4.3 Supply Voltage

4.3.1 Lighting fixtures & accessories meant for 24OV A.C. operation shall be suitable for operation on 240V A.C. 50 Hz, supply With specified voltage & frequency variation between 168 to 264 volts

4.3.2 Lighting fixtures & accessories meant for 220V D.C. operation shall be suitable for operation on 220V D.C. with variation between 190 to 240 Volts.

4.4 Lighting Fixture

The Lighting fixtures & accessories shall be Phillips or Bajaj or Crompton greaves make only. The different types of lighting fixtures are as indicated at Annexure-I.

4.4.1 All fixtures shall be designed for minimum glare. The finish of the fixtures shall be such that no bright spots are produced either by direct light source or by reflection.

4.4.2 All Lighting fixtures shall be complete with fluorescent tubes/ incandescent lamps/mercury vapour / sodiumvapour lamps as specified & shall be suitably wired up.

4.4.3 All mercury vapour & sodium vapour lamp fixtures shall be complete with accessories like ballasts, ignitrons, power factor improvement capacitors etc., These shall be mounted as far as possible in the fitting assembly only. If these cannot be accommodated inside , then a separate metal enclosed box shall be included to accommodate the accessories in addition with a fuse & terminal block suitable for loop-in , loop-out connections . Outdoor type fixtures shall be provided with outdoor type weather-proof box. The Bidder shall indicate starting time of these lamps to attain full light output. Curves for starting, characteristics with varying supply voltage etc., are to be furnished by the contractor.

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4.4.4 All fluorescent lamps fixture shall be complete with all accessories like ballasts. power factor improvement capacitors, lamps, starters, Holders etc.,

4.4.5 High bay fixtures shall be suitable for pendeng Mounting & the floodlights shall have suitable base Plate / frame for mixing on structural steel member. Hook mounted High bay figures are not acceptable.

4.4.6 Each fixture (other than bull head fixtures) shall have Terminal blocks suitable for 2.5 sq mm stranded copper conductor. The internal wiring should be completed by the manufacture & terminated on the above terminal blocks. Tae bidder shall specifically furnish details of internal size of wires, type of installation including other technical particulars & indigenous availability. In certain cases the fluorescent fixtures, which are located adjacent to each other, shall require adequate terminals to facilitate loop in - loop out connections of 2.5sqmm. Stranded copper conductor The above shall be as curtained by the tendered at the Time of erection. The terminal blocks shall be as specified in clause no. 9 of this section.

4.4.7 Each lighting, fixture shall be provided with an earthing terminal suitable for connection to 16 SWG GI earthing conductors.

4.4-8 All metal or metal enclosed parts of the housing shall be suitably constructed so as to ensure satisfactory earthing continuity throughout the fixture upto the earthing terminal

4.4-9 The mounting facility & conduit knock-outs for the fixtures shall be as specified & shall be suitable for minimum 20-conduit entry.

4.4-10 On completion of manufacture, all surfaces of the fixtures shall be thoroughly cleaned & degreased. The fixtures shall be free from scale, rust, sharp edges & burrs.

4.4-11 All enamel finishing shall have a minimum thickness of 2 mils for outside surface & 1.5 mils for inside surface. The finish shall be non-porous & free from blemishes, blisters & fading,

4.4.12 The housing shall be stove -enameled or vitreous enameled or anodized aluminum as indicated in the specification of the relevant fixture.

4.4.13 The surface shall be scratch resistant & shall show no sign to cracking or flaking when bent through 90 degree. Over 1/2 inch diameter mandrel.

4.4 14 the light reflecting surfaces shall have optimum light reflecting, co-efficient such as to ensure the overall light output as specified by the manufacturer.

4.4.15 The diffusing levels used in the fluorescent fixtures specified (as applicable) shall be made of height compact.. Polystyrene sheet & shall have no yellowing property over prolonged use.

4.4.16 For certain areas the fixtures offered shall be suitable for provision of vibration dampers, if required during installation to enable the lamps to perform the full lamp life. Bidder shall indicate the cost of such dampers separately.

4.4.17 The different types of lighting, fixtures required are as indicated in clause 2 above.

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4.4.18 Accessories

4.5.1 Reflectors

The reflectors shall be manufactured from sheet steelaluminum as applicable of not less than 22 SWGthickness. They shall be securely fixed to the captivetype.

4.5.2 Lamp holders & starter holders

4.5.3 a) Lamp holders &starter holders for florescent tubes shall be of the spring loaded, low contact resistance, begin rotor type, resistant to wear & suitable for operation at the specified temperature, I out deterioration in with insulation value, contact resistance or retention of the lamp/starter. They shall hold the lamp/starter in position under normal shock & variation.

(b) Lamp holders /starter for incandescent lamps &HPMV/HPSV lamps shall be of screwed, manufactured in accordance with relevant standard &designed to give long & satisfactory service.

4.5.4 BALLASTS:

a) The Ballasts shall be designed, manufactured &supplied in accordance with relevant standard &function satisfactorily under site condition specified.The ballasts shall be designed to have a long service life& low power loss.

b) Ballasts shall be mounted using self-locating anti-vibration during & shall be easy to remove withoutdismantling the fixtures. They shall be totally enclosedunits.

c) The Ballasts shall be of the inductive, heavy dutyfilled the thermosetting insulating moisture polyester compound filled under pressure or vacuumingThe ballast wiring shall be of copper wire. They shall befree from hum. Ballasts which produce humming soundshall be replaced free of cost by the contractor -Ballasts for high pressure mercury vapour/HAPSVlamps shall be provided with suitable to set thevoltage within the range specified End connections &taps shall be brought out in a suitable terminal block,rigidly fixed to the ballast enclosure.

d) Separate ballast for each lamp shall be provided in caseof multi-lamp fixtures.

e) The successful Bidder has to submit G.A. & wiringdiagram with all terminal details for owner's approval.

4.5.4 Starter:

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Starters shall have bimetal electrodes & high mechanical strength. Starters shall be replaceable without disturbing the reflector or lamps & without the use of any tool. Starters shall have brass contacts & radio interference suppressing capacitor.

4.5.5 CAPACITORS:

a) The capacitors shall have a constant value of capacitance & shall be connected across the supply of individual lamp circuits.

b) The capacitors shall be suitable for operations at supplyvoltage as specified & shall have of capacitance so as tocorrect the power factors of its corresponding lampcircuit to the extent of 0.98 lag.

c) The capacitors shall be hermetically, sealed in a metalenclosure.

4.6 Lamps:

4.6.1 General Lighting Services (GLS) lamps shall be providedwith screwed caps shall be of 'clear' type unlessotherwise specified.

4.6.2 The fluorescent lamps MDS shall be 'Day-light-colour' typeunless otherwise specified & shall also be provided, features to avoid blackening of lamp ends. The biddershould clearly state these, features in the bid.

4.6.3 Mercury vapour lamps, sodium vapour lamps shall becolour corrected type, with screwed caps.

4.6.4 The lamps shall be suitable for use in any position.Restrictions, if any, shall be clearly stated in the bid.

4.6.5 The lamps shall be capable of withstanding smallvibrations & the connections at lead-in-wires &filaments / electrodes shall not break under suchcircumstances.

4.6.6 The constructional features of gas discharge lamps forspecial applications shall be included in the bid.

4.6.7 The contractor shall supply and install all the abovetype of lamps. The cost of the lamps shall be included inthat of the lighting figures as specified.

4.7 The bidder shall furnish typical wiring diagram forfluorescent. HPMV HPSV fitting including allaccessories. The diagram shall include technical detailsof accessories the, starters , chokes, capacitors etc.,

4.8 Flexible conduits if required, for any fixture shall be of 409

deemed to be included in the contractor's scope.

5.0 RECEPTACLES

a) All receptacles shall be of cost steel/aluminum, heavyduty type, suitable for fixing on wall/column & completewith individual switch.

b) In general the receptacles to be installed are of thefollowing types

i) TYPE RO- 15A, 240V, 2 pole, 3 pin type with third pingrounded, metal clad with gasket having cable glandentry suitable for m2C x 6 sq mm. PVC armored cable &a metallic cover tied to it with a metallic chain &suitable for installation in most location indoor/outdoor. The switch

shall be of rotary type. Receptacles shall be housed in an enclosure made out of 2mm thick G1 -sheet with hinged door quality padlocking arrangements. Door shall be lined with good quality gasketing and shall conform to IP-55.

ii) Type RI - Combination of 5A & 15 A, 240V, 3 pin type with third pin grounded, suitable for flush mounting. The switch shall be

of piano key type & shall be flush mounted.

iii) Type RP-63A, 415%!, 3 phase, 4 pin interlocked plug &switch with contacts. Other requirements shallbe same as The receptacle shall be suitable for3.5Cx.25/3.5x70sqmm. Aluminum conductor cablesentry & shall also be suitable for loop-in & loop-outconnection of cables’ of identical size. Receptacle shallbe suitable for outdoor application. Receptacles shall behoused in a box made out of 2mrn thick G.I.sheet, withhinged door with radio arrangement. Door shall belined with good quality casketing . They shall conformto IP-55.

6.0 SWITCH & SWITCH BOARDS

a) All switch boards/boxes~ shall be of bent steel construction, fabrication of 16 SWG sheet with 6mm thick Bakelite or 3mm thick Perspex sheet cover.

b) Switch board/boxes located M* office building areas shall be flush mounted type or brick wall with only the switch knob projecting outside.

c) Switch board/boxes shall have conduit knock outs on all the sides. Adequate provision shall be made for ventilation of these boxes.

d) Flush type receptacles provided shall be so located that only the plug project outside.

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e) Switches shall be of piano key type having quick make & quick-break mechanism complete with position indicator & shall conform to relevant standard.

f) Regulator for fans wherever present shall be mountedon a separate board.

g) All the components housed in the switchboard shall be used to an outgoing terminal block by 2.5sqmm. Stranded copper wire (as specified in clause 15 of this section). The terminal block shall be of adequately rated & shall be as specified in Clause No. 9 of this section,

suitable for termination of sizes up to 2 nos. 10mm stranded Aluminum conductor:- on the outgoing side.

h) The exact number of switch of the same in the switchboard shall be to the requirement during installation.

7.0 CONDUITS & CONDUIT ACCESSORIES:

7.1 The contractor shall supply & install] all rigid steel, heavy duty conduits all accessories required like associated couplers, pull out boxes, elbows, tees, reducers, junction boxes, steel wire for cable/wire pulling, GI saddles, screws, bolts, nuts required. The size of conduits to be used shall be as required supply erection of ail accessories excepting GI wire & junction boxes shall be included in unit rates quoted for erection of conduits.

7.2 All conduits shall be seemed by wedding, shall be of heavy gauge & shall be hot dip galvanized.

7.3 The conduits shall conform to IS: 9537. The minimum size of conduit shall be 20mm.

7.4 Each of conduits shall be straight, free from blister & other defects & furnished in standard length of 3.0 Mts. threaded at both ends. The manufacturer's name shall be stamped on each piece.

7.5 Flellble conduits wherever required shall be made with bright, cold rolled annealed & electro-galvanized mild steel strips.

7.6 All conduits accessories shall conform to relevant IS & shall be hot dip galvanized.

8.0 JUNCTION BOXES:

8.1 The contractors shall supply & install the junction boxes.

8.2 The junction boxes shall be suitable for mounting on walls, columns, lighting poles, structures etc., The supply & erection of brackets, bolts, nuts & screws required for the erection shall be included in the installation rates.

8.3 Junction boxes shall be of square /rectangular type of 1.6mm sheet steel with minimum 6mm thick pressure die cast aluminum material LM-6 & shall have bolted cover with good quality gasket lining ..Bidder shall quick separate price for both types of junction boxes.

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8.4 The junction box & cover shall be hot dip galvanic.

8.5 The junction boxes shall be complete with conduit knockouts/ thread nuts & provided with terminal strips which shall be as specified under clause No. 9 of this section. The junction boxes shall be suitable for termination of conduit/glands of dia. 20mm, 25mm, 32mm, and 40mm on all sides. The junction boxes shall be provided with 4 way terminals suitable for two numbers 10 sq.mm. wire and for street Earthing / switchyard lighting suitable for 2 No. 4Cx16 sq mm Aluminum cable.

8.6 The junction boxes shall have the following indelible markings.

I) Circuit Nos. on the top.

ii) Circuit Nos. with ferrules (inside) as per drawings.

iii) DANGER sign in case of 415 volt junction box

8.7 The junction boxes shall be weather proof type with gaskets conforming to IP-55 as per IS:13947 (Part-!). The conduit connections shall also be properly, scaled to prevent entry of water.

9.1 Multi way terminal blocks shall be ESSEN/Tosha make, complete with screws, nuts, washers & marking strips. Terminals shall be stud types.

9.2 Each terminal shall be suitable for terminating up to 2 Nos. 10 sq. mm stranded Aluminum conductors without any damage to the conductors or any looseness of connections. Terminal strips provided in street-lighting poles shall be suitable for terminating up to 2 Nos. 4C x 16 sq mm aluminum cables.

10.0 PULL OUT BOXES

10.1 The contractor shall supply & install the pull out boxes.

10.2 The pull out boxes shall be suitable for mounting on walls, column, structures etc. The supply of bolts, nuts screws required for the erection shall be included in the installation.

10.3 The pull out boxes shall be circular of cast n or 16 SWG sheet steel & shall have cover with good gasket lining.

10.4 The pull out boxes & cover shall be galvanized.

10.5 The pull out boxes shall be completed with conduit knock outs/threaded hubs & provided at approximately 3 meters intervals in a conduit run.

10.6 The pull out boxes used outdoors shall be weather proof type with gaskets conforming to IP-55 as per IS:13947(part-l).

10.7 Bidder shall include the cost of pull out boxes in the installation rates of conduits.

11.0 VOID.

12.0 EMERGENCY PORTABLE LIGHTING FIXTURES of 409

12.1 The contractor shall supply, store & install Emergency Lighting Fixtures.

12-2 The portable fixtures shall have a built in battery rated for hours, battery chargers & solid inverters. These shall be of approved make.

12.3 The portable fixtures shall be of a single unit, completely tropicalised & suitable for prolonged use with no maintenance.

12.4 The portable fixtures shall be supplied & necessary-supporting brackets of galvanized steel suitable forwall/column mounting shall also be supplied.

12.5 The portable fixture shall come-up automatically in the event of failure of normal supply.

12.6 The contractor shall submit schematic along with all details & GA drawing for owner’s approval.

13.0 LIGHTING POLES

13.1 The contractor shall supply, store & install the following types of steel tubular lighting poles required for street lighting,

a) Type Al Street Lighting Pole - for one fixture.

b) Type El Post top lantern Pole - for one fixture.

13.2 Street/ flood light poles shall conform to the drawings. The complete civil works for erection of the lighting poles shall be 'included in the scope of work.

13.3 Lighting poles shall be complete with fixing brackets & junction boxes. Junction boxes should be mounted one meter above ground level.

13.4 The lighting poles shall be coated with preservation paint on the inside as well as on the embedded outside surface. Exposed outside surface shall be coated with coats of metal primer (comprising) of red oxide & zinc chromate in a synthetic medium).

13.5 The galvanized sheet steel junction box for street lighting poles shall be completely weather proof conforming to IP-55 & provided with a lockable door &HRC fuse mounted on a fuse carrier & fuse base assembly. The junction box shall be as specified at Clause No. 8, however, terminals shall be stud typesuitable for 6 Nos. 16sqmm cable.

13.6 Distance of center of pole from street edged should be approximately 1000 to 1200 mm.

13.7 Earthing of poles should be connected to the switchyards and main earth mat wherever it is available & the same should be earthed though 3M long, 20mm diameter, earth electrode.

14.0 CEILING FANS AND REGULATORS.

14.1 The contractor shall supply & install 1400m sweep ceiling fans complete with electronic regulator & switch, suspension rod, canopy & accessories.

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14.2 The contractor shall supply & install the switch, electronic regulator & board for mounting switch & electronic regulator.

14.3 Winding of the fans & regulators shall be insulated with class-E insulating material. Winding shall be of copper.

14.4 Electronic regulator smooth control shall be provided. Precautions shall be taken in manufacture of fans regulators to ensure reasonable degree of silence at, all speeds.

14.6 Type tests, acceptance tests & routine tests for the fans & regulators shall be carried out as per latest relevant standard.

14.7 Fans & electronic regulators shal.1 be of Compton Greaves /Bajaj Electrical /Usher Electrical make.

15.0 LIGHTING WIRES

15. 1 The wiring used for lighting shall be standard products of reputed manufacturers.

15.2 The wires shall be of 1100V grade, PVC insulated product of reputed manufacturers.

15.3 The conductor sizes for wires used for beyond lighting panels shall be single core 4sqmm, 6 sqmm & 10 sq. stranded aluminum wires & 2.5 sqmm,4 sq.mm, 6 sq.mm & 1.5 sq. mm stranded copper-wire.

15.4 The. wires used for connection of a lighting fixture from a nearest junction box or for loop-in loop-out connection between two fluorescent fixtures shall be single core copper stranded conductor, I 100V grade flexible PVC insulated cords, unsheathed, conforming to IS: 694 with nominal conductor cross sectional areas of 2.5 sq. mm.

15.5 The contractor's scope covers the supply & installation of the above wires.

15.6 The wires shall. be colour coded as follows:

Red for R-PhaseYellow for Y-PhaseBlue for B-PhaseBlack for NeutralWhite for DC (Positive)Grey for (Negative)

16.0 PAINTING OF SHOP MADE ITEMS:

16.1 All sheet steel work shall be phosphated in accordance with the following procedure & steel mi accordance with IS:6005 'Code of practice for phosphate Iron & Steel.

16.2 Oil grease & dirt. shall be thoroughly removed by emulsion cleaning.

16.3 Rust & scale shall be removed by pickling with dilute acid followed by washing with water, rinsing with slightly alkaline hot water & drying.

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16.4 After phosphate thorough rinsing shall be carried out with clean water, followed by final rinsing with diluted dichromate solution & oven drying.

16.5 The phosphate coating shall be sealed by the application of two coats of ready mixed stoving type metal primer (comprising of red oxide & zinc chromatein a synthetic medium). The first coat may be flash dried 'while the second coat shall be staved.

16.6 After application of the primer, two coats . of finishing synthetic enamel paint shall be applied with each coat followed by stoving. The second finishing coat for external of panels shall be applied after completion of tests.

16.7 Both outside & inside of lighting panel, sheet metal fabricated junction boxes etc., & outside of lighting fixtures shall be finished in light Grey (IS-5 shade 631). Inside of lighting fixtures shall be finished in white.

16.8 Each coat of primer & finishing paint shall be of slightly different shade so as to enable inspection of the painting.

16.9 The final finished thickness of paint film on steel shall not be less than 100 microns & shall not be more than 150 microns.

16.10 Finished painted appearance on equipment shall not be present on aesthetically pleasing appearance, free dents, & uneven surfaces.

17.0 TESTS AND TEST REPORTS

17.1 Type tests, acceptance tests & routine test for the lighting fixtures & accessories covered by the specification shall be carried out as per the relevantstandard for the respective fixtures & their accessories.

17.2 Manufacturer's type and & routine test certificates shall be submitted for the fixtures & accessories. The type test certificates shall be furnished shall be furnishied along' the bid.

18.0 LIGHTING SYSTEM INSTALLATION WORKS

18.1 General

18.1.1 In accordance with the specified instructions as shown on manufacturer drawings or as directed by owner, Contractor shall unload, erect, install, test & put into commercial use all the electrical equipment included, in the contract. Equipment shall be installed in a neat, workmanship manner so that it is level, plump square & properly aligned & oriented. Tolerances shall be as established in manufacturer drawings or as stipulated by owner.

18.1.2 Contractor shall furnish all supervision, labor, tools, equipment's, rigging materials & incidental materials such as bolts, wedges, anchors, concrete inserts etc., required to complete the 'installation test & adjust the equipment.

18.1.3 Manufacturer's drawings, instructions & recommendations shall be correctly followed in handling, setting, testing & commissioning of allequipment & care shall be exercised in handling to avoid distortion to structures, the marring of finish or damaging of delicate instruments or other electrical

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parts. Adjustment shall be made as necessary to the stationary structures for plumb & level for the sake of appearances or to avoid twisting of frames, bending of hinged members etc.,

18.1-4 All apparatus, connections -& cabling shall be designed so as to minimize risk of fire or any damage, which will be caused in the event of fire.

18.2 CONDUIT SYSTEM

18.2.1 Contractor shall supply, store & install conduits required for the lighting installation as specified. All accessories/ fittings required for making, thecomplete, 'including but not limited tom pull out boxes (as specified in Clause No.. 10) ordinary & tees & elbow, checkouts, male & female bushings (brassor galvanized steel), caps square headed make plugs, nipples, gland sealing fittings, pull boxes, conduits terminal boxes, glands, gaskets & box covers, saddle terminal boxes, & all steel supporting work shall be supplied by the contractor. The conduit fittings shall be of same maternal as conduits.

18.2.2 All un-armoured cables shall run within the conduits from lighting panels to lighting fix wires, receptacles. Etc.,

18.2.3 Size of conduit shall be selected as required.

18.2.4 Exposed conduits shall be run in straight lines parallel to building columns, beams & walls. Unnecessary-y bends crossings shall be avoided to present a neat appearance.

18.2.5 Conduit support shall be provided at an interval of 750mm for horizontal runs & 1000 mm for vertical runs.

18.2.6 Conduit supports shall be clamped on the approved type spacer plates or brackets by saddles or U-bolts. The spacer plates or brackets in turn shall be securely fixed to the building steel by welding & to concrete or brickwork by grouting or by nylon raw plugs. Wooden plus, inserted 'in the masonry or concrete for conduit support is not acceptable.

18.2.7 Embedded conduits shall be securely fixed in position to preclude any movement. In fixing embedded conduit, if welding or brazing is used, extreme care should be taken to avoid any injury to the inner surface of the conduit.

18.2.8 Spacing of embedded conduits shall be such as to permit flow of concrete beem them & in no case shall be less than 40mm.

18.2.9 Where conduits are along With cable trays they shall be clamped to supporting steel at an interval of 600 mm.

18.2.10 For directly embedding in soil, the conduits shall be coated with an asphalt base compound. Concrete pier or anchor shall be provided wherever necessary to support the conduit rigidly & to hold it in place.

18.2-11 Conduit shall be installed in. such a way as to insure against trouble from tapped condensation.

18.2.12 Running threads shall be avoided as far as practicable. Where it is unavoidable, check nuts shall be used.

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18-2.13 Conduits shall be kept, - wherever possible, at least 30-Omm away from hot pipes, heating devices etc., when it is evident that such property may reduce the service life of cables

18.2.14 Slip joints shall be provided when conduits cross structural expansion joints or where long run of exposed conduits are 'installed, so that temperature change shall cause no distortion due- to expansion orcontraction of conduit run.

18.2.15 For long conduit run, plug boxes shall be provided at suitable intervals to facilitate ,wiring.

18.2-16 Conduit shall be secure1v fastened to junction boxes or cabinets, each with a lock nut inside & outside the box.

18.2.17 Conduit lengths shall be joined by screwed couplers. Couplers shall be cleanly cut.

18.2.18 Conduit joints &n connections shall be made through watertight & rust proof by application of a thread compound which insulates the joints. White lead is suitable for application on embedded conduit & lead for exposed conduit.

18.2.19 Field bends shall have a minimum radius of four (4) times the conduit diameter shall bends shall be free of kinks, indentations of flattened surfaces. Heat shall not be applied in melding any conduit bend. Separate bendsray be used for this purpose.

18.2.20 The entire metallic conduit system, whether embedded or exposed, shall be electrically continues & thoroughly grounded. Where slip joints are used, suitable bounding shall be provided around the joint to ensure a continues,ground circuit.

18-2.21 Conduits & fittings shall be properly protected during construction period against mechanical injury. Conduit ends shall be plugged or capped to prevent entry of fore material.

18.2-22 After installation, the conduits shall be thoroughly cleaned by compressed air before pulling, in the Wire.

18.2-23 Lighting fixtures shall not be suspended directly from the junction box in the main conduit run.

18.3 WIRING:

18.3.1 Wiring shall be generally carried out by PVC wires in conduits. All wires in a conduit shall be drawn simultaneously. No subsequent drawing of wires ispermissible.

18.3.2 Wires shall not be pulled through more than two equivalent 90-degree bends in a single conduit run. Where required, suitable junction boxes shall be used.

18.3.3 Wiring shall be spliced only at junction boxes with approved type terminal strip.

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18.3.4 For lighting fixtures, connection shall be teed off through suitable round conduit or junction box, so that the connection can be attended without tiling down the fixture.

18.3.5 For vertical run of wires in conduit, wires shall be suitably supported by means of wooded/hard rubber plugs at each pull/junction box.

18.3.6 Maximum two wires can be terminated to each way of terminal connections.

18.3.7 Separate neutral wires are to be provided for each circuit.

18.3.8 AC & DC wires should not run through the same conduit.

18.4 LIGHTING FIXTURES & RECEPTACLES:

18.4. 1 Continuous rows of fluorescent tubes shall be mounted on a continuous MS channel for each row of lights.

18.4.2 Floodlights shall be mounted on steel base facing the tentative direction shown on drawings. Fixing hole shall be provided with slot to turn the fixture by about 5 degree on both sides. Bolts shall be finally tightened with spring washer. The contractor shall supply & install the steel base, channels, angles etc., for the floodlights on the flood light towers. Terminal connection to the floodlight shall be through flexible conduits, & these flexible conduits shall be quoted along. with the fixture itself.

18.4.3 The installation rate of lighting fixtures shall include the supply of necessary brackets except GI conduits for pendant mounted f=res.

18.4.4 The drawings showing the mounting details of each fixture shall be flushed to the owner & necessary, approval to be obtained prior to installation.

18.4.5 The receptacles shall be installed in the locations shown in the drawing.

18.5 LIGHTING PANELS VOID

18.5.1 VOID

18.5.2 VOID

18.6 STREET LIGHTING / FLOOD LIGHTING POSTS

18.6.1 Street lighting / flood lighting posts shall be installed at a distance not more than 30 meter. In front of control room & other buildings decorative post lantern (Type El) poles shall be installed.

18.6-2 The steel tubular poles which are specified for the above purpose to be pained with two coats of aluminum paints after completion of installation. Contractor shall erect the poles ('including foundation works), mount theassembled fittings & install necessary cabling.

18.7 JUNCTION BOXES

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18.7.1 Junction boxes having volume less than 1600 cc shall be installed without any support other than that resulting from connecting conduits where two or morerigid metallic conduits enter & accuracy position in box.

18.7.2 Junction boxes with volume equal or greater than 1600 cc & small boxes terminating, on less Than two rigid metallic conduits or other reasons not rill-.Idly held shall be adequately supported by auxiliary steel of standard steel shapes or plates to be fabricated & installed.

18.7.3 Necessary holes for conduit / cable entry shall be made during installation depending on the requirement. The holes shall be drilled / punched neatly & shall be dust vermin proof after 'installation of the conduit.

18.7.4 The welds bolt holes, conduit entry holes etc., made during installation as mentioned above shall be wire brushed & touched up with metal primer specifiedunder clause No. 16 of this section.

18.8 FOUNDATION & CIVIL WORKS:

18.8.1 Foundation for street lighting poles / Flood lighting, poles & panel foundation & transformer shall be done by the contractor. The rates for these civil works shall be included 'in the erection rates of respective items.

18.8.2 The contractor shall check these foundation before commencement of erection to ensure their suitability.

18.8.3 All final adjustment of foundation levels, chipping & dressing of foundation surfaces, setting & grouting of anchor bolts, sills, inserts & fastening devices shall be carried out by the contractor including minor modification of civil works as may be required for erection.

18.8.4 Any cutting of masonry / concrete work, which is necessary shall be done by the contractor at his own cost & shall be made good to match the original work. The contractor shall obtain approval of the site Engineer before proceeding with any cutting of masonry concrete work.

18.9 EXCAVATION & BACKFILLING

18.9. 1The contractor shall perform all excavation & backfilling as required for ground connections and for foundations for street lighting poles, panels & transformers.

18.9.2 Excavation shall be performed up to the required depth. Such sheeting & shoring shall be done as may be necessary for protection of the work.

18-9.3 The contractor shall make his own arrangements for pumping out any water that may be accumulated in the excavation.

18.10 STEEL FABRICATION:

18.10.1 The steel structures fabricated by the contractor shall be cleaned of rust etc. All fabrications shall be free of sharp edges.

18.10.2 All steel fabrications shall be painted with two coats of metal primer (comprising of red oxide & zinc chromate in a synthetic medium) followed by two coats of aluminum paint.

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18.11 TESTING & COMMISSIONING

18.11-1 On completion of erection work, the contractor shall request the owner, for Inspection &.test with minimum of fourteen- (14) days advance notice.

18.11.2 The owner shall arrange for joint inspection of the installation for completeness & correctness of the work. Any defect pointed out during such inspection shall be promptly by the contractor.

18.11.3 The installation shall be then tested & commissioned in presence of the engineer.

18.11.4 The contractor shall provide all men, materiel & equipment required to carry out the tests.

18.11.5 All rectification's, repairs or adjustment work found necessary inspection, testing & commissioning, shall be carried out by the contractor, without any extra cost.

19.0 SYSTEM DESCRIPTION:

The lighting shall comprise of the following:

19.1 AC NORMAL LIGHTING:

AC lights will be connected to AC lighting panels. All the lights connected to AC lighting system in different areas woo be connected to the main lighting distribution boards.

19.2 AC EMERGENCY LIGHTING (only for 220KV stations)

This system will be available in control room building, switchyard & D. G. Building AC lighting load will be connected to this system which will be normally 'ON'.The lighting panels of this system will be connected to the Emergency lighting board, which is fed from diesel generator during the emergency.

19.3 D.C.EMERGECY LIGHTING:

A few DC emergency lighting fixtures operated in the DC system will be provided in the strategic locations so that the operating; personal can safely find their way even during emergency of a total AC failure. These lights will be normally 'OFF& -,will be switched 'ON' automatically in 220K-V stations when under-voltage occurs in the AC main lighting distribution board. in 1 10K-V stations the DC emergency lighting will be switched on manually.

19.4 PORTABLE FIXTURES:

At other places, at off sites, like pump houses for extra areas, where it is not possible to have DC system, portable incandescent fixtures will be provided. These -fixtures will be provided at important locations in the above mentionedareas.

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SECTION-5.6


LT TRANSFORMER

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VOLUME - II


Section 5.6 - LT Transformer


1.0 Technical Requirements

2.0 Scope

3.0 General Information

4.0 Technical Requirements

5.0 Inspection and Testing

6.0 inspection

7.0 Factor Test

8.0 Fittings

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9.0 Spare Parts

10.0 Technical Parameter

1.0 This specification is intended to cover outdoor type oil filled11/0.433KV, 250KVA/100KVA transformers, 2x250KVAtransformers are intended to be used in 220 KV stations &1x100KVA Transformer is intended to be used 'in 110 KVstations.

1.1 Technical Requirements:

1.1.1 Qualifying requirements:

Please refer volume-1, Section - IFB, Clause 11.0

2.0 Scope of work:

2.1 Scope of Supply:

Transformers as listed above, with insulating oil, allmaterials & accessories, & complete in all respects.Gland plates, power cable, lugs, anchor bolts & hardware’s.Mediator & optional spares & special maintenance

2.2 Scope of Service:

The scope includes but is not limited to the following items ofwork to be performed for all equipment & materials furnishedunder this section:

a) manufacturing, shops testing, packingdispatch.

b) Transportation inclusive of insurance & delivery, for sitebasis.

c) Unloading, handling, storming, transportation at site up tofoundations, oil filling & treatment, erection, testing &commissioning.

d) Civil Works.e) Supply of external cables &, termination as required.

3.0 General information of 409

3.1 Bidders may specifying. note that owner propose to insist onshort circuit test as per Clause No.16.11 of IS:2026 (Part-1) 1977 & dielectric test as per IS:2026 The type test certificatefor the Similar equipment not older than 5 years as on Bidopening date shall be furnished, otherwise owner insistsconducting type test at the cost of contractor.

4.0 TECHNICAL REQUIREMENTS:

4.1 CORE:

The core shall be constructed from high grade, non-aging, coldrolled grain oriented silicon steel laminations. The maximumflux density in any part of the cores & yoke at normal voltage& frequency shall be such that the flux density at any tapposition with 10 % -voltage variation from the voltagecorresponding to the tap shall not exceed 1.9 wb/sq-m.

4.2 Windings:

The conductor shall be electrolytic copper, free from scalesand burrs.

4.3 Insulating oil:

The oil supplied with transformer shall be unused & have theparameters for unused new oil conforming to IS:3335 whiletested at oil contractor's premises, No inhibitor's shall be usedin oil. 10% extra oil shall be supplied for tapping up aftercommissioning, in non-returnable containers suitable for

outdoor storage.

4.4 Terminal Arrangement:

a) Bushing terminals shall be provided with suitable terminalconnectors of approved type &, size for cable/overheadconductors termination of HV side & cable termination on LVside.

b) The neutral terminals of 433V winding shall be brought out ona bushing along with the 433V volt phase terminals to form a4-wire system for the 433V. Additional neutral bushing shallalso be provided for earthing.

c) The type test certificate for the similar equipment not otherthan 5 years as on Bid opening date shall be furnished,otherwise owner insist conduct nor more rest on the cost ofcontractor.

4.5 Off Circuit Tap Changing Equipment:

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The tap change switch shall be three phase, hand operated forsimultaneous switching of similar taps on the three phases byoperating an external hand wheel. There shall be 5 taps withstep voltage of 2.5% of 11 KV with tap range of + 5 %. to -5%.

4.6 Marshalling Box:A metal enclosed, whet-her, vermin & dust proof marshallingbox shall be provided with each transformer to accommodatetemperature indicators, terminal blocks etc. It shall have adegree of protection of IP 55 as per IS: 13947.

4.7 Cable boxes :

Whenever cable connections are required, suitable cable boxesshall be provided & shall be air insulated. They shall be ofsufficient size to accommodate cables & shall have removableside/top cover to facilitate cable termination & inspection.Cable boxes shall be dust & vermin proof.

5.0 Inspection & Testing:

The contractor shall- draw up & carry out a comprehensiveinspection & testing program during manufacture &commissioning of the transformer. The programme shall beduly approved by the owner.

6.0 Inspection:

6.1 Tank & Accessories:

a) Physical dimensional check of transformer tank &accessories.

b) Crack- detection of major strength weld seams by dyepenetration test.

6.2 Core:

a) Physical inspection & check of quality of varnish, if used.

b) Sample testing of core material for checking specific loss,bend properties, magnetization, characteristics thickness.

c) Check on completed core measurement of iron losscheck for any hot spot by exciting the core so as toinclude the designed value of flux density in the core.

d) HV Test

6.3 Insulating Material:

a) Sample checks for physical properties of the material of 409

b) Check for dielectric strength

c) Check for the reaction of hot oil on insulating material.

6.4 Winding:

a) Sampling checks on winding conductor for mechanicalproperties & electrical conductivity & on insulationcovering.

b) Sample check on 'insulation paper for pH value, burstingstrength, Electric strength.

6.5 Assembled Transformer:

Check complete transformer against approved outline drawingprovision for all fittings, finish etc.,

6.6 Oil :

All standard tests in accordance with relevant standards shallbe carried out on oil samples taken from the transformerbefore & after testing of the transformer.The contractor shall also prepare a comprehensive inspection& testing programme for all bought out sub-contracted items& shall submit the same to the owner for approval- Suchprogramme shall include the following components:

a) Bushings

b) Marshaling Box

c) Tap changer switch

7.0 Factory test:

7.1 All standard routine tests in accordance with latest issue of IS:2026 shall be carried out on each transformer.

7.2 In addition to all type & routine tests, following special testsshall also be carried out on one transformer of each racing as

per IS: 2026.

a) Test on oil samples.

7.3 All auxiliary equipment shall be tested as per the relevant ISTest Certificates shall be submitted for bought out items.

7.4 High voltage withstand test shall be performed on auxiliaryequipment & wiring after complete assembly. of 409

7.5 Tank Tests:

a) Routine Tests: As per CBIP Manual on Transformers.

b) Type Tests:

I) Vacuum Tests: As per CBIP Manual on Transformers.

ii) Pressure Tests: As per CBIP Manual on Transformers.

7.6 In addition to the above , the following checks should becarried out at manufacturer's works before dispatch for alltransformers :

a) Check for interchangeability of components of similartransformer & for mounting dimensions.

b) Check for proper packing & preservation of accessories likeradiators, bushings explosion vent, dehydrating breather,conservator etc.,

c Check for proper - provision of to arrest themovements of core & windding assembly 'inside the transformer

7.7 The contractor shall submit a detailed inspection & testingprogramme for field activities, covering areas -tight from thereceipt of material stage upto commission 1 stage as per IS:1886 - code of practice for *installation & maintenance oftransformers. The indicative checks & tests are given below

a) Physical checks on each transformer on receipt at site for anydamage or short suppl3,.

b) Tests on oil samples.

c) Oil leakage, test

d) Physical checks for colour of silica in breather.

e) Check for oil level in breather housing, conservator tank, etc.,

f) Check for correct operation of all protections & alarms.

g) Insulation Resistance Measurement for Main Winding, Controlwiring etc.,

h) Continuously observe the transformer operation at no load for24 hours.

8.0 Fittings:

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The following shall be provided with each transformercovered under this specification.

a) Conservator & Radiator with drain plug & oil filling hole withblanking plate.

ii) Plain oil Gauge.

iii) Silicagel Breather

iv) Pressure Relief Vent

v) Pocket on tank cover for Thermometer.

vi) Valves

vii) Earthing Terminals

viii) Rating & Terminal Marking Plates

ix) Lifting., Lugs

x) Rollers

xi) Air Release Plug

The Listed above are only indicative & any other fittingswhich generally are required for satisfactorily operation oftransformer are deemed to be included.

9.0 Spare Parts:

9.1 The list of spares for outdoor type transformers covered underthis section shall be specified in section -l(General)

9.2 In addition, the bidder shall also recommend optional spareparts & maintenance equipment necessary for 3 years ofsuccessful operation of the equipment. The prices of theseshall be indicated in respective schedules & these shall not beconsidered for the purpose of evaluation.

10.j Technical Parameters:

SI.No. Description Parameters

a) Type Two windirigb) Service Outdoorc) Number of phases Threed) Frequencv 150 Hze) Type of cooling ONANf) Rating 250K-VA for 220 KV stationsg) Ratio 11/0.433 kV

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h) Impedance at 750C 0.05 + / -10%. with tolerance

I) DutyOverload As Der IS: 6600

k) maximum temperaturerise over 50deg C ambient

i) Oil (Temperature risemeasurement bythermometer) 50deg C

ii) Winding (Temperaturerise measurement byresistance method) 55deg C

SECTION-5.7


FIRE FIGHTING

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Section 5.7 - Fire Fighting


I. 0 Scope

2.0 standard

3.0 General Technical Requirements

4.0 Material, Design and Workmanship

5.0 Test

6.0 Specifications for Nitrogen InjectionPresentation and Extinguishing Systemfor Transformers

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VOLUME IIASECTION 5.7 - FIRE FIGHTING

TECHNICAL SPECIFICATION FOR FIRE FIGHTINGEQUIPMENTS:

1.0 SCOPE:

1.1 This specification provides for manufacture, inspection and testing before despatch, packing and delivery FOR destination of fire fighting equipments required for 220KV, 110 KV substations.

a) Chemical foam type extinguisher.

1. 45 liters capacity.2. 9.0 liters capacity.

b) Water type (gas pressure extinguisher).

1. 9.0 Liters capacity.

c) C02 Type extinguisher.

1. 6.0 liters capacity.

d) GI Buckers-

1. 9.0 liters capacity.

e) Steel stand for Buckets.

1.2 The fire fighting equipments shall conform in all respects to high standards of engineering, design, workmanship and latest revisions of relevant standards at the time of offer and purchaser shall have the power to reject any work or material, which in his judgment, is not full accordance there with-

1.3 Technical requirements of fire fighting equipments are as furnished in clause No.3.0

2.0 STANDARD:

2.1 The fire fighting equipments to be supplied shall conform to the latest revisions there of the following Indian standards (IS).

IS:933-1976 Portable chemical fire extinguisher foam type

IS:940-1972 Portable chemical fire extinguisher water type(gas pressure)

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IS:2546-1974 Galvanized mild steel fire bucketsIS:2878-1964 Portable chemical fire extinguisher carbon-

dioxide typeIS:5490-1969 Refills for portable fire extinguishers and

chemical fire engines

THE STANDARD MENTIONED ABOVE ARE AVAILABLE FROM:

STANDARD NAME AND ADDRESSIS Bureau of Indian standards, Mank Bhavan,

9 , Bahadur Shah Zafar Marg, New Delhi - 110001.

2.2 Fire fighting equipments offered by the supplier if conform to other standards, salient points of difference between the standards adopted and the specified standard shall clearly be brought out in the offer. Four (4) copies of the reference standards in English language shall be furnished along with the offer. 3.0 GENERAL TECHNICAL REQUIREMENTS:

The portable chemical foam type extinguisher shall conform to IS: 933 - 1976. It shall have capacity of 45.0 liters, 9.0 liters 2.0 liters. The portable chemical &e extinguisher, water type (gas pressure) shall conform to IS: 940-1972, It shall have capacity of 9.0 liters. The portable fire extinguisher, carbon dioxide type shall conform to IS: 2546 -1974. It shall have capacity of 6.0 liters. The steel stand for' hanging buckets shall conform relevant IS standards.

4.0 MATERIAL, DESIGN AND WORKMANSHIP:

4.1 The fire fighting equipments shall be suitable for outdoor use.

4.2 The portable fire extinguishers shall be complete with handle, bracket, trolley (wherever necessary and other connected accessories. The bracket design shall be such that the extinguisher can be easily removed during the fire emergency.

4. 3 Front of the portable fire extinguishers shall be clearly marked with the type of extinguisher capacity contents and method of operation.4.4 In case, of GI buckets, suitable stand hooks shall be provided for keeping 4 Nos. at a place. The buckets shall be secured at a height of 0.9 Mtrs an aboveground level. The buckets shall be enamel painted (RED) with the contents indicated on each bucket.

4.5 Reputed makes of various fire extinguishers shall be offered which is subject to approval of the purchaser. All extinguishers shall be approved by the National standards Institution.

50 TEST:

51 All type tests and routine/ acceptance tests shall be conducted as per relevant IS.

TYPE TESTS:

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5.2 Bid shall contain the type tests certificates, as per relevant IS not older than 5 years in respect of fire fighting equipments from the date of bid opening.

5.3 In case the fire fighting equipments offered, has already been type tested. The bidder shall furnish four sets of type. test report along with the offer. In case these type tests are conducted earlier than five years, all the type tests as per the relevant standards shall be carried out by the successful bidder in the presence of owner's representative at free of cost.

The owner reserves the right to demand repetition of some or all the type tests in the presence of his representative. For this purpose, the bidder may quote unit rates for carrying out each type test. The prices quoted by the bidder towards conductance of the type tests and additional tests shall be taken into consideration for bid evaluation. For any change in the design /type already type tested and the design/ type offered against this specification, the purchaser reserves the right to demand repetition of tests without any extra cost.

TECHNICAL SPECIFICATIONS FOR NITROGEN INJECTION FIRE PREVENTION & EXTINGUISHING SYSTEM FOR TRANSFORMERS.

1. The power transformers shall be supplied with Nitrogen Injection FireProtection System.

2. GENERAL DESCRIBED.

Nitrogen Injection Fire Protection System designed for oil transformers, shall prevent tank explosion and the fire during internal faults resulting in an are where tank explosion will normally take 3-4 seconds after arc generation and also extinguish the external fires on transformer top cover due to tank explosion and / or external failures like bushing fires, OLTC fires and fire from surrounding equipments. it should be fully automatic and shall require minimum maintenance and practically no running cost.

The system shall work on the principle of Drain & stir and on activation,shall drain a pre-determined quantity of oil from the tank top throughoutlet valve to reduce the tank pressure and inject nitrogen gas at highpressure from the lower side of the tank through inlet stirring action and reduce the temperature of top oil surface below flash point to extinguish the fire. Conservator tank oil shall be isolated during tank explosion and oil fire to prevent of fire.

Transformer isolation shall be an essential pre-condition for activating the system. The system shall consist of following equipments.

1 Fire extinguishing cubicle placed on a plinth at about 5-10 metresaway from the transformer.

2. Control box placed in the control room3. Pre-stressed non-return valve in the conservator pipe / high speed

pneumatically operated ball valves. Backup valve may be providedto the main valve, if necessary. These backup valves could beoperated on the same principle or by a different principle as themain valve.

4. Required number of fire detectors on the tank top cover.5. Signal box fitted on the tank top or tank side wall.

Terminating signals from PRV, fire detectors! differential relay.buchcholtz relay, PNRV Pneumatic valve and for cable

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connecting to control box.6. On line testing facility of the

3. OPERATION CONTROLS

The system shall be provided with automatic controls for fire prevention and fire extinction and besides remote electrical push button control on control box and local manual control in the fire extinguishing cubicle shall be provided.

4. SYSTEM ACTIVATING SIGNALS:

(a) To avoid transformer explosion two fast trip signals given by circuit

breaker of transformer and Buchholtz relay paralleled with pressurerelief valve / pressure & temperature sensors to initiate.

I. Explosion prevention by opening quick depressurization valve to release the internal pressure and to prevent the transformer

explosion.

ii. Oil cooling - by injecting a large flow of nitrogen at thetransformer base to limit the damages of overheated partsaffected by short circuit and to evacuate the very explosivehydrogen gas by dielectric oil.

(b) I. The fire protection back up system should be initiated by two signals from one of the high temperature sensors, located on the transformer cover and by the operation of Buchholtz relay paralleled with pressure relief device / pressure & temperature sensors. The drain valve should open out within 3 second. The nitrogen injection shall cause stirring of transformer oil and should immediately drop its surface point to extinguish fire with a minimum possible time. Nitrogen injection should continue for sufficient time, which will further cool the transformer and prevent any recombustion

ii. Fire protection back up system shall be provided to function in case if all transformer electrical protections leading to breaker

trip or if all pressure sensors have failed during the 'incident, bythe conventional nitrogen fire extinguishing method. in case of fire, even if the circuit breaker

has not tripped the system shall inject nitrogen into the transformer tank even when the transformer is live but after giving warning signal to the operating personnel to manually isolate the circuit breaker.

(c) The system shall be of automatic operation and in addition, remotepush button control through control box and manual local control infire extinguishing cubicle are to be provided.

(d) During The initiation / activation of sensing devices mentioned in 4(a) & (b) above, for prevention of tank explosion or for fire protection, the

oil from the conservator tank should be isolated, by action of PNRVPOBV.

5. TECHNICAL PARTICULARS:

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(a) Power supply, for control box 220V DCFire extinguishing cubicle (lighting) 230V AC

(b) Fire Extinguishing Cubicle Dimension Suitable for 31.5MVA and 150MVAWeight / capacity Transformer

(c) Control Box Suitable for 31.5MVA and 150MVAdimensions / weights Transformer

(d) Nitrogen Cylinder Capacity Suitable for 31.5MVA and 150MVATransformer withApproximately 40 to50 Tonnes ofTransformer oil

(e) Fire detectors Heat sensing 141 deg CTemperature

6. DETAILS OF SUPPLY OF SYSTEM EQUIPMENTS AND OTHERRELATED ACTIVITIES

A. SYSTEM EQUIPMENT

1. Fire extinguishing cubicle with base frame and containingNitrogen gas cylinder of sufficient capacity with pressure regulator and manometer with sufficient number of adjustable NO contacts.

-Oil Drain Assembly

-Mechanical release device for oil drain and nitrogen release

-Limit switches for monitoring of the systems

-Panel lighting

Flanges on top of the panel for connecting oil drain and nitrogen injection pipes for transformer

-Oil drain pipe extension of suitable size for connecting pipes to oil pit.

-Limit switch for pressure switch / sensor.

2. Control box to be installed in the control room of the stationfor monitoring system operation, automatic control andremote operation, with alarms, indication light, switches,push buttons, audio signal, suitable for tripping andsignaling on 220V DC supply.

3. Pre-stressed non-return valve (PNRV) high speedpneumatically operated ball valve (POBV) with sufficient of 409

number of NC contacts for remote alarm indication and withvisual position indicator.

4. Required number of fire detectors rated for heat sensing at141 deg C or suitable temperature recommended by themanufacturer and each fitted with two numbers PG 13.5 sizecable glands.

5. Signal box for terminating cable connections from PRVPressure Sensor, PNRV / POBV, fire detectors and circuitbreaker tip signal.

B. Arrangements required on transformer tank

1 Oil drain opening with pipe flange and manual gate valve atabout 120mm below the top cover.

2. Nitrogen injection openings with suitable size of pipe withflange and manual gate valve on tank sides at about 5C-200mm from the bottom plate.

3. Flanges on the conservator pipe between buchholz relay and conservator tank for fixing PNRV / POBV.

4. Provision for Pressure & Temperature Sensors if required.

5. Supply and welding of the fire detector brackets on topcover.

6. Supply and welding of the brackets for flang signal box at asuitable location on top cover or tank side wall.

Guidelines be given for transformer manufacturers to make arrangements on new transformer during tank fabrication.

C. Pipe connections between transformer, fire extinguishing cubicleand oil pit.

1. Oil drainpipe connection between outlet valve provided onthe transformer tank and the flange provided on FE cubicletop.

2. Oil drain pipe connection between oil drainpipe bottom(in FE cubicle) to the oil pit.

3. Nitrogen injection pipe connection between inlet openings ontransformer tank and flange provided on FE cubicle top.

D. The scheme of operation of prevention of tank explosion and fireprotection, along with a flow chart, along with time of operation ofvarious devices shall be furnished.

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E. CABLING:

I Connecting fire detectors, PNRV / POBV, buchholz relay andother signals on transformer top cover and terminals insignal box, using fire retardant cable of size 4 core, 2.5mmsquare.

2. Connecting signal box mounted on transformer and controlbox placed in the control room, as well as control box and FEcubicle using FRLS cable of size 12 core 1.5mm square.

F Installation and pre-commissioning test.

Pre commissioning tests shall be carried jointly with the purchaser's representative prior to handing over the system. Not with standing above technical specifications any additions be incorporated for correct operating of nitrogen injection fire protection system without extra cost.

7. DEVIATION FROM TECHNICAL SPECIFICATION

The tenderer shall furnish the details of deviation modification proposed by him to improve overall performance of the system. The deviation if any shall be brought 'in the tender clause by clause.

8. TESTS:

Type test certificates not later than 5 years as per relevant standards for Nitrogen injection fire protection system as a whole unit shall be furnished.

9. PERFORMANCE GUARANTEE:

the equipment offered shall be guaranteed for satisfactory performance for a period of 18 months from the date of satisfactory commissioning of equipment. The equipment found defective / failed within the above guarantee period shall be replaced or repaired by the supplier free of cost within one month from the receipt of intimation. If the defective / failed nitrogen injection fire protection system are not replaced / repaired as per the above guarantee class, the KPTCL shall recover an equivalent amount plus 15% supervision charges from any of the supplier’s bills.

10. MINIMUM EXPERIENCE FOR QUALIFYING AS BIDDER:

the bidder shall have a minimum experience of 5 years in design, manufacture, testing and commissioning oh nitrogen injection fire protection system in the present enquiry. At least 50% of the quantity called for in the present enquiry shall be in successful operation for a minimum period of 2 years. The tenderer shall also furnish the details of similar nitrogen injection fire protection system supplied by them so far, giving order reference name and address of the customer etc, also indicating the period of commissioning. The bidder shall also furnish performance certificates for a period of minimum 2 years of similar nitrogen injection fire protection system in proof of satisfactory operation of the equipment.

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The purchaser however reserves the right to waive the minimum experience condition stipulated:i. in case of firms having collaboration with well experienced firms in manufacture of

similar equipment not less than 10 years. The waiving of minimum experience condition will be considered by the purchaser only on furnishing the performance guarantee of the nitrogen injection fire protection system by the collaborating firm.

ii. In case of new entrant who had supplied to KPTCL one system free of cost for watching performance for a period of 1 year and for having worked satisfactorily.

iii. Furnish type test certificates for the operation of the entire system as a whole instead of individual components.

iv. Furnish guarantee for performance for a period of 5 years.

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SECTION 5.8

TECHNICAL SPECIFICATIOND.G. SET

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VOLUME-IIA


SECTION 5.8 D.G SET

CLAUSE PARTICULARS

1.00 SCOPE OF SUPPLY.

2.00 SCOPE OF SERVICE.

3.00 SPARE PARTS.

4.00 TECHNICAL PARAMETERS AND GENERALREQUIREMENTS.

5.00 TESTS.

6.00 COMMISSIONING CHECKS.

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VOLUME IIASECTION 5.8 - D.G.SET

D.G.SET (Only for 220KV Station)

1.0 Scope of Supply

The scope covers supply of Diesel Generator Set of stationary typehaving a net electrical output of 63KVA capacity at specified siteconditions of 500C ambient temperature & 100% relative humidityon FOR site basis. DG set shall be equipped with:

i) Diesel engine complete with all accessories.

ii) An alternator directly coupled to the engine throughcoupling, complete with all accessories.

iii) Complete starting arrangement, 'including battery & charger.

iv) Base frame, foundation bolts etc.,

v) Interconnection piping, cables, cabling & accessories.

vi) Double compression type brass cable glands & timed copperlugs for all cables.

vii) All lubricants consumable, touch up paints etc., for firstfilling testing & comrnissioning at site. The fuel oil for firstcommissioning will also be provided by the contractor.

viii) Earthing with Interconnection.

ix) Day tankx) Automatic voltage Regulatorxi) Exhaust silencer packagexii) AMF panel for control, metering and alarmxiii) Enclosure of silent type DG Setxiv) Set of GI pipes, valves, stainer, unloading host pipe as required for fuel transfer

system from storage tank to fuel tank including motor driven fuel pump

2.0 Scope of Service: The contractor shall provide following, services: of 409

a. Design, manufacture, shop testing including assemblytest.

b. Dispatch transportation to Site.

c. Erection, testing & commissioning with allequipments / materials required for the purpose.

d. Drawings, data, design calculations & printederection, operation & maintenance manual.

e. Certificate and compliance for meeting noise level and commission parameters and other requirements in accordance with latest notification

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3.0 Spare parts

3.1 Mandatory spare parts

The list of Mandatory spares, which are considered essential by the owner, is indicated at Annexure-I of Section-I (GENERAL). Whenever spares have been defined as 'of each type' the type (rating) of the spares shall also be defined.

3.2 Optional Spares

In addition to the mandatory spares, Bidder shall indicate the recommended optional spares with unit & total prices for three- (3) years of normal operation of the equipment. The owner reserves the night to buy any or all-recommended spares.

4.0 Technical Parameters & General Requirements

4.1 The ratings of DG sets are as follows.

1) D.G.Set net output after considering for engine and alternator separately due to temperature rise inside the enclosure and on account of power reduction due to auxiliaries shall be 63 KVA, 1500 RPM, 0.8 p.f., 415 V, 3 phase, 50 Hz. The above ratings are the minimum requirements. However standard capacity D.G.sets meeting the above mentioned requirement shall be provided.

4.2 DG sets shall also be rated for I 10% of full load for I hour/day of continuous running,

4.3 The output voltage, frequency & limits of variation from open circuit to full load shall be as follows

Voltage variation ±5% of the set value provisionshall exist to a4just the set valuebetween 90% to I 10% of nominalGenerator voltage of 415V.

Frequency 50 Hz ± 5% of 409

Efficiency > 90%

4.4 The equipment shall be suitable for continuous full load operation for 140 hours.

4.5 The equipment shall be suitable for site conditions.

4.6 The Diesel generator and other auxiliary motor shall be of H class with temperature rise limited to class F for temperature rise consideration.

4.7 Noise level and commission parameters shall be as per latest notification of MOEF

4.8 Based on above, the systems envisaged each D.G.Set shall generally comprise of the following equipments.

a) DG set of min. 63 KVA rating complete with all accessoriescontrol & protections.

b) A control & metering panel automatic voltage regulator(AVR) & a generator Circuit Breaker (CB).

c) Starter batteries & battery charger.

d) Fuel system including day .

e) Engine Cooling & lubrication system.

f) Engine air-filtering system.

g) Exhaust silencer package.

h) Set of piping, valves, stainers, unloading hose pipes asrequired.

4.9 Diesel Engine

A : Design Parameters

The engine shall comply with the IS 10002/BS 5514/ ISO 3046 latest edition.

a) The capacity of Day tank is designed to provide at least 24hours storage of diesel oil when the generator, is running atfull load. The tank- shall be painted with oil resistant paint &shall be erected in accordance with Indian explosive act of1932.

b) Facility for manual start of diesel engine& connection to 415V AC Bus bar shall be provided. This shall be done locally.

c) A three (3) attempt starting facility using two Hinpulse timers of 409

& summation timer for enome shall be provided & if thevoltage fails to develop within specified time from receivingthe first impulse, the set shall block.

d) The generator Term Mal box shall be suitable to housenecessary cables & current Transformers for protectionpurposes.

B: System Design

a) The Diesel Generator units shall be installed indoors. Suctionof air shall be from indoor for ventilation and exhaust fume will be let out to outside atmosphere- Condensate traps shall be provided on the exhaust pipe. The exhaust pipe, & silencer shall be thermally insulated.

b) The fuel used shall be high Speed Diesel oil(HSD) or Light Diesel Oil(LDO) as per IS: 1466.

c) The diesel engine shall be directly water cooled. Cooling of water through radiator & fan is envisaged.

d) The engine shall have closed loop-lubricating system. Nomoving parts shall require lubrication by hand prior to the start of engine or while it is in operation.

C PLANT DESIGN

a) The engine with all accessories shall be enclosed in a enclosure to make it work silently (within permissible noise level) without any degradation in its performance.

b) The equipment shall be safe & proper & without unduevibration or stored for continuous operation at all loads up torated output at operating & test conditions.

c) The equipment shall have proposition for easy maintenance,overall cleaning & 'inspection & replacement of parts. Alltools for operation & maintenance of equipment shall be supplied.

d) Diesel engine shall be turbo charged multi-cylinder V-type in line type with mechanical fuel injection system.

e) Manual electric starting by DC star-ter motor shall beprovided. Necessary battery with battery charger shallbe provided.

f) Air suction and Filteration

g) The filter shall be dry type air filter with replaceable element.

h) Fuel injection and regulator:(i) The engine shall be with electronic governor suitable for class A-1 as per

IS 10000.

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(ii) The engine shall be fitted with a heavy, dynamically balanced fly wheel suitable for constant speed governor duty.

4.10 Alternator:(a) The Alternator shall comply with BS 2613/ IS 4722/ IEC 34 latest edition.(b) The Alternator shall be continuously rated duty suitable for 415V, 3 Phase, 50

Hz power development having brush-less, synchronous, self excited, self regulating system.

(c) The Alternator shall be drip proof, screen protected as per IP-23 degree of protection.

(d) The rotor shall be dynamically balanced to minimize vibration(e) The Alternator shall be fitted with shaft mounted centrifugal fan.(f) It shall the winding of class H but limited to class F for temperature rise

consideration.(g) The Alternator regulator shall be directly coupled to the engine and shall be

complete with the excitation system, automatic voltage regulation and of + - % Voltage adjusting potentiometer and under/over speed protection.

4.11 Terminal Box:(a) Output terminals shall be provided in Alternator terminal box. Terminals shall be

suitable for 1 no. of single core …… sq.mm. XLPE/PVC cable per phase for 63 KVA D.G.Set. The neutral shall be formed in AMF panel. The generator terminal box shall be suitable to house necessary cables and should be made of non-magnetic materials.

(b) The Alternator with all accessories shall be enclosed in a enclosure to made it work silently (within permissible noise level)

4.12 Coupling:(h) The engine and alternator shall be directly coupled by means of self aligning

flexible flange coupling to avoid misalignment.(i) The coupling shall be provided with a protecting guard to avoid accidental

contact.

4.13 Mounting arrangement:(a) The engine and alternator shall be mounted on a common heavy duty, rigid fabricated

steel base frame constructed from ISMC of suitable section.(b) Adequate no. of antivibration mounting pad shall be fixed on the common base frame

on which the engine and the alternator shall be mounted to isolate the vibration from passing on to common base frame or foundation of DG Set.

4.14 Control & Instrumentation

a) Each D.G.Set shall be provided with suitable instruments,interlock & protection arrangernent suitable annunciation's& indications etc., for proper start up, control, monitoring &safe operation of the one local AMF control panel along Witheach D.G.Set ( D.G.Control Panel ) shall be provided by thesupplier to accommodate these instruments i.e., protectivecircuits, relays, lamps etc., The AMF Panel shall have IP-52 degree protection as per IS: 2147.

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b) Following instruments shall be provided with Diesel Engine:

i) Lub oil pressure gauge (en ine panelgin

ii) Lub oil temperature thermometers (both on engine & at local panel)

iii) Water temperature thermometers (both on engine & at local panel)

iv) Exhaust gas pyrometer 111krith temp. s%Vitch (at, local panel)

v) Engine tachometer /HR ( engine panel)

Any other instruments necessary for DG Set operation shall be provided.

vi) Meters: Ammeter, Voltmeter with selector switch phase, KWHr meter with 5 Amp CT, frequency.

c) The Diesel Generator & other auxiliary motor shall have epoxy thermosetting type insulation but limited to class B for temperature rise consideration.

d) BATTERY AND BATTERY CHARGER

(i) 24V batteries complete with all leads, terminals and stand shall be provided. Each battery shall have sufficient capacity to give 10nos. successive starting impulse to the diesel engine.

(ii) The battery charger shall be complete with transformer, suitable rating (415 V, 3ph., 50Hz./230V, 1Ph., 50Hz) rectifier circuit, charge rate selector switch for “trickle”/’boost’ charge, D.C. ammeter & voltmeter, annunciation panel for battery charge indication/ loading/ failures.

(iii) The charger shall float and Boost Charge the battery as per recommendation of manufacturer of battery. The charger shall be able to charge a fully discharged battery to a state of full charge in 8 Hrs. with 25% spare capacity.

(iv) Manual control for coarse and fine voltage variation shall be provided. Float charger shall have built-in load limiting features.

(v) Ripple shall not be more than 1% (r.m.s) to get smooth DC voltage shall be provided.

(vi) Charger shall be provided with Out-put Voltmeter & Ammeter. of 409

(vii) Change over scheme for selecting battery charger by changeover switch should be provided.

e) Diesel Generator Shut-down: Interlocking to prevent theshutdown of DG while the DG circuit breaker is closed shallbe provided.

f) The diesel generator shall commence a shutdown sequencewhenever any of the following conditions appear in the systern.

Over speedOverloadHigh temperature of engine and cooling systemHigh temperature inside enclosureLow lub oil pressure

Short circuit protectionReverse powerUnder voltageUnder frequencyUnder VoltageOver voltage

Generator differential protectionFurther interlocking of breaker shall ble provided to

prevent parallel operation of DG set With normalstation supply.

g) Following indication lamps for purposes mentioned as under shall be provided in AMF panel:

(i) Pilot indicating lamps for the following:Mains ONAlternator ONCharger ON/OFFBreaker ON/OFFMain LT supply ON/OFF

(ii) Visual annunciation shall be provided for set shut down due to :Engine overheatingLow oil pressureLack of fuelSet failed to start in 30 secs after receiving the first start impulseHigh cooling water temperatureLow level in daily service fuel tankOverspeed tripAudio & visual annunciation for alternator fault.

h) Thermostatically controlled space heaters and cubicle

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illumination operated by Door Switch shall be provided in AMF panel. Necessary isolating switches and fuses shall also be provided.

i) AMF panel shall have facility for adjustment of speed and voltage including fine adjustments in remote as well as in local mode.

Following shall also be provided in AMF panel:(i) Frequency meter(ii) 3 Nos. single phase CT’s for metering(iii) 3 Nos. (Provided by LT swgr manufacturer) single

phase CT’s with KPV 300V & RCT 0.25 ohm for differential protection of DG set on neutral side only for 250KVA.

(iv) One (1) DC Ammeter (0-40A)(v) One (1) DC Voltmeter (0-30V)(vi) One (1) DC Voltmeter Selector switch (vii) One (1) AC Ammeter(viii) One (1) AC Voltmeter(ix) Three (3) Timers (24V DC)(x) Two (2) Auto/Manual Selector Switch(xi) Two (2) Auto/test/Manual Selector Switch(xii) Eleven (11) Aux. Contractors suitable for 24V DC(xiii) One (1) Motorised Potentiometer for voltage

adjustment(xiv) Two (2) Set Battery charger as specified in Technical

Specification(xv) One (1) Set phase & Neutral busbars(xvi) Any other item required for completion of Control

scheme shall be deemed to be included.

5.0 D.G. Set Enclosure

5.1 General requirements

a) Diesel engine, alternator, AMF panel, Batteries and chargers shall be installed outdoor in a suitable weather-proof enclosure which shall be provided for protection from rain, sun, dust etc. Further, in addition to the weather proofing, acoustic enclosures shall also be provided such that the noise level of acoustic enclosure DG set shall meet the requirement of MOEF The diesel generator sets should also conform to Environment (Protection) Rules, 1986 as amended. An exhaust fan with louvers shall be installed in the enclosure for temperature control inside the enclosure. The enclosure shall allow sufficient ventilation to the

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enclosed D.G. Set so that the body temperature is limit to 50Degree C. The air flow of the exhaust fan shall be from inside to the outside the shelter. The exhaust fan shall be powered from the DG Set supply output so that it starts with the starting of the DG Set and stops with the stopping of the DG Set. The enclosure shall have suitable viewing glass to view the local parameters on the engine.

b) Fresh air intake for the Engine shall be available abundantly; without making the Engine to gasp for air intake. A Chicken mess shall be provided for air inlet at suitable location in enclosure which shall be finalized during detailed engineering.

c) The Enclosure shall be designed and the layout of the equipment inside it shall be such that there is easy access to all the serviceable parts.

d) Engine and Alternator used inside the Enclosure shall carry their manufacturer’s Warranty for their respective Models and this shall not degrade their performance.

e) Exhaust from the Engine shall be let off through silencer arrangement to keep the noise level within desired limits. Interconnection between silencer and engine should be through stainless steel flexible hose/pipe.

5.2 All the Controls for Operation of the DG Set shall be easily assessable there should be provision for emergency shut down from outside the enclosure.

5.3 Arrangement shall be made for housing the battery set in a tray inside the enclosure.

5.4 CONSTRUCTION FEATURES:

a) The enclosure shall be fabricated from at least 14 Gauge CRCA sheet steel and of Modular construction for easy assembling and dismantling. The sheet metal components shall be pre-treated by seven Tank process and Powder coated (PURO Polyester based) both-in side and out side-for long life. The hard-ware and accessories shall be high tensile grade. Enclosure shall be given a lasting anti-rust treatment and

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finished with pleasant environment friendly paint. All the hardware and fixtures shall be rust proof and able to withstand the weather conditions.

b) Doors shall be large sized for easy access and provided with long lasting gasket to make the enclosure sound proof. All the door handles shall be lockable type.

c) The enclosure shall be provided with anti-vibration pads (Suitable for the loads and vibration they are required to carry) with minimum vibration transmitted to the surface the set is resting on.

d) High quality rock wool of required density and thickness shall be used with fire retardant thermo-setting resin to make the enclosure sound proof.

5.5 Provision for Neutral/Body Earthing

Points shall be available at two side of the enclosure with the help of flexible copper wires from alternator neutral, and electrical panel body respectively. The earthing point shall be isolated through insulator mounted on enclosure.

6.0 Installation Arrangement.DG Set enclosed in enclosure shall be installed on Concrete Pedestal 300mm above FGL.

7.0 TESTS:

The diesel generator sets shall be tested as per the relevant IECstandards. The supplier shall submit test repots as per thefollowing but not limited to

-Quality test of materials

-Crack detection & ultrasorlic tests of foreign & castings.

-Hydrostatic tests on pressure parts.

-Static balancing on rotating parts, shafts shall be statically & dynamically balanced.

-Bench tests on safety control devices

-Performance tests on fuel pump & injectors.

a) Routine tests

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-Measurements of the open circuit & short circuit characteristics

-High voltage test

-Regulation test

-Phase sequence test

-Noise & vibration test

b) Type tests:

The alternator & start motor shall be type tested as per therelevant specifications. Type test shall 'include following tests:

Resistance measurement & air gap measurement.

Measurement of leakage reactance & pottier reactance.

Short circuit characteristics(Alternator)

Efficiency test

Momentary overload test

Over speed test

Installation test ( Before & after HV test)

Determine deviation of voltage wave form

Measurement of polarisation index.

Load characteristics test.

8.0 Commissioning Checks

In addition to the checks & test recommended by the manufacturer,the contractor shall supervise the following commissioning checks to be carried out at site.

a) Load Test :

The engine shall be given test run for a period of at least 6 hours.The set shall be subjected to the maximum achievable load asdecided by the owner without exceeding the specified DG Set rating:

During the load test, half-hourly records of the following shall betaken: i) Ambient temperature. of 409

ii) Exhaust temperature if exhaust thermometer is fitted

iii) Cooling water temperature at a convenient point adjacent tothe water output from the engine jacket.

iv) Lubricating oil temperature where oil cooler fitted.

v) Lubricating oil pressure

vi) Colour of exhaust gas.

vii) Speed

viii) Voltage, Wattage & current output.

ix) Oil Lank level

The necessary load to carryout the test shall be provided by theowner.

b) Insulation Resistance Test for Alternator

Insulation resistance in mega-ohms between the coils & the frameof the alternator when tested with a 500V megger shall not be lessthan

IR = 2 x (rated voltage in KV) + 1.

c) Check of fuel Consumption

A check of the fuel consumption shall be made during the load run test. This test shall be conducted for the purpose of proper tuning of the engine.

d) Insulation Resistance of Wiring

Insulation resistance of control panel wiring shall be checked by500 V megger. The IR shall not be less than one mega ohm

e) Functional Tests

i) Functional tests on control panel.

ii) Funct:ional tests on staruing provision on the engine.

iii) Functional tests on all field devices.

iv) Functional tests on AVR and speed governor.

f) Measurement of vibration :

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The vibration shall be measured at load as close to maximum achievable load & shall not exceed 250 microns.

g) Noise Level (Sound pressure level) checkNoise level measurement shall be done generally following the include lines given

in IS: 12065. The measurement shall be carried out with a calibrated integrating sound level meter as per IS: 9779.

Sound level shall be measured a1l round the diesel Generator set at a distance of 1 meter from the nearest surface of the machine & at a helght of 1. 5 meter from the floor level as illustrated in IS: 12065 for electrical machines.

A minimum of 8 points (5 around diesel engine & 3 around alternator)shall be covered for measurement. Additional measurement points shall be considered in case the criteria indicated in Clause of IS: 12065 is not met.

The measurement shall be done with slow response meter on the A-weighing scale. The average of the A-welghed sound level measurement expressed in decibels to a reference of 0.0002 microbar shall not generally exceed 93 dbA.

The tests shall be carried out with the D.G.Set operating at rated speed & at maximum achievable load. DG set shall be located in a room having an approximate dimension of 10m x 8m. Necessary correction for Test environment condition & background noise will be applied as per IS: 12065.

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SECTION 5.9

TECHNICAL SPECIFICATION11KV UG CABLE

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Volume IIATechnical specification

Section 5.9 11kv UG cable

Clause No. Particular

1.0 Qualifying requirement

2.0 General

3.0 Technical

4.0 Cable drums

5.0 Tests

6.0 Cable laying

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VOLUME IIASECTION 5.9 - 11 kV U.G.CABLE

TECHNICAL SPECIFICATIONS FOR 11 KV U.G CABLE

1.0 QUALIFYING REQUIREMENT FOR MANUFACTURER:

Please refer volume- 1 section IFB, clause 11.6.2

2.0 GENERAL

The bidder shall quote for the entire scope of work. The preferred cable size is 3 core, 95 sq. mm ,240 sq. mm,400 sq. mm & 1 core 1000 sq. mm

2.1 Successful bidder shall prepare the entire laying, jointing and termination schedule.

3.0 TECHNICAL

3.1 Standard: The underground cable shall conform to IS: 7098 part (2), 1985 with amendments. "Specification for cross linked polyethylene insulated PVC insulated cables.

3-2 Technical requirement

a) Specific requirement:

3 core 6.35/ 11 KV grade, 90 deg C rating, heavy duty power cable with stranded compacted circular aluminium conductor shielded with extruded semi-conducting compound, cross linked polyethylene insulated, shielded with extruded semiconducting compound and copper tape, shielded cores laid up with fillers inner sheath of extruded PVC, Galvanised round steel wire armored and PVC ST- 2 overall sheath.

b) Single core cables

Single core, 6.35/11 KV grade, 90 deg. C and rating, heavy duty power cable with stranded compacted circular aluminium conductor, shielded with extruded semiconducting compound cross linked polythene insulated, shielded with extruded semiconducting compound, and a copper tape, inner sheath of extruded PVC, hard drawn alurninium round wire armored and PVC type ST-2 overall sheath.

3.3 DESIGN CRITERIA:

I) The cables will be used for connection of the station. Auxiliary 250 KVA, 11/0.433/KV transformers with the 11 KV switchgear.

ii) The cable will be laid direct in ground/duct with uncontrolled backfill, with channels of logging.

iii) The cable shall be designed to with stand the mechanical electrical and thermal stresses under steady and transient conditions.

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iv) The conductor insulation shield, XLPE insulation and insulation shield shall be by triple extrusion process.

v) Core identification shall be by coloured strips or by numerals.

4.0 CABLE DRUMS:

I) Cable shall be supplied on non-returnable seasoned, strong wooden drums. The wood pre-protective shall be applied on the entire drums.

ii) The cable ends on the drums shall be sealed with good quality heat shrinkable cable end seals

4.1 CABLE LENGTH:

The cable length on the drum shall generally the specified so as to avoid unnecessary joint The normal delivery lengths shall be

I core - 1000 sq mm - 500 Mtr. 3 core - 95 sq. mm - 300 Mtr. 3 core - 240 sq. mm - 250 Mtr. 3 core - 400 sq.mm - 250 Mtr.

5.0 TESTS:

5.1 The cable supplied should have been already type test tested and reports furnished to the owner.

5.2 The owner reserves the right to witness the acceptance test.

5.3 The routine test reports should be approved by the owner.

6.0 CABLE LAYING:

6.1 The cable shall be laid generally as per the cable installation shall be as per IS: 1255-1983 section 3, clauses 8 to 11 as per IS 1255 - 1967 direct in ground except at the point of terminations where they shall be in air and at road crossing or drains where they shall be laid in stoneware pipes or cement concrete Hume or span pipes.

6.2 The excavation shall be open cut and its width shall be that minimum as is necessary for drawing the cable in the trenchwithout causing any damage to the cable.

6.3 The minimum depth of laying from ground surface to the top of the cable shall be 0.9 m.

6.4 The excavated earth shall be stacked by the side of the trench itself duly ensuring that the heaped earth does not cave into the trench.

6.5 Where trenching is done in looses soils which are prone to collapse, the side of the trench shall be shored with wooden planks or such other strutting so as to prevent the trench sides from collapsing or caving in.

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6.6 The bottom of the trench shall be filled with a sand cushion of not less than 50 mm in depth and the cable shall be laid over this cushion by being drawn steadily over cable rollers without any sharp bends and crossings. No surface damages shall be caused during laying to the cable. The rollers shall preferably be of the wooden sheaved type free hand rollers.

6. 7 The cable on being laid shall again be provided around with another layer of Protective sand cushion of not less than 75 mm and finally covered with cable tiles. The minimum bending radii shall not exceed indicated in clause 5.3 of IS 1255-1967. The tiles shall be clay fired embossed with the words KPTCL. The trench shall finally be covered with the excavated earth and consolidated.

TECHNICAL SPECIFICATION FOR JOINTS AND TERMINATIONS SUITABLE FOR 11 kV CLASS XLPE INSULATED UNDER GROUND CABLE

1.0 QUALIFIYING REQUIREMENTS FOR MANUFACTURER:

Please refer volume 1, section IFB, clause 11.6.2

1.1 SCOPE:

This specification covers, in brief, the manufacture, testing,inspection, packing & supply of heat shrinkable type power cableaccessories, such as, straight through joints, indoor and outdoortermination's, suitable for the underground cables manufacturedin general conformity to IS: 7098 part (2) - 1985

i) The accessories shall be suitable for 3 core and single core.6.35/11 kV grade XLPE insulated compacted circularaluminium conductor ar-moured and overall PVC sheathedunderground cables.

ii) Definition: The term "accessory" shall mean; straight throughjoints indoor/outdoor terminations used in cable powertransmission systems.

2.0 SERVICE CONDITIONS:

2-1 The straight through joints shall be suitable for use with cables directly buried in ground.

2.2 The indoor terminations shall be suitable for use indoor/outdoor type switchgear cubicles.

2.3 The outdoor terminations shall be suitable for use in directlyexposed to atmospheric conditions.

3.0 POWER SYSTEM PARTICULARS:

1) System voltage 11 KV2) Highest voltage 12 KV3) Neutral Effectively earthed4) Frequency 50 Hz5) Cross sectional area of conductor

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3 x 95 sq.mm. Aluminum3 x 240 sq.nm Aluminiurn3 x 400 sq.mm AluminumI x 1000 sq.mm Aluminium

6) Continuous rated current at 90deg C of cables (approx) 3x240 sq.mm 300 Amps

3x400 sq.mm 400 Amps1x1000 sq.mm 650 Amps

7) Maximum short circuit capabilityof cables KA for one sec. 25 KA

8) Approx. overall diameter of 3x95 sq.mm 62 to 64 mmcables 3x140 sq.mm 80 to 82 mm

3x400 sq.mm 94 to 96 mm1x1000 sq.mm 64 to 66 mm

4.0 STANDARDS:

4.1 The testing of the completed system of accessory, with cable of heat shrinkable joints and terminations shall be in accordance with the standard, with latest amendments there of and revisions.

I) IS 13573 - 1992 : Joints and terminations of polymeric cables for worldng voltages from 6.6 W up to and including 33 kV, performance requirements and type tests, with latest amendments

ii) Accessories tested in accordance with any other recognised national/International standards are also acceptable.

5.0 DESIGN REQUIREMENTS:

5.1 The heat shrinkable accessory system shall be suitable for6.35/11 KV grade, cross-linked polyethylene insulated, and aluminium conductor (of specified area of cross section) underground cables.

The accessories should be compatible with the operating conditions of the cable and suitable for the service conditions. The accessory shall provide effective stress control, insulation, and environmental seal and should have non-tracking properties, irnpervious; to moisture and resistant to ultraviolet radiation.

STRAIGHT THROUGH JOINTS:

The joint shall provide for the following performance functions:

I) Electric stress control between the cable semiconducting screen and over the ferrule.

ii) Continuity of armour.

iii) Reinstatement of cable insulation and screen, similar to cable construction.

iv) Environmental protection and moisture sealing.

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v) Mechanical strength and protection.

5.3 TERMINATION:

The termination shall be designed to provide:

I. Electric stress control for the cable insulation shield terminus.

ii. Complete external leakage insulation between the cable conductor/ conductors and earth.

iii Sealing the cable against ingress of moisture and other atmospheric agencies.

iv. The entire core length from lug seal to cable breakout shall have voltage, non-tracldng material.

5.4 The main components of the accessories shall be

I. The internal insulating and external protective tubings.

ii. Stress control tubings.

iii. Anti tracking and weather resistant tubing - indoor/outdoor.

iv. Break- out/Glove made from HV anti-tracking material.

v. Lug sealing sleeve made from HV anti-tracking material.

vi. Rain sheds made from HV non-tracking material.

vii. All other items like, lugs, ferrules connectors, earth continuity material etc., necessary), for a complete joints/terminal

6.0 TESTS

6.1 ROUTINE TESTS

a) Visual inspectionb) Dimensional checkc) Physical verification of kit contents as per bill of materials

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SECTION 6.0

SWITCHYARD ERECTION

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VOLUME-IIATECHNICAL SPECIFICATION

SECTION 6.0 SWITCHYARD ERECTION

CLAUSE NO. PARTICULARS

1.0 GENERAL.

2.0 ACSR CONDUCTOR.

3.0 GALVANIZED STEEL EARTH WIRE.

4.0 TUBULAR BUS CONDUCTORS. 5.0 EARTHING CONDUCTORS.

6.0 VOID.

7.0 BUS POST INSULATORS.

8.0 EARTHING.

9.0 MAIN BUS BAR.

10.0 BAY EQUIPMENTS.

11.0 LIGHTING PROTECTION.

12.0 TERMINAL POINTS.

13.0 EQUIPMENT ERECTION NOTES.

14.0 EARTHING MATERIAL

15.0 DIRECTLY BURIED CABLES.

16.0 INSTALLATION OF CABLES.

17.0 JUNCTION BOX

18.0 TESTING AND COMMISSIONING

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VOLUME - IIASECTION 6.0 - SWITCHYARD ERECTION

TECHNICAL SPECIFICATION FOR SWITCHYARD ERECTION

1.0 GENERAL

220 KV switchyard will consist of either double main bus or single main bus switching scheme. For exact type of switching scheme the single line diagram may be referred. The main bus will be of rigid type with Aluminium tube of size 75 mm. The equipment connection will be with a combination of aluminium tube of 63 - mm size.

The detailed scope of work :includes design, engineering,manufacture, testing at work, supply on F.O.R destination site basis, insurance, handling, storage, erection testing and commissioning of various items, (along with its spares) as detailed herein.

This section covers the description of the following items.

- String insulators and hardware - ACSR conductor - Galvanised steel Earthwire - Aluminum tubular bus bars - Bus post insulators - Earthing & Earthing materials - Lightning protection - Cabling material, etc. - Bay marshalling kiosk.

1.1 String insulators & Hardwares Power Connectors:

The insulators for suspension and tension strings shall conform to IS: 731 insulator hardware shall conform to IS: 2486.

1.2 CONSTRUCTION FEATURES:

1.2.1 Suspension and tension insulators shall be of wet processPorcelain with ball and socket connection. Insulators shall be interchangeable and shall be suitable for forming either suspension or strain strings. Each insulator shall have rated strength markings onporcelain printed and applied before firings.

1.2.2 Porcelain used in insulator manufacture shall behomogeneous, free from laminations, cavities and other fiaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture.

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1.2. 3 Glazing of the porcelain shall be uniform brown colour,free from blisters, burrs and other similar defects.

1.2.4 When operating at normal rated voltage there shall beno electric discharge between conductor and insulator which would cause corrosion or injury to conductors or insulators by the formation of substance due to chemical action. No radio interference shall be caused when operating at normal rated voltage.

1.2.5 The design of the insulator shall be such that stressesdue to expansion and contraction in any part of the insulator shall not lead to deterioration. All ferrous parts shall be hot dip galvanised in accordance with the latest edition of IS: 2629. The zinc used for galvanizing shall be of grade Zn-99.95 as per IS-209. The zinc coating shall be uniform, adherent, smooth, reasonably bright, continuous and free from imperfections such as flux, ash, rust stains bulky white deposits and blisters.

1.2.6 Bidder shall make available data on all the essentialfeatures of design including the method of assembly of discs and metal parts, number of discs per insulators, the manner in which mechanical stresses are transmitted through discs to adjacent parts, provisionfor ineetinc, expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions.

1.2.7 VOID

1.2.8 Insulator hardware shall be of forged steel. Malleable cast iron shall not be used except for insulator disc cap. The surface of hardware must be clean, smooth, without cuts, abrasion or projections. No part shall be subjected to excessive localised pressure. The metalparts shall not produce any noise-generating- corona under operating conditions.

1.2.9 VOID

1.2.10 The tension string assemblies shall be supplied along with suitable turnback. Sag compensation springs if required may also be provided.

1.2.11 All hardware shall be bolted type.

The following types of clamps are required:

a) Tension type - both for single and twin conductor b) Suspension type - both for single and twin conductorc) Post insulator clamps - both for single and twin conductord) Spacer clamp - for twin conductor

1.2.12 VOID

1.2.13 Tests:

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In accordance with the stipulations under section - 2, the suspension and tension strings, insulator discs and hardware shall be subjected to the following type tests, acceptance tests and routine tests:

1.2.13.1 Type tests on insulator strings:

a) Dry and wet power frequency voltages withstand test with corona control rings as per IS-731.

b) Lightning impulse voltage withstand test (dry) with corona control rings as per IS-731.

c) Voltage distribution test (Dry)

The string shall be energised with 100 KV power frequency voltage. The voltage across each insulator unit shall be measured by using a high impedance voltmeter. The voltmeter shall be calibrated before and after the measurement. The voltage across any disc shall not exceed 13% for 220 KV suspension and tension insulator strings.

d) Corona test (Dry)

As per Annexure-A of Section -2

e) RIV test (Dry)

As per Annexure-A of Section -2

f) Mechanical strength test

The complete insulator string along with its hardware fittings shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for 5 minutes & then removed. After removal of the load, the static components shall not show any visual deformation and it shall be possible to dismantle them by hand. Hand tools may be used to remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded.

1.2.13.2 Type tests on disc insulators

a) Thermal mechanical performance tests as per IEC: 575, clause 3.

1.2.13.3 Acceptance tests for disc insulators:

a) Visual examination.

b) Verification of dimensions as per Cl no. 10.5 of IS: 731.

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c) Temperature cycle test as per Cl no. 10.6 of IS: 731.

d) Puncture test as per Cl No. 10.10 of IS 731.

e) Galvanising test as per Cl no. 10.12 of IS: 731.

f) Mechanical performance test as per Cl. 4. of IEC-575.

g) Test on locking device for ball and socket coupling as per IEC 372(2).

h) Porosity test as per Cl no. 10.11 of IS: 731.

1.2.13.4 Acceptance test on hardware fitting:

a) Visual examination as per Cl. 5.10 of IS :2486 (Part-I)

b) Verification of dimensions as per Cl. 5.8 of IS:2486(Part - 1)

c) Galvanising/ electroplating tests as per Cl. 5.9 of IS2486 (par-t-1)

d) Slip strength test as per Cl 5.4 of IS:2486 (par-t-1)

e) Shore hardness test for the Elastometer (if applicable as per the value guaranteed by the bidder).

f) Mechanical strength test for each component ("includingcorona control rings and arcing horns).

g) The load shall be so applied that the component is stressed "in the same way as it would be actual service and the procedure as given in 1.2.13.1 above should be followed.

f) Test on lockng devices for ball and socket coupling as per IEC : 372 (2)

1.2-13.5 Routine test disc insulator

a) Visual inspection as per Cl no. 10. 13 of IS : 731b) Mechanical routine test as per C1 No. 10. 14 of I S:703 1c) Electrical routine test as per Cl no. 10. 15 of IS:73 1

1.2.13.6 Routine test on hardware fittings: a) Visual examination as per Cl 5.10 of IS:2486 (part- 1)b) Mechanical strength test as per Cl. 5.11 of IS : 2486

(part - 1)

1.2.13.7 Test during manufacture on all components asapplicable on disc insulator:

a) Chemical analysis of zinc used for galvanising. of 409

Samples taken from the zinc ingot shall be chemically analysed as per IS: 209. The purity of Zinc shall. not be less than 99.95%.

b) Chemical analysis, mechanical hardness tests and magnetic particle inspection for malleable casting. The chemical analysis, hardness tests and magnetic particle inspection for malleable casting will be as per

the internationally recognised procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding tests will be discussed and mutually agreed to by the contractor and owner in quality assurance programme.

1.2-13.8 Tests during, manufacture on all. components as applicable on hardware fittings:

a) Chemical analysis of zinc used for galvanizingSamples taken from the zinc ingot shall be chemically analysed as per IS: 209. The purity of zinc shall not be less than 99.95%..

b) Chemical analysis, hardness tests and magnetic particle for forging:The chemical analysis, hardness tests and magnetic particle inspection. for malleable casting will be as per the internationally recognised procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding tests will be discussed and mutually agreed to by the contractor and owner in quality assurance programme.

c) Chemical analysis and mechanical hardness tests and magnetic particle inspection for fabricator hardware.The chemical analysis, hardness tests and magnetic particle inspection for fabricated hardware will be as per the internationally recognised procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding test will be discussed mutually and agreed to by contractor and owner in quality assurance programme.

1.2.14. PARAMETERS

1.2.14.1 DISC INSULATORS

220 110 66 331 Type of insulators Fog type Fog type Fog type Fog type2 Size of insulator units

(mm)255 x 145 255 x 145 255 x 145 255 x 145

3 Electromagnetic strength

120 KN for tension 90 KN for suspension

90 KN 90 KN 90 KN

4 Creepage distance of individual insulator units (minimum and as required to meet total creepage distance)

430mm 292mm 292mm ----

5 Markings Markings on porcelain

Markings on

Markings on

Markings on

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shall be printed applied before firing

porcelain shall be printed applied before firing



6 Power frequency puncture withstand voltage

1.3 times the actual wet flashover voltage




1.2.14.2 INSULATOR STRING

Power frequency withstand voltage of string with corona control ring(wet)-KV rms

395 230 140 70

Lighting impulse withstand voltage of string with corona rings (dry) KVP

+ / - 900 550 325 170

Switching surge withstand voltage of string with corona rings (wet) –KVP

NA --- --- ---

Minimum corona extinction voltage level of string with corona control rings (dry) –KV rms

156 --- --- ---

RIV level in micro volts of string with corona control control rings at 305 KV(rms) for 400 KV string and 156 KV for 220KV string across 300 ohms resistor at 1 MHz

1000(MAX) --- --- ---

Total creepage distance of the insulator string (mm)

6125 --- --- ---

Total number of discs per string

16 for tension 14 for suspension

--- --- ---

Note: For tension purpose double insulator strings and for suspension purpose single suspension insulator string shall be used.

2.0 ACSR CONDUCTOR:

2.1 Details of conductor:

2.1.1 The conductor shall be Drake & conform to IS : 398 (Part - V) 1982 except where other wise specified herein.

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2.1.2 The details of the conductor are tabulated below

DrakeStranding and wire diameter 26 / 4.442mm + 7/3.454 mm steelSectional area of aluminium 402.9 sq. mmTotal sectional area 468.4 sq.mmOverall diameter 28.14 mmApproximate weight 1624 kg / kmCalculated DC Resistance at 20 degC 0.0715 ohm / kmMinimum UTS 141.75 KN

2.2 WORKMANSHIP

2-2.1 The finished conductor shall be smooth, compact, from uniform and free from all imperfections including spills, die marks, scratches, abrasions. Scuff marks, kinks (protrusion of wires), dents, press marks, cut marks, wire cross over, over riding, looseness (wire being dislocated by finger/hand pressure and /or unusual bangle noise on tapping, material inclusions. white rust powder formation or black spots (on accounting of reaction with trapped rain water etc), dirt, grit etc.

1.2.2 All the aluminium. and steel strands shall be smooth, uniform and free from all imperfections such as spills and splits, diemarks scratches abrasions and kinks after drawing,

1.2.3 The steel strands shall be hot dip galvanised and shall have minimum zinc coating of 260 gms / sq mm after stranding of the uncoated wire surface. The zinc coating

shall be smooth, continuous and of uniform thickness, free from Imperfection and shall withstand minimum three dips after stranding in standard Preece Test. The Finished strands and the individual wire shall be of uniform quality and have the same property and the characteristics as prescribed in ASTM designation : B 498-74 and relevant IS.

2.2.4 The steel strands shall be preformed and postformed in order to prevent the spreading of the strands in the event of cutting of composite core wire. Care shall be taken to avoid damage to galvanisation during preforming and postforming operation.

2.3 Joints in wires

2.3.1 Aluminium wires

No joints shall be permitted in the individual wire in the outermost layer of the finished conductor. However joints in the 12 wire and 18 wire inner layers of the conductor shall be allowed but these joints shall be made by cold pressure butt welding shall and be such that no such joints are within 15 mtr of each other in the complete stranded conductor.

2.3.2 Steel wires

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There shall be no Joints of any kind in the finished wire entering into the manufacture of the strand. There shall also be no strand splices in any length of the completed stranded steel core of the conductor.

2.4 Tolerances

The manufacturing tolerance to the extent of the following limits off shall be permitted in the diameter of individual aluminium and steel strands and lay-ratio of the conductor:

a) Diameter of Aluminium and steel strands

Standard maximum Minimum

Aluminium 3.53 mm 3.55 mm. 3.51 mmSteel 3.53 mm 3.60 mm 3.46 mm

b)Lay ratio of conductor

Maximum MinimumSteel 7 wire layer 18 16Aluminium 12 wire layer 14 12

18 wire layer 13 1126 wire layer 12 10

2.5 Materials

2.5.1 Aluminium

The aluminium strands shall be hard drawn from electrolytic aluminium rods having purity not less than 99.5 % and a copper content not exceeding 0.04%.

2.5.2 Steel

The steel wire strands shall be drawn from high carbon steel wire rods and shall conform to the following chemical composition:

Element % composition

Carbon - 0.50 to 0.8SManizanese - 0.50 to1.10Phosphorous - not more than 0.035Sulphur - not more than 0.045Silicon - 0.10 to 0.35

2.5.3 Zinc

The zinc used for galvanising shall be electrolytic high grade Zinc of 99.95 % purity. It shall conform to and satisfy all the requirements of IS:209-1979.

2-6 Standard length

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2.6.1 The conductor shall be supplied in standard length of 1500/1800 meters as required. No joint shall be allowed within a single span of stringing.

2.7 Tests:

2.7.1 The following type, acceptance & routine tests and tests during manufacturing shall be carried out on the conductor.

2.7.2 Type testsThe following type tests shall be conducted on samples of conductor. The testing charges for the type tests shall be indicated separately in the prescribed schedule of the bid.

a) UTS test on stranded The number of samples shall be mutuallyconductor agreed between contractor and owner)

b) Corona extinction voltage As per Annexure-Atest (dry)

c) Radio interference voltagetest (dry)

d) DC resistance test onon standard conductor

2 Acceptance Tests

2.7.3

a) Visual check for jointsscratches etc., and As per Annexure - Alength of conductor

b) Dimension checks onSteel and aluminiumstrands

c) Check- for lay ratiosof various layers -do-

d) Galvanising test on steelstrands

e) Torsion and Elongationtest on steel strands

f) Breaking load test onsteel and aluminium

g) Wrap test on steel IS:39S (p-T-.i N7) 1982aluminium strands clauses 1-15.2, 12.7

& 12. 8h) DC resistance test

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aluminium strands

i) UTS test on welded As per.Amnexure - Ajoints of aluminiumstrands

NOTE:All the above tests except test mentioned at ( i ) shall be carried out on aluminium and steel strands after stranding oniy.

Routine Tests

a) check to ensure that the joints are as per specifications.b) Check that there are no cuts, fins etc, on the strands.c) All acceptance test as mentioned in clause 2.7.3 above to be carried out on each coil.

2.7.5 tests during manufacture :

a) chemical analysis if zinc used for galvanizingb) chemical analysis of aluminium used for making aluminium strands.c) Chemical analysis of steel used for making steel strands.

For all these please refer ANNEXURE – A

2.7.6 Sample batch for type testing:

The contractor shall offer material for selection of samples for type testing, only after getting approval for quality assurance plan from owner.

The samples shall be manufactured strictly in accordance with the quality assurance plan approved by owner.

3.0 VOID

4.0 TUBULAR BUS CONDUCTORS

4.01 GENERAL: (Supply and erection)

4.02 This specification is in two parts, part-II and part - III in addition to part-I (general condition)

4.03 Part - II relates to technical specification in regard of manufacture, testing and supply of Aluminium pipes and accessories like post insulator clamps, corona bells, expansion joints etc.

4.04 Part - III relates to erection of aluminium bus bars with accessories supplied as per specification in part - II and includes bending, and welding of aluminiurn pipes, fixing corona, bells, making expansion joints etc.

4.05 The scope of this specification covers the erection of tubular aluminium bus bars as detailed below:

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i) Erection of 220KV, 110 KV or 66 KV main bus of 75 mm/ 63 mm, 33KV single main bus of 50 mm aluminiurn pipe with rigid cross bus connection to disconnects.

The scope of work covered by this specification is indicated in the layout plan drawings annexed . The main rigid bus is to be connected to the expansion type connectors of the disconnects through rigid cross bus aluminium pipes. Supply of terminal connectors of the disconnects, is not in the scope of supply.

4.06 VOID

4.07 The schedule of requirements is indicated in schedule of quantities, Volume II section - I General.

4.08 STANDARDS:

4.10 The materials offered shall conform to the relevant IS standards

4.11 Qualifying requirement : Refer Section IFB Volume I

4.12 The quantities and arrangement based on the drawing furnished by the purchaser may be altered by the successful bidder for ensuring better working arrangements with the written consent of the purchaser. The tenderer shall filrnise reasons in detail for suggesting such alterations. The purchaser reserves the right to accept or to reject any or all of the alterations or suggestions made by the bidder without assigning any reason whatsoever.

The following points shall be kept in view while submitting the offer:

a) The vertical connections from main bus bar to disconnects shall be as follows

i. Through "inverted Y" tap or 'V' tap of height of 2500 mm with 63 mm. Aluminiurn pipe in case of 220 KV side bus connections. The Y and 'V' tap shall be connected by bolted type clamp at top and bottom. Through a straight tap of height 1750mm and 1250 mm with 63 and 50 mm aluminium pipe in case of 110 KV and 66KV side bus connectors. The straight tap shall be connected by bolted type clamps both at top and bottom.

ii. Through a straight tap of height 1200 mm with 38 mm aluminium pipe in case of 33KV side bus connectors. The straight taps shall be connected by bolted type clamps both at top and bottom.

b) The horizontal connector from vertical tap to disconnects shall be of aluminium pipe of the same size as that of vertical connectors and be rounded off at the end.

c) Length of the horizontal connector from tap to disconnects is assessed, based upon the width of isolators of standard make. Hence there may be slight difference in the total length of horizontal connectors required, depending upon the make of disconnects which are being procured

4.13 OPERATING CONDITIONS

The materials supplied and the workmanship involved shall be suitable for operating conditions, which are detailed below

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Particulars 220 KV 66KV 110KV 33KVNormal current to base handled

As per normal rating Al. pipes indicated in annexure




Impulse withstand voltage(KV)

1050 325 550 170

Power frequency withstand voltage(KV)

460 140 230 75

4.14 DRAWING FOR APPROVAL:

Detailed layout drawings indicating the various components as detailed below shall be got approved by the successful tenderer before execution of work.

a) Aluminium pipes of various size.

b) Position of post insulator clamps indicating various types i.e., rigid expansion / sliding type.

c) Position of welds

d) Cross - section at vital points like welding points, connection of vertical taps of 220KV, I IOKV and 33 KV main bus bars, post insulators, clamps points rigid, expansion and sliding types.

e) Detailed drawings of various components namely length and cross section of pipes, straight taps, post insulators clamps, rigid, sliding, expansion clamps, aluminium pipe connectors 75 mm to 63 mm, 63 mm to 50mm, 50mm to 38mm used for connecting main bus bars to disconnects.

4.15 ALUMINIUM PIPE: (Supply of aluminium pipes and accessories)

4.16 The purchaser proposes to use the under mentioned nominal size of aluminium pipes

220KV 110KV 66KV 33KVMain busbars 75mm 75mm 63mm 50mmCross bus connecting main busbars and disconnects

63mm 63mm 50mm 38mm

4.17 Aluminium pipe to be supplied shall conform to BS-1600 schedule 40(EPS) standard pipe sizes or equivalent standard having mechanical and electrical characteristics as detailed in annexure-I.

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4.18 The aluminium pipe to be supplied should be of aluminium alloy of type 6340 WP as per IS-5082 of 1981 and shall have the chemical composition and electrical characteristics as detailed in annexure-I and II respectively.

4.19 The requirement for total lengths of various sizes of aluminium pipe is indicated in section I of volume II. The tubes shall be supplied in convenient lengths so as to keep wastages to a minimum without diminishing any of the mechanical and electrical properties. The length of the pipes indicated is based on the drawings furnished. Any increase in lengths of pipes owing to any practical reasons, miscalculation will be to the account of the bidder.

4.20 The material shall be suitable for operating conditions detailed elsewhere of thisspecifications.

4.21 The aluminium pipes to- be supplied should withstand high temperature encountered during welding and no stress should develop in the pipe adjacent to the welding portion.

4.22 CORONA BELLS

4.23 These are required to be fixed at both ends of main buses to reduce corona effect.

4.24 The requirement of corona bells is indicated in the schedule of requirement.

4.25 SOLID CYLINDRICAL POST INSULATOR CLAMPS:

4.26 These are envisaged for holding the 220KV, 110KV, 66KV, and 33KV main bus supported on cylindrical type solid core post insulators. The clamps to be supplied shall be suitable for mounting holes on the insulator and size of the pipe which is detailed below :

Nominal diameter of Aluminium pipe (inches)

Cylindrical solid core post insulator

Pitch circle diameter of mounting holes on top (mm)

Number of holes (numbers)

i. 75 mm

a) 220KV main busb) 110KV main bus

As per IS 5350Part II

127127

44

ii. 63 mm a) 66KV main bus

As per IS 5350Part II

127 4iii. 50 mm

a) 33 KV main bus

As per IS 5350

Part II 76 4

4.27 The clamps shall conform to latest edition of IS : 5561

4.28 The clamps required are of three types viz. Rigid, sliding and expansion types

i RIGID TYPE CLAMPS : Are required to hold the aluminium pipe rigidly allowing for no lateral movement of pipe. These are required at points marked 'R' in the layout drawings and shall be suitable for insulator and aluminium pipe details indicated in clause 4.24. At

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all rigid clamp locations, there shall be vertical straight tap connections in case of 220KV, 110KV, 66KV and 33KV main buses for connecting disconnects respectively.

ii) SLIDING TYPE CLAMPS : Are the ones located in between a rigid clamp and expansion type clamp, which shall allow for movement of pipes. These are marked as 'S' in layout drawing. These clamps may be bolted type or plain type i.e, without bolts. As in case of rigid type clamps, vertical straight line tap connections are located on sliding clamps also.

iii) EXPANSION TYPE CLAMPS : Are the ones located between two rigid clamps and marked 'E' in the layout drawing. These clamps are meant for allowing for expansion of aluminium pipes used for main bus. The expansion joints so used in the clamps shall be complete in all respects with required aluminium straps, filler inserts, etc., and should allow for proper expansion of the portion of aluminium pipes between two rigid clamps.

4.29 ‘V’ OR 'Y' TAPS OR STRAIGHT LINE TAPS:

4.30 As detailed in clause 4.23 and clause 4.12 in part-I, the main bus is to be connected to equipment of various terminal bays by means of straight taps in case of 'Y' or 'V' taps in case of 220KV main bus, 110KV, 66KV, and 33KV main buses.

4.31 The vertical taps are to be connected to disconnects by means of horizontal taps

4.32 The tap connections shall be with 63 mm aluminium pipe for 220KV, 110KV system and with aluminium pipe for 66KV (38mm) aluminium pipe for 33KV system.

4.33 The height of vertical taps shall be 2500mm for 220KV system, 1750 mm for 110KV system, 1250 mm for 66KV system and 1200mm for 33KV system.

4.34 The joints between the main bus and vertical tap and vertical tap to horizontal tap shall be made up of suitable clamps, which should conform to the latest edition of IS-5561.

4.35 WELDED JOINTS, INSERTS, ETC:

4.36 The main bus shall consists of standard lengths of aluminium pipe joined at various points by welded joints or expansion joints as the case may be.

4.37 Welded joints to an extent of 10% of the total quantity for each KV class shall be tested by radio-graphic test to prove the soundness of the weld joints. Further if desired by the owner, the tenderer shall arrange for the radio-graphic test of more number of joints for which the unit rates are to be indicated in price schedule.

4.38 The welded joint or the expansion joint shall be complete in all respects with required number of pipe filler inserts, proper welding etc.

4.39 The successful tenderer shall submit the quality assurance plan for the work and welder qualification for approval. The weld should be cut open to see the quality of the welds at no extra cost to the purchaser .

4.40 DRAWING

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4.41 The tenderer should submit drawing in respect of all the components detailed in clause 1.00 to 5.00 and other essential and necessary components required for without which the tender will be rejected.

4.42 As stated in clause 6.00 of part-1 the tenderer shall submit drawings of various components for purchaser's approval. The material shall be offered for inspection only after purchaser's approval is accorded to the drawing.

4.43 The drawings of clamps and connectors should be exhaustive i.e, various views shall be depicted and current rating (Amp capacity) mentioned.

4.44 MATERIALS:

4.45 The material used for the various pipe joints, connectors shall be of proven tested quality and workmanship. The composition of alloys used shall be made available to the purchaser for verification. The bolts and nuts shall conform to IS-1363- 1967 with latest revisions.

4.46 The clamps offered shall be complete in all respect and shall perfectly suit the required size of aluminium pipes specified in clause 1.00 of part-II.

4.47 All ferrous metal parts like bolts, nuts of size l2mm and above shall be hot dip galvanised and bolt sizes below 12mm may be electro galvanised. The threads in nuts shall be cut after galvanising and shall be lubricated and greased. All other threads shall be cut to take care of increase in diameter due to galvanising.

4.48 All bolts shall be provided with a lock nut along with fastening nut.

4.49 All casting shall be free from blow holes and other casting defects such as cracks etc.

4.50 The connectors shall have the same electrical characteristics as the associated aluminium bus bars and, shall be capable of carrying the normal and short time current rating detailed in clause 5.00 of part-I.

4.51 Special care should be taken in clamp design to account for (i) Galvanic corrosion,(ii) cold flow or creep of aluminium, (iii) thermal cycling.

The clamp body shall be of high conductivity aluminium alloy of high strength and non-corrosive. The aluminium alloy shall be copper free. The bolts and nuts used shall be of high tensile, non-corrosive galvanic resistant material. Aluminium alloy, phosphorous bronze or galvanised iron may be used as required by the clamp design.

4.52 Bolting pressure shall be well distributed. The outer surface of the clamp shall be smooth and free from sharp edges.

4.53 TESTS

4.54 Aluminium pipe, associated clamps and corona bell shall be designed for trouble free operation in the climatic and atmospheric conditions enumerated in the project data.

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Hence, the tests and especially the Corona discharge test, Special features of design to meet the requirement shall be brought out in the tender.

4-55 TYPE TESTS: Tenderer shall furnish the following type test certificates in respect of the aluminium pipe and accessories.

Aluminium Pipe Clamps Corona bells

1. Tensile test ------------ Applicable --------------2. Resistance test Applicable Applicable Applicable3. Temp.rise test Applicable Applicable Applicable4. Short time current test Applicable Applicable Applicable5. Visual discharge test. Applicable Applicable Applicable

4.56 Acceptance tests: The following acceptance tests are to be conducted in presence of owner's representative.a) Tensile test.b) Resistance test.c) Temperature rise test.d) Visual and dimensional verification

4.57 The visual discharge is specified to know the corona effect. Special care shall be taken to design and manufacture to minimise corona discharge. Corona discharge shall not be visible from the clamps when the system consisting of pipe with clamps is energised to phase ground system.

4.58 For the purpose of temperature rise and other tests, the current carrying capacity of various clamps may be reckoned as follows clamps or part thereof in contact with IPS aluminium pipe of nominal diameter.

a) 75 mm 2000 Amps.b) 63 mm 1250 Amps.c) 50 mm 1250 Amps.d) 38 mm 800 Amps,

4.59 The purchaser reserves the right to conduct temperature rise tests at rated current on any erected portions of the bus works. Total temperature of clamps more than 85 deg C (temperature rise plus ambient) will not be acceptable. Clamps which are found to show the usual corona discharge at the rated voltage will not be acceptable

4.60 SAMPLES

4.61 The tenderer shall furnish typical samples of tubular bus bar materials of 500 mm. Minimum length and one unit of each of components like clamps, corona bell, power connectors, etc., used in the above works, to enable the purchaser to assess the quality of workmanship of the products.

4.62 ERECTION AT SITE

4.63 WORKS AND WORKMANSHIP :

To elaborate the work involved at site of 409

i) It consists of cutting of tubular bus bars to required sizes.ii) Making of straight tap.iii) Welding of aluminium tubes after installation and mounting of tubular bus bars.iv) Welding of heater platesv) Bending and assembly of aluminium tubes with other accessories and equipments as

shown in the tender drawings. vi) Radiographic test of all welded Joints.

4.64 The workmanship shall be of highest order. The cutting shall be smooth, even without any burrs on the cut edges. The welding shall be perfect and the successful tenderer shall take radiographs and furnish the same to the purchaser to depict the perfectness of welding,

4.65 WELDING OF JOINTS:

4.66 Surface to be welded shall be cleaned thoroughly so that the same are free from grease, dust and loose particles. Sleeves shall be used for welded joints under short circuit conditions.

4.67 Pure argon gas shall be used for welding. In view of argon gas shield around the arc, the welding operation shall be shielded from wind that could displace the gas envelope.

4.68 The welding process shall be carried out at the rate of 15-30 cms per minute. After completion of welding, the surface shall be cleaned.

4.69 The ' weld ' shall have an average strength ranging from 120 to 155 KG/cm2.

4.70 TESTING AND COMMISSIONING

4.71 After satisfactory completion of works as detailed in clause 1.05 and 2.01 above, the tubular bus bars will be energised in the presence of the tenderer or his authorised representative.

4.72 TESTS

4.73 Radio - graphic tests:a) The test is intended for the presence of the cracks, discontinuity in the welds.b) A minimum of 10 % of the welded joints are to be subjected to radiographic tests. These

welded Joints shall be selected at random by the purchaser.c) Further if the purchaser desires for the radiographic test for more number of welded

joints, the contractor shall arrange for the same.

4.74 Test to prove the mechanical strength i.e, to withstand 155 KG/ cm2 shall be conducted on 5% of the welded joints.

SL No. Particulars Unit 75 mm 63 mm 50 mm 38 mm1 Nominal size mm 75 63 50 382 Outer diameter mm 88.9 73.03 60.33 48.263 Inner diameter mm 77.92 62.71 52.51 40.894 Wall thickness mm 5.449 5.16 3.91 3.685 Area of cross-section Sq. mm 1439 1100 693.55 516.136 Weight per unit length Kg/mtr 3.884 2.97 1.878 1.4

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7 Section modules Cubic cm

28.258 17.451 9.186 5.345

8 Movement of inertia Cm 4 125.606 63.683 27.709 12.99 Radius of gyration Cm 2.957 2.406 1.999 1.58110 DC Resistance (max)

at 20 deg CMicro ohm/mtr

21.8 28.4 45.149 60.73

11 Reactance at 304.8 mm ( 1 foot ) spacing at 50 Hz

Micro ohm/mtr

123.7 136.2 148.3 162.73

12 Current rating at 50 Hz for outdoor conditions

Amps 2350 1950 1440 1160

ANNEXURE -II

CHEMICAL PROPERTIES OF ALUMINIUM ALLOY

(Clause 10.03)

1. I.S specification 5082-1981 6340-wp type orequivalent of anyinternational standards.

2. Chemical composition percentage Cu - 0.04 MaxMg - 0.4 to 0.9.Si - 0.3 to 0-7.Fe- 0.5 Max.

- 0.03 MinAl - remaining part

3. Minimum 0.2% proof stress 16.5 Kg. Per Sq.rrm

4. Minimum ultimate tensile strength 20.5 Kgs/Sq.mm

5. Minimum toleration on 50 mm. 10%

6. Electrical resistivity (max) at 20* C 1133 Micro ohms cm

7. Minimum electrical conductivity 55% I.A.C.S

8. Temperature co-efficient of resistanceper centigrade degree 0.00364

9. Linear temperature co-efficient ofexpansion (20 deg C - 200 Q percentigrade degree 0.000023

10. Thermal conductivity(Calories/sec/sq. mm/cm/deg. Qat 100 deg C 0.43

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11. Modulus of elasticity 6700 Kgs./sq.mm.

5.0 EARTHING CONDUCTORS

5.1 General

All conductors buried in earth and concrete shall be of mild steel. All conductors above ground level and earthing leads shall be of galvanized steel, except for cable trench earthing. The minimum sizes of earthing conductor to be used are as indicated in clause 8.4 of this section.

5.2 Constructional features 5.2.1 Galvanised steel

a) Steel conductors above ground level shall be galvanized according to IS : 2629.b) The minimum width of the zinc coating shall be 618 gms/sq.m and minimum

thickness shall be 85 microns.c) The galvanized surface shall consist of a continuous and uniformly thick coating

of zinc, firmly adhering to the surfaces of steel. The finished surface shall be clean and smooth and shall be free from defects like discoloured patches, bare spots, unevenness of coating, spelter which is loosely attached to the steel globules, spiky deposits, blistered surface, flaking or peeling off etc. The presence of any of these defects noticed on visual or microscopic inspection shall render the material liable to rejection

5.3 Tests

In accordance with stipulations under section - 2 galvanised steel shall be subjected to four one minute dips in copper sulphate solution as per IS .- 2633.

6.0 VOID

7.0 BUS POST INSULATORS

The post insulators shall conform in general to latest IS 2544, IEC – 168, IEC – 815 and IS: 5350.

7.1 Constructional Features

7.1.1 Post type insulators shall consist of a porcelain part permanently secured in a metal base to be mounted on the supporting structures. They shall be capable of being mounted upright. They shall be designed to withstand any shocks to which they may be subjected to, by the operation of the associated equipment. Only solid core insulators will be acceptable.

7.1.2 Porcelain used shall be homogeneous free from lamination cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture.

7.1.3 Glazing of the porcelain shall be of uniform brown in colour, free from blisters, burrs and other similar defects.

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7-1.4 The insulator shall have alternate long and short sheds with aerodynamic profile. The shed profile shall also meet the requirements of IEC - 815 for the specified pollution level.

1.1.5 When operating at normal rated voltage there shall be no electric discharge between conductor and insulators which would cause corrosion or injury to conductors or insulator by the formation of substance produced by chemical action.

7.1.6 The design of the insulators shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration.

7.1.7 All ferrous parts shall be hot dip galvanised in accordance with the latest edition of IS : 2633, & IS : 4579. The zinc used for galvanising shall be grade Zn 99.95 as per IS : 209. The zinc coating shall be uniform, adherent smooth, reasonably bright, continuous and free from imperfections such as flux ash, rust stains bulky white deposits and blisters. The metal parts shall not produce any noise generating corona under the operating conditions.

7.1.8 a) Every bolt shall be provided with a steel washer under the nut so that part of the threaded portion of the bolts is within the thickness of the parts bolted together.

b) Flat washer shall be circular of a diameter 2.5 times that of bolt and of’ suitable thickness. Where bolts heads/nuts bear upon the levelled surfaces they shall be provided with square tapered washers of suitable thickness to afford a seating square with the axis of the bolt.

c) All bolts and nuts shall be of steel with well formed hexagonal heads forged from the solid and shall be hot dip galvanised. The nuts shall be good fit on the bolts and two clear threads shall show through the nut when it has been finally tightened up.

7.1.9 Bidder shall make available data on all the essential features of design including the method of assembly of shells and metals parts, number of shells per insulator. The manner in which mechanical stresses are transmitted through shells to adjacent parts, provision for meeting expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions.

7.2 Tests

In accordance with the stipulations under section - 2 the post insulators shall be subject to type, acceptance, sample and routine tests as per IS : 2544 and IEC - 168

7.2.1 In addition to acceptance/sample/ routine tests as per IS : 2544 and IEC-168, the following tests shall also be carried out.

a) Ultrasonic test as an acceptance testb) Soundness test, metallurgical tests and magnetic test on MCI caps and pedestal tests as

acceptance test.c) All hot dip galvanised components shall be subject to check for uniformity of thickness

and weight of zinc coating on sample basis.d) The bending test shall be carried out at 50% minimum falling loads in four directions as a

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e) Acceptance norms for visual defects allowed at site and also at works shall be agreed in the quality plan

7.2.2 The following type tests are proposed to be conducted on the post insulators. The test charge for conducting these tests shall be indicated in the offera) Power frequency withstand test (dry & wet) .b) Lightning impulse test (dry).c) Measurement of R.I.V. (Dry).

As per Annexure - A. section - 2.d) Corona extinction voltage test (Dry).

As per Annexure - A, section - 2.e) Test for deflection under load.f) Test for mechanical strength

7.3 Technical parameters of Bus post insulators

Sl No. Type Solid coreA Voltage class (KV) 245 123 72.5 36B Dry and wet one

minute power frequency withstand voltage (KV rms)

460 230 140 70

C Dry lighting impulse withstand voltage (KVP) + / - 1050 550 325 170

D Wet switching surge withstand voltage (KVP)

- - - -

E Max radio interference voltage ( in microvolts) at voltage 156(rms) for 220KV between phase to ground

1000 - - -

F Corona extinction voltage( KV rms)

245 KV 123 KV 72.5 KV 36 KV

G Total minimum cantilever strength (KN)

6 6 6 6

H Minimum torsional moment

As per IEC 273

As per IEC 273

As per IEC 273

As per IEC 273

I Total height of insulator(mm)

2300 1220 770 445

J PCDTop (mm) 127 127 127 76Bottom (mm) 254 225 127 76

K No. of bolts

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Top (mm) 4 4 4 4Bottom (mm) 4 4 4 4

L Diameter of bolt holes (mm)Top (mm) M16 M16 M16 M12Bottom (mm) 18 18 16 12

M Pollution level as per IEC 815

Heavy(III) Heavy(III) Heavy(III) Heavy(III)

N Minimum total creepage distance for heavy pollution (mm)

6125 3075 1815 900

7.3.4 If corona extinction voltage is to be achieved with the help of corona ring or any other similar device, the same shall be deemed to be included in the scope of the contractor.

8.0 EARTHING

8.1 The earthing shall be in accordance with requirements given here under. The earthmat design/drawing to be furnished by successful bidder.

8.2 Neutral points of system of different voltages, metallic enclosures and frame works associated with all current carrying equipments and extraneous metal works associated with electric system shall be connected to a single earthing system unless stipulated otherwise.

8.3 Earthing and lightning protection system installation shall be in strict accordance with the latest editions of Indian electricity rules, relevant Indian electricity rules, relevant in the locality where the system is installed.

a) Code of practice for earthing IS : 3043b) Code of practice for the protection of Building and allied structures against

lightning IS: 2309c) Indian electricity rules 1956 with latest amendments.d) National electricity- safety code IEEE - 80

8.4 Details of earthing system

Item Size Material

a) Main earthing conductorto be buried in ground

b) Conductor above ground As per approved design && earthing leads drawing(for equipment)

c) Conductor above ground& earthing leads (forcolumns & aux. Structures)

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d) Earthing of indoor LT panelsand out door marshalling boxes,MOM boxes, junction boxes& lighting panels etc.,

e) Rod earth electrode

f) Pipe earth electrode (in treated 100mm dia, C. I pipeearth pit) as per IS. 2750mm long

g) Earthing for motors 25x3mm GS flat --- do---

h) Earthing conductor along 5Ox6mm MS Mild steeloutdoor cables trenches flat

8.5 Earthing Conductor Layout

8.5.1 Earthing conductors in outdoor areas shall be buried at least 600 mm below finished ground level unless stated otherwise

8.5.2 Whenever earthing conductor crosses cable trenches, underground service ducts, pipes, tunnels, railways tracks etc., it shall be laid minimum 300mm. below them and shall be re-routed in case it fouls with equipment/ structure foundations.

8.5.3 Tap connections from the earthing grid to the equipment/structure to be earthed shall be terminated on the earthing terminals of the equipment/structure as per "Earthing Details-

8.5.4 Earthing conductors or leads along their run on cable trench ladder columns, beams, walls etc., shall be supported by suitable welding/cleating at intervals of 750 mm. Wherever it passes through walls, floors etc., galvanised iron sleeves shall be provided for the passage of the conductor and both ends of the sleeve shall be sealed to prevent the passage of water through the sleeves.

8.5.5 Earthing conductor around the building shall be buried in earth at a minimum distance of 1500 mm from the outer boundary of the building. In case high temperature is encountered at some location, the earthing conductor shall be laid minimum 1500 mm away from such location.

8.5.6 Earthing conductors crossing the road shall be laid 300mm below road or at greater depth to suit the site conditions.

8.5.7 Earthing conductors embedded in the concrete shall have approximately 50 mm concrete cover

8.6 Equipment and Structure Earthing

8.6.1 Earthing pads shall be provided for the apparatus/equipment at accessible position. The connection between earthing pads and the earthing grid shall be made by two short earthing leads (one direct and another through the support structure) free from kinks and

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splices. In case earthing-pads are not provided on the item to be earthed, same shall be provided in consultation with owner.

8.6.2 Whether specifically shown in drawings or not, steel/RCC columns, metallic stairs etc., shall be connected to the nearby earthing grid conductor by two earthing leads.

Electrically continuity shall be ensured by bonding different sections of hand-rails and metallic stairs.

8.6.3 Metallic pipes, conduits and cable tray sections for cable installation shall be bonded toensure electrical continuity and connected to earthing conductors at regular

interval. Apart from intermediate connections, beginning points shall also be connected to earthing system.

8.6.4 Metallic conduits shall not be used as earth continuity conductor.

8.6.5 A separate earthing conductor shall be provided for earthing lighting fixtures receptacles, switches, junction boxes, lighting conduits etc.

8.6.6 Wherever earthing conductor crosses or runs along metallic structures such as gas, water, steam conduits, etc., and steel reinforcement in concrete it shall be bonded to the same.

8.6.7 Light poles, junction boxes on the poles, cable and cable boxes/glands, lockout switches etc., shall be connected to the earthing conductor running alongwith the supply cable which inturn shall be connected to earthing grid conductor at a minimum two points whether specifically shown or not.

8.6.8 Railway tracks within switchyard area shall be earthed at a spacing of 30m and also at both ends.

8.6.9 Earthing conductor shall be buried 1500mm away from the switchyard fence. All thegates and every alternate post of the fence shall be connected to earthing arid as

specified in earthmat design.

8.6.10 Flexible earthing connectors shall be provided for the moving parts.

8.6.11 All Lighting panels, junction boxes, receptacles fixtures, conduits etc., shall be bonded in compliance with the provision of I.E. rules

8.6.12 A continuous wound conductor of 16 SWG wire shall be run all along each conduit run and bonded at every 600mm. by not less than two turns of the same size of wires. The conductor shall be connected to each panel ground bus. All junction boxes, receptacles, lighting fixtures etc., shall be connected to this 16 SWG ground conductor.

8.6.13 50mm x 6mm MS flat shall run on the top tier and all along the cable trenches and the same shall be welded to each of the racks. Further this flat shall be earthed at both ends and at an interval of 30 Mtrs. The M.S. flat shall be finally painted with two coats of red oxide primer and two coats of post office red enamel paint

8.7 Jointing

8.7.1 Earthing connections with equipment earthing pads shall be bolted type. Contact surface shall be free from sales, paint, enamel, grease, rust or dirt. Two bolts shall be provided for

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making each connection. Equipment bolted connections, after being checked and tested, shall be painted with and corrosive paint/compound.

8.7.2 Connection between equipment earthing lead and main earthing conductors and between main earthing conductors shall be welded type. For rust protections, the welds should be treated with red lead and afterwards coated with two lavers bitumen compound to prevent corrosion

8.7.3 Steel to copper connections shall be brazed type and shall be treated to prevent moisture ingression.

8.7.4 Resistance of the joint shall be more than the resistance of the equivalent length of the conductor.

8.7.5 All ground connections shall be made by electric arc welding. Ail welded joints shall be allowed to cool down gradually to atmospheric temperature before putting any load on it. Artificial cooling shall not be allowed.

8.7.6 Bending of earthing rod shall be done preferably by gas heating.

8.7.7 All arc welding with large dia. Conductors shall be done with low hydrogencontent electrodes

8.7.8 The 50x 6 mm 41 flat shall be clamped with the equipment support structures at1000mm interval.

8.8 Power Cable Earthing

Metallic sheaths and armour of all multicore power cables shall be earthed at both equipment and switchgear end. Sheath and armour of single core power cables shall be earthed at switchgear end only.

8.9 Specific Requirement for Earthing Systems

8.9.1 Each earthing Iead from the neutral of the power transformer shall be directly connected to two pipe electrodes in treated earth pit (as per IS ) which in turn, shall be burred in cement concrete pit with a cast iron cover hinged to a cast iron frame to have an access to the joints. All accessories associated with transformer like cooling banks, radiators etc., shall be connected to the earthing grid at minimum two points.

8.9.2 Earthing terminal of each lightning arrester & capacitor voltage transformer shall be directly connected to rod earth electrode which in turn shall be connected to station earthing grid,

8.9.3 Auxiliary earthing mat comprising of closely spaced (300mm x 300mm)conductors shall be provided at depth of 300 mm from ground level below the operating handles of the M.0.M box of the isolators. M.0.M boxes shall be directly connected to the auxiliary earthing mat.

9.0 Main Bus Bars

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The brief description of the bus switching scheme, bus bar layout and equipment connection to be adopted are indicated in section-1. The bus bar arrangements are shown in drawings enclosed with the bid documents.

9.1 The welds in the aluminium tubes shall be kept to the minimum and there shall not be more than one weld per span. The procedure and details of welding shall be subject to owner's approval. Material for welding sleeve shall be same as that of aluminium tube. Welding sleeve shall be of 600mm length.

9.1.1 Corona bells be provided wherever the bus extends beyond the clamps and on free ends, for sealing the ends of the tubular conductor against rain and moisture and to reduce the electromagnetic discharge loss at the end points. There shall be a small drain hole in the corona bell. The material of corona cell shall be aluminium alloy similar to that of clamps & connectors.

9.1.2 Details of past experience of the persons proposed to be employed for Aluminium tube welding and the test reports of the welded pieces to prove the electric and mechanical characteristics shall also be furnished along with the bid. Welding at site shall be done by adopting a qualify procedure and employing qualified welders as per ASME - section IX.

10.0 BAY EQUIPMENT:

10.1 The disposition of various bay equipment is shown in single line diagrams and layout drawings.

10.2 Bay Marshalling Kiosk

One number of bay marshalling kiosk shall be provided for each 220 KV bay. The bay marshalling kiosk shall be provided in 110 KV bays and 66 KV bays as per necessity. In addition to the requirement specified in section 2 (GTR). the bay marshalling kiosk shall have three distinct compartments for the following purpose:

i) 200 nos. terminal blocks in vertical formation for lnterlocking facilities.

Additional marshalling kiosk shall be provided in case the existing marshalling kiosks do not have adequate spare feeders.

11.0 LIGHTNING PROTECTION:

11.1 Direct stroke lightning protection (DSLP) shall be provided in the EHVswitchyard by lightning masts and shield wires. The layout drawings enclosed indicate the tentative arrangement.

11.2 The lightning protection system shall not be in direct contact with underground metallic service ducts and cables.

11.3 A 40 mm dia. 2750 mm long earth electrode with test links , CI frame and cover shall be provided to connect down conductor of lightning masts and towers with peak.

11.4 conductors of lightning protection system shall not be connected with the conductors of safety earthing system above ground level.

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11.5 Down conductors shall be cleated on the structures at 2000 mm interval.

11.6 Connection between each down conductor and rod electrode shall be made via test joint ( pad type compression clamp ) located approx. 1500 mm above ground level.

11.7 Lightning conductors shall not pass through or run inside G.I conduits.

11.8 All metallic structures within a vicinity of 2000 mm in air and 5000 mm below ground shall be bound to the conductors of lightning protection system.

12.0 TERMINAL POINTS

The terminal points for the scope of work of switchyard are given below

12.1 Line Feeders

12.1.1 The transmission line shall terminate on line side gantry structure. The supply and erection of tension insulator string for line termination and tension clamps for earth wire termination are included in the scope of the Bidder.

12.1.2 Lightning protection down conductor at this end, tap offs and jumper connections from this dead end to all equipment in the switchyard are also in the Bidder's scope.

13.0 EQUIPMENT ERECTION NOTES

13.1 All support insulators, circuit breaker interrupters and other fragile equipment shall preferably be handled with cranes having suitable booms and handling capacity.

13.1.1 The slings shall be of sufficient length to avoid any damage to insulator due to excessive swing, scratching by sling ropes etc.

13.1.2 Handling equipment, sling ropes etc., should be tested periodically before erection for strength.

13.1.3 Bending of compressed air piping if any should be done by a bending machine and through cold bending only. Bending shall be such that inner diameter of pipe is not reduced

13.1.4 Cutting of the pipes wherever required shall be such as to avoid flaring of the ends. Hence only a proper pipe cutting tool shall be used. Hack saw shall not be used.

13.1.5 Muslin or leather cloth shall be used for cleaning the inside and outside of hollow insulators.

13.1.6 All the equipment, instruments and auxiliaries required for testing andcommissioning of equipment shall be arranged at site by the contractor.

13.2 STORAGE

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13.2.1 The contractor shall provide and construct adequate storage shed for proper storage of equipments, where sensitive equipments shall be stored indoors. All equipments during storage shall be protected against damage due to acts of nature or accidents.

The storage instructions of the equipment manufacturer / owner shall be strictly adhered to.

14.0 EARTHING MATERIAL

Cable tags and Markers

Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedule.

14.2 The tag shall be of aluminium with the number punched on it and securelyattached to the cable conduit by not less than two turns of 20 SWG GI wire conforming to IS : 280. Cable tags shall be of rectangular, shape for power cables and of circular shape for control cables.

14.3 Location of cables laid directly underground shall be clearly indicated with cable marker made of galvanised iron plate.

14.4 Location of underground cable joints shall be indicated with cable marker with an additional inscription "cable Joints".

14.5 The marker shall project 150 mm above ground and shall be spaced at an interval of 30 meter and at every change in direction. They shall be located on both sides of road and drain crossings.

14.6 Cable tags shall be provided on all cables at each end ( just before entering the equipment enclosure ), on both sides of a wall or floor crossing, on each duct/conduit entry and at every twenty meters ( 20 m ) in cable tray/trench runs. Cable tags shall be provided inside the switchgear, motor control centres, control and relay panels etc., wherever required for cable identification, where a number of cables enter together through a gland plate.

14.7 Storage and handling of cable drums

14.7.1 Cable drums shall be unloaded, handled and stored in an approved manner and rolling of drums shall be avoided as far as possible. For short distances, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In the absence of any indication the drums may be rolled in the same direction as it was rolled during taking up the cables.

14.8 Cable Supports and Cable Tray Mounting Arrangements

14.8.1 The contractor shall provide embedded steel inserts on concrete floors/walls to secure supports by welding to these inserts or available building steel structures, for the purpose of casting in the control room.

14.8.2 The supports shall be fabricated from standard structural steel members.

14.8.3 Insert Plates and the Cable support angles shall be provided as per the drawings enclosed. of 409

14.9 Cable Termination and Connections

14.9.1 The termination and connection of cables shall be done strictly in accordance with cable and termination and kit manufacturer's instructions, drawing and / or as directed by the owner.

14.9.2 The work shall include all clamping fittings, fixing, plumbing, soldering, drilling, cutting taping heat shrinking ( where applicable), connecting to cable terminal shorting and grounding as required to complete the job.

14.9.3 Supply of all consumable material shall be in the scope of contractor.

14.9.4 The equipment will be generally provided with undrilled gland plates for

cables / conduit entry. The contractor shall be responsible for drilling of gland plates, painting and touching up. Holes shall not be made by gas cutting.

14 9.5 Control cable cores entering control panel, switchgear / MCCB / miscellaneous panels shall be neatly bunched, clamped and tied with nylon strap or PVC perforated strap to keep them in position.

14.9.6 The contractor shall tape / ferrule control cable cores at all termination's, as instructed by the owner. In panels where a large number of cables are to be terminated and cable identification may be difficult, each core ferrule may include the complete cable number as well.

14.9.7 Spare cores shall be similarly tagged with cable numbers and coiled up.

14.9.8 All cable entry points shall be scaled and made vermin and dust proof. Unused openings shall be effectively closed.

14.9.9 Double compression type nickel plated ( coating thickness not less than 10 microns) brass cable glands shall be provided by the contractor for all power and control cables to provide dust and weather proof termination's.

14.9.10 The cable glands shall be tested as per BS : 6121. They shall comprise of heavy duty brass casting, machine finished and nickel plated, to avoid corrosion and oxidation. Rubber components used in cable glands shall be neoprene and of tested quality. Cable glands shall be of approved make.

14.9.11 The cable glands shall also be tested for dust proof and weather proof termination. The test procedure has to be discussed and agreed to between owner and cable gland manufacturer.

14.9. 12 If the cable- end box or terminal enclosure provided on the equipment is found unsuitable and requires modification, the same shall be carried out by the contractor, as directed by the owner.

14.9. 13 Crimping tool used shall be of approved design and make.

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14.9.14 Cable lugs shall be of tinned copper solderless crimping type conforming to IS - 8309 & 8394 . Cable lugs shall be of approved make.

14.9.15 Solderless crimping of terminals shall be done by using corrosion inhibitory compound. The cable lugs shall suit the type of terminals provided.

15.0 DIRECTLY BURIED CABLES

15.1 The contractor shall construct the cable trenches required for directly buried cables. The scope of work shall include excavation, preparation of sand bedding, soil cover, supply and installation of brick or concrete protective covers, back filling and ramming, supply and installation of route markers and Joint markers. The bidder shall ascertain the soil conditions prevailing at site, before, submitting the bid.

15.2 The cable (power and control) between LT station, control room and DG set room and fire lighting pump house shall be laid in the buried cable trenches. In addition to the above, for lighting purpose also, buried cable trench can be used in outdoor area.

15.3 Cable route and joint markers and RCC warning covers shall be providedwherever required. The voltage grade of cables shall be engraved on the marker.

16.0 INSTALLATION OF CABLES

16.1 Cabling shall be on cable racks, in built-up trenches, vertical shafts, excavated trenches for direct burial, pulled through pipes and conduits laid in concrete ducts, run bare and clamped on wall/ceiling/steel structures etc., as shown in the drawings in detailed Engineering stage. Where specific cable layouts are not shown on drawings, Contractor shall route these as directed by the owner.

16.2 The contractor shall fabricate and install mounting arrangements for the support and installation of all the cables on angles in the trenches. These mounting structures/cable racks shall be fabricated from structural steel members (channels, angles and flats) of the required size. The fabrication, welding and erection of these structures shall conform to the relevant clauses of chapter - STRUCTURES in addition to the specification given herein.

16.3 Cable racks and supports shall be painted after installation with two coats of metal primer (comprising of red oxide and zinc chromate in a synthetic medium) followed by two firiishing coats of aluminium paint. The red oxide and zinc chromate shall conform to IS : 2074. All welding works inclusive of the consumables required for fabrication and installation shall be 'in the scope of the contractor.

16 4 All interpole cables (both power and control) for all equipment, shall be laid in cable trenches conduit pipes of NTB 50/100 mm diameter, class medium as per IS: 1239/part-I and IS : 4736 which shall be buried in the ground at a depth of 250 mm. The interpole cabling piping of breakers shall be laid in cable trenches. The scope shall

include all labour, material, equipment, for transporting, laying, burying etc., including required bends and end seals.

16.5 Cables shall be generally located adjoining the electrical equipment through the pipe insert embedded in the floor. In the case of equipments located away from cable trench either pipe inserts shall be embedded in the floor connecting the cable trench and the

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equipment or in case the distance is small notch / opening on the floor shall be provided. In all these cases necessary bending radius as recommended by the cable manufacturer shall be maintained. Cabling in the control room shall be done on ladder type cable trays.

16.6 Cables from the equipment to trench shall run in conduits. Necessary conduits of adequate sizes and length shall be supplied and installed by the contractor. Flexible conduit should be used between fixed conduit/cable trays (perforated type) and equipment terminal boxes, where vibrations are anticipated. The flexible conduit shall be as per the relevant IS

16.7 Power and control cables shall be laid in separate tiers. The order of laying of various cables shall be as follows, for cables other than directly buried.

a) Power cables on top tiers,b) Control, instrumentation and other service cables in bottom tiers.

16.8 Single core cables in trefoil formation shall be laid with a distance of three times the diameter of cable between trefoil centre lines. All power cables shall be laid with a minimum centre to centre distance equal to twice the diameter of the cable.

16.9 Trefoil clamps for single core cables shall be of pressure die cast aluminium (LM- 6), Nylon - 6 or fibre Pads and shall include necessary fixing GI nuts, bolts, washer etc., These are required at every 2 meter of cable runs.

16.10 Power and control cables shall be securely fixed to the trays/supports with self locking type nylon ties with de-interlocking facility at every 5 meter interval for horizontal run. Vertical and inclined cable runs shall be secured with 25 mm wide and 2mm thick aluminiurn strip clamps at every 2m

16.11 Cables shall not be bent below the minimum permissible limit. The permissible limits are as follows:

Power cable - 12DControl cable - 10 Dwhere D is overall diameter of cable

16.12 Where cables cross roads, drains and rails tracks, these shall be laid in reinforced spun concrete or steel pipes buried at not less than one metre depth,

16. 13 In each run some extra length shall be kept at a suitable point to enable one (for LT cables)/two (for H.T. cables) straight through joints to be made in case the cable develop fault at a later date.

16.14 Selection of cable drums for each run shall be so planned as to avoid using, straight through joints. Cable splices will not be permitted except where called for by the drawings, unavoidable or where permitted by the owner. If straight through joints are unavoidable, the contractor shall use the straight through joints kit of reputed make.

16.15 Control cable termination's inside equipment enclosure shall have sufficient lengths so that changing of termination In terminal blocks can be done without requiring any splicing

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16.16 Metal screen and armour of the cable shall be bonded to the earthing system of the station, wherever required by the owner

16.17 Rollers shall be used at intervals of about two meters while pulling cables.

16.18 All due care shall be taken during unreeling, laying and termination of cable to avoid damage due to twist, kinks, sham bends, etc,

16.19 Cable ends shall be kept sealed to prevent damage.

16.20 Inspection on receipt, unloading and handling of cables shall generally be in accordance with IS : 7255 and other Indian Standard Codes of practices

16.21 Wherever cable pass through floor or through wall openings or other partitions, wall sleeves with bushes having a smooth curved internal surface so as not to damage the cable should be supplied, installed and properly sealed by the contractor.

16.22 Contractor shall remove the RCC / steel trench covers before taking up the work and shall replace all the trench covers after the erection work in that particular area is completed or when further work is rot likely to be taken up for some time.

16.23 Contractor shall furnish three copies of the report on work carried out in aparticular week, indicating cable numbers, date on which laid, actual length and route, testing carried out, terminations carried out, along with the marked up copy of the cable schedule and interconnection drawing wherever any modification are made.

16.24 Contractor shall paint the tray identification number on each run of trays at an interval on 10 m

16.25 In case the outer sheath of a cable is damaged during handling / installation, the contractor shall repair it at his own cost to the satisfaction of the owner. In case any other part of a cable is damaged, the same shall be replaced by a healthy cable at no extra cost of' the owner, i.e. the contractor shall not be paid forinstallation and removal of the damaged cable.

16.26 All cable terminations shall be appropriately tightened to ensure secure and reliable connections. The contractor shall cover the exposed part of all cable lugs whether supplied by him or no, %kith insulating tape, sleeve or paint.

16.27 Tests on Cable Trays

The contractor shall perform all tests and inspection to ensure that material and workmanship are according to the relevant standards. Contractor shall have to demonstrate all, tests as per specification and equipment shall comply with all requirements of the specification.

a) Test for galvanising ( Acceptance Test)

The test shall be done as per approved standards.

b) Deflection Test : (Type Test) of 409

A 2.5 metre straight section of 300 mm, 600 mm wide cable tray shall be simply supported at two ends. A uniform distributed load of 76 Kg-m shall be applied along with the length of the tray. The maximum deflection at the mid-span shall not exceed 7mm.

16.28 Conduits, Pipes and Duct Installation

16.28.1 Contractor shall supply and install all grid conduits, mild steel pipe & flexible conduits, hume pipes etc including all necessary sundry materials such as tees, elbows, check nuts, bushing reducers, enlargers, coupling cap, nipples, gland sealing fittings, pull boxes etc as specified and to be shown in detailed drawing. The size of the conduit/pipe shall be selected on the basis of 40% fill criterion.

16.28.2 Contractor shall have his own facility for bending cutting and trenching the conduits at site. Cold bending should be used. Ail cuts & threaded ends shall be made smooth without leaving any sharp edges. Anti-corrosive paint shall be applied at all field threaded portions.

16.28.3 All conduit/pipes shall be extended on both sides of wall/floor openings. The fabrication and installation of supports and the clamping shall be included in the scope of work by contractor.

16.28.4 When two lengths of conduits are joined together through a coupling. Running threads equal to twice the length of coupling shall be provided on each conduit to facilitate easy dismantling of two conduits.

16.28.5 Conduit installation shall be permanently connected to earth by means of special approved type of earthing clamps. GI pull of adequate size shall be laid in all conduits before installation.

16.28.6 Each conduit run shall be painted with its designation as indicated on the drawings such that it can be identified at each end.

16.28.7 Embedded conduit shall have a minimum concrete cover of 50 mm.

16.28.8 Conduit run sleeves shall be provided with the bushings at each end.

16.28.9 Metallic conduit runs at termination shall have two locknuts and a bushing for connection. Flexible conduits shall also be suitably clamped at each with the help of bushings. Bushings shall have rounded edges so as not to damage the cables.

16.28.1 Where embedded conduits turn upwards from a slab or fill, the termination dimensions shown on the drawings, if any, shall be taken to represent the position of the straight extension of the conduit external to and immediately following the bend. At least one half of the arc length of the bend shall be embedded.

16.28.11 All conduits/pipes shall have their ends closed by caps until cables are pulled. After cables are pulled, the ends of conduits/pipes shall be sealed in an approved manner to prevent damage to threaded portions and entrance of moisture and foreign material.

16.29.12 For underground runs, contractor shall excavate and back fill as necessary.

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16.28.13 Contractor shall supply, unload, store and install conduits required for the lighting installation as specified. All accessories/fittings required for making the installation complete, including but not limited to pull out boxes, ordinary and inspection tees and elbow, check-nuts, male and female bushings (brass or galvanised steel), caps, square headed male plugs, nipples, gland sealing fittings, pull boxes, conduits terminal boxes, gaskets and box covers, saddle terminal boxes, and all steel supporting work shall be supplied by thecontractor. The conduit fittings shall be of the same material as conduits.

16.28.14 All unarmoured cables shall run within the conduits from lighting panels to lighting fixtures, receptacles etc.

16.28.15 Size of conduit for lighting (shall be selected as per the table given in the drawings enclosed with the bid documents).

16.28.16 Exposed conduits shall be run in straight lines parallel to building columns, beams and walls. Unnecessary bends and crossings shall be avoided to present a neat appearance.

16.28. 17 Conduit supports shall be provided at an interval of 750 mm for horizontal runs and 1000mm for vertical runs.

16.28.18 Conduit supports shall be clamped on the approved type spacer plates or brackets by saddles or U-bolts. The spacer plates or brackets in turn, shall be securely fixed to the building steel by welding, and to concrete or brick –work by grouting, or by nylon raw plugs. Wooden plug inserted in the masonry or concrete for conduit support is not acceptable.

16.28.19 Embedded conduits shall be securely fixed in position to preclude any movement. In fixing embedded conduit, If welding or brazing is used, extreme care should be taken to avoid any injury to the inner surface of the conduit.

16.28.20 Spacing of embedded conduits shall be such as to permit flow of concrete between them and in no case shall be less than 38 mm.

16.28.2 1 Where conduits are along with cable trays, they shall be clamped to supporting steel at an interval of 600 mm.

16.28.22 For directly embedding in soil, the conduits shall be coated with an asphalt-base compound. Concrete pier or anchor shall be provided wherevernecessary to support the conduit rigidly and to hold it in place.

16.28.23 Conduit shall be installed in such a way as to ensure against trouble from trapped condensation

16.28.24 Conduits shall be kept, wherever possible, at least 300 mm away from hot pipes, heating devices etc., when it is evident that such proximity may reduce the service life of cables.

16.28.25 Slip joints shall be provided when conduits cross structural expansion joints or where long run of exposed conduits are installed, so that temperature change will cause no distortion due to expansion-or contraction of conduit run.

16.28.26 For long conduit run, pull boxes shall be provided at suitable intervals to facilitate wiring.

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16.28.27 Conduit shall be securely fastened to Junction boxes or cabinets, each with a lock nut inside and outside the box.

16.28.28 Conduit joints and connections shall be made thoroughly water-tight and rust proof by application of a thread compound which insulates the joints. White lead is suitable for application on - embedded conduit and red lead for exposed conduit.

16.28.29 Field bends shall have a minimum radius of four (4) times the conduit diameter. All bends shall be free of kinks, indentations of flattened surfaces. Heat shall not be applied in making any conduit bend. Separate bends may be used for this purpose.

16.28.30 The entire metallic conduit system, whether embedded or exposed, shall be electrically continuous and thoroughly grounded. Where slip joints are used, suitable binding shall be provided around the joint to ensure a continuous ground circuit.

16.28.31 After installation, the conduits shall be thoroughly cleaned by compressed air before pulling in the wire.

16.28.32 Lighting fixtures shall not be suspended directly from the junction box in the main conduit run.

17.0 JUNCTION BOX

a) The contractor shall supply and install junction boxes complete withterminals as required. The brackets, bolts nuts, screws etc required forerection are also included in the scope of the contractor.

b) Junction boxes having volume less than 1600 cubic centimeters may beinstalled 'Without any support other than that resulting from connectingconduits where two or more rigid metallic conduits enter and accuratelyposition the box. Boxes shall be installed so that they are level, plumband properly aligned to present a pleasing appearance.

c) Boxes with volumes equal to or greater than 1600 cubic cm, and smaller boxes terminating on less than two rigid metallic conduits or for other reasons not rigidly held, shall be adequately supported by auxiliary steel of standard steel shapes or plates to be fabricated and installed. The contractor shall perform all drilling, cutting, welding, shimming and bolting required for attachment of supports.

18.0 TESTING AND COMMISSIONING:

18.1 An indicative list of tests are given below. Contractor shall perform an additional test based on specialties of the items as per the field Q.P/ instruction of the equipment contractor or owner without any extra cost to the owner. Thecontractor shall arrange all instruments required for conducting these testsalongwith calibration certificate and shall furnish the list of instruments to theowner for approval.

18.2 GENERAL CHECKS

a) Check for physical damage.

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b) Visual examination of zinc coating/plating.

c) Check from name plate that all items are as per order/specification

d) Check tightness of all bolts, clamps and connecting terminals using torque wrenches.

C) For oil filled equipment, check for oil leakage, if any. Also check oil leveland top up wherever necessary.

f) Check around connections for quality of weld and application of zinc richpaint over weld joint of galvanised surfaces.

g) Check cleanliness of insulator and bushings.

h) All checks and tests specified by the manufacturers and their drawings and manuals as well as all tests specified in the relevant code or erection.

i) Check for surface finish of grading rings (Corona control ring).

j) Pressure test on all pneumatic lines at 1.5 times the rated pressure shall be conducted .

18.3 STATION EARTHING

a) Check soil resistivity

b) Check continuity of grid wires

c) Check earth resistance of the entire arid as well as various sections of thesame.

d) Check for weld joint and application of zinc rich paint on galvanisedsurfaces.

e) Dip test on earth conductor prior to use.

18.4 TUBULAR BUS WORK AND POWER CONNECTORS

a) Physical check for finish

b) Electrical clearance check

c) Testing of torque by torque-wrenches on all bus bar power connectors and other accessories.

d) Millivolt drop test on all power connectors.

e) Sag and tension check on conductors

18.5 ALUMINIUM TUBE WELDING

a) Physical check

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b) Millivolt drop test on all joints

c) Dye penetration test & Radiography test on 10% samples basis on weldjoints

d) Test check on 5% sample joints after cutting the weld piece to observe any voids etc.

18.6 INSULATORS

Visual examination for finish, damage, creepage distance etc.,

19.0 In case of switchyard materials, although the quantities arc indicated in bid proposal sheets, the successful bidder shall supply the exact quantifies required to commission the substation as per the scope. The payment will be made for the quantity indicated in the Bid proposal sheets vis-a-vis the actual quantities (arrived at after the Engineering) whichever is lower.

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ANNEXURE- "A"

(Testing Procedure for ACSR DRAKE Conductor)

1.0 UTS Test on Stranded Conductor

Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor of minimum 5 m length suitably compressed with dead end clamps at either end. The load shall be increased at a steady rate upto 80 KN and held for one minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter the load shall be increased at a steady rate to 141.75 KN and held for one minute. The applied load shall then be increased until the failing load is reached and the value recorded.

2.0 VOID

3.0 VOID

4.0 D.C Resistance Test on Stranded Conductor

On a conductor sample of minimum 5 m length two contact clamps shall be fixed witha pre-determined bolt torque. The resistance shall be measured by a Kelvin double -

bridge by placing the clamps initially zero meter and subsequently one meter apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 20 deg C as per clause no. 12.8 of IS :398 (part V) 1982 . The resistance corrected at 20 deg C shall conform to the requirements of this specification

5.0 Chemical Analysis of Zinc

Sample taken from the zinc ingots shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this specification.

6.0 Chemical Analysis of Aluminium and Steel.

Sample taken from the aluminium ingots/strands shall be chemically spectrographically analysed. The same shall be in conformity to the requirements stated in this specification.

7.0 Visual Checks for Joints, Scratches etc.

Conductor drums shall be rewound in the presence of the inspector. The inspector shall visually check for scratches, Joints etc., and that the conductor generally conform to the requirements of this specification. The length of conductor wound on the drum shall be measured with the help of counter meter during re-winding.

8.0 Dimensional Checks for Steel and Aluminium Strands.

The individual strands shall be dimensionally checked to ensure that they conform to the requirements of this specification.

9.0 Check for Lay-ratios of Various Layers.

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The lay-ratios of various layers shall be checked to ensure that they conform to the requirements of IS specification and clause no- 9.4 and 9.5 of IS-398 (PartV) 1982.

10.0 Galvanising Test

The test procedure shall be as specified in 1S:4826-1968. The material shall conform to the requirements of this specification

11.0 Torsion and Elongation Tests on Steel strands

The test procedure shall be as per relevant clause of IS:398 (part V) 1982. In torsion test, the number of complete twists before fracture shall not be less than 18 on a Length equal to 100 times the standard diameter of the strand before stranding & 16 after stranding. In case test sample length of less or more than 100 times the standard diameter of the strand, the minimum number of twist will be proportionate to the length and if number comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the elongation of the strand shall not be less than 4% for a gauge length of 200mm

12.0 Breaking load test on welded Aluminium strands .

Two Aluminium wires, shall be welded as per the approved quality plan and shall be subjected to tensile load. The welded point of the wire shall be able to withstand the minimum breaking load of the individual strands guaranteed by the bidder

ANNEXURE B

(Testing Procedure for Galvanised Steel Earthwire)

UTS TEST

Circles perpendicular to the axis of the earth wire shall be marked at two places on sample of earth wire of minimum 5m length suitably compressed with dead end clamps at either end. The load shall be increased at steady rate upto 34 KN and held for one minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter, the load shall be increased at a steady rate of 56.98 KN and held for one minute. The earthwire sample shall not fail during this period. The applied load shall then be increased until the failing load is reached and value recorded.

2. D.C RESISTANCE TEST

On an earth wire sample of minimum 5 m length, two contact clamps shall be fixed with a pre-determined bolt torque. The resistance shall be measured by a Kelvin double-bridge by placing the clamps initially zero meter and subsequently one meter apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 20 deg C shall conform to the requirements of this specification.

3. Visual Check for joints, scratches etc. and length of earthwire

EarthWire drums shall be rewound in the presence of the inspector. The inspector shall usually check for Joints, scratches etc., and see that the earthwire generally conforms to the requirements of this specification. The length of earthwire wound on the drum shall be measured with the help of counter meter during rewinding.

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4 TORSION AND ELONGATION TESTS

The test procedure shall be as per relevant clause of IS:398 (part-V). The minimum number of twists which a single steel strand shall withstand during torsion test shall be eighteen for a length equal to 100 times the standard diameter of the strand. In case the test sample length is less or more than I00 times the standard diameter of the strand, the minimum number of twists will be proportionate to the length and if number comes in the fraction then it will be rounded off to next higher whole number, In elongation test, the elongation of the strand shall not be less than 64 for a gauge length of 200 mm.

5. DIMENSIONAL CHECK

The individual strands shall be dimensionally checked to ensure that they conform to the requirements of this specification.

6. LAY LENGTH CHECK

The length shall be checked to ensure that they conform to the requirements of this specification.

7, GALVANISING TEST

The test procedure shall as specified in IS : 4826-1968. The material shall conform to the requirements of this specification.

S. CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING

Samples taker, from zinc ingots shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this specification.

9. CHEMICAL ANAYSIS OF STEEL

Samples taken from ingots / coils / strands shall be chemically spectrogaphicallyanalysed. The same shall be in conformity to the requirements stated in thisspecification.

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SECTION – 7.0


STRUCTURES

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SECTION 7.0 STRUCTURES

CLAUSE PARTICULARS

1.00 GENERAL.

1.1 SCOPE.

1.2 LIGHTING MASTS.

1.3 DESIGN, DRAWINGS, BILL OF MATERIALS ANDDOCUMENUS.

1.4 FABRICATION OF STEEL.

1.5 ASSEMBLY.

1.6 BOLTING.

1.7 WELDING

1.8 STABILITY OF STRUCTURE.

1.9 GROUTING.

1.10 GALVANIZING.

1.11 INSPECTION BEFORE DISPATCH.

1.12 TEST CERTIFICATES.

1.13 ERECTION.

1.14 SAFETY PRECAUTIONS. of 409

VOLUME - IIATECHNICAL SPECIFICATIONS

SECTION 7.0(STRUCTURE)

1.0 GENERAL

1.1 The scope of specification covers fabrication, protoassembly, supply& erection of galvanized steel structure of towers, girders, &equipments structure. Towers, girders, support structure shall belattice/tubular type structure fabri6ated from structural steel conforming toIS:2062 (latest). Single line diagrams are provided for lattice type towers/ girders/lightning mass. Bidder has to develop the structural drawing for the same based on the single- line diagrams and switchyard diagram. Based on the switchyard requirements like live- point height, phase to phase dimension and weight, dimensions of the equipment / post insulators, the supporting structures are to be designed by the successful bidder, which shall be approved by the owner. Lattice type structures are proposed for all equipments and tubular type is proposed for post insulators.

The scope shall include all types of bolts, nuts, hangers shackles, clamps step bolts, inserts in concrete , gusset plates, equipment mounting bolts, structure earthing bolts, foundation bolts, spring washers, fixing plates angles & bolts for stiucture mounted or ground mounted marshalling boxes AC/DC Marshalling box & equipment control cabinets) and any other item as required to complete the job.

The connection of all structures to their foundations shall be by base plates embedded anchor/ foundation bolts. All steel structures & anchor/ foundation bolts shall be fully galvanized. The weight of the zinc coating shall be atleast 0.610Kg/sq m for anchor/ foundation bolts & for structural members. One additional nut shall be provided below the base plate, which may be used for the purpose of leveling.

1.2 Lighting masts

The lighting masts shall be fabricated as per owner's design and fabrication drawings lighting masts shall be provided with the structural steel ladder. The ladder shall be provided with protection rings. Platform shall be provided for mounting of lighting fixtures. The platform shall also have protection railing.

1.3 DESIGN DRAWINGS, BILL OF MATERIALS AND DOCUMENTS

The towers beams and lightning masts shall be fabricated as per the single line diagrams furnished. In the part 1 of Technical specifications, only the single line diagrams enclosed.

In respect of support (mounting) structures, the bidder has to quote as per their own designs. Successful bidder has to furnish the design/ drawings based on the equipments to be supplied, heights to be maintained which shall be approved by owner. Only after getting the due approval of the owner the fabrication work shall be taken up.

1.3.2 The fabrication drawing and Bill Of Materials(BOM) in respect of towers and beams shall be developed by the bidder based on the single-line diagram furnished. In case of

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support structures the bidder has to develop the fabrication drawing and the BOM based on the inputs from switchyard drawings and parameters of the equipment to be supplied.

1.4 FABRICATION OF STEEL :

1.4.1 the contractor shall bear the expenditure at all stage on account of loading unloading transportation and other miscellaneous expenses and losses and damages for all materials up to the fabrication yard shop and there-after to the erection site including all other expenses till the erection of work has been completed and accepted. The unit rates shall be deemed to be inclusive of all such incidental expenses and nothing extra shall be payable on any account in this regard.

1.4.2 The fabrication and erection shall be carried out generally in accordance with IS: 802 (latest). A reference however may be made to IS: 800(latest) in case of non-stipulation of some particular provision in IS: 802 (latest). All materials shall be completely shop fabricated furnished with proper connection material & erection marks for ready assembly in the field.

1.5 ASSEMBLY:

i) The component parts shall be assembled in such a manner that they are neither twisted nor otherwise damaged & shall be so prepared that the specified camber, if any, is provided. In order to minimize distortion in member the component parts shall be positioned by using the clamps, clips, dogs, jigs & other suitable means & fasteners (bolts & welds) shall be placed in a balanced pattern. If the individual components are to be bolted paralleled & tapered, drifts shall be used to align the part so that the bolts can be accurately positioned.

ii) Sample towers, beams & lightening masts shall be trial assembled keeping in view the actual site conditions, before erection, in the fabrication shop & shall be inspected & approved by owner before mass fabrication. Necessary match marks shall be made on these components in the shop before disassembly & dispatching,

1.6 BOLTING

i) Every bolt shall be provided with a spring washer under the nut so that no part of the threaded portion of the bolt is within the thickness of the parts bolted together.

ii) All steel items, bolts, nuts & washers shall be hot dip galvanized.

iii) 2% extra nuts & bolts shall be supplied for erection-

1.7 WELDING:

The work shall be done as per approved fabrication drawing which clearly indicate various details of joints to be welded, type of weld, length & size of weld, whether shop or site weld. Symbols for welding on erection & shop drawings shall be according to IS: 8 13. Efforts shall be made to reduce site welding so as to avoid improper welding due to constructional difficulties.

1.7 FOUNDATION BOLTS:

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1.7.1 Foundation bolts for the towers & equipment supporting structures & elsewhere shall be embedded in first stage concrete while the-foundation is cast. The contractor shall ensure the proper alignment of these bolts to match the holes in the base plate.

1.7.2 The contractor shall be responsible for the correct alignment & leveling of all steelwork on site to ensure that the towers/ structures are plumb.

1.7.3 All foundation bolts for lattice structure, pipe structure are to be supplied by the contractor.

1.7.4 All foundation bolts shall be fully galvanized so as to achieve 0.61 Kg per.sq m. of zinc coating as per specifications

1.8 STABILITY OF STRUCTURE:

The supplier shall be responsible for the stability of the structure at all stages of its erection at site & take all necessary by the additions of temporary bracing's & giving equipment & their operations.

1.9 GROUTING:

The method of grouting the column basts shall be subject to approval of owner & shall be such as to ensure a complete uniformly of contact over the whole area of the steel base. The contractor will be fully responsible for the grouting operations.

1.10 GALVANIZING:

1.10.1 All structural steel works & single pipe supports shall be galvanized after fabrication as per IS:2629(latest) IS:4759 (latest).

1.10.2 Zinc required for galvanizing shall have to be arranged by the manufacturer. Purity of zinc to be used shall be 99.5% as per IS:209 (latest revision)

1.10.3 The contractor shall be required to make arrangement for frequent inspection by the owner as well as continuous inspection by a resident representative of the owner, if so desired for fabrication work.

1.11 INSPECTION BEFORE DISPATCH:

Each part of the fabricated steelwork shall be inspected certified by the owner or his authorized representative as satisfactory before it is dispatched to the erection site. Such certification shall not relieve the contractor of his responsibility regarding adequately & completeness of fabrication.

1.12 TEST CERTIFICATE:

Copies of all test certificates relating to materials procured by the contractor for the works shall be forwarded to the owner.

1.13 ERECTION: of 409

The contractor should arrange his own erection plant & equipment, welding- set, tools tackles, scaffolding, trestles equipment's etc-, & any other accessories & ancillaries required for the work. The erection work shall be started after concrete has acquired its full strength i.e, 14 days . The members shall not be subjected to any undue stress, damage to steel or galvanizing during erection.

1.14 SAFETY PRECAUTIONS:

The contractor shall strictly follow at all stages of fabrication, transportation & erection of steel structures, raw materials & other tools & Tackles, the stipulation contained in Indian Standard Code for erection for structural steel work as per IS: 7205. (Latest revision).

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SECTION – 8


CIVIL WORKS

(Please refer the uploaded Civil Specifications separately)

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SECTION – 9.0


RELAY & PROTECTION PANELS WITH SUB-STATION AUTOMATION SYSTEM FOR 220KV SUB-STATIONS

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TECHNICAL SPECIFICATION FOR RELAY & PROTECTION PANELS WITH SUB-STATION AUTOMATION SYSTEM FOR

220KV SUB-STATIONS

SECTION –1 RELAY & PROTECTION PANEL

CLAUSE PARTICULARS

1.00 SCOPE.2.00 BRIEF DESCRIPTION OF PROJECT.3.00 STANDARDS.4.00 CLIMATIC & GEOGRAPHICAL CONDITONS5.00 SYSTEMS DETAILS.6.00 AUXILLARY SUPPLY.7.00 TYPE OF PANEL.8.00 CONSTRUCTIONAL FEATURES.9.00 MOUNTING.10.00 PAINTING.11.00 WIRING.12.00 TERMINAL BLOCKS AND TERMINAL

CONNECTORS.13.00 SPACE FOR CONTROL CABLE AND CABLE

GLANDS.14.00 VOID.15.00 NAME PLATE AND MARKINGS.16.00 INTERNALLY MOUNTED EQUIPMENTS,17.00 FUSES.18.00 EARTHING.19.00 VOID20.00 TEST TERMINAL BLOCKS.21.00 CONTROL SWITCHES,22.00 VOID23.00 PUSH BUTTON SWITCHES.24.00 SYNCHRONIZING EQUIPMENTS.25.00 VOID.26.00 INDICATING AND INTEGRATING EQUIPMENTS.27.00 RELAYS.28.00 PROTECTION SCHEME.29.00 PROTECTION PHILOSOPHY30.00 CO-ORDINATION OF DRAWINGS OF ASSOCIATED

EQUIPMENTS OF OTHER MANUFACTURES.31.00 DRAWINGS AND LITERATURES32.00 TESTS, TEST CERTIFICATES AND INSPECTION33.00 SPARES34.00 MAINTENANCE TOOLS & EQUIPMENT35.00 QUALITY ASSURANCE PLAN

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36.00 MINIMUM EXPERIENCE FOR QUALIFYING AS A TENDER.

37.00 PERFORMANCE GUARANTEE38.00 TRAINING TO BOARD ENGINEERS39.00 DESPATCH

40.0 DEVIATON FROM TECHNICAL SPECIFICATION41.00 SCHEDULE OF REQUIREMENTS & DELIVERY42.0 SCHEDULE OF PRICE.43.0 GUARANTEED TECHNICAL PARTICULARS.

ANNEXURE-RPP1-SASANNEXURE- RPP2-SASANNEXURE- RPP3-SASANNEXURE- RPP4-SASANNEXURE- RPP5-SASANNEXURE- RPP6-SASANNEXURE- RPP7-SAS ANNEXURE - SAS

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SECTION-2 SUB-STATION AUTOMATION:

CLAUSE PARTICULARS

1.0 GENERAL

2.0 SYSTEM DESIGN

3.0 BAY LEVEL FUNCTIONS

4.0 SYSTEM HARDWARE

5.0 SOFTWARE STRUCTURE

6.0 TESTS

7.0 SYSTEM OPERATION

8.0 POWER SUPPLY

9.0 DOCUMENTATION

10.0 TRAINING, SUPPORT SERVICE, MAINTENANCE &

SPARES

11.0 MAINTENANCE RESPONSIBILITY

12.0 RELIABALITY & AVAILABALITY

13.0 SPARES

14.0 LIST OF EQUIPMENTS

ANNEXURE – I (GTP IAS)ANNEXURE-RRP-TVM

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SECTION-1


TECHNICAL SPECIFICATION FOR RELAY & PROTECTION PANELS WITH SUB-STATION AUTOMATION SYSTEM FOR

220KV SUB-STATIONS

SECTION – RELAY & PROTECTION PANEL

1.00 SCOPE:

1.01 This Technical specification covers design, manufacture, inspection, testing at works and supply of relay and protection panels, with sub-station automation system for 220KV Sub-Stations of KSPDCL.

1.02 The equipment should conform in all respects to the relating standards and shall be manufactured to the highest quality of Engineering, design and workmanship. The equipment manufactured shall ensure satisfactory and reliable performance throughout the service life.

1.03 The equipments offered shall be complete in all respects. Any material / component / accessories/software not specifically stated in this specification but which is otherwise necessary for trouble free operation of the equipment specified in this specification shall be deemed to be included unless excluded expressly. All such components/ accessories / software shall be supplied at no extra cost.

1.04 The design and manufacturing shall be such that the equipment / components/ accessories/software of the same type and of identical rating shall be interchangeable. Likewise similar or corresponding parts/ components or accessories thereof shall also be interchangeable.

1.05 Wherever and whenever a material or article or component is specified or described by the name of a particular brand or manufacturer or vendor, the specific item mentioned shall be understood as establishing type, function and quality and not as limiting competition. However, tenderers are invited to offer other similar equipments/components/accessories provided they meet with the required standards, design, duties and performance.

1.06 All equipments offered shall confirm to type tests and shall also be subjected to acceptance and routine tests in accordance with the requirements stipulated herein. The purchaser reserves the right for conducting any or all of the type tests in accordance with the relevant standards. Such type tests shall be done free of cost. Where type tests have already been conducted the tenderer shall submit copies of the same along with tender. The type tests certificates should however be not older than

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five years as on the date of bid opening. Any extra cost for repeating the type tests shall be indicated in the relevant price schedules.

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2.00 BRIEF DESCRIPTION OF PROJECT:

2.01 The details of the project are as per Annexure enclosed.

2.02 The protection to be provided for various lines, transformers etc., shall be as follows:

i. Main protection i.e. distance scheme and differential scheme shall be of fast acting numerical type.

ii. Back up protection shall be of numerical type.

2.03 There may be changes in components ordered as per purchase order and as per approved drawing. However, subsequent inspection and supply of panels shall conform to the approved drawing.

3.00 STANDARDS:

Unless specified otherwise, equipment covered by this specification shall conform to the Indian Electricity Rules and to the latest editions of relevant Indian Standards, British or American IEC or other equivalent standard. In the event of supplies confirming to other equivalent international standards, the salient features of comparison shall be brought out in the tender. One copy of such standard specification in English language shall be enclosed with the tender. A general reference list of standards is furnished as follows:

Sl. No. Particulars IS BS IEC

1 Application guide for electrical relays for protection and other relays

3842 142 50

2 Electrical relays for power system 3231 ---- 502553 Current transformers 2705 ---- ----4 Voltage transformers 3156 ---- ----5 Push buttons and control switches (LV

switching devices for control and auxiliary circuits)

6875 ---- ----

6 AC electricity meter 722 ---- ----7 Static protective relay 8686 ---- ----8 Indicating instruments & recorders ---- 89/90 ----9 Fuses 2203 88 6610 AC static watt hour meter for active energy ---- --- 68611 Colours for ready mixed paints and enamels 5 ---- ---12 Ready mixed paints, brushing, finishing

exterior and semi glass for general purpose white

127 ---- ----

13 Paints, finishing interior white 641 ---- ----14 Direct acting indicating analog electrical

measuring instruments and their accessories1258

part : 1-57-9

---- ----

15 Degree of protection provided by enclosures for low voltage switch gear and control gear.

2147 ---- -----

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Sl. No. Particulars IS BS IEC16 Performance tests for protective

scheme used in protection of light gauge steel against corrosion

4177 ---- ----

17 Sub-Station Automation System ---- ---- 6185018 Communication Protocol ---- ---- 60870-5-10419 Numerical relays ---- ---- 6100020 Environmental testing ---- ---- 6821 Insulation co-ordination for

equipment with low-voltage system

---- ---- 664

4.00 CLIMATIC AND GEOGRAPHICAL CONDITIONS:

4.01

Sl.No. Particulars

1. Altitude Not exceeding 1000 Mtrs.2. a) Max. ambient air temperature 50 deg.C

b) Average daily ambient air temperature 35 deg.C3. Minimum ambient temperature 5 deg. C4. Relative humidity 10-100%5. Average annual rainfall 1000 to 3000mm / 5000mm6. Average period of rainfall in a year 5 months7. Maximum wind pressure in Kg/Sq. mt. 1508. Isoceraunic level 46

4.02 The climate is moderately hot, tropical climate conducive to rust and fungus growth.

4.03 The climatic conditions are given to indicate wide range of variation in ambient conditions.

4.04 All electrical devices shall be tropicalised and given fungicidal treatment. They shall also be capable of satisfactory operation under the hot and humid climatic conditions that would prevail at the site.

4.05 All the equipments, contacts, etc., shall be designed to withstand seismic acceleration equivalent 0.3 g. Air conditioning is not available in the control room.

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5.00 SYSTEM DETAILS:

5.01 Following is salient particulars of the system.

Sl. No.

Particulars 220 KV 110KV 66 KV 33 KV

1 Nominal system voltage (KV)

220 110 66 33

2 Highest system voltage (KV)

245 123 72.5 36

3 No. of phases 3 3 3 34 Frequency ( Hz) 50 50 50 505 Method of

groundingEffectively

earthedEffectively

earthedEffectively

earthedEffectively

earthed

5.02 The relays and meters shall be suitable for operation at 1 Amp Current Transformer secondary and 110V phase to phase and 63.5 volts phase to neutral, secondary voltage of the Voltage Transformer.

6.00 AUXILIARY SUPPLY:

6.01 The Purchaser shall make separate arrangement for providing low tension AC & DC power supply for control and auxiliary use. The tenderer shall give in his tender the estimate for AC & DC power required for the equipment covered by this specification.

6.02 The auxiliary supply voltage available is as follows:

Sl. No. Particulars Details

1 Power devices (like drive motors etc)

415V, 3 phase, 4 wire, 50Hz AC supply with one point grounded

2 AC control and protective devices

240V, 1 phase, 2 wire, 50 Hz AC supply with one point grounded

3 DC for alarm, control and protection devices

a) 220V for 220KV Stations. - 2 wire ungrounded DC supply from batteries and battery charger. The ripple content in the DC supply from the charger will be less than 2%

The above supply voltage may vary as follows:

1 AC supply Voltage variation +10% to –30%Frequency variation ± 5%Both variations may occur simultaneously or independently

2 DC supply +10% to –20%

6.03 Each of the foregoing supplies will be made available by purchaser at one terminal point for each equipment for operation of accessories and auxiliary equipments. In case of 110V, AC supply is required, the tenderer shall include adequately rated 415/110V control transformers for each equipment. Bidders scope of supply shall include

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distribution beyond the points of supply, including supply of interconnecting cables between instruments and terminal blocks.

7.00 TYPE OF PANEL:

7.01 VOID

7.02 VOID

7.03 Simplex Panel: Simplex Panel shall consist of vertical front panel with equipments mounted there on and wiring occurs from rear of the control panel and either from rear or front of relay panel. In case of panels having width of more than 800 mm, double leaf doors shall be provided, the door shall have handles with either built in locking facility or shall be provided with pad lock.

8.00 CONSTRUCTIONAL FEATURES:

8.01 Relay Panel shall be of Simplex type design. It is the responsibility of the bidder to ensure that the equipments specified and such unspecified complementary equipment required for completeness of the protective/ control schemes be properly accommodated in the panels without congestion and if necessary, provide either more number of panels or panels with larger dimensions. No price increase at a later date on this account shall be allowed. However the width of the panels that are being offered to be placed in existing control room should be in conformity with space availability in the control room.

8.02 Panels shall be completely metal enclosed and shall be dust, moisture and vermin proof. The enclosure shall provide a degree of protection not less than IP-31 in accordance with IS : 2147.

8.03 Panels shall be free standing, floor mounting type and shall comprise structural frames completely enclosed with specially selected smooth finished, Cold rolled sheet steel of thickness not less than 3mm for weight bearing members of the panels such as base frame, front sheet and door frames, and 2.0mm for sides, door, top and bottom portions. There shall be sufficient reinforcement to provide level surfaces, and resistance to vibration and rigidity during transportation and installation.

The dimensions of the panels shall be as given below:Height - 2312 mm including base channel height of 102mm.Depth - 610mmWidth - 800/ 1000 mm.

8.04 All doors, removable covers and panels shall be gasketed all around with Synthetic gaskets. Neoprene/EPDM generally conforming with provision of IS-11149. However XLPE gasket can also be used for fixing protective glass doors. Ventilating louvers, if provided shall have screens and filters. The screens shall be made of either brass or GI wire mesh.

8.05 Design, materials selection and workmanship shall be such as to result in neat appearance, inside and outside with no welds, rivets or bolt heads appearing from outside, with all exterior surfaces smooth.

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8.06 Panels shall have base frame with smooth bearing surface, which shall be fixed on the embedded foundation channels/insert plates. Anti-vibration strips made of shock absorbing materials, which shall be supplied by the bidder, shall be placed between panel & base frame.

8.07 Cable entries to the panels shall be from the bottom. Cable gland plate fitted on the bottom of the panel shall be connected to earthing of the panel/ station through a flexible braided copper conductor rigidly.

8.08 Relay panels of modern modular construction would also be acceptable.

8.09 The purchaser reserves the right to order the panels in full or part of the quantity indicated in the annexure. However, the breakup will be station – wise.

8.10 The offer shall include dummy panels and filler plates wherever necessary to have continuous formation. However the purchaser reserves the right to order the dummy panels and filler plates.

9.00 MOUNTING:

9.01 All equipment on and in panels shall be mounted and completely wired to the terminal blocks ready for external connections. The equipments on front of panel shall be mounted flush with only their bezels projection.

9.02 Equipment shall be mounted such that removal and replacement can be accomplished individually without interruption of service to adjacent devices and are readily accessible without use of special tools. Terminal marking on the equipment shall be clearly visible.

9.03 The centre lines of switches, push buttons and indicating lamps shall be not less than 750mm from the bottom of the panel. The center lines of relays, meters and recorders shall be not less than 450 mm from the bottom of the panel.

9.04 The centre lines of switches, push buttons and indicating lamps shall be matched to give a neat and uniform appearance. Like wise the top lines of all meters, relays and recorders etc.., shall be matched.

9.05 Final arrangement of control instruments & relays shall be as per the drawing approved by the purchaser.

9.06 No equipment shall be mounted on the doors.

9.07 At existing station, panels shall be matched with other panels in the control room in respect of dimensions, colour, appearance and arrangement of equipment (center lines of switches, push buttons and other equipment) on the front of the panel.

9.08 All the equipment connections and cabling shall be designed and arranged to minimize the risk of fire and damage which may be caused by fire.

9.09 The contractor shall carry out cut out, mounting & wiring of free issue items supplied by other which are to be mounted in this panel in accordance with corresponding equipment manufacturers drawing.

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If any cutouts are left blank for mounting of future equipment, it shall be properly blanked off with metal plates, and wires left shall be properly insulated or terminated to a terminal block.

10.00 PAINTING:

10.01 All sheet steel work shall be phosphated in accordance with the IS: 6005 "Code of practice for phosphating iron and steel”.

10.02 Sheet steel shall be sand blasted to remove rust and scale, oil grease, dirt and swarf shall be thoroughly removed by emulsion cleaning.

10.03 Rust and scale shall be removed by pickling with dilute acid followed by washing with running water, rinsing with a slightly alkaline hot water and drying.

10.04 After phosphating, thorough rinsing shall be carried out with clean water followed by final rinsing with dilute dichromate solution and oven drying.

10.05 The phosphate coating shall be sealed with application of two coats of ready mixed, stoved type zinc chromate primer. The first coat may be “flash dried” while the second coat shall be stoved.

10.06 After application of Primer, the panel exterior shall finally be painted with two coats of synthetic enamel paint, each coat applied by stoving. The colour of the finishing paint shall generally be "Siemens grey" corresponding to shade No. RAL 7032of IS-5 for panel exterior. All cubicle interiors shall be painted white, so as to give a contrasting effect with cubicle wiring

10.07 Each coat of primer and finished paint shall be of slightly different shade to enable inspection of painting. The final finished thickness of paint film shall not be less than 60 microns and shall not be more than 100 microns.

10.08 The finished paint appearance shall be aesthetically pleasing and shall be free from scratches, dents or unevenness. A small quantity of paint shall be supplied free of cost for minor touching up, if any that may be required at site.

10.09 In case the tenderer proposes to follow any other established painting procedure like electrostatic painting, the procedure shall be submitted along with offer/bid for purchaser's review and approval.

11.00 PANEL INTERNAL WIRING:

11.01 All wiring shall be of switch board type super flexible multi-stranded, tinned, annealed copper wire with suitable PVC insulation of 1.1KV grade conforming to IS-694 which has proved its utility in tropical regions against hot and moist climate and vermin (mice, white ants and cockroaches, etc.) and of fire retardant type.

11.02 The size of wiring in different circuits shall not be less than those specified below:

Sl. No. Circuits

Area of cross-section of conductor ( minimum

permissible size of wire) of 409

1 Metering and relaying circuits connected to CTs and PTs

2.5 sq. mm

2 Audio visual annunciation, signaling and control circuits

1.5sq. mm

3 AC/DC Auxiliary control supply circuits 1.5sq. mm

11.03 Following colour scheme shall be used for the wiring.Colour of the

wire Circuit where used Colour of the ferrule

Red Red phase of instrument transformer circuits

Red

Yellow Yellow phase of instrument transformer circuits

Yellow

Blue Blue phase of instrument transformer circuits

Blue

Green Neutral connections earthed or not earthed in the instrument transformer circuits

Green

White AC control wiring circuits using 415/ 240V auxiliary supply and cubicle lighting

Respective phase:Red, Yellow and blue

Neutral : greenGrey DC control wiring circuits Red : Trip circuit

Blue : indicating circuitYellow: alarm circuitGreen : relay, auxiliary and other interconnections

Lower voltage DC supply (from DC to DC converter)

- “ -

11.04 All cubicle wiring shall be of the grouped type and laid out in flat formation on the framework, in the interior of the panel cubicles and secured to it by means of cleats. Wiring shall be run straight and given right angle bends wherever necessary. Wiring round the hinges shall be of extra flexible conductors twisted around the axis of the wires.

Longitudinal throughs extending through out the full length of the panel shall be preferred for inter panel wiring. Interconnection to adjacent panel shall be brought out to a separate set of terminal blocks located near the slots of holes meant for taking the interconnecting wires. All potential bus wiring, audible alarm, bus wiring, AC & DC control supply bus wiring, wiring for cubicle lighting and such other wiring which runs from cubicle to cubicle within the switchboard shall be laid down in gutters and shall be carefully screened.

Wiring connected to the space heaters in the cubicle shall have porcelain headed insulation over a safe length from the heater terminals.

Each wire shall be continuous from end to end and shall not have any joints within itself. Individual wires shall be connected only at the connection terminal or studs of the terminal blocks, meters, relays, instruments and other switch board devices.

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Terminal ends of the wires shall be provided with numbered self-locking ferrules suitably coloured for phase identification. At points of intersection where a change of number is necessary, duplicate ferrule shall be provided with the appropriate numbers on the changing end.

Wire ends shall be elegantly hooked with Ross - Courtney solder less Terminals. At the terminal connection, washers shall be interposed between wire terminals and the holding nuts. All holding nuts shall be secured with locking nuts. The connection stud shall project at least 3 mm from the lock nut surface,

Wiring shall be so connected at the terminal studs that no wire terminal number ferrule gets masked due to succeeding connections. All wire shall be suitable for bending and shall meet the terminal studs at right angles with the stud axis and they shall not be skewed.

All studs, nuts, bolts, screws etc., shall be threaded according to the IS practice unless purchaser's approval to any other practice of threading is obtained. Spare quantity of nuts, lock nuts and washers of all varieties used on the switchboard shall be supplied to the extent of 10% of the used quantities. The supplier should note that there would be no mezzanine floor for the control room building for cable spreading and the method of taking the cables directly into panel from the duct shall be clearly indicated.Contractor shall be solely responsible for the completeness & correctness of the internal wiring and for the proper functioning of the connected equipments.

12.00 TERMINAL BLOCKS AND TERMINAL CONNECTORS:

12.01 Terminal blocks shall be of the projecting stud type with check nuts and washers. The insulation housing of the terminal connector along with barriers shall be moulded from thermosetting resin dielectric and shall be of AC 1100V grade. The studs shall be fully threaded and shall be of tin plated brass. The size of the studs shall be suitable for a continuous rating of not less than 35 Amps and shall accommodate the conductor terminal with a close fit, check nuts and washers shall also be of tin plated brass. Check nuts shall be hexagonal and shall be suitable for being tightened with tubular box type spanners. The end termination facility shall be suitable for tightening with screw driver. Tin plated brass inserts shall be provided between the terminal connector studs for effective resistance free, electrical contact between the incoming and outgoing terminations.

12.02 Terminal connectors shall be preferably of bolt and nut type for being assembled on to standard mounting channels for multi-way grouping to form terminal blocks. These terminal blocks shall be mounted vertically in columns inside the panel in a pillar type formation and shall be so located that the incoming tail ends of the control cables can be terminated to these terminal blocks easily.

12.03 All terminal blocks shall be provided with removable shrouds made of transparent dielectric material rated for 1100V grade. Each shroud shall be etched or provided with a plastic marker strip to identify the circuits that are terminated.

12.04 Each terminal block shall be provided with at least 30% spare terminals on each panel and these spare terminals shall be uniformly distributed on all terminal blocks.

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12.05 All studs, nuts, screws etc., shall be threaded according to IS:7684. Sufficient spare quantities of all varieties and size of bolts, studs, nuts, washers and screws used in the cubicle shall be supplied along with cubicle free of cost.

12.06 Where terminal blocks are arranged in different columns or rows then minimum clearance of 150 mm shall be provided between the terminal block. A minimum clearance of 250 mm shall be kept between Terminal blocks and associated cable gland plates.

12.07 Terminal blocks containing CT secondary leads shall be provided with test, isolating, short circuiting & earthing facilities / sliding link type and VT’s secondary leads shall be provided with isolating features.

12.08 Arrangement of terminal block assemblies & wiring channel within the enclosure shall be such that a row of terminal blocks is run in parallel & close proximity along each side of the wiring duct to provide for convenient attachment of internal panel wiring. The side of terminal block opposite to wiring duct shall be reserved for the owner’s external cable connections. All the adjacent terminal blocks shall also share the field wiring corridor. All wiring shall be provided with adequate support inside the panels to hold them firmly & to enable free & flexible termination without causing strain on terminals.

13.00 SPACE FOR CONTROL CABLES AND CABLE GLANDS:

All control and supply cable will be conducted at the bottom of the cubicles. The bottom plates of panels shall be fitted with removable gland plates and fixed with the cable glands, the size of which shall suit the owner's external cables. Cable glands shall be screened type and made of brass or nickel plated steel and shall be suitable for PVC unarmoured cable. Necessary drawing showing the cable entry position and foundation bolt location shall be supplied by the bidder. The required quantities of cable glands suitable for the cable sizes as described below shall be provided in each panel.

19 C x 2.5 Sq. mm for Power Transformer.19 C x 2.5 Sq. mm for Circuit Breaker.10 C x 2.5 Sq. mm for Circuit Breaker.4 C x 6.0 Sq. mm for CT Circuits.2 C x 10 Sq. mm for NCT Circuits.4 C x 10 Sq. mm for PT Circuits and D.C.10 C x 2.5 Sq. mm for Isolator.2 C x 2.5 Sq. mm. for coupling capacitor.

14.00 MIMIC DIAGRAM: VOID

15.00 NAME PLATE & MARKINGS

15.01 Each unit panel shall be provided with a circuit label of size 40mm x 200mm (min) located prominently at the top on the front and rear face of the panel. Circuit labels shall be located inside the cubicle also for easy identification on both halves of the panel. These name plates and labels shall bear the name of the circuit or equipment etc., to which the panel is associated with. The letter shall have a minimum height of 20mm.

15.02 The name plate shall be 50mm width plates made of brass or black plastic and shall be etched with 3mm sized letters of the name of the associated circuit / equipment. The

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etched letters shall be duly filled in with white enamel paint, if the plate is of black plastic or with black enamel if the plate is of brass.

15.03 All instruments, relays and such other electrical devices and accessories mounted in the control panel shall be provided with name plate bearing the name of the manufacturer, serial number, type and technical rating data. These name plates shall be installed at the rear of the device inside the cubicle.

15.04 VOID

15.05 Each panel shall be provided with a label located at the bottom corner on the front and shall contain the following details:

i. Manufacturer's name.ii. P.O. No. & date.iii. Drawings reference No. that pertains to that panel.iv. Serial No. of the panel.

The letters on name plates shall have minimum height 4 mm and the gap between lines / words shall be more than 2 mm.

16.00 INTERNALLY MOUNTED EQUIPMENTS:

16.01 SPACE HEATERS:

Each control and relay panel shall be provided with a strip type or coil type tubular enclosed space heaters to prevent condensation of moisture within the panel. It shall be installed at the base of the cubicle and operated on 240V AC single phase supply. The surface temperature shall be well below visible heat. Space heaters shall be provided with an independent switch control, fuse and an adjustable thermostat to regulate the temperature.

16.02 PANEL LIGHTING:

The interior of the cubicles shall be illuminated by fluorescent lamps. The illumination shall be free from hard shadows and shall be planned to avoid any strain or fatigue to a wire man working inside the cubicle due to any abnormal or non-uniform illumination. These lamps shall be operated through switches or door push buttons. It shall operate on 240V, AC single phase supply.

16.03 POWER SOCKETS:At least 3 nos. of 5 Amps three pin multiple plug points and 2 nos. of 15 Amps, 3 pin power plug outlets shall be provided at convenient points in each set of the 220KV, 110KV, 66KV and 33KV control panels. The plug points shall be provided with electrical and mechanical cover with chain. For simplex panels, a single phase 5A plug and socket and a 15 Amp. 3 Pin power plug & socket with switch is to be provided with security cover

17.0 FUSES:

17.01 H.R.C. fuses of adequate current and voltage rating shall be provided inside the cubicle for the various protection, control and incoming auxiliary AC & DC supply circuits.

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The fuse bases and carriers shall be mounted inside the cubicle in an easily accessible location. They shall conform to relevant standard and shall be designed to carry HRC cartridge fuse links. The fuse bases and carriers shall be moulded from the thermosetting resin dielectric or moulded standard grades phonolic Bakelite or equivalent thereof and shall be black in colour. The selection of the main and sub-circuit fuse ratings shall be such as to ensure selective clearance of sub-circuit faults. All accessible live connections to fuse bases shall be adequately shrouded. Fuses shall have operation indicators for indicating blown fuse condition. Fuse carriers and bases shall have imprints of the fuse rating and voltages.The short time fuse rating of fuses shall be not less than 9KA.

There shall be individual fuse units for each of the following circuits:

i) Signaling and Annunciation circuits.ii) V.T. secondary instrument circuits.iii) V.T. secondary, relay circuits.iv) AC & DC control circuits (shall be separate for CB & Isolators).v) AC auxiliary circuits.vi) AC Power socket, cubicle space heater and lighting.vii) Others if any.

18.00 EARTHING:

18.01 All panels shall be provided with a bare copper tinned earthing bus extended throughout the length of the panel. Location of earth bus shall ensure no radiation interference for earth system under various switching conditions of isolators and breakers. The material size of the earthing bus shall not be less than 25 mm x 6 mm,perforated copper with threaded holes at a gap of 50mm with provision of bolts & nuts for connection with cable armours& mounted equipmentsetc for effective earthing. When several panels are mounted adjoining each other, the earth bus shall be made continuous and necessary connection and clamps for this purpose shall be included in the scope of supply. Provision shall be made for extending the earth bus bars at a future date into new adjacent panels to be installed if any. Provision shall be made at the end panels for connecting the same to the system earth ground mat.

18.02 All metallic cases of instruments, relays, accessories installed within the cubicle shall be connected to the earth bus with 1100V grade standard multicore 2.5 sq. mm PVC insulated conductor of green colour. The run of the wires shall be continuous without any joints and shall be crimped at either end with open type solder less lugs.

18.03 Looping of earth connections, which would result in loss of earth connection to other devices when the loop is broken, shall not be permitted. However, looping of earth connections between equipment to provide alternative paths to earth bus shall be provided.

18.04 VT & CT secondary neutral or common lead shall be earthed at one place only at the terminal blocks where they enter the panel. Such earthing shall be made through links so that earthing may be removed from one group without disturbing continuity of earthing system for other groups.

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18.05 An electrostatic discharge arrangement shall be provided in each panel so as to discharge human body before handles the equipments inside the panels.

19.00 INDICATING LAMPS: VOID

20.00 TEST TERMINAL BLOCKS:

20.01 Each panel where metering is involved shall be installed with instrument test terminal blocks. These test terminal blocks shall be designed for use on panels with poly-phase meters to facilitate their in-situ testing. The test terminal blocks shall be mounted at the bottom end of the front face of the panel. They shall be of the projecting type semi-flush mounted with wire connected at the back. All wiring to indicating, integrating and recording instruments shall be done through the Test Terminal Block. The test terminal block shall be provided with screw type front cover such that the removal of this cover shall grant access to the terminals in the front for connecting check meters or for injection of external supply to the panel instruments.

20.02 The test terminal blocks shall facilitate in-situ testing of instruments without interrupting the primary load circuit. The current terminals shall therefore be provided with shorting arrangement through links before interrupting the normal circuit for insertion of external check meters or for injection of an external supply into the panel instruments without causing an open circuit in the current transformer secondaries. The potential terminal shall be provided with sliding links for isolation of the normal supply voltage to the panel instruments from the secondaries of voltage transformer.

20.03 The test terminal block shall have its insulation housing made of a moulded dielectric materials such as phonolic Bakelite or equivalent thereof with adequate insulation between current and potential terminals of different phases. The potential testing studs shall preferably be housed in narrow recesses of the block moulded insulation to prevent accidental short circuit between potential studs themselves or between potential and current terminals. The cover studs to be provided shall be suitable for sealing with lead seals so as to prevent unauthorized access to the test studs.

20.04 The test terminal block rating shall be 1100 volts, 35 Amps, The terminals shall be nickel-plated brass and their contact resistance shall be less than 1 milli ohm. The test Terminal Block shall preferably be of IMP make or any other standard link type makes.

21.00 CONTROL SWITCHES:

21.01 Control and instrument switches shall be rotary operated type with escutcheon plates clearly marked to show operating position and circuit designation plates and suitable for flush mounting with only switch front plate and operating handle projecting out. Handles of different shapes and suitable inscriptions on switches shall be provided as an aid to switch identification.

21.02 The selection of operating handles for the different types of switches shall be as follows;

a) Selector switches Oval or knob, black

b) Trip transfer switches Pistol grip, lockable, black

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21.03 VOID

21.04 VOID

21.05 Lockable type of switches, which can be locked in particular positions, shall be provided when specified. The key locks shall be fitted on the operating handles.

21.06 All control switches wires shall be connected at the back. The contact mechanism shall become operated. The contacts shall be silver plated and designed for liberal rating of the duty involved. The contacts shall be provided with a dust and vermin proof removable protection cover. The protection cover shall preferably be of transparent, inflammable material made of moulded dielectric materials. Springs to be provided in the switch shall not be used as current carrying parts.

The contacts provided in the switch shall not be used as continuous current carrying parts.

The contact combination and their operation shall be such as to give completeness to the interlock and function of the scheme. The contact rating of the switches shall be as follows :

DescriptionContact rating in Amps

220V/110V DC 240V AC

a) Make and carry continuously 10 10

b) Make and carry for 0.5 seconds 30 30 c) Break:

1. resistive load2. inductive load with L/R = 40 ms

30.2

7---

21.07 VOID

22.00 SYNCHRONIZING SWITCHES: VOID

23.00 PUSH BUTTON SWITCHES

a) Push button switches provided, shall be of the momentary contact type wired back connected. They shall be semi-flush mounted and where required they shall be shrouded to prevent inadvertent or undesirable operation. They shall be provided with integral inscription plates engraved with their functions.

b) All push buttons shall be with two sets of Normally Open (NO) and Normally Closed (NC) contacts. The contact faces shall be silver plated and shall be able to make/break and carry the rated current. The rated current shall be appropriate to the duty of the desired function, but not less than 5 Amps.

24.00 SYNCHRONIZING EQUIPMENT: (Applicable for 220KV Sub-Station only)

24.01 The model sequence of synchronizing of various voltage classes in the station is as follows:

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a) Synchronizing outgoing 220 kV lines with any one of the main buses.b) Synchronizing 220KV and 110/66 kV breaker of Power transformer.c) Synchronizing outgoing 110/66 kV lines with any one of the main buses.

25.00 ANNUNCIATION SYSTEM: VOID

26.0 INDICATING & INTEGRATING INSTRUMENTS:

26.01 VOID

26.02 VOID

26.03 VOID

26.04 VOID

26.05 INTEGRATING METERS:

a) It shall of static type, 3 phase, 4 wire, 2 element trivector meter suitable for 1 Amp, CT and 110 volts phase to phase VT secondaries. It must be flush mounted type and tropicalisesd. It shall have separate registers for recording KWh and KVARh consumption separately and also demands with automatic resetting at the end of the month and also to record EXPORT AND IMPORTS.

b) The meter should be of 0.2 accuracy class.

c) The meters shall have legible LED/LCD minimum 6 digits auto-cycle display. The meter shall have non-volatile memory requiring no battery back up.

d) The meters shall conform to the detailed specification enclosed as Annexure.

26.06 VOID

26.07 VOID

27.00 RELAYS:

27.01 GENERAL:

a) All relays shall conform to the requirements of IS3231/IEC 50255/IEC 61000 or other applicable standards. Relays shall be suitable for flush or semi flush mounting on the front with connections from the rear.

b) All main protective relays shall be numerical type & communication protocol shall be as per IEC 61850. Further the test levels of EMI as indicated in IEC 61850 shall be applicable to these.

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c) A detailed note regarding the various quality control procedures adopted by the manufacturer should be given with special reference to static / numerical relay components on their quality assurance tests. Information should be furnished regarding various equipment used for quality assurance tests.

d) The numerical relays offered must have proven performance. The bidder shall give a detailed account of the field experience of the relays offered, information regarding experience in designing etc.

e) The protection scheme at the other end of the transmission line will be furnished to the successful bidder if required. The other particulars like distance of the lines, impedance, CT ratios, PT details will be furnished to the successful bidder and should provide the protection schemes suitable for parameters furnished.

f) The relay codes mentioned in the wiring/ schematic diagram, for auxiliary relays etc., which are part of a composite relay, shall be marked on the name plate provided. This is required to facilitate the field staff, to identify the auxiliary relay provided in the composite unit at the time of trouble shooting.

g) All relays, other components, wiring etc shall withstand a test voltage of 2.5kV RMS, AC, 50 Hz.

h) The tenderer shall give a detailed account of the field experience of the relays offered. Information regarding experience within the country should be indicated, giving the approximate quantity of similar relays supplied in India. The bidder should also give an account of his experience in designing coordinating similar protective gear within the country.

i) The tenderer shall indicate what facilities are available with him within the country for repair / recalibration of the relays offered by him. Whether such facilities are available for the repair of imported relays included in his offer shall also be stated in the tender.

j) The tenderer shall indicate what facilities are available with him for commissioning these Relays. Such facilities shall cover indigenous and imported equipment. The bidder shall arrange to train at his cost the engineering staff of KPTCL for trouble- free operation and maintenance of these relays.

27.02 a) The protective and auxiliary relays offered shall be of proven design and based on sound principles and should conform to BS : 142 and IS : 3231 and IEC : 255 wherever applicable. The protection equipment shall be designed and applied to provide maximum discrimination between faulty and healthy circuits and its performance shall be in accordance with the BS standard 3950. The equipment shall remain in operation during transient phenomenon, which may arise during switching or other disturbances to the system. They shall be in standard cases and shall be provided with dust and vermin proof cases and covers, The covers shall be transparent and shall be removable from the front. The relay shall be suitable for semi-flush mounting only the flanges projecting in the front and with connection from the rear. The relays shall be rectangular in space and dull black or egg shell black enamel painted cases.

b) All protective relays shall be in draw-out or plug-in type / modular cases with proper testing facilities. The testing facilities provided on the relays shall be of 409

specifically stated in the tender. Necessary test plugs shall be supplied loose and shall be included in bidder's scope of supply. Test block and switches shall be located immediately below each relay for testing. As an alternative to test block and test plug arrangements the bidder shall also quote alternative testing facility of protective relays by providing a push button which when pressed connects the testing equipment to the relay coils and injects current in the coil and automatically disconnects the trip circuits and on operation of relay gives a signal that the equipment and the circuits are correct. The above tests shall be carried out without short circuiting the CT secondary connections. The Purchaser reserves the right for accepting any one of the above two testing facilities. Unless otherwise specified all auxiliary relays and timers shall be supplied in non-draw out cases/ plug-in type modular cases.

c) All AC relays shall be suitable for operation at 50 Hz AC Voltage operated relays shall be suitable for 110 Volts VT secondaries and current operated relays for 1 Amp CT secondaries as specified. DC auxiliary relays and timers shall be designed for the DC voltage specified, and shall operate satisfactorily between 80% and 110% of rated voltage. Voltage operated relays shall have adequate thermal capacity for continuous operation.

d) All relays coils requiring a continuous voltage shall have adequate thermal capacity for continuous operation. The current and voltage coil shall be rated for the current and voltage rating specified under system details and auxiliary supply.

e) The power supply unit shall be fully rated with liberal design in capacity.

f) The DC supply for solid state relay shall be from DC / DC converters and these shall be amply and fully rated for all operating conditions in service. Provision of DC stand by power supply will however not be acceptable.

g) The protective relays shall be suitable for efficient and reliable operation of the protection scheme described in the specification. Necessary auxiliary relays and timers required for interlocking schemes for multiplying of contacts/ suiting contact duties of protective relays and monitoring of control supplies and circuits, lockout relay monitoring circuits etc. and also required for the complete protection schemes described in the specification shall be provided. All protective relays shall be provided with at least two pairs of potential free isolated output contacts. Auxiliary relays and timers shall have pairs of contacts as required to complete the scheme, contacts shall be silver faced with spring action. Relay case shall have adequate number of terminals for making potential free external connections to the relay coils and contacts, including spare contacts. Relay cases size shall be so chosen as not to introduce any limitations on the use of available contacts on the relay due to inadequacy of terminals. Paralleling of contacts, if any shall be done at the terminals on the casing of the relay.

h) All protective relays, auxiliary relays and timers except the lock out relays and interlocking relays specified shall be provided with self-reset type contacts. All protective relays and timers shall be provided with externally hand reset positive action operation indicators with inscription subject to purchaser's approval. All protective relays which do not have built in hand-reset operation indicators shall have additional auxiliary relays with operating indicators (Flag relays) for this purpose. Similar separate operating indicator (auxiliary relays) shall also be of 409

provided in the trip circuits of protections located outside the board such as buchholtz relays, oil and winding temperature protection, sudden pressure devices, fire protection etc.

i) There shall be no relay in the protective circuits, which shall cause tripping of the circuit breaker when the relay is de-energized.

j) Timers shall be of solid or static type. Pneumatic timers are not acceptable. Time delay in terms of milliseconds obtained by the external capacitor/resistor combination is not preferred & shall be avoided.

k) Provision shall be made for easy isolation of trip circuit of each relay for the purpose of testing & maintenance.

l) All protective relays & alarm relays shall be provided with one extra isolated pair of contracts wired to terminals exclusively for further use.

m) The setting range of relays offered, if different from ones specified shall also be acceptable if they meet the functional requirement.

n) Any alternative/additional protection of relays considered necessary for providing complete effective & reliable protection shall also be offered separately. The acceptance of this alternative/additional equipment shall lie with KPTCL.

o) Auxiliary seal-in-units provided on the protective relays shall preferably be of shunt reinforcement type. If series relays are used the following shall be strictly ensured.i) The operating time of the series seal-in-units shall be sufficiently shorter

than that of the trip coil or trip relay in series with which it operates to ensure definite operation of the flag indicator of the relay.

ii) Seal-in-units shall obtain adequate current for operation when one or more relays operate simultaneously.

iii) Impedance of the seal-in-units shall be small enough to permit satisfactory operation of the trip coil on trip relays when D.C supply voltage is minimum.

iv) Trip-Circuit seal – in is required for all trip outputs irrespective of the magnitude of the interrupted current. The trip-circuit seal-in logic shall not only seal –in the trip outputs but also the relevant initiation signals to other scheme functions (e.g. initiate signals to the circuit breaker failure function, reclosing function etc.,) and the alarm output signals.

v) Two methods of seal-in are required, one based on the measurement of AC current, catering for those circumstances for which the interrupted current is above a set threshold, and one based on a fixed time duration, catering for those circumstances for which the interrupted current is small (below the set threshold).

vi) For the current seal-in method, the seal-in shall be maintained until the circuit breaker opens, at which time the seal-in-shall reset and the seal in-

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method shall not now revert to the fixed time duration method. For this seal-in method, the seal-in shall be maintained for the set time duration. For the line protection schemes, this time duration shall be independently settable for single –and three –pole tripping.

vii) Seal-in by way of current or by way of the fixed duration timer shall occur irrespective of whether the trip command originates from within the main protection device itself (from any of the internal protection functions), or from an external device with its trip output routed through the main protection device for tripping Trip-circuit seal-in shall not take place under sub-harmonic conditions.

p) For numerical relays the scope shall include the following:

i) Necessary software & hardware to up/down load the date to/from the relay from/to the personal computer provided in the station.

ii) The relay shall have suitable communication facility for connectivity to sub-station system/SCADA. The relay shall be capable of supporting IEC 870-5-103 and 61850 protocol.

27.03 a) The materials, the components of static/ numerical relays shall be designed to withstand the most severe tropical climatic conditions such as corrosive atmosphere, saline, fog, damp, heat and fungus prone environment. These devices as such shall be tropicalised in such a manner so as to meet with the IEC-68 standard.

b) The components shall be loaded by less than half of their rated values. The resistor shall be of carbon composition or metal oxide type and the capacitors shall be plastic film or tantalum type. Stringent measures including shielding of long internal wiring should be taken to make relays immune to voltage spikes. As per IEC, the relays must meet the requirements of IEC-255-4, appendix 'E'. Class-III regarding HF disturbance tests, IEC-255-4 regarding impulse test at 5kV and fast transient test as per IEC-801-4. Insulation barriers shall be provided to ensure that transients present in CT & VT connections due to extraneous source do not cause damage to static circuits.

c) The. cases, racks and sub-units shall preferably be of stainless steel. The screws used in cases, racks and sub-units shall be either of stainless steel or zinc plated steel.

d) The material of connector terminal blocks shall be of dielectric moulded type resin. The connector plugs shall be corrosion resistive and the lugs shall be made of tinned brass with the contact face silver / gold plated. All connections with the connector plug shall be by wire wrapping.

e) The static/ numerical components forming the electronic solid state circuitry shall be mounted on printed circuit board of adequate thickness and made of stratified glass epoxid. A protective lacquer shall be applied when all the components are soldered. Transformers in the circuitry shall also be impregnated with the same lacquer. All components shall be clearly marked and all wiring colour coded and tagged. Flat ribbon cable is exempted from being tagged. of 409

f) The relays shall be modular units assembled in fully tropicalised draw out cases with the modules or sub-units plugged into racks. They shall be electrically isolated on the measuring side through intensity or voltage input transformers with shield bonded (at the over voltage/fixed voltage) and on the operation side through on/off relays. The layout of measurement inputs, output relays, detection circuits and visual display such as to eliminate mutual interference of the circuits involved. Internal test points shall be provided on the printed circuit at typical points of the relay diagram. These test points, if possible shall be provided on the front of the relay to enable testing during operation without having to disconnect the relay.

g) Insulation barriers shall be provided to ensure that transients present for CT and VT connections due to extraneous sources do not cause damage to static circuits. The static relays offered shall be tested to withstand both 5 kV impulse tests and high frequency disturbance stipulated by IEC. Details of the equipment used for tests shall be furnished.

h) The relay shall be designed for designed for shock wave resistance, temperature resistance, humidity resistance, transportation resistance and storage resistance and to be insensitive to radio frequency interferences.

i) The performance of static/numerical relay shall not be affected by transient, common mode and transient mode electromagnetic interference..

j) The solid state relays shall be stable and suitably protected against transient/ induced over voltages and noise signals. The bidder shall state clearly in his bid, special requirements, if any, for DC input arrangement or cabling considered necessary for satisfactory operation of solid state relays quoted by him.

28.00 PROTECTION SCHEME:

28.01 Protection scheme shall consist of following :

a) The main protection, distance and differential protection relays are required to protect the 220KV, 110KV, 66KV lines and 220/110/11KV or 220/66/11KV, 110/33-11KV, 66/33KV, 66/11 KV and 33/11KV Power Transformers and clear the fault within shortest possible time with reliability, selectivity and full sensitivity to all type of faults. The relay shall be fast acting numerical type.

b) Back up protection shall be of numerical type.

28.02 Protection Scheme for 220KV lines :

The line protection relays are required to protect the line & clear the faults on line within shortest possible time with reliability, selectivity & full sensitivity to all types of faults on the lines.The general concept is to have two main protections having equal performance requirement specially in respect of time called as Main-I & Main-II for 220kV lines & cables and to have Main & backup protection for 110/66kV Lines.

The maximum fault current could be as high as 40KA at 220KV and 31.5KA at 110KV & 66KV, but the minimum fault current could be as low as 20% of the rated current of CT

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secondary. However for stations in Bangalore city, the maximum fault current could be 40KA at 66KV. The starting & measuring relays characteristic should be satisfactory under the extremely varying conditions.

For 220KV lines the protection relays shall be suitable for use with capacitor voltage transformers having non-electronic damping and transient response as per IEC.

Fault Recorder, Distance to fault Locator and Over voltage relay (Stage-I) functions if offered as an integral part of line protection relay, shall be acceptable provided these meet the technical requirements as specified in the respective clause.

Auto reclose relay function if offered as an integral part of line distance protection relay, shall be acceptable for 220kV lines only provided the auto reclose relay feature meets the technical requirements as specified in the respective clause.

Following protections shall be provided for each of the transmission lines:

For 220kV Lines:Main-I : Numerical distance protection scheme.Main-II : Numerical distance protection scheme of a make different from that of main-I.

For 220kV XLPE Cables:Main-I : Numerical line differential protection scheme.Main-II : Numerical line differential protection scheme of make different from that of Main-I.

A) Numerical Distance Main-I & Main-II Distance Protection scheme for 220 kV lines:

Numerical distance protection shall be suitable for use with permissive under reach and over reach required. Relay shall have continuous self-monitoring and diagnostic feature.

The detailed description of protection is given here under:

Numerical Distance Protection scheme shall :

i. Be suitable for one amp CT secondary and 110/3V AC potential from potential transformer of 220 KV Bus.

ii. Be modular in construction.

iii. Have high speed non-switched distance relay for three phase systems to clear all type of line faults within the set reach of the relay.

iv. It should cover at least two line sections completely with 25% additional margin.

v. Measure all type of faults without the need to switch the measuring elements to the faulty phase or phases. Zone switching to extend the reach of the measuring elements is not allowed. The reach of each zone shall be independently and individually adjustable over vide range in suitable steps, for each of the zone measuring elements in steps of 1%. The memory circuits with defined characteristics shall be provided in all three phases to ensure correct operation during close-up 3 phase faults and other adverse conditions.

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vi. Have a maximum operating time up to trip impulse to circuit breaker, (with CVT being used on line side) under source to line impedance ratios under all possible combinations of fault (with all filters included) at 50% of zone-1 reach, as given below:

For SIR 0.01-4 - About 30 ms at nearest end and 40 ms at other end of line.

ANDFor SIR 4 –15 - About 35 ms at nearest end and 45 ms at other end

of line.

(Carrier transmission time is not included in the operating time indicated above. The maximum carrier transmission time may be taken as 20ms. However, any reduction in carrier time should be directly reflected as reduction in maximum operating time)

vii. Have stepped time-distance characteristics and shall have at least two directional and one non-directional independently variable time graded distance protection zones to cover two adjacent line sections.

viii. a) Three zones and one reverse zone of operation shall be available. The reach of the relay for zones 1, 2 & 3 should be able to cover line lengths as per clause (iv) above. The relay shall have an adjustable characteristics angle setting range of 30-75 degree.

(b) Be field selectable for various over reaching, under reaching setting and blocking/ inter tripping communication scheme.

(c) Have quadrilateral or lens characteristics with a facility to set resistance and reactance independently to cater for arc resistance on short lines and load discrimination for long lines.

ix. Ensure that this long coverage is consistent with limitations imposed by heavy loading and sound phase components of fault current.

x. The scheme shall not become inoperative even under severe system fault condition near the location of the relay when the potentials applied to the relay are very small. If characteristics of starting relays are such that it cannot pick up because of very low infeed, under-voltage relays may also be used as supplementary relays.

xi. Have two independent continuously variable time setting range of 0-3 seconds for zone-2 and 0-5 seconds for zone-3.

xii. Have a maximum resetting time of about 35 milli sec.

xiii Have facilities for offset features with adjustable 10-20% of zone-3 setting.

xiv. Have residual compensation variable from 30- 150%.

xv. Operate instantaneously when circuit breaker is closed to zero volt 3-phase fault.

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xvi. Be suitable for single & three phase Auto re-closing and auto tripping at both ends.

xvii Have a continuous current rating of two times of rated current. The voltage circuit shall be capable of operation at 1.2 times rated voltage. The relay shall also be capable of carrying a high short time current of 70 times rated current without damage for a period of 1 sec.

xviii Be selective between internal and external faults.

xix. Include fuse failure protection which shall:

a1) Monitor all the three fuses of CVT/IVT circuit, and associated cable against open circuit

a2) Inhibit trip circuits on operation and initiate annunciation. a3) Have an operating time less than 7 milliseconds. a4) Remain inoperative for system earth faults. a5) Be of solid state type.

xx. Have facility for under voltage & over voltage protection.

xxi. Have self diagnostics feature.

xxii. Have facility for current & voltage supervision.

xxiii. The circuit failure protection be provided as a back up protection in case of failure protection be provided as a backup protection as required by object protection.

xxiv. Suitable number of potential free contacts (if required, multiplied through reed relays only) be provided, on each distance scheme for carrier aided tripping, auto re-closing, circuit breaker failure sequence of events recorder and data acquisition system..

xxv. Mutual compensation unit shall be provided such that healthy feeder protection shall not mal-operate for faults in other lines of multi circuit lines.

xxvi. The scheme shall be adaptable for carrier blocking principle for purpose of simultaneous inter tripping of breakers connected to the fault section and to prevent tripping of breakers connected to healthy section. The directional elements at the two ends of the protected line shall be inter locked by the power line carrier and shall trip the breakers at the two ends of the protected line breakers at the two ends simultaneously for fault in the protected zone. The blocking signal shall be transmitted to prevent the circuit breakers from tripping in the event of fault external to the protected zone. This shall not prevent the breakers tripping due to the second and third zone elements acting as back-up protective relays. The direction comparison carrier relaying shall provide instantaneous back-up protection and the second and third zone elements delayed back-up.

xxvii. A separate out of step or power swing blocking relay shall be included to prevent tripping of the breaker during power swings and system disturbances. The breaker shall however be caused to trip if the disturbance lasts for an interval of time equal to or greater than the third zone time setting.

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Nevertheless the impedance loci of the distance relays shall be such that they have maximum tendency to operate on power swings caused by system disturbances.

Note: Provision of optional features other than those indicated above may be indicated separately. Provision may be made in the relay for up-dating these optional features at a later date whenever required by KPTCL.

xxviii. The distance relay shall be compatible for use with PLCC equipments and auto re-close scheme existing. Further, the complete scheme shall also be flexible.

xxix. The distance protection scheme shall be suitable for any length (short lengths also) of transmission line. Any limitations in this regard shall be clearly specified by the bidder.

xxx. Include a directional and non-directional backup Inverse Definite Minimum Time (IDMT) over current & earth fault relay with normal inverse characteristics as per IEC-60255-3 as a built in feature.

xxxi. The relays shall have following features either built-in or separately:

a) Fault locator of an accuracy of 3% or better. b) Synchronizing check.c) Weak end in feed.d) Power swing blocking.e) Broken conductor detection.f) Compatibility with carrier protection scheme. g) Compatibility with Single pole/three pole auto re-closer. h) Disturbance Records.i) Compatibility with sub-station automation even logger..j) Auto Re-Closer.k) Direction & Non-directional OCR & EFR

xxxii) All trip relays used in transmission line protection scheme shall be of self/electrical reset type depending on application requirement.

B) Auto Re-Closing:

Auto re-closing relay shall

i) Be provided only for 220 kV line protection scheme. It shall be preferably built in feature of the Main-I/Main-II distance relaying scheme. The bidder shall co-ordinate the auto re-close relaying scheme with that of the circuit breaker so as to ensure satisfactory and reliable operation of the auto re-closing scheme.

ii) Have single-phase or/ and three phase re-closing facilities.

iii) Have a continuously variable single phase dead time range of 0.1 – 2 secs.

iv) Have a continuously variable three phase dead time range of 0.1-2 secs.

v) Have a continuously variable reclaim time range of 5-25 seconds.

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vi) Incorporate a four-position selector switch from which single phase/three phase/single and three phase auto re-closer and non-auto re-closure mode can be selected.

vii) Have facilities for selecting check synchronizing or dead line charging features. It shall be possible at any time to change the required feature by reconnection of links.

viii) Be of single shot type.

ix) Include check synchronizing relay which shall: a) Have a time setting continuously variable between 0.5-5 seconds with

facility of additional 10 secs.b) Have a response time within 200milli seconds with the timer disconnected.c) Have a phase angle setting not exceeding 35 degree.d) Have a voltage difference setting not exceeding 10%.

x) Include dead line charging relay which shall:

a) Have two sets of relays and each set shall be able to monitor the three phase voltage.

b) Have one set connected to the line CVTs with a fixed setting of 20% of rated voltage.

c) Have one set connected to the bus IVTs with a fixed setting of 80% of rated voltage.

d) Incorporate necessary auxiliary relays and timers to give comprehensive scheme.

xi) Also be possible to lockout the auto re-closing transformer scheme relays when the carrier protection associated with main distance protection schemes are out of service/ faulty.

xii) Have separate “Auto re-close operation” and “circuit breaker lock out” annunciation shall be provided.

C) Fault Locators function:

The fault locator shall be based on the impedance measurement of the line and shall be static, microprocessor based only. It shall be capable of measuring the location of the fault from the relaying point with an accuracy of 3% or better, for all types of faults including broken conductor detection. It shall be ON LINE type. The fault locator shall measure the measuring signals prior to the fault, during fault, before tripping of the breaker and store them in the memory and process them at later stages. The accuracy of the measurement shall not be affected / influenced by line loading prior to the fault, remote in feed, magnitude of the fault resistance or mutual effect of parallel line(s), CVT transients, DC component in fault current, heavy load conditions, temperature variations, frequency divisions. The fault locator shall have built in display unit for showing fault location, faulty phase(s), current and voltage magnitudes and their phase relationships. The fault locator shall be capable of being combined with the respective distance protection for phase selection information. The calculation of line protection shall take place when any of the line protections operate on fault. The calculation by the fault locator shall be based on measuring values prior to and during the fault. These data shall be stored in the memory of fault locator and calculation shall be made after tripping of the

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line breakers. The distance to fault shall be shown as % of line length or actual fault location in KM. The fault locator shall be suitable for its application with three (3) cycle circuit breaker.

D) DISTURBANCE RECORDER FUNCTION

Disturbance recorder (DR) shall be microprocessor based and shall be used to record the graphic form of instantaneous values of voltage and current in all three phases, open delta voltage and neutral current, open or closed position of relay contacts and breakers during the system disturbances.

Necessary auxiliary VTs to generate open delta voltage, shall be supplied by the bidder. The bidder shall furnish along with the offer a typical printout for simulated conditions on original paper.

The disturbance recorder system shall be capable of accommodating eight analog and sixteen event channels for each feeder. DR shall acquire the fault data and store them in non-volatile memory.

Necessary software and hardware for down loading the data captured by disturbance recorder to the personal computer available in the sub-station shall be included in the scope

The disturbance recorder shall incorporate the features as described below:

i. Simplicity of maintenance and repair:The number and type of modules employed shall be minimized.The modules shall be of plug-in type and shall be easily accessible for maintenance and repair wherever required.

ii. Immunity from the effects of hostile environment:

The equipment shall be designed to operate satisfactorily even when subject to the effects of severely hostile electrical environment -such as interference signals arising out of switching transients.

iii. Interface with PC

The DR should have an interface arrangement for transfer / storage of data to a PC. Necessary PC software, special cables etc., shall be part of DR and should be included in the offer.

PC based user friendly, disturbance recorder evaluation software shall be provided for the analysis and evaluation of the, record data made available in the PC. The software features shall include repositioning of analog and digital signals, selection and amplification of time and amplitude scales of each analog and digital channel, calculation of MAX / MIN frequency, phase difference values, recording of MAX / MIN values etc., of analog channel, group signal to be drawn on the same axis etc, listing and numbering of all analog and digital "channels and current, voltage, frequency and phase difference values at the time of fault tripping.

iv. Scan Rate

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The frequency response shall be 5 Hz on lower side and 250 Hz or better on upper side. The DR shall have a scan rate of 1000 Hz/channel or better.

v Starting Sensors

The, equipment shall have inherent to it starting sensors based on over voltage, rate of change of current, and rate of change of frequency. The starting sensors, on pick up, shall preserve the fault data acquired during the period of system disturbance, including pre-fault and post fault time in solid state memory. Preserved fault data shall not get erased unless operator erases.

vi. Pre-fault and Post-fault Time:

Pre-fault shall not be less than 160 ms and the post-fault time adjustable at a minimum of 2 seconds and a maximum of not less than 5 seconds. If another system disturbance occurs during one post-fault run time the recorder shall also be able to record the same.

vii Amplitude and event ResolutionAmplitude resolution shall not be less than 8 bit. Event resolution shall be 2 ms or better.

viii Print outThe print out shall contain the following:a. Feeder identity.b. Date & time (1 hour, minute & second up to 100th of a second)c. Identity of trigger source.d. Graphic form of analog and event signals of all the channels.

ix. Time generatorEach disturbance recorder shall have its own time generator. Facility shall exist of synchronize the time generator from station time synchronization equipment having output of following types at 30 min interval.

a. Voltage signal:(0-5V continuously settable with 50m sec. Min. pulse duration).

b. Potential Free Contact-(Minimum pulse duration of 50m second)

c. IRIG - B.d. RS232C/RS 485.

Sub-stations where station time synchronization equipment is not available, time generator of any one of the disturbance recorders can be taken as master and facility shall exist to synchronize the time generators of other disturbance recorders and event loggers in that station with respect to it. The recorder shall give annunciation in case of absence of synchronization pulse within a specified time. The clock of the time generator shall be such that, the drift is limited to ±0.5 seconds / day, if allowed to run without synchronization. Facility shall exist to display the time in hour, minute and seconds on the front of panel.

28.02.A Protection Scheme for 220kV cables:

The cable protection relays are required to protect the cable and clear the faults on cable within shortest possible time with reliability, selectivity and full sensitivity to all type of

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faults on lines. In case of 220kV XLPE cables, the general concept is to have two fast operating protection scheme. The current differential protection will be used as Main-I & Main-II protection.

I. Numerical Main-I & Main-II Current Differential Protection Scheme:

The line Differential Protection IED (Intelligent Electronic Device) protection relay should be Numerical with full compliance to IEC 61850 standards in every respect and Interoperability with other manufacturers IEDs and tools should be verified.

The IED shall be suitable for Protection, control and monitoring of overhead lines and cables for all Voltage levels in solidly grounded or impedance grounded networks.

The protection unit should be based on Phase segregated Line differential Principle and use.

Advanced and proven algorithms shall support user friendly Engineering tool and Disturbance handling tool.

It should be possible to integrate Protection and control functionality for several objects in the IED. The IED shall have complete functionality for single and multi breaker arrangements with single or three phase tripping.

At least Four/Five independent parameter setting groups shall be included.

IED shall have extensive self supervision including analogue channels. At new installations or at extensions and replacements in existing installations it

shall be possible to integrate the IED into a substation automation or monitoring system or use the IED as a stand-alone multifunction unit.

It shall be possible to equip the IED with a HMI for local access of all information.

A Restrained dual Bias operate characteristic shall be used and the highest phase current in any line shall be utilized as bias current.

Charging current compensation for increased sensitivity for long lines and cables shall be included.

The IED should be suitable for multiplexed, route switched or dedicated fibre networks.

Two time synchronization methods shall be available, the echo-method when channels with stable and equal delays in both directions are used and GPS to be used in switched networks with unequal channel delays in both directions.

The communication channel shall be continuously monitored and an automatic switchover to a redundant channel shall be possible.

IED shall be provided with programmable logic for tripping and indications as well as a high number of logic blocks and timers for user adaptation.

For Line differential communication it shall be possible to select between a master-master system or master slave system depending on the functional or economical requirements. An automatic changeover to Master-slave communication should take place if an interruption occurs in communication channel in master-master communication system.

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A backup high speed full scheme distance protection with at least three zones should be possible to include in order to get fault clearance in case of communication failure.It shall be possible to have the distance protection continuously in operation or only released for operation at communication failure. The distance Protection shall have characteristics that will give load encroachment discrimination and load current compensation of the reactance line in the first zone to avoid over reach. It should be possible to set the distance Protection zone in forward, reverse or non directional mode. Each zone should have individual resistive and reactive reach settings. Separate phase selection logic and automatic switch onto fault logic should be included.

Disturbance recording, event recording shall be built in features and included in the IED.

IED shall be provided with a front mounted HMI and front port for connection to a Personal Computer.

The IED shall be provided with communication interface for connection to Substation Automation system and substation monitoring system. IEC 61850-8-1 & IEC 60870-5-103 communication protocol shall be available. The IED shall meet the IED 61850 standard in every respect and interoperability with other manufactures IEDs and tools should be verified.

Power supply modules from 48V to 250V AC/DC shall be available.

It shall be possible to select different mounting alternatives such as rack, flush or wall mounting. Depending of the required numbers of I/O modules in the IED 1/1 x 19”, ¾ x 19” and ½ x 19” cases shall be available.

GPS time synchronization module with GPS receiver used for time synchronization shall be available.

28.03 Protection Scheme for 110 & 66kV lines

1. Numerical Distance protection scheme for 110 & 66KV Lines:

Numerical distance protection shall be suitable for use with permissive under reach and over reach required. Relay shall have continuous self monitoring and diagnostic feature.

The detailed description of protection is given here under.

The numerical distance protection shall:

i. Be suitable for one amp CT secondary and 110/√3V AC Potential from potential transformer of 110KV/ 66 KV Bus.

ii. Be static and modular in construction.

iii. Have high speed switched distance relay for three phase systems to clear all type of line faults within the set reach of the relay, under all operating conditions.

iv. It should cover at least two line sections completely with 25% additional margin.

v. Measure all type of faults by switching over to the measuring elements. The reach of each zone shall be independently and individually adjustable over wide range in suitable steps

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of 1%. Memory circuits with defined characteristics shall be provided in all three phases to ensure correct operation during close-up 3 phase faults and other adverse conditions.

vi. The protection scheme shall be fast and first zone shall energize the circuit breaker trip coil in about one and half cycle. The tripping time of the second and third zone should be adjustable to any desired value through a separate timing unit.

vii. Have stepped time distance characteristics and shall have at least two directional and one non-directional independently variable time graded distance protection zones to cover two adjacent line sections.

viii. (a) Three zones and one reverse zone of operation shall be available. The reach of the relay for zones 1, 2 & 3 should be able to cover line lengths as per clause (iv) above. The relay shall have an adjustable characteristics angle setting range of 30-75 degree.

(b) Be field selectable for various over reaching, under reaching setting and blocking/ inter tripping communication scheme.

(c) Have mho/rectangular/polygonal/circular/oval/lens/quadrilateral characteristics with a facility to set resistance and reactance independently to cater for arc resistance on short lines and load discrimination for long lines.

ix. Ensure that this long coverage is consistent with limitations imposed by heavy loading and sound phase component of fault current.

x. The scheme shall not become inoperative even under severe system fault condition near the location of the relay when the potentials applied to the relay are very small. If characteristics of starting relays are such that it cannot pick-up because of very low infeed, under voltage relays may also be used as supplementary relays.

xi Have facilities for offset features with adjustable 10-20% of zone -3 setting.

xii. Have residual compensation variable up to 150%.

xiii. Operate instantaneously when circuit breaker is closed to zero volt 3 phase fault.

xiv Have a continuous current rating of two times the rated current. The voltage circuit shall be capable of operation at 1.2 times rated voltage. The relay shall also be capable of carrying a high short time current of 70 times rated current without damage for a period of 1 sec.

xv Be selective between internal and external faults.

xvi Include fuse failure protection which shall:

al) Monitor all the three fuses of VT circuit, and associated cable against open circuit.a2) Inhibit trip circuits on operation and initiate annunciation. a3) Have an operating time less than 7 milliseconds.a4) Remain inoperative for system earth faults.a5) Be of solid state type.

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xvii. Have facility for under voltage and over voltage protection.

xviii. Have self-diagnostic feature.

xix. Have facility for current & voltage circuit supervision.

xx. Suitable number of potential free contacts (if required, multiplied through reed relays only) be provided, on each distance scheme.

xxi. Mutual compensation unit shall be provided such that healthy feeder protection shall not mal-operate for faults in other lines of multi circuit lines. (This clause applicable for line protection of 110 and 66KV lines of 220KV sub-stations only).

xxii. A separate out of step or power swing blocking relay shall be included to prevent tripping of the breaker during power swings and system disturbances. The breaker shall however be caused to trip if the disturbance lasts for an interval of time equal to or greater than the third zone time setting.

Nevertheless the impedance loci of the distance relays shall be such that they have minimum tendency to operate on power swings caused by system disturbance.

xxiii. The relay shall have the following features either built-in or separately.a) Weakend in feed.b) Power swing blocking.c) Broken conductor detection.

xxiv. All trip relays used in transmission lines protection scheme shall be of self/electrical reset type depending on application requirement.

NOTE: Provision of optional features other than those indicated above may be indicated separately. Provision may be made in the relay for updating these optional features at a later date whenever required by KPTCL.

2. Protection Scheme for 110 & 66kV Cables:

The Cable protection relays are required to protect the cable and clear the faults on cable within shortest possible time with reliability, selectivity and full sensitivity to all type of faults on lines. In case of 110kV & 66kV XLPE cables the current differential protection will be used as Main protection.

Numerical Current Differential Protection Scheme:

The line Differential Protection IED (Intelligent Electronic Device) protection relay should be Numerical with full compliance to IEC 61850 standards in every respect and Interoperability with other manufacturers IEDs and tools should be verified.

The IED shall be suitable for Protection, control and monitoring of overhead lines and cables for all Voltage levels in solidly grounded or impedance grounded networks.

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The protection unit should be based on Phase segregated Line differential Principle and use.

Advanced and proven algorithms shall support user friendly Engineering tool and Disturbance handling tool.

It should be possible to integrate Protection and control functionality for several objects in the IED. The IED shall have complete functionality for single and multi breaker arrangements with single or three phase tripping.

At least Four/Five independent parameter setting groups shall be included.

IED shall have extensive self supervision including analogue channels. At new installations or at extensions and replacements in existing installations it

shall be possible to integrate the IED into a substation automation or monitoring system or use the IED as a stand-alone multifunction unit.

It shall be possible to equip the IED with a HMI for local access of all information.

A Restrained dual Bias operate characteristic shall be used and the highest phase current in any line shall be utilized as bias current.

Charging current compensation for increased sensitivity for long lines and cables shall be included.

The IED should be suitable for multiplexed, route switched or dedicated fibre networks.

Two time synchronization methods shall be available, the echo-method when channels with stable and equal delays in both directions are used and GPS to be used in switched networks with unequal channel delays in both directions.

The communication channel shall be continuously monitored and an automatic switchover to a redundant channel shall be possible.

IED shall be provided with programmable logic for tripping and indications as well as a high number of logic blocks and timers for user adaptation.

For Line differential communication it shall be possible to select between a master-master system or master slave system depending on the functional or economical requirements. An automatic changeover to Master-slave communication should take place if an interruption occurs in communication channel in master-master communication system.

A backup high speed full scheme distance protection with at least three zones should be possible to include in order to get fault clearance in case of communication failure, it shall be possible to have the distance protection continuously in operation or only released for operation at communication failure. The distance Protection shall have characteristics that will give load encroachment discrimination and load current compensation of the reactance line in the first zone to avoid over reach. It should be possible to set the distance Protection zone in forward, reverse or non directional mode. Each zone should have individual resistive and reactive reach settings. Separate phase selection logic and automatic switch onto fault logic should be included.

Disturbance recording, event recording shall be built in features and included in the IED.

IED shall be provided with a front mounted HMI and front port for connection to a Personal Computer.

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The IED shall be provided with communication interface for connection to Substation Automation system and substation monitoring system. IEC 61850-8-1 & IEC 60870-5-103 communication protocol shall be available. The IED shall meet the IED 61850 standard in every respect and interoperability with other manufactures IEDs and tools should be verified.

Power supply modules from 48V to 250V AC/DC shall be available.

It shall be possible to select different mounting alternatives such as rack, flush or wall mounting. Depending of the required numbers of I/O modules in the IED 1/1 x 19”, ¾ x 19” and ½ x 19” cases shall be available.

GPS time synchronization module with GPS receiver used for time synchronization shall be available.

28.04. Protection scheme for 220/110/11KV, 220/66/11KV, 110/33-11KV, 66/33KV and 66/11kV Power Transformer Numerical Differential Protection.

A) Numerical Differential Relay

a) It shall consist of fully numerical/digital type, variable percentage, biased type differential relay. It shall be triple pole type, with faulty phase identification/ indication.

b) The percentage bias shall be low near rated current, sufficient to allow for OLTC tap variation and CT errors, but shall increase automatically for severe through faults to ensure stability even under CT saturation errors. It shall offer low burden to CTs.

c) The relays shall be suitable for rated current of 1 Amp and have three instantaneous high set over current units.

d) The relay shall remain stable under initial magnetizing inrush current, sympathetic inrush when adjacent transformers are charged, through fault stability and over fluxing conditions. The relay shall have second harmonic restraint feature.

e) The relay shall be very fast in operation with an operating time not greater than 30 milli seconds at 5 times setting.

f) The relay shall be accompanied by interposing auxiliary current transformers for angle and ratio correction or have internal features in the relay to take care of angle and ratio corrections.

g) The bias setting of the relay shall be adjustable with range of 20 – 50 %.

h) The relay shall have a disturbance feature to record graphic form of instantaneous values of current in all two/three winding transformer in 6 analog channels, during faults and disturbances for pre fault and post fault period. The disturbance recorder shall have the facility to record the following external digital channel signals apart from the digital signals pertaining to differential relay.

i) REF Protection operated.ii) HV & LV breaker status.iii) Bucholtz/OLTC surge relay alarm / trip.

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iv) WTI/OTI/PRD alarm/trip of transformer necessary hardware and software for down loading the data captured by disturbance recorder to personal computer available in the sub-station automation system shall be included in the scope.

Note: Disturbance recorder shall be provided only for 100MVA/150MVA-220/66/11KV Transformer/100MVA 220/110/11KV Transformer.

B) Restricted Earth fault Protection:

The restricted earth fault protection shall

a) Be single pole static/Numerical type.

b) Be of high speed, instantaneous current operated and high impedance type.

c) Have a current setting range of 10-40% of 1 Amp.

d) Be tuned to the system frequency. It shall have high rejection of DC component of fault current.

e) Have suitable non-linear resistor to limit the peak voltage to 1000 volts.

C) Over fluxing protection:

a) Over flux protection relays shall be provided for HV side of 220/110/11KV transformer / 220/110/66KV transformer and shall be of static type.

b) The relay shall monitor the voltage (volts)/frequency (Hertz) and shall have a continuous adjustable setting between 100 to 130% of nominal volts/ hertz ratio.

c) Relay shall have inverse time characteristic compatible with transformer over fluxing.

d) The relay shall be energized by two separate time delay relays to work in two stages for a time delayed alarm and time delayed trip. The variable time setting of alarm shall be in the range of 2-5 secs and that for trip in the range of 5-30 secs. Relay shall have a high resetting ration of 98% or better.

D) Transformer overload relay:

Transformer overload relay shall be provided with two stages. One stage as non-trip alarm & the second stage is to extend trip command to breakers to have required load relief.

E) Auxiliary relay:The transformer protection panel shall be wired for buchholz alarm and trip, oil temperature alarm and low oil level. The auxiliary flag relays shall be provided for contact multiplication wherever they are needed for buchholz alarm/trip, winding temperature alarm/trip, oil temperature alarm/trip, pressure relief device trip, oil surge relay trip. Current operated relays shall be preferred to voltage operated relays.

Note: REFT, Over flux relay & auxiliary relays shall be separately provided externally and shall not be inbuilt features of differential relay.

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28.05 BACK UP PROTECTION:

28.05A) Back-up Directional Over Current & Earth fault protection scheme for 110kV & 66kV Lines & UG Cable :

a) Shall have three over current and one earth fault element (s) which shall be

either independent or composite unit (s).

b) Shall be of Numerical type.

c) Shall include necessary VT fuse failure relays for alarm purposes.

d) Shall (for over current protection)

have IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times

setting

have a variable setting range of 50-200% of rated current.

have a characteristic angle of 30/45 degree lead.

include hand reset flag indicators or LEDs.

e) Shall (for earth fault protection)

have IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times

setting

have a variable setting range of 20-80% of rated current.

have a characteristic angle of 45/60 degree lead.

include hand reset flag indicators or LEDs.

include necessary separate interposing voltage transformers or have internal

feature in the relay for open delta voltage to the relay.

i. The operating coil of the DEFR shall be connected in the residual circuit of the star connection of the line CT's. The polarizing voltage for DEFR shall be obtained from the open delta connection of the VT secondary circuit.

ii. The backup protection as aforesaid shall operate independently of the main protection distance relay, to provide protection for the line section, in the event of failure of the distance relays, to clear the faulty section or failure of the main protection scheme relay.

iii. It should be possible to convert the directional relays to non-directional type by suitable means.

28.05-B Numerical Back-up Over Current & Earth fault protection scheme with high set feature for Power Transformer:

b) Shall have three over current and one earth fault element (s) which shall be either independent or composite unit (s).

c) The scheme shall include necessary VT fuse failure relays for alarm purposes.

d) Over current relay shall

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have directional IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting and have a variable setting range of 50-200% of rated current.

have low transient, over each high set instantaneous unit of continuously variable setting range of 500-2000% of rated current.

have a characteristic angle of 30/45 degree lead. include hand reset flag indicators or LEDs.

e) Earth fault relay shall

have directional IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting and have a variable setting range of 20-80% of rated current.

have low transient, over each high set instantaneous unit of continuously variable setting range 200-800% of rated current.

have a characteristic angle of 45/60 degree lead. include hand reset flag indicators or LEDs. include necessary separate interposing voltage transformers or have internal

feature in the relay for open delta voltage to the relay.

i. The backup protection as aforesaid shall operate independently of the main protection differential relay, to provide protection for the transformer section, in the event of failure of the differential relays, to clear the faulty section or failure of the main protection scheme relay.

ii. It should be possible to convert the directional relays to non-directional type by suitable means.

28.06 Local Breaker Back up protection:

a) Each breaker shall be provided with breaker fail protection to overcome failure of breaker mechanism. In such a case adjacent circuit breaker and/or remote end breaker are required to be tripped.

b) The relay shall be based on current principle and be set to operate after main protection operates and CB has not opened out, with some safety margin.

c) It shall have the following features:

i) It shall be triple pole type and suitable for station DC supply. It shall have three over current elements. Each element shall be arranged to get individual initiation from the corresponding phase of line/transformer protection.

ii) Static measuring element with short consistent pick up time of approximately 4 to 5 ms and short setting time.

iii) It shall have an operating time of less than 15 milliseconds and a resetting time of less than 15 milliseconds.

iv) It shall have a setting range of 5 - 80% of rated current and have a continuous thermal withstand of two times rated current irrespective of the setting.

v) It shall have a timer with continuously adjustable setting range of 0.1 - 1 seconds. of 409

vi) No power consumption from DC auxiliary circuit during normal service.

vii) It shall trip through bus bar protection scheme and lock out all the local breakers. Simultaneously a direct trip signal shall be sent to remote end circuit breaker and lock out its auto re-closing features.

It shall be provided with necessary auxiliary relays to make comprehensive schemes.

Note: LBB relay as inbuilt function of Main-I/Main-II distance relay is also acceptable.

28.07 Bus Coupler Panel:

a) Bus coupler is used for transferring circuits or feeder or transformer from one bus to another. In case of outage of circuit breaker in respect of the line/transformer circuits, the bus coupler breaker is used for the same.

b) It is proposed to provide transfer trip protection scheme to all the line / transformers, to facilitate transfer of open and close commands from line/ transformer panels to the bus coupler panel, when one of the lines/transformers CB is faulty.

c) The control panel wiring of all feeders and transformers shall include the above facility.

d) Bus coupler shall be suitable for bi-directional power flow.

e) Two numbers of non-directional over current relays and one number non-directional earth fault relay shall be provided when the breaker is used as bus coupler.

28.08 Tripping Relay:

Each panel shall be provided with instantaneous DC operated tripping relay. The relay shall have adequate number of normally open and normally close contacts to meet the requirement of scheme, other functions like auto re-closing relay, LBB relay, fault locator disturbance recorder, event logger wherever applicable. The maximum operating time of the relay shall not exceed ten milliseconds and reset within 20 milliseconds. Relay shall be provided with operation indicator for each element coil.

28.09 Tripping Circuit Supervision Relay.

a) Each trip coil of circuit breaker shall be provided with an independent trip circuit supervision relay. These relays shall be mounted in the control panel associated with the circuit breakers. Two trip coils will be provided in each pole of 220 KV CB. However, in respect of 110KV, 66KV & 33KV CB there will be only 2 nos. of trip coils for all the three poles of CB.

b) These relays shall monitor the healthiness of each phase of the trip circuit while the breaker is in open or closed position and give an alarm for the loss of DC supply or for faults in the trip coil or for faults in the trip circuit such as leads, auxiliary contacts. The relay shall have a time delay on drop off of not less than 200 milliseconds and be provided with operation indication.

c) Trip supervision relay shall be located in the panel. of 409

d) The relay shall have adequate contacts for providing connection to alarm and event logger.

28.10 DC Supply monitoring relay:

The relay shall be capable of monitoring the failure of DC supply to which it is connected. Separate DC supply monitoring relay shall be provided for DC main circuit, control circuit of tripping relay and protection circuit of each panel. It shall have adequate potential free contact to meet the scheme requirement. The relay shall have a time delay on drop off of not less than 100msecs and be provided with operation indicator/flag. Indicating lamp and separate alarm for DC fail shall be provided and shall be operated by 230V AC single phase supply. Push buttons for test and accept shall be provided.

28.11 Voltage Selection Relay:

The relay shall operate from auxiliary DC supply voltage and it shall have sufficient number of contacts for extending bus VT supply voltage to relays and meters depending on the bus to which that particular line is connected.

Under no circumstances there shall be either paralleling of two VT supplies through voltage selection relay or reserve charging of VT secondaries. The relay design shall be such that operation of the selector relay used will open the operating circuit of the other relay.

28.12 INTERLOCKING:

The control circuits for operation of the disconnecting switches in the line shall be so designed that the following interlocking features are provided for usual conditions of operation and all the necessary devices, auxiliary relays shall be included in the supply of control panels.

The other interlocks required are (a) it should not be possible to operate either of the bus selector isolators unless the other bus selector isolator, bypass isolator and line breaker is in de-energized condition. (b) it should not be possible to operate the by-pass isolator when the main breaker and the breaker disconnect isolators (on either side of the breaker) all are in closed position. (c) during change over from the line breaker to bus coupler control, both breakers will be closed and it will be necessary to close both the bus selector isolators for making the change over. The interlock required is that it should not be possible to operate either of the bus selector isolators when the line is in service, unless the bus coupler is also closed. (d) If the earth switch of the line isolator is connected to ground, it shall not be possible to close the bus isolator, by-pass isolator or the line isolator or the breaker.

28.13 220KV BUS BAR PROTECTION:

a) The bus bar protection shall be of numerical and modular construction.

b) The bus bar protection scheme offered shall be very fast acting and have maximum operating time up to trip impulse to trip relay, for all types of faults of 15 millisecond at 5 times setting value.

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c) The scheme shall be based on the percentage-biased differential and low impedance, circulating current principle with a slope varying from 50 to 85%. In order to guard against mal-operations due to any spurious operation of the basic differential relay, a check feature shall also be incorporated. This check feature shall be built in feature of the relay. The check feature may be high speed over current starting relay normally set to coincide with the largest line CT primary current rating and high speed 3 phase under voltage relay connected to the bus VTs.

d) The bus bar protection scheme shall not give rise to false operation during normal load flow in bus bar. The bus bars protection shall be stable for heavy through faults condition upto maximum 40KA fault level for 220KV and shall operate correctly positively for all faults within the protected zone(s) even under conditions of CT saturation. For every severe internal faults the relay shall operate and seal-in within the above time i.e. the relays decision shall be made before CT saturation takes place.

e) The bus bar protection scheme offered shall be adaptable to different CT ratios in different bays in any particular substation. The scheme shall allow the use of multi-tap interposing CTs for ratio matching purposes. It should be possible to extend the scheme for any limits on the number of additional bays or on the increasing fault level of the bus. The scheme offered shall include the cost of ICT’s required for this purpose.

f) i) The scheme shall be single zone protection. The entire bus consisting of two sections shall be treated as single zone.

ii) The scheme shall be provided with independent zones of protection for each bus of double bus with zone indication. (two zone protection) This scheme shall be provided wherever called for. However, during bypassing of line transformer breaker through bus coupler, two zone protection will be converted to single zone protection.

g) The protection scheme shall provide continuous supervision for the various CT secondary pilot wires. In case of any open circuiting of CT secondary the relevant zone of protection shall be shorted and an appropriate alarm initiated.

h) The bus bar protection scheme shall include continuous DC supply supervision.

i) It shall include high speed tripping relays conforming to clause 28.08 for each feeder / transformer circuits including future ones.

j) As an optional feature the scheme shall provide facilities for built-in automatic testing at regular intervals. The automatic testing feature shall incorporate injection of currents through each input circuit of the relay and shall check for basic operation as well as stability against external faults. The total time taken for automatic testing shall be less than 30 milliseconds, during which time the tripping shall be blocked. In case of failure of any zone the relevant zone shall be blocked and an alarm initiated.

k) In case of sub-stations where the C&R Panels are located in the switchyard AC Kiosk, distributed type bus bar protection shall be provided. of 409

l) Shall include trip relays, CT switching relays(if applicable), auxiliary CTs (if applicable) as well as additional power supply module, input modules etc as may be required to provide a bus bar protection scheme for the complete bus arrangement ie., for all the bays or breakers including future bays as per the single line diagram and also for additional 1 No. transformer of the same rating and also 4 numbers of 220kV future lines. In case of distributed bus bar protection, the bay units for future bays may be installed in a separate panel & same shall be located where bus bar protection panel is installed.

m) It shall have 'CT' selection incomplete alarm wherever CT switching is involved.

o) If CT switching relays are provided then the switching relays shall be provided only after an ICT. Switching of main CT secondaries shall not be carried out.

p) Include protection “IN/OUT” switch for each zone.

28.14 Time Synchronization Equipment:

a) The Time synchronization equipment shall receive the co-ordinated universal Time (UTC) transmitted through Geo positioning satellite system (GPS) and synchronize equipments to the Indian standard time in a sub-station.

b) Time synchronization equipment shall include antenna, all special cables and processing equipment etc.

c) It shall be compatible for synchronization of Event Loggers, Disturbance recorders and SCADA at a sub-station through individual port or through Ethernet realized through optic fibre bus.

d) Equipment shall operate up to the ambient temperature of 50 degree centigrade and 100% humidity.

e) The synchronization equipment shall have 2 micro second accuracy, Equipment shall give real time corresponding to IST (taking into consideration all factors like voltage, & temperature variations, propagation & processing delays etc).

f) Equipment shall meet the requirement of IEC 60255 for storage & operation.

g) The system shall be able to track the satellites to ensure no interruption of synchronization signal.

h) The output signal from each port shall be programmable at site for either one hour, half hour, minute or second pulse, as per requirement.

i) The equipment offered shall have six (6) output ports. Various combinations of output ports shall be selected by the customer, during detailed engineering, from the following.

Voltage signal: Normally 0-5V with 50milli seconds minimum pulse duration. In

case any other voltage signal required, it shall be decided during detailed

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Potential free contact (minimum pulse duration of 50 milli seconds).

IRIG-B

RS232C/RS 485

j) The equipment shall have a periodic time correction facility of one second periodicity

k) Time synchronization equipment shall be suitable to operate from 220V DC or 110V DC as available at sub-station.

l) Equipment shall have real time digital display in hour, minute, second (24 hour mode) & have a separate time display unit to be mounted on the top of control panels having display size of approx. 100 mm height.

28.15 Rely Test Kit

One relay test kit shall comprise of the following equipment as detailed here under:

3 sets Relay tools kits

2 Nos. Test plugs

1 No. Special type test plugs for using with modular type cases (if applicable).

28.16 VOID

29.00 PROTECTION PHILOSOPHY: 220kV substations are provided with dual DC source. The Main-1 & Main- II distance

protection are to be connected to different DC sources ie source -1 and source -2. The trip coils TC1 & TC2 of circuit breakers are also to be energized by different DC sources ie source -1 & source-2.

A) 220 KV Line protection

Carrier aided, high speed, numerical distance scheme (with fault locator, auto re-close, disturbance records and event recorder) as Main-I & Main-II protection. The Main-IIprotection shall operate independent of Main-I protection. In addition to this if cable is used for lines, line differential protection is used as Main- I and Main-II–protection.

The voltage source from three nos. of C.V.T. provided for each line shall be used for line charged indication, auto re-close and synchronization etc., The voltage source for protection and meter circuits of the line feeder will be from the selected bus/line CVT. Provision can be made in the panel with change over switch to transfer potential to bus VTs, in case of failure of CVT.

B) 110 KV / 66 KV LINE PROTECTION

Numerical distance scheme as principal protection and directional over current / directional earth fault numerical relays as back-up protection. The back-up protection shall operate independent of primary protection. In addition to this, if cable is used for lines, line differential protection is used as Main protection and directional over current/directional earth fault relays as back up protection.

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The voltage source for protection and meter circuits of the line feeder will be from the bus VTs.

a) For 220KV sub-stations.

The voltage source from line CVTshall be used for line charged indication and synchronization etc.The voltage source for line feeder for protection circuits shall be from selected line CVT/Bus VT and for metering circuits will be from the bus V.T’s.

b) For 110 & 66 KV sub-stations:

The voltage source for protection and metering circuits of the line feeder will be from Bus V.T’s

C) Power Transformer Protection:

The protection scheme should trip the circuit breaker on HV and MV/ LV side of transformer for any fault in the transformer.

a) The differential protection scheme and REF as principle protection.

b) The directional numerical OCR / EFR provided on HV side and DOCR/DEFR provided on MV/LV side shall act as back up protection.

c) Three number of circulating current relay for protection of 11kV Tertiary winding in case of 220/110/11KV, 100MVA and 220/66/11KV, 100MVA/150MVA Transformer provided.

d) The trip impulses received from Buchholz relay, winding temperature relay, pressure relief device, oil surge relay etc., provided by the transformer manufacturer, shall trip the breaker through an auxiliary relay.

e) The necessary matching transformers required for the protection scheme shall be supplied by the bidder and is deemed to be part of differential protection.

f) The back up protection shall operate independent of primary protection.

D) Bus Bar Protection:

a) The 220KV bus bars shall be protected by a high speed circulating current / differential protection.

b) The relays shall be of numerical design and the scheme shall cover all the 220KV Bus and feeder circuits.

30.00 Co-ordination of Drawings of associated equipments of other manufacturers:

1. The purchaser intends to procure all outdoor equipments associated with these panels from other manufacturers. The supplier is therefore required to co-ordinate the control and wiring schematics of these panels with control and wiring schematic of the outdoor equipment manufacturer.

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2. The purchaser will intimate the supplier the details of the outdoor equipments manufacturers on whom purchaser orders have been placed for the supply of these equipments along with such relevant details such as P.O. No. and date, delivery period, and all other technical details such as rating data, wiring diagrams etc. The supplier shall co-ordinate these diagrams with that of the associated relay and protection panels, and shall also seek such clarifications as are necessary from these manufacturers under intimation to the purchaser.

3. The purchaser will assist and or furnish the supplier with all relevant data as are necessary for completeness of co-ordination of the wiring diagrams and interlocking of equipment circuits.

31.00 DRAWINGS AND LITERATURES:

31.01 Tender drawings and literatures:

The following drawings and literatures shall be submitted along with tender documents.

a) Principal layout drawings of the SIMPLEX Relay and protection with disposition of meters and control switches, relays. These layout drawings shall be for the following views:

i. Front face of panel.ii. Inside view of panel.

b) Illustrated literature with photographs of similar panels supplied by the manufacturer.

c) Pictorial and sectional views of control switches, test terminal blocks, indicating instruments, exploded views of draw out type instruments etc.,

d) Printed copies of illustrated, literature, general technical data, performance application, and specifications of relays, fault locators, etc.,

e) Elementary schematic wiring diagrams of the various metering and protective schemes.

31.02 Contract Drawing:

In the event of an order, the supplier shall submit drawings, GTP and type test reports in triplicate for approval of the purchaser, prior to manufacture. After the drawings are approved six copies of each of the drawings printed on 90 GSM paper shall be supplied for immediate use.

The successful bidder should forward the drawings as follows.

a) One set of reproducible, originals and 12 sets of copies of all approved drawings along with 12 sets of literature commissioning and maintenance manuals to the Chief Engineer, Electy., Tendering & Procurement, KPTCL, Kaveri Bhavan, Bangalore -560 009.

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b) Three sets of copies of all approved drawings along with three sets of literature and manuals to each of the consignee.

c) Non supply or part supply of drawings, literature and manual will be deemed as incomplete supply of equipment.

The contract drawings shall cover the following

a) Principal layout drawing as per clause No. 31.01 (a).

b) Details of construction and dimensions of the cubicle and complete switch board.

c) Foundation drawings indicating the cable entries and trenches etc.

d) Elementary diagrams of all controls, metering, protection, annunciation and other circuits. All devices shall be numbered according to ASA code.

e) Cabling and wiring diagram of the front and rear cubicles and interconnections between them. Ferrule numbers device members, grouping for cable take offs etc., shall be distinctly shown.

f) Inter-connection diagram between switch board and switchgear equipment, power transformers, instrument transformers and other associated equipment.

g) Dimensional outline, drilling diagram and special mounting arrangement, if any, of each type of the various devices on the switch board.

h) Individual internal wiring diagram of all devices and elementary wiring diagrams or relays for internal wiring.

i) Construction details of the switches, terminal blocks and test blocks etc.

31.03 LITERATURE:

In the event of an order, seven copies of each set of the following literatures shall be supplied.

a) Literature describing construction, operation, testing, calibration, adjustment, rating, specifications, setting details of all the protective and auxiliary relays and control switches.

b) Literature giving rated data, details of adjustments for calibration for the indicating instruments and integrating instruments.

c) List of spare parts, identification number from removable parts of relays, instruments and switches etc., with the help of which the purchaser will be able to procure spare parts from the supplier at any subsequent time.

d) Performance application of relays.

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e) Detailed internal drawings of all units / schematic diagrams of all, PCB's of the relays, reference voltages at convenient test points, functional description, operational details. This is essential for trouble shooting of the relays.

f) The literature shall contain wave forms / voltages etc at selected points for easy identification of faulty units with in the modular unit.

32.00 TESTS, TEST CERTIFICATES AND INSPECTION:

32.01 The following routine tests shall be carried out on the panels at the factory:

a) Checking of overall dimensions, thickness of panel sheet and paint film.

b) Checking wiring and continuity of circuits.

c) One minute HV withstand test – All equipment on panel and internal wiring shall be tested to withstand a voltage of 2KV to earth for one minute.

d) Insulation resistance of the complete wiring, circuit by circuit with all equipment mounted on the panel.

e) Verification of degree of protection as per IS –2147

32.02 All relays shall be subject to type tests and routine tests as per relevant standards, that is IS - 3231 or IEC - 60255.

32.03 All other components including indicating instruments and accessories installed within the panel shall be subject to type tests, routine tests and acceptance tests according to the standards to which they conform.

32.04 All routine and acceptance tests shall be conducted in the presence of the purchaser’s representatives. No material shall be dispatched unless the purchaser communicates his written approval to these test certificates.

32.05 Type Tests Reports:

The reports for following type tests shall be submitted by the bidder for the protective relays, fault locator, Disturbance recorder and Event logger.

a) Insulation tests as per IEC 60255-5

b) High frequency disturbance test as per IEC 60255-4( Appendix-E) – Class III (not applicable for electromechanical relays)

c) Fast transient test as per IEC 1000-4 level III (not applicable for electromechanical relays).

d) Relay characteristics, performance and accuracy test as per IEC 60255

Steady state characteristics and operating time. Dynamic characteristics and operating time for distance protection relays and

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For disturbance recorder and event logger only performance tests are intended under this item.

e) Tests for thermal and mechanical requirements as per IEC 60255-6

f) Tests for rated burden as per IEC 60255-6

g) Contact performance test as per IEC 60255-0-20 (not applicable for Event logger distance to fault locator and Disturbance recorder).

32.06 Steady state & dynamic characteristics test reports on the distance protection relays as type test, shall be based on general guidelines specified CIGRE Committee 34 report on evaluation of characteristics and performance of power system protection relays and protective system A on simulator/network analyzer /PTL alternatively, the files generated using electromagnetic transient programme (EMTP) can also be used for carrying out the above tests Single source dynamic tests on transformer differential relay shall be /should have been conducted based on general guidelines specified in CIGRE committee 34 report.

33.00 Spares

33.01 The tenderer shall recommend in his offer a set of spares as are required for a period of 5 (five) years in respect of relays and instruments quoted. All like spare parts shall be interchangeable with respect to each other and shall therefore be suitable for the parts/components that they would replace.

33.02. The tenderer shall indicate the life expectancy or shelf life of all such spares and their recommended method of storage.

33.03 Itemized unit price rate for each component shall be furnished in the schedule of prices in tender proposal sheets. The purchaser reserves the right to order for the spares which in his assessment are actually required.

34.00 MAINTENANCE TOOLS AND EQUIPMENT:

34.01 a) The tenderer shall offer in his tender a set of special tools as are necessary for routine maintenance and testing of the equipment. These shall include amongst others relay test jacks, patch cords, etc.

b) The tenderer is required to supply these tools arranged neatly in wooden boxes.

34.02 a) The tenderer shall offer in his tender, instruments and equipment’s for conducting tests on relays and instruments. The relay testing kits shall be suitable for conducting dynamic tests on the relays to ascertain their characteristics as also to conduct periodical calibration and maintenance tests.

b) The testing kits, shall be self contained compact portable units with built in power supply units and timers. If the test equipment contains more than one unit then no extensive inter unit wiring shall be involved at site. The kits shall be capable of being operated off the auxiliary AC & DC power supplies specified in this tender document.

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34.03 Itemized unit price rate of each such tool/equipment shall be furnished in the schedule of prices in tender proposal sheets.

35.00 QUALITY ASSURANCE PLAN:

The tenderer shall invariably furnish the following information along with his offer failing which his offer shall be liable for rejection.

a) Names of sub-suppliers of individual accessories.b) Information and copies of test certificates in respect of bought out accessories.c) List of manufacturing facilities available.d) List of areas in manufacturing process where stage inspections are carried out for

quality assurance and details of such tests and inspection.e) Type test certificates not older than three years as on the previous date of tender

opening.

35.01 The supplier shall within 30 days of placement of order, submit following information to the purchaser.

i) List of bought out accessories and the names of sub-suppliers selected from those furnished along with offer.

ii) Type test certificates of the bought out accessories.iii) Quality assurance plan (QAP) with hold points for purchaser’s inspection. The quality

assurance plan and hold points shall be discussed between the purchaser and supplier before the QAP is finalised.

35.02 The supplier shall submit the routine test certificates of bought out items, at the time of routine testing of the fully assembled panel.

36.00 MINIMUM EXPERIENCE FOR QUALIFYING AS A TENDERER :

i. Tenderers shall have a minimum experience of five years in the design, manufacture, testing and commissioning of Control and Relay panels, similar to the type specified in the present enquiry. At least 50% of the quantity of similar type of main protection relays i.e., distance and differential, over fluxing, REF relays and Bus bar protection relays called for in the present enquiry shall be in successful operation for a minimum period of two years. The tenderer shall furnish performance certificate for satisfactory operation of similar main protection relays for a minimum period of two years. The tenderer shall furnish the type test certificates for tests conducted on a similar relay not later than three years from the previous date of bid opening.

ii. The tenderer should be the original manufacturer of at least 50% of the total relay types mentioned, viz., distance relays, auto re-close relays, differential relays and back up protection relays, High speed trip relays, LBB, Bus bar protection relays, over-fluxing and REF relays.

iii. The purchaser however reserves the right to waive the minimum experience condition stipulated in clause 36.00 (i) in case of Firm having collaboration with well experienced Firms. The experience of the collaborating Firms in the manufacture of similar type of main protection relays shall be not less than five years. The waiving of minimum experience condition will be considered by the purchaser only on furnishing the

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performance guarantee for the main protection relays manufactured by the collaborating Firms.

37.00 PERFORMANCE GUARANTEE :

The control and relay panels along with the main protection relays offered shall be guaranteed for satisfactory performance for a period of 24 months from the date of satisfactory commissioning of C & R Panels. The equipment/relays if found defective/failed within the above guarantee period shall be replaced or repaired by the supplier free of cost within one month from receipt of intimation. If the defective/failed equipments/relays are not replaced/repaired as per the above guarantee clause, the corporation shall recover an equivalent amount plus 15% supervision charges from any of the supplier’s bills.

38.0 TRAINING TO BOARD ENGINEERS :

38.01 The purchaser requires that training be imparted to eight Engineers of the Purchaser’s organization in the testing, commissioning, calibration, adjustment, trouble shooting and attending to routing defects, mal-operations in the relays and instruments supplied. Such training shall be imparted at the supplier’s works for a period of not less than 2 (two) weeks and shall be imparted free of cost. The to and fro travel expenses of these Engineers will be borne by the purchaser. However boarding, lodging and other incidental expenses related there to shall be borne by the supplier.

38.02 In case training is to be imparted at the works of the supplier’s collaborators. Then the same shall be arranged for by the supplier.

38.03 The training shall be imparted before dispatch of the equipment.

39.0 DESPATCH :

39.01 The control and relay panels shall be dispatched in suitable crates with all instruments, relays, switches and other devices mounted in position and wired. Instruments which cannot be sent in this manner may be separately dispatched.

39.02 The detailed dispatch schedule for each control & relay panel board shall be supplied well in advance. In the schedule, items accompanying the control panel items separately despatched in crates and items for which only drilling and wiring is provided shall be separately listed.

39.03 The packing list for each shipment shall indicate complete details of equipment being shipped to enable to consignee to identify the parts and to ensure that no equipment stated to have been shipped has either lost in transit or if damaged, to initiate replacement proceedings and also to enable the insurance claims to be preferred. If the invoice does not contain full details, if any part not specifically mentioned in the packing list is missing in transit the supplier shall be responsible for supply of such parts to the purchaser without any extra cost.

40.0 DEVIATION FROM TECHNICAL SPECIFICATIONS :

40.01 The tender can suggest modification in the protective scheme detailed in the specification if it improves the discrimination selectivity and overall performance of the protection scheme, clearly giving all the details.

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41.0 SCHEDULE OF REQUIREMENTS AND DELIVERY :

41.01 The schedule of requirement of components is detailed in annexure. The tenderer should furnish the breakup prices for various relays and meters for future addition and deletion.

41.02 Station wise schedule of requirement along with the desired delivery is detailed in Annexure. In case of new stations the basis of comparison will be on package basis i.e. on the complete requirement of a station.

41.03 The purchaser may ask for addition or deletion of some items during the time of verification of drawings. The Firm shall agree to supply any additions(at extra cost, if any).

41.04 In case of new 220KV stations space constraints may result in the layout being modified into single bus both on 220 KV & 110/66 KV sides. In this event the bus coupler panel will be deleted from requirement.

41.05 In view of 41.04 and also due to other reasons, there may be change in the components of the panels which will be decided at the time of approval of drawings. In the event of difference of components between purchase order and approved drawing, payment will be made as per approved drawing.

42.00 SCHEDULE OF PRICE:

42.01 The tenderer should furnish the schedule of prices for each type of panel station wise. The supplies should be complete in all respects as stipulated in annexure and preference will be given to tenederers who confirm that this delivery can be met. The tenderer should indicate in this offer the breakup of time required for (1) collecting design parameters from purchaser, (2) Designing of panels and preparation of detailed drawings, (3) Approval of drawing, (4) fabrication of panels and testing and (5) transportation to site. This information will be used for the purpose of calculating penalty etc.

42.02 The tenderer shall furnish the breakup price for each of the component of panels. Decision in regard to adding or deleting any of the component rests with the purchaser.

43.0 GUARANTEED TECHNICAL PARTICULARS:

43.01 The tenderer should furnish the guaranteed technical particulars as called for in Annexure, failing which the offer is liable to be overlooked.

43.02 Guaranteed technical particulars for panels for different voltage class shall be furnished separately.

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SECTION -2 - SUBSTATION AUTOMATION SYSTEM

1.0 GENERAL:

1.1 The substation automation system shall be offered from a manufacturer who must have designed, manufactured, tested, installed and commissioned Substation Automation System which must be in satisfactory operation on 220 KV system or higher for at least 2 (two) years as on the date of bid opening.

1.2 The Substation Automation System (SAS) shall be installed to control and monitor all the substation equipments from Remote Control Centre (RCC) as well as from local control centre.The SAS shall contain the following main functional parts:

Bay control Intelligence Electronic Devices (IEDs) for control & monitoring.

Station Human Machine Interface (HMI)

Redundant managed switched Ethernet Local Area Network communication infrastructure with hot standby.

Gateway for remote control via industrial grade hardware (to RCC) through IEC 60870-5-104 protocol.

Gateway for remote supervisory control (to RSCC), the gateway should be able to communicate with RSCC on IEC 60870-5-104 protocol. The specific protocol to be implemented shall be handed over to successful bidder. It shall be bidders responsibility to integrate his offered system with existing RSCC system for exchange of desired data. The exact IO point shall be decided during detailed engineering.

Remote HMI.

Peripheral equipment like printers, display units, key boards, Mouse etc.

1.3 It shall enable local station control via a PC by means of human machine interface (HMI) and control software package, which shall contain an extensive range of Supervisory Control And Data Acquisition (SCADA) functions.

1.4 It shall include communication gateway, intelligent electronic devices (IED) for bay control and inter IED communication infrastructure. An architecture drawing for SAS is enclosed.

1.5 The communication gateway shall facilitate the information flow with remote control centers. The bay level intelligent electronic devices (IED) for protection and control shall provide the direct connection to the switchgear without the need of interposing components and perform control, protection and monitoring functions.

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2.0 SYSTEM DESIGN:

2.1 General system design .

The Substation Automation System (SAS) shall be suitable for operation and monitoring of the complete substation including future extensions as given in Section-Project.

The system shall be of the state-of-the art suitable for operation under electrical environment present in Extra high voltage substations follow the latest engineering practice, ensure long-term compatibility requirements and continuity of equipment supply and the safety of the operating staff.

The offered SAS shall support remote control and monitoring from Remote Control centers via gateways.

The system shall be designed such that personnel without any background knowledge in Microprocessor-based technology are able to operate the system. The operator interface shall be intuitive such that operating personnel shall be able to operate the system easily after having received some basic training.The system shall incorporate the control, monitoring and protection functions specified, self-monitoring, signaling and testing facilities, measuring as well as memory functions, event recording and evaluation of disturbance records.Maintenance, modification or extension of components may not cause a shutdown of the whole substation automation system. Self-monitoring of components, modules and communication shall be incorporated to increase the availability and the reliability of the equipment and minimize maintenance.

Bidder shall provide the Bay control IED (a bay comprises of one circuit breaker and associated disconnect or, earth switches and instrument transformer in the simplex relay and protection panels itself (described in other sections of technical specifications) located in control room. Station HMI is also located in Control Room for overall optimization in respect of cabling.

2.2 System Architecture .

The SAS shall be based on a decentralized architecture and on a concept of bay-oriented, distributed intelligence.Functions shall be decentralized, object-oriented and located as close as possible to the process.

The main process information of the station shall be stored in distributed databases. The typical SAS architecture shall be structured in two levels, i.e., in a station and a bay level.

At bay level, the IEDs shall provide all bay level functions regarding control, monitoring and protection, inputs for status indication and outputs for commands. The IEDs should be directly connected to the switchgear without any need for additional interposition or transducers.

Each bay control IED shall be independent from each other and its functioning shall not be affected by any fault occurring in any of the other bay control units of the station.

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The data exchange between the electronic devices on bay and station level shall take place via the communication infrastructure. This shall be realized using fibre-optic cables, thereby guaranteeing disturbance free communication. The fibre optic cables shall be run in G.I. conduit pipes. Data exchange is to be realised using IEC-61850 protocol with a redundant managed switched Ethernet communication infrastructure.

The communication shall be made in 1+1 mode, excluding the links between individual bay IEDs to switch, such that failure of one set of fibre shall not affect the normal operation of the SAS. However, it shall be alarmed in SAS. Each fibre optic cable shall have four (4) spare fibres.

At station level, the entire station shall be controlled and supervised from the station HMI. It shall also be possible to control and monitor the bay from the bay level equipment at all times. Clear control priorities shall prevent operation of a single switch at the same time from more than one of the various control levels, i.e., RCC, station HMI, bay level or apparatus level. The priority shall always be on the lowest enabled control level.

The station level contains the station-oriented functions, which cannot be realised at bay level, e.g. alarm list or event list related to the entire substation, gateway for the communication with remote control centres.

The GPS time synchronising signal (as specified in the section relay & protection) for the synchronization of the entire system shall be provided.

The SAS shall contain the functional parts as described in para 1.2 above.

2.3 Functional Requirements :

The high-voltage apparatus within the station shall be operated from different places: Remote control centres. Station HMI. LocalBay controller IED

Operation shall be possible by only one operator at a time.

The operation shall depend on the conditions of other functions, such as interlocking, synchrocheck, etc. (see description in “Bay level control functions”).

2.3.1 Select-before-execute :

For security reasons the command is always to be given in two stages: selection of the object and command for operation under all mode of operation except emergency operation. Final execution shall take place only when selection and command are actuated.

2.3.2 Command supervision :Bay/station Interlocking and blocking.

Software Interlocking is to be provided to ensure that inadvertent incorrect operation of switchgear causing damage and accident in case of false operation does not take place. In addition to software interlocking hardwired interlocking are to be provided for:

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a) Bus Earth Switch Interlocking.b) Transfer Bus Interlocking (if applicable).

It shall be a simple layout, easy to test and simple to handle when upgrading the station with future bays. For software interlocking the bidder shall describe the scenario while an IED of another bay is switched off or fails.

A software interlock override function shall be provided which can be enabled to bypass the interlocking function.

2.3.3 Run Time Command cancellation .

Command execution timer (configurable) must be available for each control level connection. If the control action is not completed within a specified time, the command should get cancelled.

2.3.4 Self-supervision .

Continuous self-supervision function with self-diagnostic feature shall be included.

2.3.5 User configuration .

The monitoring, controlling and configuration of all input and output logical signals and binary inputs and relay outputs for all built-in functions and signals shall be possible both locally and remotely.

It shall also be possible to interconnect and derive input and output signals, logic functions, using built-in functions, complex voltage and currents, additional logics (AND-gates, OR gates and timers). (Multi-activation of these additional functions should be possible).

The functional requirement shall be divided into following levels:

a) Bay (a bay comprises of one circuit breaker and associated disconnector, earth switches and instrument transformer) Level Functions.

b) System Level Functions.

3.0 BAY LEVEL FUNCTIONS :

3.1 In a decentralized architecture the functionality shall be as close to the process as

possible. In this respect, the following functions can be allocated at bay level:

Bay control functions including data collection functionality.

Bay protection functions.

Separate IEDs shall be provided for bay control function and bay protection function.

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3.1.1 Bay Control functions .

3.1.1.1 Overview.

Functions.

Control mode selection

Select-before-execute principle.

Command supervision:

Interlocking and blocking

Double command.

Synchrocheck, voltage selection.

Run Time Command cancellation

Transformer tap changer control (for power transformer bays)

Operation counters for circuit breakers and pumps

Hydraulic pump/Air compressor control and runtime supervision /spring mechanism

supervision

Operating pressure supervision.

Display of interlocking and blocking.

Breaker position indication per phase

Isolator Position Indication

Alarm annunciation

Measurement display

Local HMI (local guided, emergency mode)

Interface to the station HMI.

Data storage for at least 200 events.

Extension possibilities with additional I/O’s inside the unit or via fiber-optic

communication and process bus.

3.1.1.2 Control mode selection .

Bay level operation:

As soon as the operator receives the operation access at bay level the operation is normally performed via bay control IED. During normal operation bay control unit allows the safe operation of all switching devices via the bay control IED.

Emergency operation:

It shall be possible to close or open the selected Circuit Breaker with ON or OFF push buttons even during the outage of bay IED.REMOTE mode

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Control authority in this mode is given to a higher level (Remote Control Centre) and the installation can be controlled only remotely. Control operation from lower levels shall not be possible in this operating mode.

3.1.1.3 Synchronism and energizing check.

The synchronism and energizing check functions shall be bay-oriented and distributed to the bay control and/or protection devices. These features are:

Settable voltage, phase angle, and frequency difference.

Energizing for dead line – live bus, live line – dead bus or dead line – dead bus with

no synchro-check function.

Synchronizing between live line and live bus with synchro-check function.

Voltage selection.

The voltages relevant for the Synchro-check functions are dependent on the station topology, i.e., on the positions of the circuit brakers and/or the isolators. The correct voltage for synchronizing and energizing is derived from the auxiliary switches of the circuit breakers, the isolator, and earthing switch and shall be selected automatically by the bay control and protection IEDs.

3.1.1.4 Transformer tap changer control .

Raise and lower operation of OLTC taps of transformer shall be facilitated through Bay controller IED.

3.1.2 Bay protection functions :

3.1.2.1 General.

The protection functions are independent of bay control function. The protection shall be provided by separate protection IEDs (numerical relays) and other protection devices as detailed in Section-Relay & Protection panels.

IEDs, shall be connected to the communication infrastructure for data sharing and meet the real-time communication requirements for automatic functions. The data presentation and the configuration of the various IEDs shall be compatible with the overall system communication and data exchange requirements.

Event and disturbance recording function:

Each IED should contain an event recorder capable of storing at least 200 time-tagged events. This shall give alarm if 70% memory is full. The disturbance recorder function shall be as per detailed in section –Relay & Protection panles.

3.2 System level functions :

3.2.1 Status supervision:

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The position of each switchgear, e.g., circuit breaker, isolator, earthing switch, transformer tap changer etc., shall be supervised continuously. Every detected change of position shall be immediately displayed in the single-line diagram on the station HMI screen, recorded in the event list, and a hard copy printout shall be produced. Alarms shall be initiated in the case of spontaneous position changes.

The switchgear positions shall be indicated by two auxiliary switches, normally closed (NC) and normally open (NO), which shall give ambivalent signals. An alarm shall be initiated if these position indications are inconsistent or if the time required for operating mechanism to change position exceeds a predefined limit.

The SAS shall also monitor the status of substation auxiliaries. The status and control of auxiliaries shall be done through separate one or more IED and all alarm and analog values shall be monitored and recorded through this IED.

3.2.2 Measurements.

a) Analog inputs for voltage and current measurements shall be connected directly to the voltage transformers (VT) and the current transformers (CT) without intermediate transducers. The values of active power (W), reactive power (VAR), frequency (Hz) and the rms values for voltage (U) and current (I) shall be calculated. The measured values shall be displayed locally on the Station HMI and in the Control Centre. The abnormal values must be discarded. The analog values shall be updated every 2 seconds.

Threshold limit values shall be selectable for alarm indications.

3.2.3 Event and alarm handling:

Events and alarms are generated either by the switchgear, by the control IEDs or by the station level unit. They shall be recorded in an event list in the station HMI. Alarms shall be recorded in a separate alarm list and appear on the screen. All, or a freely selectable group of events and alarms shall also be printed out on an event printer. The alarms and events shall be time-tagged with a time resolution of 1 ms.

3.2.4 Station HMI .

3.2.4.1 Substation HMI Operation:On the HMI the object has to be selected first. In case blocking or interlocking conditions are not met, the selection shall not be possible and an appropriate alarm annunciation shall occur. If a selection is valid the position indication will show the possible direction and the appropriate control execution button shall be pressed in order to close or open the corresponding object.

Control operation from other places (e.g. REMOTE) shall not be possible in this operating mode.

3.2.4.2 Presentation and dialogues.

General:

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The operator station HMI shall be redundant with hot standby and shall provide basic functions for supervision and control of the substation. The operator shall give commands to the switchgear on the screen via mouse clicks or keyboard commands.

The HMI shall give the operator access to alarms and events displayed on the screen. Aside from these lists on the screen, there shall be a printout of alarms or events in an event log.

An acoustic alarm shall indicate abnormalities and all unacknowledged alarms shall be accessible from any screen selected by the operator.

The following standard pictures shall be available from the HMI.

Single-line diagram showing the switchgear status and measured values.

Control dialogues with interlocking and blocking details. This control dialogue shall

tell the operator whether the device operation is permitted or blocked.

Measurement dialogues.

Alarm list, station / bay-oriented.

Event list, station / bay-oriented.

System status.

3.2.4.3 HMI design principles:

Consistent design principles shall be adopted with the HMI concerning labels, colours, dialogues and fonts. Non-valid selections shall be dimmed out.The object status shall be indicated using different status colours for: Selected object under command

Selected on the screen

Not updated, obsolete values, not in use or not sampled

Alarm or faulty state

Warning or blocked

Update blocked or manually updated

Control blocked

Normal state

3.2.4.4 Process status displays and command procedures:

The process status of the substation in terms of actual values of currents, voltages, frequency, active and reactive powers as well as the positions of circuit breakers, isolators and transformer tap-changers shall be displayed in the station single-line diagram.

In order to ensure a high degree of security against undesired operation, a “select-before-execute” command procedure shall be provided. After the “selection” of a switch, the operator shall be able to recognize the selected device on the screen and all other switchgear shall be blocked. As communication between control centre and device to be

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controlled is established, the operator shall be prompted to confirm the control action and only then final execute command shall be accepted. After the “execution” of the command the operated switching symbol shall flash until the switch has reached its new position.

The operator shall be in a position to execute a command only, if the switch is not blocked and if no interlocking condition is going to be violated. The interlocking statements shall be checked by the interlocking scheme implemented at bay and station level.

After command execution the operator shall receive a confirmation that the new switching position has been reached or an indication that the switching procedure was unsuccessful with the indication of the reason for non-functioning.

3.2.4.5 System supervision & display.

The SAS system shall be comprehensively self-monitored such that faults are immediately indicated to the operator, possibly before they develop into serious situations. Such faults are recorded as a faulty status in a system supervision display. This display shall cover the status of the entire substation including all switchgear, IEDs, communication infrastructure and remote communication links and printers at the station level etc.

3.2.4.6 Event list.

The event list shall contain events that are important for the control and monitoring of the substation.

The event and associated time (with 1 ms resolution) of its occurrence has to be displayed for each event.

The operator shall be able to call up the chronological event list on the monitor at any time for the whole substation or sections of it.

A printout of each display shall be possible on the hard copy printer.

The events shall be registered in a chronological event list in which the type of event and its time of occurrence are specified. It shall be possible to store all events in the computer for at least one month. The information shall be obtainable also from a printed event log.

The chronological event list shall contain:

Position changes of circuit breakers, isolator and earthing devices.

Indication of protective relay operations.

Fault signals from the switchgear.

Indication when analog measured values exceed upper and lower limits. Suitable

provision shall be made in the system to define two level of alarm on either side of the

value or which shall be user defined for each measured.

Loss of communication.

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Filters for selection of a certain type or group of events shall be available. The filters

shall be designed to enable viewing of events grouped per:

Date and time.

Bay

Device

Function e.g., trips, protection operations etc.

Alarm class.

3.2.4.7 Alarm list:

Faults and errors occurring in the substation shall be listed in an alarm list and shall be immediately transmitted to the control centre. The alarm list shall substitute a conventional alarm tableau and shall constitute an evaluation of all station alarms. It shall contain unacknowledged alarms and persisting faults. The date and time of occurrence shall be indicated.

The alarm list shall consist of a summary display of the present alarm situation. Each alarm shall be reported on one line that contains:

The date and time of the alarm. The name of the alarming object. A descriptive text. The acknowledgement state.

Whenever an alarm condition occurs, the alarm condition must be shown on the alarm list and must be displayed in a flashing state along with an audible alarm. After acknowledgment of the alarm, it should appear in a steady (i.e., not flashing) state and the audible alarm shall stop. The alarm should disappear only if the alarm condition is physically cleared and the operator has reset the alarm with a reset command. The state of the alarms shall be shown in the alarm list (Unacknowledged and persistent, Unacknowledged and cleared, Acknowledged and persistent).

Filters for selection of a certain type or group of alarms shall be available as for events.

3.2.4.8 Object picture:

When selecting an object such as a circuit breaker or isolator in the single-line diagram, the associated bay picture shall be presented first. In the selected object picture, all attributes like

Type of blocking

Authority

Local / remote control

RSCC / SAS control

Errors etc.,

shall be displayed.

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3.2.4.9 Control dialogues:

The operator shall give commands to the system by means of mouse click located on the single-line diagram. It shall also be possible to use the keyboard for command activation. Data entry is performed with the keyboard. Dedicated control dialogues for controlling at least the following devices shall be available:

Breaker and disconnector

Transformer tap-changer.

3.2.5 User-authority levels:

It shall be possible to restrict activation of the process pictures of each object (bays, apparatus...) within a certain user authorisation group. Each user shall then be given access rights to each group of objects e.g.:

Display only.

Normal operation (e.g. open/close of switchgear)

Restricted operation (e.g. by-passed interlocking)

System administrator

For maintenance and engineering purposes of the station HMI, the following

authorisation levels shall be available:

No engineering allowed.

Engineering/configuration allowed.

Entire system management allowed.

The access rights shall be defined by passwords assigned during the log-in procedure. Only the system administrator shall be able to add / remove users and change access rights.

3.2.6 Reports:

The reports shall provide time-related follow-ups of measured and calculated values. The data displayed shall comprise:

Trend reports:

Day (mean, peak)

Month (mean, peak)

Semi-annual (mean, peak)

Year (mean, peak)

Historical reports of selected analog values:

Day (at 15 minutes interval)

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Month

Year

It shall be possible to select displayed values from the database in the process display on-line. Scrolling between e.g. days shall be possible. Unsure values shall be indicated. It shall be possible to select the time period for which the specific data are kept in the memory.

Following printouts shall be available from the printer and shall be printed on demand:

i. Daily voltage and frequency curves depicting time on X-axis and the appropriate parameters on the Y-axis. The time duration of the curve is 24 hours.

ii. Weekly trend curves for real and derived analog values.

iii. Printouts of the maximum and minimum values and frequency of occurrence and duration of maximum and minimum values for each analog parameter for each circuit in 24 hours period.

iv. Provision shall be made for logging information about breaker status like number of operation with date and time indications.

v. Equipment operation details shift wise and during 24 hours.

vi. Printout on adjustable time period as well as on demand for MW, MVAR, Current, Voltage on each feeder and transformer as well as Tap positions, temperature and status of pumps and fans for transformers.

vii. Printout on adjustable time period as well as on demand system frequency and average frequency.

viii. Reports in specified formats, which shall be handed over to successful bidder.

3.2.7 Trend display (historical data):

It shall be possible to illustrate all types of process data as trends – input and output data, binary and analog data. The trends shall be displayed in graphical form as column or curve diagrams with a maximum of 10 trends per screen. Adjustable time span and scaling ranges must be provided.

It shall be possible to change the type of value logging (direct, mean, sum or difference) on-line in the window. It shall also be possible to change the update intervals on-line in the picture as well as the selection of threshold values for alarming purposes.

3.2.8 Automatic disturbance file transfer:

All recorded data from the IEDs with integrated disturbance recorder as well as dedicated disturbance recording systems shall be automatically uploaded (event triggered or once per day) to a dedicated computer and be stored on the hard disc.

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3.2.9 Disturbance analysis:

The PC-based work station shall have necessary software to evaluate all the required

information for proper fault analysis.

3.2.10 IED parameter setting:

It shall be possible to access all protection and control IEDs for reading the parameters (settings) from the station HMI or from a dedicated monitoring computer. The setting of parameters or the activation of parameter sets shall only be allowed after entering a password.

3.2.11 Automatic sequences:

The available automatic sequences in the system should be listed and described (e.g., sequences related to the trip transfer). It must be possible to initiate pre-defined automatic sequences by the operator and also define new automatic sequences.

3.2.12 A set of following ETVM reading display and reports (ETVM Provided in Relay & Protection Panel) are required in the Station HMI.

i) To present data read from meters.ii) To schedule meter reading and to select individual meters for manual

reading.iii) To remotely program the electronic meters.iv) To manage the billing data and prepare it for exporting to other systems.

Other than the above parameters, those specified in the Annexure CRP-TVM shall also be provided.

The contents and format of meter reading displays shall be subject to approval by the purchaser

3.3 Gateway:

3.3.1 Communication Interface:

The Substation Automation System shall have the capability to support simultaneous communications with multiple independent remote master stations.

The Substation Automation System shall have communication ports as follows:

a) Two ports for Remote Control Centre.

b) Two ports for Regional System Coordination Centre (RSCC).

The communication interface to the SAS shall allow scanning and control of defined points within the substation automation system independently for each control centre. The substation automation system shall simultaneously respond to independent scans and commands from employer’s control centres (RCC & RSCC). The substation automation system shall support the use of a different communication data exchange rate (bits per

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second), scanning cycle, and/or communication protocol to each remote control centre. Also, each control centres data scan and control commands may be different for different data points within the substation automation systems database.

3.3.2 Remote Control Centre Communication Interface:

Employer will supply communication channels between the Substation Automation System and the remote control centre. The communication channels provided by Employer will consist either of power line carrier, microwave, optical fibre, VSAT or leased line, the details of which shall be provided during detailed Engineering.

3.3.3 Interface equipment:

The Contractor shall provide interface equipment for communicating between Substation Automation System and Remote control centre and between Substation Automation System and Regional System Coordination Centre (RSCC). However, the communication channels available for this purpose are specified in the section project.In case of PLCC communication any modem supplied shall not require manual equalization and shall include self-test features such as manual mark/space keying, analog loop-back, and digital loop-back. The modems shall provide for convenient adjustment of output level and receive sensitivity. The modem should be stand alone complete in all respects including power supply to interface the SAS with communication channel. The configuration of tones and speed shall be programmable and maintained in non-volatile memory in the modem. All necessary hardware and software shall also be in the scope of bidder except the communication link along with communication equipment between substation control room and Remote Control Centre.

3.3.4 Communication Protocol:

The communication protocol for gateway to control centre must be open protocol and shall support IEC 60870-5-104 and IEC 61850 for all levels of communication for substation automation such as Bay to station HMI, gateway to remote station etc.

4.0 SYSTEM HARDWARE :

4.1 Redundant Station HMI, HMI View Node, Remote HMI and Disturbance Recorder Work Station:

The contractor shall provide redundant station HMI in hot standby mode.

It shall be capable to perform all functions for entire substation including future requirements as indicated in the SLD. It shall use industrial grade components. Processor and RAM shall be selected in such a manner that during normal operation not more than 30% capacity of processing and memory are used. Supplier shall demonstrate these features.

The capacity of hard disk shall be selected such that the following requirement should occupy less than 50% of disk space.

1. Storage of all analog data (at 15 minutes interval) and digital data including alarm, event and trend data for thirty (30) days.

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3. 20 GB space for OWNER’s use.

Supplier shall demonstrate that the capacity of hard disk is sufficient to meet the above requirement.

4.1.1 HMI (Human Machine Interface):

The VDU shall show overview diagrams (Single Line Diagrams) and complete details of the switchgear with a colour display. All event and alarm annunciation shall be selectable in the form of lists. Operation shall be by a user friendly function keyboard and a cursor positioning device. The user interface shall be based on WINDOWS concepts with graphics & facility for panning, scrolling, zooming, decluttering etc.

4.1.2 Visual Display Units/TFT’s (Thin Film Technology):

The contractor shall provide three display units, one for station HMI, one for redundant HMI and one for DR work station. These shall have high resolution and reflection protected picture screen. High stability of the picture geometry shall be ensured. The screen shall be at least 21” diagonally in size and capable of colour graphic displays.The display shall accommodate resolution of 1280 x 1024 pixels. The HMI shall be able to switch the key board and cursor positioning device, as unit among all the monitors at a consol vis push button or other controls.

4.1.3 Printer:

It shall be robust & suitable for operation with a minimum of 132 characters per line. The printing operation shall be quiet with a noise level of less than 45 dB suitable for location in the control room. Printer shall accept and print all ASCII characters via master control computer unit interface.

The printer shall have in built testing facility. Failure of the printer shall be indicated in the Station HMI. The printer shall have an off line mode selector switch to enable safe maintenance. The maintenance should be simple with provisions for ease of change of print head, ribbon changing, paper insertion etc.

All printers mounted in the control room shall be provided with a separate printer enclosure each. The enclosure shall be designed to permit full enclosure of the printers at a convenient level. Plexiglas windows shall be used to provide visual inspection of the printers and ease of reading. The printer enclosures shall be designed to protect the printers from accidental external contact and each should be removable from hinges at the back and shall be provided with lock at the front.

All reports and graphics prints shall be printed on laser printer. One dot matrix printer shall be exclusively used for hourly log printing.

All printers shall be continuously online.

4.1.4 Mass Storage Unit:

The mass storage unit shall be built-in to the Station HMI. All operational measured values and indications shall be stored in a mass-storage unit of CD-ROM / DVD-ROM with 700 MB or more capacity. The unit should support at least read (48X), Write (24X) and Re-write (10X) operations with Multi-Session capability. It should support ISO9660, Rockridge and Joliet Filesystems. It should support formatting and use under the

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operating system provided for Station HMI. The monthly back up of data shall be taken on disc. The facility of back up of data shall be inherent in the software.

4.1.6 Interconnection Cables & Wiring:

The contractor shall provide all interconnecting wires, cables, connectors, terminations, local area network (LAN) cables and other wiring required by field devices and IED’s including cabling required for interfacing with Marshalling Box.

4.1.5 Switched Ethernet Communication Infrastructure:

The bidder shall provide the redundant switched optical Ethernet communication infrastructure for SAS. The bidder shall keep provision of 50-100% spare capacity for employer use. One switch shall be provided to connect all IEDs bays of 220 KV, 110 KV/66 KV yard to communication infrastucture.

4.2 Bay level unit:

The bay unit shall use industrial grade components. The bay level unit, based on microprocessor technology shall use numerical techniques for the calculation and evaluation of external input analog signals. They shall incorporate select-before-operate control principles as safety measures for operation via the HMI. They shall perform all bay related functions, such as control commands, bay interlocking, data acquisition, data storage, event recording and shall provide inputs for status indication and outputs for commands. They shall be directly connected to the switchgear. The bay unit shall acquire and process all data for the bay (Equipment status, fault indications, measured values, alarms etc) and transmit these to the other devices in substation automation system. In addition, this shall receive the operation commands from station HMI and control centre. The bay unit shall have the capability to store all the data for at least 24 hours.

One no. bay level unit shall be provided for supervision and control of each 220 KV. , 110 KV & 66 KV bays (a bay comprises of one circuit breaker and associated disconnector, earth switches and instrument transformer). The bay level unit shall be equipped with analog and binary inputs / outputs for handling the control, status monitoring and analog measurement functions. All bay level interlocks are to be incorporated in the bay level unit so as to permit control from the bay level unit local bay mimic panel with all bay interlocks in place, during maintenance and commissioning or in case of contingencies when the Station HMI is out of service.

The bay level unit shall meet the requirements for withstanding electromagnetic interference according to relevant parts of IEC 61850. Failure of any single component within the equipment shall neither cause unwanted operation nor lead to a complete system breakdown.

4.2.1 Input / Output (I/O) modules:

The I/O module shall form a part of the bay level unit and shall provide coupling to the substation equipment. The I/O modules shall acquire all switchgear information (i.e., data coming directly from the switchgear or from switchgear interlocking devices) and transmit commands for operation of the switchgear. The measured values of voltage and current shall be from the secondaries of instrument transformers. The digital inputs shall be reported by exception with 1 ms resolution. Contact bouncing in digital inputs shall not be assumed as change of state.

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4.3 Extendibility in future:

Offered substation automation system shall be suitable for extension in future for additional bays indicated in SLD & additional 4 bays for each KV reference. During such requirement all the drawings and configurations, alarm/event list etc., displayed shall be designed in such a manner that its extension shall be easily performed by the employer. During such event, normal operation of the existing substation shall be unaffected and system shall not require a shutdown. The contractor shall provide all necessary software tools along with source codes to perform addition of bays in future and complete integration with SAS by the user. These software tools shall be able to configure IED, add additional analog variable, alarm list, event list, modify interlocking logics etc., for additional bays / equipment which shall be added in future. There shall be provision for change of designation of bay as and when necessity arises.

5.0 Software structure:The software package shall be structured according to the SAS architecture and strictly divided in various levels. Necessary firewall shall be provided at suitable points in software to protect the system. An extension of the station shall be possible with lowest possible efforts. Maintenance, modification or an extension of components of any feeder may not force a shut-down of the parts of the system which are not affected by the system adaptation.

5.1.1 Station level software

5.1.1.1 Human-machine interface (HMI)

The base HMI software package for the operator station shall include the main SAS functions. The base HMI software package for the operator station shall include the main SAS functions and it shall be independent of project specific hardware version and operating system. It shall further include tools for picture editing, engineering and system configuration. The system shall be easy to use, to maintain and to adapt according to specific user requirements Systems shall contain a library with standard functions and applications.

5.1.2 Bay level software: System software:

5.1.2.1 The system software shall be structured in various levels. This software shall be placed in a non-volatile memory The lowest level shall assure system performance and contain basic functions, which shall not be accessible by the application and maintenance engineer for modifications The system shall support the generation of typical control macros and a process database for user specific data storage. In case of restoration of links after failure, the software along with hardware shall be capable of automatically synchronising with the remaining system Without any manual interface. This shall be demonstrated by contractor during integrated system test

5.1.2.2 Application Software:

In order to ensure robust quality and reliable software functions, the main part of the application software shall consist of standard software modules built as functional block elements. The functional blocks shall be documented and thoroughly tested. They form part of library. The application software within the control/protection devices shall be programmed in a functional block language.

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5.1.2.3

5.1.2.4

6.0

6.16.1.1

Network Management System:

The contractor shall provide a network management system software for

following management functions:

a. Configuration Management.

b. Fault management.

c. Performance Monitoring.

This system shall be used for management of communication devices and other IEDs in the

system. This NMS can be loaded in DR workstation and shall be easy

to use. user friendly and menu based. The NMS shall monitor all the devices in the SAS and

report if there is any fault in the monitored devices. The NMS shall

a) Maintain performance. resource usage and error statistics for all managed

links and devices and present this information via displays, periodic reports

and on demand reports.

b) Maintain a graphical display of SAS connectivity and device status.c) Issue alarms when error conditions occurs.

d) Provide facility to add and delete addresses and links.

The contractor shall provide each software in two copies in CD to load into thesystem in case of any problem related with Hardware communication etc.

T EST S:

The substation automation system offered by the bidder shall be subjected to

following tests to establish compliance with IEC 61850 for EHV substationequipment installed in the control room and specified ambient conditions:

Type Tests:

Control IEDs and Communication Equipment:

1) Power Input:1. Auxiliary Voltage.

ii. Current Circuits.

iii. Voltage Circuits.

iv. Indications.

2) Accuracy Tests:1.

II.

111.

IV.

3) Insulation Tests:

Operational Measured Values.

Currents.

Voltages.

Time resolution.

1. Dielectric Tests.

4) Influencing Quantities.

11. Impulse Voltage withstand Test.

1. Limits of operation.

Permissible ripplesII.

111. Interruption of input voltage.

5) Electromagnetic Compatibility Test:1 MHZ burst disturbance test1.

11. Electrostatic Discharge Test.

6) Function Tests:

111. Radiated Electromagnetic Field Disturbance Test.

Electrical Fast Transient Disturbance Test.IV.

V. Conducted Disturbances Tests induced by Radio Frequency Field.

Magnetic Field Test.VI.

VI1. Emission (Radio Interference level]) Test.

Conducted Interference Test.Vlll.

1. Indication

11. Commands

Measured Value Acquisition111.IV. Display Indications

7) Environmental tests:1.

Cold Temperature.

Dry Heatn.

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6.2

6.3

iii. Wet heat

lV. Humidity (Damp Heat Cycle)

v. Vibration

VI. Bump.

Shock.Vl1.

Factory Acceptance Tests:

The supplier shall submit a test specification for factory acceptance test (FAT)

and commissioning tests of the station automation system for approval. For the individual

bay level IED's applicable type test certificates shall be submitted. The manufacturing phase

of the SAS shall be concluded by the factory acceptancetest (FAT). The purpose is to ensure that the Contractor has interpreted the

specified requirements correctly and that the FAT includes checking to the degree required

by the user. The general philosophy shall be to deliver a system to site only after it has been

thoroughly tested and its specified performance has been verified, as far as site conditions

can be simulated in a test lab. If the FAT comprises only a certain portion of the system for

practical reason, it has to be assured that this test configuration contains at least one unit of

each and every type of equipment incorporated in the delivered system.

Integrated Testing:

The integrated system tests shall be performed as detailed in subsequent clausesas per the following configuration:. Redundant Station HMI, DR workstation with all IEDs & printers.

All other switches for complete substation as detailed in section project shall be simulated

as needed:-

"

If the complete system consists of parts from various suppliers or some pans arc

already installed on site, the F AT shall be limited to sub-system tests. In such a case,

the complete system test shall be performed on site together with the site acceptance test

(SAT).

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6.3.1 Hardware Integration Tests:

The hardware integration test shall be performed on the specified systems, to be

used for Factory tests when the hardware has been installed in the Factory. The

operation of each item shall be verified as an integral part of system. Applicable

hardware diagnostics shall be used to verify that each hardware component is

6.3.2

completely operational and assembled into a configuration capable of supporting

software integration and factory testing of the system. The equipment expansion

capability shall also be verified during the hardware integration tests.

Integrated System Tests:

Integrated System Tests shall verify the stability of the hardware and the software.

During the tests all functions shall run concurrently and all equipment shall operate

a continuous 100 Hours period. The integrated system test shall ensure the SAS is

free of improper interactions between software and hardware while the system is

operating as a whole

6.4 Field tests:

The field tests shall completely verify all the features of SAS hardware and software

7.0 SYSTEM OPERATION:

7.1 Substation Operation:

7.1.1 Normal Operation:Operation of the system by the operator from the remote RCC or at the substation

shall take place via industry standard HMI (Human Machine Interface) subsystem

consisting of graphic colour VDU, a standard keyboard and a cursor positioning

device (mouse).

The coloured screen shall be divided into 3 fields:1. Message field with display of present time and date.

ii. Display field for single line diagrams.

iii. Navigation bar with alarm/condition indication.

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For display of alarm annunciation, lists of events etc., a separate HMI view mode

shall be provided.

All operations shall be performed with mouse and/or a minimum number of function

keys and cursor keys. The function keys shall have different meanings depending on

the operation. The operator shall see the relevant meanings as function tests displayed

in the command field (i.e., operator prompting) For control actions, the switchgear

(i.e., circuit breaker etc.) requested shall be selectable on the display by means of the

cursor keys. The switching element

selected shall then appear on the background that shall be t1ashing in a different

color. The operator prompting shall distinguish between:

Prompting of indications e.g., fault indications in the switchgear. and Prompting of

operational sequences e.g., execution of switching operations.

The summary information displayed in the message field shall give a rapid

display of alarm/message of the system in which a fault has occurred and alarm

annunciation lists in which the fault is described more fully.

Each operational sequence shall be divided into single operation steps, which are

initiated by means of the function keys WINDOW command by mouse. Operator

prompting shall be designed in such a manner that only the permissible keys are

available in the command field related to the specific operation step. Only those

switching elements shall be accessed for which control actions are possible. If the

operation step is rejected by the system, the operator prompting shall be supported

by additional comments in the message field. The operation status shall be reset

to the corresponding preceding step in the operation sequence by pressing one of the

function keys. All operations shall be verified. Incorrect operations shall be

indicated by comments in the message field and must not be executed.

The offer shall include a comprehensive description of the system. The aboveoperation shall also be possible via Windows based system by mouse.

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.8.0 POWER SUPPLY:

Power for the substation automation system shall be derived from substation 220 VDC system.

Inverter of suitable capacity shall be provided for station HMI and its peripheraldevices e.g., printer etc. In the event of Power failure. necessary safeguard

9.0software shall be built for proper shutdown and restart.

DOCUMENTATION:

The following documents shall be submitted for employer's approval during detailed

engineering:

a) System Architecture Drawing.

b) Hardware Specification.

c) Sizing Calculations of various components.

d) Response Time Calculation.

e) Functional Design Document.

Following documentation to be provided for the system in the course of theproject shall be consistent, CAD supported and of similar look/feel. All CADdrawings to be provided in “dfx” format. .

List of drawings.

Substation Automation System architecture."

Block Diagram.

Guaranteed Technical Parameters, Functional Design Specification and.

.Guaranteed availability and reliability.

Calculation for power supply dimensioning.. I/O Signal lists.. Schematic diagrams~

List of Apparatus.

List of Labels... Logic Diagram (hardware & software). -Panel

Panel layout drawing..

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4" ,~.c..~,""-,,~~,,- '.

. GA of and GTP.

. Control Room Layout.

Test Specification for Factory Acceptance Test (FAT)... Product Manuals.. Assembly Drawing.

Operators Manual...

Complete documentation of implemented protocols between various elements.

Listing of software and loadable in CD ROM... Other documents as may be required during detailed engineering.

Two sets of hard copy and Four sets of CD ROM containing all the as-built

documents/drawings shall be provided to CEE (T&P) and to each of the consignee. "

10.0 10.1

TRAINING, SUPPORT SERVICES. MAINTENANCE AND SPARES:

Training:

Contractor personnel who are ,experienced instructors and who speak understandable

English shall conduct training. The contractor shall arrange on hisOwn cost all hardware training platform required for successful training and

understanding in India. The Contractor shall provide all necessary training

material. Each trainee shall receive individual copies of all technical manuals and all

other documents used to training. These materials shall be sent to Employer

at least two months before the scheduled commencement of the particular training

course. Class materials, including the documents sent before the training courses

as well as class handouts, shall become the property of Employer. Employer reserves

the right to copy such materials, but for in-house training and use only.

Hands-on training shall utilize equipment identical to that being supplied to Employer.

For all training courses, the travel (e.g., airfare) and per-diem expenses will be borne by the

participants.

The Contractor shall quote training prices individually for each of the courses as. indicated in

Price Schedule.

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Employer will have the option to cancel any or all-training courses. In the case of

cancellation, the rate quoted against the respective course will not be paid to the Contractor.

The schedule. location and detailed contents of each course will be finalized

10.2

during Employer and Contractor discussions.

Computer System Hardware Course:A computer system hardware course shall be offered, but at the system level only.

The training course shall be designed to give Employer hardware personnel

sufficient knowledge of the overall design and operation of the system so thatthey can correct obvious problems, configure the hardware, perform preventive

maintenance, run diagnostic pro grams and communicate with contract

maintenance personnel. The following subjects shall be covered:

a) System Hardware Overview: Configuration of the system hardware.

b) Equipment Maintenance: Basic theory of operation. maintenance techniques

and diagnostic procedures for each element of the computer system. e.g..

processors, auxiliary memories, LAN's routers and printers. configuration of

all the hardware equipment's.

c) System Expansion: Techniques and procedures to expand and add equipment

such as loggers, monitors and communication channels.

d) System Maintenance: Theory of operation and maintenance of the redundant

hardware configuration, tail over hardware, configuration control panels and failover

switches. Maintenance of protective devices and power supplies.

e) Subsystem Maintenance: Theory of design and operation. maintenance

techniques and practices, diagnostic procedures and (where applicable)

expansion techniques and procedures. Classes shall include hands-on training for the

specific subsystems that are part of Employer's equipment or part of similarly designed

and configured subsystems. Computing Al1 interfaces to the computing equipment shall

be taught in details

.

f) Operational Training:: Practical training on preventive and corrective

maintenance of all equipment, including use of special tools and instruments.

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This training shall be provided on Employer equipment or on similarly

configured systems.10.3 Computer System Software Course:

The Contractor shall provide a computer system software course that covers the

following subjects:

a) System Programming: Including all applicable programming languages and

all stand-alone service and utility packages provided with the system. An introduction to

software architecture. effect of tuning parameters (OS software, Network software,

database software etc.) on the performance of the system.

b) Operating System: Including the user aspects of the operating system, such as

program loading and integrating procedures, scheduling, management, service

and utility functions and system expansion techniques and procedures.

c) System Initialization and Failover: Including design, theory of operation and

practice.

d) Diagnostics: Including the execution of diagnostic procedures and the

interpretation of diagnostic outputs.

e) Software Documentation: Orientation in the organization and use of systemsoftware documentation.

f) Hands-on Training: One week with allocated computer time for trainee

performance of unstructured exercises and with the course instructor available

10.4for assistance as necessary.

Application Software Course:

The Contractor shall provide comprehensive application software courses

covering all applications including the database and display building course. The

training shall include:

a) Overview: Block diagrams of the application software and data flows.

Programming standards and programme interface conventions.

b) Application Functions: Functional capabilities, design and major algorithms.

Associated maintenance and expansion techniques.

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c) Software Development: Techniques and conventions to be used for the

preparation and integration of new software functions.

d) Software Generation: Generation of application software from source code

and associated software configuration control procedures.

e) software Documentation: Orientation in the organization and use of

functional and detailed design documentation and of programmer and usermanuals.

f) Hands-on Training: One week, with allocated computer time for trainee

performance of unstructured exercises and with the course instructor available

10.5

for assistance as necessary.

Requirement of training:

The contractor shall provide training for two batches for two-weeks each for following

courses:

Sl. No. Name of the Course

1. Computer System Hardware2.

3. Computer System Software 4. Application Software

11.0

11.1

MAINTENANCE RESPONSIBILITY:

Maintenance Responsibility during theGuaranteed Availability Period. During

Guaranteed availability period, the contractor shall take continual actions

to ensure the guaranteed availability and shall make available all the necessary

resources such as specialist personnel spare parts, tools, test devices etc., for

replacement or repair of all defective parts and shall have prime responsibility for

keeping the system operational.

12.0 RELIABILITY AND AVAILABILITY:

The SAS shall be designed so that the failure of any single component, processor or

device shall not render the system unavailable. The SAS shall be designed tosatisfy the very high demands for reliability and availability concerning:

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. Mechanical and electrical design.. Security against electrical interference (EMI). High quality components and boards.

.Modular, well-tested hardware.

Thoroughly developed and tested modular software...

Easy-to-understand programming language for application programming.

Detailed graphical documentation and application software...

Built-in supervision and diagnostic functions.

Security.

Experience of security requirements

Process know--how

Select before execute at operation

Process status representation as double indications

'

. Distributed solution.

.Independent units connected to the local area network Back-

up functions..

Panel design appropriate to the harsh electrical environment and ambient conditions.

. Panel grounding immune against transient ground potential rise.

Outage terms:

1) Outage:

The state in which substation automation system or a unit of SAS is unavailable

for Normal Operation as defined in the clause 7.1 due to an event

directly related to the SAS or unit of SAS. In the event, the owner has taken any

equipment/system other than Substation Automation System for schedule-forced

maintenance, the consequent outage to SAS shall not be considered as outage for

the purpose of availability..

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2) Actual outage duration (AOD):

The time elapsed. in hours between the start and the end of an outage. The time

shall be counted to the nearest 1I4th of an hour; Time less than 1/4th of an hour

shall be counted as having duration of 1/4th of an hour.

3) Period Hours (PH):

The number of hours in the reporting period. In a full year the period hour are

8760h (8784h for a leap year).

4) Actual Outage hours (AOH):

The sum of actual outage duration within the reporting period

AOH=AOD

5) Availability:

Each SAS shall have a total availability of 99.98% i.e., the ratio of total time

12.1

duration minus the actual outage duration to total time duration.

Guarantees Required:

The availability for the complete SAS shall be guaranteed by the Contractor. Bidder

shall include in their offer the detailed calculation for the availability .. The

contractor shall demonstrate their availability guaranteed by conducting the availability test

on the total substation automation system as a Whole after commissioning of total

substation automation system. The test shall verify the reliability and integrity of all

sub-systems. Under these conditions the test shall establish an overall availability of

99.98%. After the lapse of 1000 Hours of cumulative test time, test records shall be

examined to determine the conformance with availability criterion. In case of any

outage during the availability test. the contractor shall rectify the problem and after

rectification, the 1000 Hours period start after such rectification. If test object has

not been met the test shall continue until the specified availability is achieved.

The contractor has to establish the availability in a maximum period of three months from

the date of commencement of the availability test.

After the satisfactory conclusion of test both contractor and employer shallmutually agree to the test results and if these results satisfy the availability

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criterion, the test is considered to be completed successfully. After that the system shall be

taken over by the employer and then the guarantee period shall start.

13.0

13.1

SPA RES:Consumables:

All consumables such as paper, cartridges shall be supplied by the contractor till

13.2the SAS is taken over by the Owner.

Availability Spares:

The bidder is required to furnish the list of spares, which 'may be required for

ensuring the guaranteed availability during the guaranteed availability period. The final list

of spares shall form part of scope of supply and accordingly the price thereof shall be

quoted by the bidder and shall be considered in the evaluation of the bids. During the

guaranteed availability period. the spare parts supplied by the Contractor shall be

made available to the contractor for usage subject to replenishment at the earliest.

Thus, at the end of availability period the inventory of spares with the Employer

shall be fully replenished by the Contractor. However, any additional spares required

to meet the availability of the system (which are not a part of the above spares

supplied by the contractor) would have to be supplied immediately by the Contractor

free of cost to the Employer.

.

14.0 LIST OF EQUIPMETNS:

Quantity of equipments shall be decided by bidder in order to achieve guaranteed

reliability and availability as declared by bidder.

i, Station HMI.

ii. Redundant Station HMI (in Hot stand by mode).

iii. Bay level units along with bay mimic.IV. Disturbance Recorder Work Station (Maintenance HMI).

v. Colour Laser Printer - 1 No. (For Reports & Disturbance Records).

vi. Dot Matrix Printer - (one each for Alarms and log sheets).vii. All interface equipment for gateway to RCC and RSCC.

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TYPICAL ARCHITECTURAL DRAWING OF SUB-STATION AUTOMATION SYSTEM

DR/ENGINEERING

CONTROLCENTER

ROUTER STATION BUS

EARTHNET RING WITH SWITCHES

NOTES:1. STATION BUS SHALL BE REALIZED BY HIGH SPPED OPTICAL BUS USING INDUSTRIAL

GRADE COMPONENTS AND SHALL BE AS PER IEC 61850.2. IEDS FOR TWO BAYS MAY BE HOUSED IN ONE PANEL ALONG WITH ITS SWITCH.3. INSIDE THE SUB STATION, ALL CONNECTIONS SHALL BE REALIZED AS PER IEC 61850

PROTOCOL.4. FOR GATEWAY, IT SHALL COMMUNICATE WITH REMOTE SUPERVISORY CONTROL

CENTRE(RSCC), REMOTE CONTROL CENTRE (RCC) ON IEC 60870-5-104 PROTOCOL

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viii. Communication infrastructure between Bay level units, Station HML Printers,gateways, redundant LAN etc.. as required.

ix. Remote workstation including HMI and along with one printer.

x. Any other equipment as necessary.

HMI VIEW NOTE

STATION HMI WORK

STATION

GATEWAYGPS CLOCK

PRINTER

BAY CONTROLLER RELAY ETV

METV

MBAY

CONTROLLER RELAY

SWITCHGEAR, CT/VT’s SWITCHGEAR, CT/VT’s

5. THE ROUTER SHALL COMMUNICATE ON IEC 60870-5-104 PROTOCOL6. THE PRINTER AS REQUIRED SHALL BE CONNECTED AT STATION BUS DIRECTLY & CAN BE

MANAGED EITHER FROM STATION HMI, HMI VIEW NODE OR DISTURBANCE RECORDER WORK STATION.

ANNEXURE – I(GTP IAS)

Basic Monitoring requirements are:

- Switchgear status indication

- Measurements (U, I, P, Q, f)

- Event

- Alarm

- Winding temperature of transformers

- Ambient temperature

- Status and display of 415 V LT system, 220V & 48 VDC system.

- Status of display of Nitrogen injection Fire protection system and Air conditioning system.

- Acquisition of all counters in PLCC panels through potential free contacts from PLCC or

independently by counting the receive/send commands, for 220 KV lines.

- Acquisition of alarm and fault record from protection relays

- Disturbance records for 220 KV lines.

- Monitoring the state of batteries by displaying DC voltage, charging current and load current

etc.

- Tap-position of transformer

List of Inputs:

The list of input for typical bays is as below:

Analog inputs:

i) For line

Current R-phase

Y-phase

B-phase

Voltage R-Y phase

Y-B phase

B-R phase

ii) For transformer

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Current R-phase

Y-phase

B-phase

WTI (for transformer)

OTI (for transformer)

Tap position (for transformer only)

iii) For bus coupler

Current R-phase

Y-phase

B-phase

iv) Common

a) Voltage for Bus-I & Bus-II

Voltage R-Y phase

Y-B phase

B-R phase

b) Frequency for Bus-I & Bus-II.

c) Ambient temperature (switchyard).

d) LT system

i. Voltage R-Y, Y-B, B-R of Main Switchboard Section-I.

ii. Voltage R-Y, Y-B, B-R of Main Switchboard Section-II.

iii. Voltage R-Y, Y-B, B-R of Diesel Generator.

iv. Current from LT transformer-I.

v. Current from LT transformer-II.

vi. Current from Diesel Generator.

vii. Voltage of 220 V DCDB-I.

viii. Voltage of 220 V DCDB-II.

ix. Current from 220 V Battery Set-I.

x. Current from 220 V Battery Set-II.

xi. Current from 220 V Battery charger-I.

xii. Current from 220 V Battery charge-II.

xiii. Voltage of 48 V DCDB-I.

xiv. Voltage of 48 V DCDB-II.

xv. Current from 48 V Battery set-I.

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xvi. Current from 48 V Battery set-II.

xvii. Current from 48 V Battery charger-I.

xviii. Current from 48 V Battery charger-II.

Digital Inputs:

The list of input for various bays/SYSTEM is as follows:

Sl. No. Particulars 220 KV 110/66 KV BC

1. Line bays:

i) Status of each pole of CB, Isolator, Earth switch

ii) CB trouble

iii) CB operation/closing lockout

iv) Pole discrepancy optd.

v) Trip coil faulty TC1/TC2

vi) LBB optd

vii) Bus bar protection trip relay optd.

viii) Main bkr auto recloser operated

ix) A/R lockout

x) Direct trip sent

xi) Direct trip received

xii) Main-I/Backup blocking

xiii) Main-I/Backup Inter trip send

xiv) Main-I/Backup Inter trip received

xv) Fault Locator Faulty

xvi) Main VT Fuse fail

xvii) Main Protn trip

xviii) Back up protn trip

xix) Main PSB Alrm

xx) Main softrip

xxi) Main R-Phase trip

xxii) Main Y-Phase trip

xxiii) Main B-phase trip

xxiv) Main Start

xxv) Main Carrier aided trip

xxvi) Main fault in reverse direction

xxvii) Main Zone-2 trip

xxviii) Main Zone-3 trip

xxix) Main weak ends infeed

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xxx) Main fault in reverse direction

xxxi) Back-up o/c optdSl. No. Particulars 220 KV 110/66 KV BC

xxxii) Back-up e/f optd

xxxiii) 220 V DC-I/II source fail

xxxiv) Speech channel fail

xxxv) PLCC protection channel fail

xxxvi) PLCC protection channel fail

xxxvii) SF6 Gas Pressure Low

xxxviii) Spares – 4 Nos

2. Transformer bays: 100/150MVA Transformer


ii) CB trouble

iii) CB operation/closing lockout


v) Trip coil faulty

vi) LBB optd.

vii) Bus bar protn. trip relay optd

viii) REF optd

ix) DIF optd

x) Over flux alarm (V)

xi) Over flux trip (V)

xii) HV Bus VT fuse (A)

xiii) MV Bus VT Fuse (A)

xiv) OTI Alarm/Trip

xv) PRD optd

xvi) Overload alarm

xvii) Bucholz trip

xviii) Bucholz Alarm

xix) OLTC oil surge relay alarm

xx) OLTC oil surge relay trip

xxi) Oil low alarm

xxii) Back-up o/c (HV) optd.

xxiii) Back-up e/f (HV) optd

xxiv) 220 V DC-I/II source fail

xxv) Tap mismatch

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xxvi) Back-up o/c (MV) optdSl.No. Particulars 220 KV 110/

66 KV BC

xxvii) Back-up e/f (MV) optd

xxviii) WTI Alaram/Trip

xxix) SF6 Gas Pressure low

xxx) Spares 4 Nos.3. Transformer bays – for others:


ii) CB trouble

iii) CB operation / closing lockout


v) Trip coil faulty

vi) LBB optd.

vii) Bus bar protn. trip relay optd

viii) REF optd

ix) DIF optd

x) HV Bus VT fuse fail

xi) OTI Alarm / trip

xii) PRD optd

xiii) Bucholz trip

xiv) Bucholz alarm

xv) Oil low alarm

xvi) Back-up o/c HV optd

xvii) Back-up E/F HV optd

xviii) 220 V DC-I/II source fail

xix) Back up o/c LV operated

xx) Back up E/F LV operated

xxi) SF6 Gas Pressure low

xxii) Spares 4 Nos.4. Bus-bar Protection:

i) Bus bar main-I trip

ii) Bus bar main-II trip

iii) Bus-bar zone-I CT open

iv) Bus-bar zone-II CT open

v) Bus protection relay fail5. Auxiliary system:

i) Incomer-I On/Off

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ii) Incomer-II On/Off

iii) 415 V Bus-I/II U/V

iv) 415 V Bus coupler breaker on/off

v) DG set bkr on/off

vi) Alarm/trip signals as listed in Section: DG Set

vii) PLCC exchange fail

viii) Time sync. Signal absent

ix) Alarm/trip signals as listed in Section: Battery & Battery charger

x) 220 V DC-I earth fault

xi) 220 V DC-II earth fault

xii) Alarm/ Nitrogen trip signals as listed in Section: Fire protection system

The exact number and description of digital inputs shall be as per detailed engineering requirement apart from the above mentioned digital inputs, minimum of 200 inputs shall be kept for KSPDCL use in future.

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ANNEXURE – RPP –TVM

TECHNICAL SPECIFICATION FOR RELAY & PROTECTION PANEL FOR 1 & 5 AMPS STATIC ELECTRONIC TRIVECTOR METERS OF ACCURACY CLASS FOR 0.5

/ 0.2 S

1. The specification covers design, Manufacturing, Testing, Supply & Delivery of HT and/or LT, Static 3 Vector Energy meter, capable of measuring Electrical energy & demand in balanced and/or unbalanced loads. The accuracy class and Current rating are stated along with the requirements.

2 STANDARD:

While drafting this specification, reference has been made to the following Indian and International standard specifications. In case certain details are not covered in 1hese specifications any other Indian/ International standard shall be applicable.

1. IEC 60687 for Class 0.2 S2. IEC 1268 for Class 1.0 Reactive Energy3. IEC 1000-4-2, for Electrostatic discharge4. IEC 1000-4-3, for Electromagnetic high frequency discharge5. IEC1000-4-4, for Electrical fast transient/burst6. IEC/CISPR 14, for Radio lnterference7 Technical report of specification for AC Static Electrical Energy

Meters CBIP, New Delhi8 IEC 62056: 1997for communication protocol.

3 QUALIFYING REQUIREMENT :

The meter manufacturer should have supplied at least 5000 meters of similar type either in India or internationally.

4 a) CLIMATIC CONDITIONS

The meters shall be suitable to work satisfactory under the following climatic conditions.

i. Minimum ambient temperature 0 deg Cii. Maximum ambient temperature 50 deg Ciii. Minimum relative Humidity 26%iv. Maximum relative Humidity 100%v. Altitude up to 1000 m above sea level.

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b) SUPPLY SYSTEM ENVIRONMENT

a) Meters shall be suitable for both balanced and/or unbalanced loads at all power factors in all the four quadrants meter shall display direct reading without built-in multiplying factor. The meters shall be suitable for working satisfactorily with following supply system variations.

(i) Operating voltage range of the meter : Vbasic + 20 % to -- 40 %

(ii) OperatingCurrentRange : Two times Ibasic

(iii) Frequency : 50 Hz ± 5 %

(iv) Power-factorRange : ±1%

b) Meter should work accurately irrespective of phase sequence of supply

c) Meters shall be of Universal type i.e, the meter shall be configurable for either 3 Phase 4 wire or 3 phase 3 wire configuration depending on the external power supply arrangement.

d) Meter shall not get damaged if phase and neutral is interchanged

5 QUANTITIES TO BE MEASURED AND MONITORED

The meters shall be capable of measuring and displaying the following electrical quantities within accuracy requirements as stipulated in clause 4.6 of IEC 1036 for polyphase balanced and/or unbalanced loads. The meters shall be capable of measuring 5OHz and Harmonic Power up to 29th Harmonics.

i) Phase wise Voltage and Currents : V, I

ii) Active Energy, Reactive Energy, : Apparent energyKWH,KVAH,

KVARH

iii) Maximum demand : KVA, KW, KVARiv) Power factor : P.Fv) Frequency : F

The Data shall not be lost in the case of Power Failure

Measuring principles are as per the Appendix - II

6 DESIGN REQUIREMENT

i) Voltage dips and short interruptions shall not produce a change in the register for more than 0.001 KWH, KVAH when the voltage is restored. The meter shall not have suffereddegradation of its metering characteristics.

ii) The voltage circuit of the meter should withstand the impulse voltage test as per IS: 13010.

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iii) The following disturbances shall be considered in the design of the meter to over come the effect of errors due to:

Harmonics voltage dips, interruptions and Voltage fluctuations Conducted Transients DC and AC Magnetic fields Electro-magnetic fields Electro-static discharges

The meter shall be designed in such a way that the above disturbances do not damage the meter. The meter shall not generate electromagnetic, eletrostatic disturbances which could interfere with other equipment. The limits of error variation for the above abnormal 'conditions shall be as per relevant standards.

iv) The meter shall be based on digital measuring principle.

v) The meters shall provide real time information and display loading conditions and anti-tamper diagnostic conditions.

vi) The meter shall have built in Modem for remote communication purpose. Alternatively meter shall have provision for upgrading on a future date.

vii) The meter should work even if any one phase supply i.e., either phase to ground or phase to phase is available. It shall record and store all parameters under these conditions.

viii) The meter shall be suitable for direct connection without using External Transducers or devices

ix) The meter shall be able to operate and sense the input supply from 70 to 415 volts phase to phase, 3 or 4 wire system

x) The meter shall have AC voltage withstanding capacity of 4 KV at 50 Hz per minute.

xi) The Meter Impulse voltage resistance shall be not less than 10 KV / 50 micro sec.

xii) Drift in real time clock should be within 2 sec per month.

xiii) Design data shall also be furnished

xiv) The meter shall have the special feature to defect common ways to tamper and fraud as indicated in Appendix - IV

7. DISPLAY

i) The meter shall have legible Alpha-Numeric LCD displays, along with legend preferably of minimum of' 3 digits for parameter identification. Minimum dimension of each display character shall be of size 8-mm height and 5 mm width. Display with Electronic Back-Lit display arrangement for better visibility can also be offered

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ii) Nomenclatures used in Display:

This shall be with universally accepted like KWH, KVA, KVARH and the abbreviations made for items like cumulative billing, TOD etc shall be clearly printed and narrated on the main cover of the meter itself.

iii) The details of requirement of scrolling parameters in automatic and manual modes shall be dynamically selectable at site without opening main cover, are furnished in Appendix - I.

iv) The meter shall have facility for indication of healthiness of battery and in the event of low battery condition the battery symbol shall be displayed,

v) The meter shall indicate the quadrant of operation

8. COMMUNICATION CAPABILITY:

i) The meter should be preferably provided with both RS232 and RS485 port to enable cascading meters in cluster and allow metering data of all the grouped meters to transfer through one communication channel

ii) All the meters shall have RS232 port for transfer of data from the meter to remote location

iii) In addition to the above the meter shall have optical interfacing for local reading or programming

iv) The data transfer from the meter either through optical I/F or through RS232/485 port shall be of open communication protocol. The protocol adopted shall confirm to ANSI Standards / European standards.

v) The bidder should clearly state the adopted protocol. It is deemed as part of the tender that the bidder will supply the required software for analysis of downloaded data on either Oracle platform or any other platform mutually agreed

The bidder shall part with protocol details for development of any other programs required for analyzing the data through third party for the following:

a) Load profile memoryb) Blackout Registerc) Demand Violationd) Exceptional reportse) Diversity and Load Factor

vi) The meter shall be compatible to external communication equipment using any one the following technologies which can be designed by third party.

a. PSTNb. GSMc. VSAT

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d. RADIOe. PLCC

9. ADDITIONAL FEATURES REQUIRED

a) The meter shall have provision for TOD tariff with the following features

i) Programmable upto 6 Energy and Demand registers.

ii) Programmable upto 4 seasons per year

iii) Provisions for assigning any particular day of the week to one or more registers.

b) In case if the bidder guarantees life of the battery for 10 years and if average life of the battery is found to be less and if the same cannot be replaced without opening main cover , then the bidder is liable for entire cost of replacements.

c) The Integration time for load survey parameters shall be selectable at site using Password without opening Factory seals. The Integration period shall be selectable between 1 min to 60 min in suitable steps.

d) The meter shall have provision to store maximum demand occurred during the integration period selected for KW, KVA and KVAR parameters during a month. The meter shall monitor the demand during the period set and record for each of the TOD zones the maximum registered values during the particular month.

e) The meter shall have provision for maximum demand resetting automatically at the end of Zero hours on the first day of every calendar month and also through an external push button. The meter shall keep track of such resets and display cumulative value of such resets. As an added feature History of few number of resets can also be offered

f) The meter should register energy even when the load is not terminated back to the meter though a neutral.

g) The meter shall be capable of recording occurrences of missing potential in any of the phases and its restoration with date and time and occurrences. The details of cumulative accounts of such occurrences and cumulative period shall also be available as part of external data output.

h) The Load Survey Parameters to be stored in memory shall be cumulative consumption of KWH, KVAH and KVARH during the integration period. In addition the meter shall have provision to store average value of voltages, Currents and Frequency . The minimum memory set shall be sufficient to store half an hour values of at least 8 parameters for 35 days on FIFO basis.

i) The meters shall identify and store in memory all occurrences and 'reset of unbalanced voltages / currents in line / phase current. The trigger value shall be furnished to the successful bidder.

278 of 409

j) The meter shall have self diagnostic facility. It shall check periodically its performance of its electronic circuits and software. The meter shall give error message on display in case of detection of any mal-functioning within the meter and also as part of external data. The self diagnostic features shall cover the following:

i) Performance of electronic circuits and softwareii) Missing Potentialiii) Low battery conditioniv) Attempt to communicate with the meter without proper Password

k) Meter shall have Provision for setting R T C of the meter periodically within ± 1 minute at the time of taking readings. The drift of the R T C and new setting shall be given in the printout.

l) The meters Preferably shall have facility for storing daily midnight value of cumulative KWH, KVARH and KVAH for 35 days on FIFO

m) The meter shall have minimum of five security levels

(i) For downloading data

(ii) for changing display Parameter of auto-scrolling

(iii) For changing Parameters of load survey.

(iv) For changing TOD register, time etc.

(v) Measuring principle, computation, self diagnostic features.

The security shared with user shall be without opening main cover. However, it is the responsibility of the meter manufacturer for the safe keeping of Password for the Security level which gives access to meter measuring principle, computation, self diagnostic feature etc.. Any losses incurred to the corporation in view of the leakage of the security level will be charged to the manufacturer.

10 ACCURACY and GUARANTEE:

The accuracy shall be corresponding to the accuracy class stipulated in the relevant standards for 0.2 / 0.5 S.

Each meter shall be guaranteed for its design, performance and accuracy for a period of ten years. If the meter goes faulty during the period of guaranteed performance and accuracy, it shall be replaced within 30 days failing which the firm will be blacklisted for further orders. If replacements are not made within stipulated period, corporation reserves the right to procure meters from outside sources for replacements and recover the cost of the same.

11 CONSTRUCTION OF METER :

279 of 409

a) The meter shall be made of high quality bakelite or other improved insulating material totally unaffected by radio frequencies, higher reliability and longer life shall be ensured. The casing and terminal cover should be sturdy enough to prevent damage during transport and installation. The meter shall be reliable in design and should be of surface mount technology, easy to transport and immune to vibration and shock. The case shall be so constructed such that any non-permanent deformation does not prevent the satisfactory operation of the meter.

All the insulation materials used in the construction of the meter shall be non-hygroscopic, non-ageing, and of tested quality. Construction of the meter should be such that it can be sealed independently and secured in such a way that the internal part of the meter shall be accessible only after breaking the seals and ensure prevention of tampering. The cover shall not be removable without the use of the tool. For degree of protection against dust and moisture the meter shall conform to IP 53 as per IS 12063/ IEC 529.

i) The base of the meter should have terminal block to facilitate front connection. The terminal block should satisfy all conditions specified in IEC 1036 and IS 13779. the terminal cover should have separate sealing facility.

ii) The various displays on the meter should have facility for cycled through up and down push button.

iii) The resetting of MD shall be achieved through a push button provided in front of the meter with sealing provision or automatic at 00: 00 Hours of the beginning of the month.

b) Every meter shall be indelibly marked with a connection diagram and abbreviations used. If the meter terminals are marked, this marking shall appear on the diagram. Tie diagram shall be either on the meter or inside of the terminal cover.

12 MARKING AND NAME PLATE:

Every meter shall be marked with the following Information and the marking shall be indelible, distinct and clearly visible from outside the meter:

a) Manufacturer’s name or trade mark and the place of manufacture.

b) Design of type which should not be same for any two of designs of meters.

c) Principal unit in which the meter records. (for KWH , KVARH)

d) Base voltage, Current and Frequency

e) Purchase order and Date.

f) The month and year in which the Guarantee period Expires.

g) Identification Number

280 of 409

13 ACCESSORIES OF THE METER-

Each meter should be accompanied by its Test certificate, present configuration, Software for down loading, Detailed literature, Suitable lugs for current and voltage circuits.

i) Necessary hardware for reading the meter through optical interfacing unit, and RS232 / RS485 port.

One set of such kit shall be supplied for every 50 meters ordered.

ii) The Bidder shall also supply suitable calibrator and Test Equipment for Testing the accuracy of the meter, communication capability etc. The calibrators offered shall have Memory to store at least 100 Nos previous calibrations test results and facility for taking a print with a portable external printer. The Accuracy class of reference meter shall be as recommended in relevant Standards for that class of meter. The necessary scanner having suitable optical head is deemed as part of the specifications. One set of Test equipments shall be supplied with every 500 meters or part thereof.

In case the calibrator does not have memory to store all the information downloaded from the meter, then one Laptop PC shall also be supplied per Calibrator for collecting the information from the meter memory.

The Bidder shall also supply necessary equipments to check the external communication outputs.

14 TESTS: TYPE TEST, ACCEPTANCE AND ROUTINE TESTS

Latest type test certificate issued only for the tender sample model has to be submitted in full and the copies shall be legible / valid.

The hard copies of the output that can be obtained through base computer from the data downloaded shall be submitted along with the bid

Recommended Type tests., Acceptance and Routine Tests are as per the table at Appendix V

Sampling plan while conducting Type/ Routine tests shall be as per IS :4905

15 APPENDIX:APPENDIX - IAPPENDIX - IIAPPENDIX - IIIAPPENDIX - IVAPPENDIX - V

281 of 409

APPENDIX - I

List of display parameters required:

Scrolling Parameters

A) BILLING PARAMETERS

1. Meter Serial number.

2. Time, Date, Month, Year

3. Billing KWH - (Universal TOD Register)

4. Billing KVA, KW MD in TOD Register (Universal TOD Register)

5. Billing P.F - (Universal TOD Register)

6. MD Reset count MD last reset date

7. Self diagnostic display

B) INSTANTANEOUS PARAMETERS

1. Phase wise Currents2. Phase wise voltages3. Instantaneous average P.F4. Demand with elapsed time5. Running period MD, P.F6. Frequency

C) CUMULATIVE PARAMETERS OF UNIVERSAL (00-24 Hours)REGISTER.

1. KWH2. KVAH3. KVARH Lag & Lead4. KVA MD, KW MD, RKVA MD

D) HIGH RESOLUTION MODE

1. KWH2. KVAH3. RKVAH4. Phase wise angles between Voltages and Currents

E) TODZone and time slabs

282 of 409

Note: The parameters for Automatic scrolling display shall be dynamically selectable through user's password and without opening of main cover

APPENDIX - II

Measuring principle to be adopted for KVAH and PF

KVAH = √ ( KWH 2 + KVARH 2 ) for lagging PF

KVAH = KWH for leading PF ( RKVAH = 0 ) (only for consumer meter or single quadrant meters)

PF = (KWH) / (KVAH)

Note : In case of single quadrant meter, the energy transfer during current reversal condition shall be added to the main register. However, it is preferred in addition to the above, if energy transfer in this quadrant is available in an independent register.

283 of 409

APPENDIX - III

Software requirement

1. Dynamic selection of scrolling parameters, demand sub-intervals (Except universal register), TOD registers time interval configuration, shall be possible with users password and without opening main cover.

2. Along with Monthly bill Records, the following information shall be downloaded to MRI or PC.

a) Meter ID, Time, Report date as HEADER in all pages b) Meter configuration consisting of the following Meter data i.e. Serial No., Software

version, Hardware version, Base current and Voltage accuracy class, Pulse output, anomaly indication etc.

c) All parameter values identified for scrolling display (i.e., auto scrolling and manual Scrolling)

d) Cumulative counts and duration of all Tamper information e) Billing data of TOD Registers selected f) Status of all parameters that can be changed with user's password g) RTC time before taking monthly reading and after taking monthly reading.

3. On Demand

a) Load Survey Data of all parameters, suitable software for obtaining Graphical and Tabular outputs of all the parameters over a selected period

b) Detailed data of abnormal conditions occurred.

c) Historical data of all cumulative parameters for previous 12 months.

d) Historical data of software changes made.

e) Historical data of cumulative parameter for previous 30 days (optional)

4. Remote Meter Reading

a) Instantaneous Parameters

b) All Parameters stated in para 2 & 3

5. Software required on base computer

a) Software for adding and sub-tracking load survey parameters of selected group of meters over a period of time..

b) Selection of Instantaneous/tamper details during defined/selected Time Zones

c) Protocol information for analyzing all data read from the meters.

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d) For generation of bills with the existing billing software.

285 of 409

APPENDIX - IV

Abnormal conditions to be identified on FIFO basis ( First In First Out)

The meter shall be capable of recording the following conditions and restoration with duration and also the account of cumulative total number of such occurrences and cumulative duration. The number of events stored in the memory shall be minimum of 250Nos. One event means one set of occurrence and restoration of that disturbance.

1. Potential missing to the meter. (single phase or all phases)2. Current reversal.3. Unbalanced voltages and current.

286 of 409

APPENDIX - VTest reports to be furnished:

SL No. Tests Laboratory

nameDate of

test

Test conforms to

IS/IEC/CBIP specification

Remarks

1 Test of insulation properties1.1 Impulse voltage test1.2 AC voltage test1.3 Insulation resistance test2 Test of accuracy requirements2.1 Test on limits of errors2.2 Test of meter constant2.3 Test of starting condition2.4 Test of no-load condition2.5 Repeatability of error test2.6 Test of ambient temperature

influence2.7 Test of influence quantities2.8 Measurement of phase current3 Test of electrical requirements3.1 Test of power consumption3.2 Test of influence of supply

voltage3.3 Test of influence of short time

over currents3.4 Test of influence of self heating3.5 Test of influence of heating4 Test of electromagnet

compatibility (EMC)4.1 Radio interference measurement4.2 Fast transient burst test4.3 Test of immunity to

electromagnetic HF field4.4 Test of electrostatic discharge5 Test of climatic influence5.1 Dry heat test5.2 Cold test5.3 Damp heat, cyclic test6 Test of mechanical

requirements6.1 Vibration test6.2 Test of protection against

penetration of dust and water6.3 Test of resistance to heat and fire7 Software7.1 Protacol7.2 Levels of security provided

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7.3 Levels of security provided to the users

288 of 409

ANNEXURE – RPP1 – SAS

RELAY & PROTECTION PANEL FOR 220 KV FEEDERS AND BUS COUPLER FOR STATIONS WITH SUBSTATION AUTOMATION SYSTEM.

(TYPE-2L – FOR 220 KV FEEDERS)

(TYPE-2BC – FOR 220 KV BUS COUPLER)The SIMPLEX panel shall generally consist of following items:

Sl. No. PARTICULARS QUANTITIES2L 2BC

A MEASUREMENT & CONTROL:1 Bay Control Intelligent Electronic Device

As per Cl. No. 3.1.1.1 – Over view3.1.1.2 – Control & Selection.3.1.1.3 – Synchronisation & energizing check.3.2 - System level function 3.2.1 - Status supervision.3.2.2 - Measurements.3.2.3 - event & alarm handling.

1 No. 1No.

2 (a) AC 3 Phase, 2 element, Electronic Tri-Vector meter (TVM), Accuracy 0.2 with ABT & TOD features and shall conform to detailed specification furnished.

1 No. 1No.

(b) Test Terminal block for TVM 1 No. 1No.3. Selector switch for control of 220KV CB & 220KV

isolator from local, RemoteBay control unit and remote – SCADA

1 No. 1No.

4 Selector Switch with indication a) For bus coupler off – FDR1-FDR2…../TR1, TR2

- 1 No.

b) For double bus arrangement, for selection of trip transfer scheme between Feeder/ Transformer and bus coupler with locking facility.

1 No. 1No.

c) For selection line CVT & bus VT 1 No. -5 Indication & alarm

As described in Annexure of specification 1 No. 1 No.

289 of 409


RELAY & PROTECTION PANEL FOR 220 KV FEEDERS AND BUS COUPLER FOR STATIONS WITH SUBSTATION AUTOMATION SYSTEM.

Sl. No. PARTICULARS QUANTITIES2L 2BC

B RELAYS1 Main Protection Relay:

a) Numerical / digital distance scheme with fault locator, disturbance recorder, event recorder suitable for 3-ph / single phase tripping with other features as described in the detailed specifications, with test switch- Main-I protection

b) Numerical / digital distance scheme with fault locator, disturbance recorder, event recorder suitable for 3-ph / single phase tripping with other features as described in the detailed specifications, with test switch- Main-II protection.

Note: Main-II numerical distance protection relay shall be of make different from that of Main-I.

1 Set

1 Set

-

-2 Back-up protection:

a) Numerical directional over current potentially polarized IDMT relays without instantaneous elements. - --

b) Numerical directional earth fault potentially polarized IDMT relays without instantaneous elements - --

c) Numerical non-directional over current IDMT relay with instantaneous element. -- 2 Nos.

d) Numerical non-directional earth fault IDMT relay with instantaneous element. -- 1 No.

e) Carrier receive relays, auxiliary relays, timers etc as per scheme requirements. Lot Lot

3 Breaker Auxiliary Relays:a) Trip circuit supervision relay 6 Sets 6 Setsb) 3 Phase Tripping relay (1 for main-I, 1 for main-

II/backup protection & 1 for bus-bar protection)c) Single phase tripping relay 3 for Main-I & 3 for Main-II

1 Set1 Set

1 Set-

d) DC supply monitoring relay 2 Sets 2 Setse) Flag relays, auxiliary relays, timers etc., as per scheme

requirement (breaker failure protection)As

required

As required

f) Local breaker back up relays 1 No. 1 No.g) Auto reclose scheme with check synchronizing and dead

line charging relay 1 Set --

4 Other devices:a) Test terminal block If required see noteb) PVC circuit labels 2 Nos. 2 Nos.c) One label indicating manufacturers name, P.O. details,

drawing reference number etc. 1 No. 1 No.

d) Internally mounted equipments 1 Set 1 Set

290 of 409

ANNEXURE – RPP1 – SASRELAY & PROTECTION PANEL FOR 220 KV FEEDERS AND BUS COUPLER FOR STATIONS WITH SUBSTATION AUTOMATION SYSTEM.

NOTE:

1. Other accessories required for operation of the protective scheme including interconnections shall be included.

2. Numerical distance scheme shall be suitable for all line lengths. Any limitation shall be clearly specified.

3. The static devices in addition to name plate, shall have labels indicating the function that are part of that particular relays and their codes in the drawings.

4. Suitable interlock arrangements shall be provided for selection of PT voltages, so that there should not be paralleling of PT secondaries or energisation of PT secondary of a PT, which is not charged.

5. Suitable interlock arrangement shall also be provided to prevent local / remote electrical operation of bus selection isolator when the corresponding breakers are closed.

6. TTB for protection circuit to be provided if the relays are of non-draw out type.

291 of 409

ANNEXURE – RPP1 –Cable – SAS

RELAY & PROTECTION PANEL FOR 220 KV CABLE FEEDERS FOR STATIONS WITH SUBSTATION AUTOMATION SYSTEM.

(TYPE-2L – FOR 220 KV CABLE FEEDERS)

The SIMPLEX panel shall generally consist of following items:

Sl. No. PARTICULARS QUANTITIES2L



1 No.


1 No.

(b) Test Terminal block for TVM 1 No.3. Selector switch for control of 220KV CB & 220KV

isolator from local, RemoteBay control unit and remote – SCADA

1 No.


-


1 No.

c) For selection line CVT & bus VT 1 No.5 Indication & alarm

As described in Annexure of specification 1 No.

292 of 409

ANNEXURE – RPP1 – Cable - SASRELAY & PROTECTION PANEL FOR 220 KV CABLE FEEDERS FOR STATIONS WITH

SUBSTATION AUTOMATION SYSTEM.

Sl. No. PARTICULARS QUANTITIES2L

RELAYS1 Main Protection Relay:

Main I - Numerical current differential protection with protection unit based on phase segregated line differential principle and restrained dual bias operating characteristic as detailed in the specification.Main II – Numerical current differential protection with protection unit based on phase segregated line differential principle and restrained dual bias operating characteristic as detailed in the specification.Note:a)Main-II numerical current differential protection relay shall be of a make different from that of Main-I b) Optic fibre is used for communication for tripping the other end relays. Communication protocol of IEC 61850 & IEC 60870-5-103 shall be used in case the other end relays are with SAS. Communication protocol of IEC 60870-5-104 shall be used in case other end relays are with SCADA system (only RTU)

1 Set

1 Set

2 Breaker Auxiliary Relays:h) Trip circuit supervision relay 6 Setsi) Tripping relay (1 for main-I, 1 for Mai-II& 1 for bus-bar

protection) 1 Set

j) DC supply monitoring relay 1 Setk) Flag relays, auxiliary relays, timers etc., as per scheme

requirement (breaker failure protection) As required

l) Local breaker back up relays 1 No.m) Auto reclose scheme with check synchronizing and dead

line charging relay 1 Set

4 Other devices:e) Test terminal block If required see

notef) PVC circuit labels 2 Nos.g) One label indicating manufacturers name, P.O. details,

drawing reference number etc. 1 No.

h) Internally mounted equipments 1 Set

293 of 409

ANNEXURE – RPP1 – CABLE-SASRELAY & PROTECTION PANEL FOR 220 KV CABLE FEEDERS FOR STATIONS WITH SUBSTATION AUTOMATION SYSTEM.

NOTE:

1. Refer Note of Annexure CRP-1 SAS wherever applicable.

294 of 409


RELAY & PROTECTION PANEL FOR 100 MVA, 220/66/11 KV STAR-STAR-DELTA, THREE WINDING POWER TRANSFORMER

OR220/110/11 KV STAR-STAR-DELTA, AUTO-TRANSFORMERS FOR STATIONS WITH

SUBSTATION AUTOMATION SYSTEM.

(TYPE-2T6 & 2T1)

2T6 FOR 220/66/11 KV TRANSFORMERS

TYPE-2T1 FOR 220/110/11 KV AUTO-TRANSFORMERS

The SIMPLEX C & R panel shall generally consist of the following items:

Sl. No. PARTICULARS QUANTITIES2T6 2T1

A MEASUREMENT & CONTROL:1 Bay Control Intelligent Electronic Device for both

HV & MV side As per Cl. No. 3.1.1.1 – Over view3.1.1.2 – Control & Selection.3.1.1.3 – Synchronisation & energizing check.3.1.1.4 – Transformer Tap changer control3.2 - System level function 3.2.1 - Status supervision.3.2.2 - Measurements.3.2.3 - event & alarm handling.

1 Set. 1 Set.

2 (a) AC 3 Phase, 2 element, Electronic Tri-Vector meter (TVM), Accuracy 0.2 with ABT & TOD features and shall conform to detailed specification furnished on both HV side &LV side.

2 Nos. 2 Nos.

(b) Test Terminal block for TVM 2 Nos. 2 Nos.3. Selector switch for control of 220KV and

110/66KV CB & 220KV and 110KV/66KV isolator from local, Remote Bay control unit and remote- SCADA

2 Nos. 2 Nos.

4 (a) For double bus arrangement, for selection of trip transfer scheme between Feeder/ Transformer and bus coupler with locking facility.

1 No. 1No.

5 Indication & alarmAs described in Annexure of specification

1 No. 1 No.

295 of 409


RELAY & PROTECTION PANEL FOR 100 MVA/150MVA, 220/66/11 KV

STAR-STAR-DELTA, THREE WINDING POWER TRANSFORMEROR

220/110/11 KV STAR-STAR-DELTA, AUTO-TRANSFORMERS FOR STATIONS WITH

SUBSTATION AUTOMATION SYSTEM. (SCADA)

Sl. No. PARTICULARS QUANTITIES2T6 2T1

B PROTECTION RELAYS:1 Main Protection Relay:

a) Numerical triple pole high speed percentage bias differential relay with high set instantaneous element suitable for three winding transformers with fixed ratio ICT’s.

1 Set 1 Set

b) Over Flux relay. 1 No. 1 No.c) Restricted earth fault relay 2 Nos. 1 No.d) Over load relay 1 No. 1 No.

296 of 409


RELAY & PROTECTION PANEL FOR 100 MVA/150MVA, 220/66/11 KV STAR-STAR-DELTA, THREE WINDING POWER TRANSFORMER

OR220/110/11 KV STAR-STAR-DELTA, AUTO-TRANSFORMERS FOR STATIONS WITH

SUBSTATION AUTOMATION SYSTEM. (SCADA)Sl. No. PARTICULARS QUANTITIES

2 Back-up protection: 2T6 2T1a) Numerical directional over current potentially

polarized IDMT relays with high set instantaneous elements (on HV side).

3 Nos. 3 Nos.

b) Numerical directional over current potentially polarized IDMT relays with high set instantaneous elements (on MV side)

3 Nos. 3 Nos.

c) Numerical directional earth fault IDMT relay with potentially polarized IDMT relays with high set instantaneous elements (on HV side).

1 No. 1 No.

d) Numerical directional earth fault potentially polarized IDMT relays with high set instantaneous elements (on MV side)

1 No. 1 No.

e) Numerical non-directional over current IDMT relay with high set instantaneous elements (suitable for 1000/1 Amps) for protection of tertiary winding due to circulating current in delta winding.

3 Nos. 3 Nos.

f) Flag relays, auxiliary relays, timers etc., as per scheme requirement

3 Breaker Auxiliary Relays:a) Trip circuit supervision relay (HV side) 6 Sets 6 Setsb) Trip circuit supervision relay (MV side) 2 Sets 2 Setsc) i. Inter tripping relay (to trip both HV & MV

side of the transformer ii. Tripping relay MV side iii. Tripping relay for Bus-bar

1 Set1 Set1 Set

1 Set1 Set1 Set

d) DC supply monitoring relay 1 Set 1 Sete) Auxiliary relays for Bucholtz trip/alarm,

winding temperature high trip/alarm, oil temperature high trip/alarm, oil surge relay trip, pressure relief device trip


f) Flag relays, auxiliary relays, timers etc., as per scheme requirement As required As required

g) Local breaker back up relays (breaker failure protection) 1 No. 1 No.

297 of 409


RELAY & PROTECTION FOR 100 MVA/150MVA, 220/66/11 KV

STAR-STAR-DELTA, THREE WINDING POWER TRANSFORMEROR

220/110/11 KV STAR-STAR-DELTA, AUTO-TRANSFORMERS FOR STATIONS WITH

SUBSTATION AUTOMATION SYSTEM. (SCADA)

Sl. No. PARTICULARS QUANTITIES4 Other devices: 2T6 2T1

a) Test terminal block If required see noteb) PVC circuit labels 2 Nos. 2 Nos.c) One label indicating manufacturers name, P.O.

details, drawing reference number etc. 1 No. 1 No.


NOTE:


298 of 409

ANNEXURE – RPP-3 SAS

SIMPLEX TYPE PANEL FOR 220 KV BUS-BAR PROTECTION

TYPE-2 BBA

FOR SUBSTATION WITH SUBSTATION AUTOMATION SYSTEM (SCADA)

Sl. No. PARTICULARS QUANTITIES1 PVC Circuit labels 2 Sets2 Internal equipment and small wiring like cubicle 1 Set3 Triple pole high speed percentage biased static /

numerical relays 1 Set

4 Bus barCT secondary wiring supervision and shorting relays As required

5 DC Controlling Voltage supervision relays 1 Set6 High speed tripping relay for tripping of breakers As required7 CT selection / switching relays with adequate number

of NO/NC contacts As required

8 Bus Zone Indication relays As required9 Terminal blocks suitable for testing of the above relay As required10 DC fail indication.

The offer should include if necessary marshalling kiosks for CT wring etc., that are needed for satisfactory working and other internal equipments. The scheme shall be suitable for adding additional line / transformer in each station and all necessary accessories are to be provided.

299 of 409

ANNEXURE – RPP -4 – SAS

RELAY & PROTECTION PANEL FOR 110/66 KV FEEDERS

(TYPE-1L – FOR 110 KV FEEDER)

(TYPE 6L – FOR 66 KV FEEDER)

FOR STATION WITH SUBSTATION AUTOMATION

(SCADA)The SIMPLEX panel shall generally consist of the following items:

Sl. No. PARTICULARS QUANTITIES1L 6L



1 No. 1No.


1 No. 1No.

(b) Test Terminal block for TVM 1 No. 1No.3. Selector switch for control of 110/66KV CB &

110/66KV isolator from local, RemoteBay control unit and remote – SCADA

1 No. 1No.


1 No. 1 No.


1 No. 1No.

c) For selection line CVT & bus VT - -

300 of 409


RELAY &PROTECTION PANEL FOR 110/66 KV FEEDERS


B RELAYS:1 Main Protection Relay:

Numerical distance scheme suitable for 3 phase tripping with other features as described in the detailed specification with test switch.

1 Set 1 Set

2 Back-up protection:a) Numerical directional over current

potentially polarized IDMT relays without instantaneous elements.

2 Nos. 2 Nos.

b) Numerical directional earth fault potentially polarized IDMT relays without instantaneous elements

1 No. 1 No.

c) Flag relays, auxiliary relays, timers etc., as per scheme requirement. As required As required

3 Breaker Auxiliary Relays:a) Trip circuit supervision relay 2 Sets 2 Setsb) Tripping relay (1 for main 1 for backup

protection) 1 Set 1 Set

c) DC supply monitoring relay 1 Set 1 Setd) Flag relays, auxiliary relays, timers, etc., as per

scheme requirement As required As required

4 Other devices:a) Test terminal block If required see noteb) PVC circuit labels 2 Nos. 2 Nos.c) Label indicating manufacturers name, P.O.

details, drawing reference number etc. 1 No. 1 No.


NOTE: Refer Note of Annexure CRP-1, wherever applicable.

301 of 409

ANNEXURE – RPP -4 - CABLES – SAS

RELAY &PROTECTION PANEL FOR 110/66 KV FEEDERS

(TYPE-1L – FOR 110 KV CABLE FEEDER)

(TYPE 6L – FOR 66 KV CABLE FEEDER)

FOR STATION WITH SUBSTATION AUTOMATION

(SCADA)The SIMPLEX panel shall generally consist of the following items:




1 No. 1No.


1 No. 1No.



1 No. 1No.


1 No. 1 No.


1 No. 1No.

c) For selection line CVT & bus VT - -

302 of 409

ANNEXURE – RPP -4 - CABLES– SAS

RELAY &PROTECTION PANEL FOR 110/66 KV CABLE FEEDERS


B RELAYS:1 Main Protection Relay:

Numerical current differential protection with protection unit based on phase segregated line differential principle and restrained dual bias operating characteristic as detailed in the specification.Note: Optic fibre is used for communication for tripping the other end relays. Communication protocol of IEC 61850 & IEC 60870-5-103 shall be used in case the other end relays are with SAS. Communication protocol of IEC 60870-5-104 shall be used in case other end relays are with SCADA system (only RTU)

1 Set 1 Set

2 Back-up protection:d) Numerical directional over current potentially polarized

IDMT relays without instantaneous elements. 2 Nos. 2 Nos.

e) Numerical directional earth fault potentially polarized IDMT relays without instantaneous elements 1 No. 1 No.

f) Flag relays, auxiliary relays, timers etc., as per scheme requirement. As required As required

3 Breaker Auxiliary Relays:e) Trip circuit supervision relay 2 Sets 2 Setsf) Tripping relay (1 for main 1 for backup protection) 1 Set 1 Set g) DC supply monitoring relay 1 Set 1 Seth) Flag relays, auxiliary relays, timers, etc., as per scheme

requirement As required As required

4 Other devices:e) Test terminal block If required see notef)PVC circuit labels 2 Nos. 2 Nos.g)Label indicating manufacturers name, P.O. details, drawing reference number etc. 1 No. 1 No.

h)Internally mounted equipments 1 Set 1 Set

NOTE:



303 of 409

RELAY & PROTECTION PANEL FOR 110/33 KV

110/11 KV & 66/11 KV DELTA-STAR POWER TRANSFORMER

(TYPE-1T3 FOR 110/33 KV TRANSFORMER)



FOR STATION WITH SUBSTATION AUTOMATION SYSTEM

The SIMPLEX panel shall generally consist of the following items:

Sl. No. PARTICULARS QUANTITIES1T3 1T1 / 6T1

A MEASUREMENT & CONTROL:1 Bay Control Intelligent Electronic Device for both

HV & LV sideAs per Cl. No. 3.1.1.1 – Over view3.1.1.2 – Control & Selection.3.1.1.3 – Synchronisation & energizing check.3.1.1.4 – Transformer Tap changer control3.2 - System level function 3.2.1 - Status supervision.3.2.2 - Measurements.3.2.3 - event & alarm handling.

1 set 1 set

Note: For LV side IED, the features shall be suitable for 11KV switchgear with single bus & VCB. Protection shall also be covered in the IED.

2 (a) AC 3 Phase, 2 element, Electronic Tri-Vector meter (TVM), Accuracy 0.2 with ABT & TOD features and shall conform to detailed specification furnished on both HV side & IV side.

2 Nos. 2 Nos.

(b) Test Terminal block for TVM 1 No. 1No.3. (a) Selector switch for control of 110KV/66KV CB

&110KV/66KV isolator from local, RemoteBay control unit and remote – SCADA

1 No. 1No.

4. b) For double bus arrangement, for selection of trip transfer scheme between Feeder/ Transformer and bus coupler with locking facility.

1 No. 1No.

304 of 409




Sl. No. PARTICULARS QUANTITIES1T3 1T1 / 6T1

B PROTECTION RELAYS:1 Main Protection Relay:

a) Numerical triple pole high speed percentage bias differential relay with high set instantaneous element suitable for two winding transformers with universal ratio ICT’s.

1 Set 1 Set

b) Restricted earth fault relay. 1 No. 1 No.2 Back-up protection:

a) Numerical directional over current potentially polarized IDMT relays with high set instantaneous elements (on HV side).

3 Nos. 3 Nos.

b) Numerical directional over current potentially polarized IDMT relays with high set instantaneous elements (on MV side)

3 Nos. --

c) Numerical directional earth fault potentially polarized IDMT relays with high set instantaneous elements (on HV side)

1 No. 1 No.

d) Numerical directional earth fault potentially polarized IDMT relays with high set instantaneous elements (on MV side)

1 No. --

e) Flag relays, auxiliary relays, timers etc., as per scheme requirement As required As required

3 Breaker Auxiliary Relays:a) Trip circuit supervision relay (HV side) 2 Sets 2 Setsb) Trip circuit supervision relay (MV side) 2 Sets 2 Setsc) Inter tripping relay (to trip both HV & MV side of

the transformer) 1 Set 1 Set

d) DC supply monitoring relay 1 Set 1 Sete) Local breaker back up relays (breaker failure

protection) 1 No. 1 No.

f) Auxiliary relays for Bucholtz trip/alarm, oil temperature high trip/alarm, winding temperature high trip/alarm, etc., for HV & MV


305 of 409




Sl. No. PARTICULARS QUANTITIES

1T3 1T1 / 6T14 Other devices:

a) Test terminal block If required see noteb) PVC circuit labels 2 Nos. 2 Nos.c) Label indicating manufacturers name, P.O. details,

drawing reference number etc 1 No. 1 No.



306 of 409


RELAY & PROTECTION PANEL FOR 110/66 KV BUS COUPLER(TYPE-1BC FOR 110 KV BUS COUPLER)(TYPE-6BC FOR 66 KV BUS COUPLER)



Sl. No. PARTICULARS QUANTITIES1BC 6BC



1 No. 1No.


1 No. 1No.



1 No. 1No.


1 No. 1 No.


1 No. 1No.

307 of 409


RELAY & PROTECTION PANEL FOR 110/66 KV BUS COUPLER

Sl. No. PARTICULARS QUANTITIES1BC 6BC

B PROTECTION RELAYS:1 Back-up protection:

a) Numerical non-directional over current IDMT relay with instantaneous element.

2 Nos. 2 Nos.

b) Numerical non-directional earth fault IDMT relays with instantaneous elements 1 No. 1 No.

c) Flag relays, auxiliary relay, timers etc., as per scheme requirement. Lot Lot

2 Auxiliary Relays:a) Trip circuit supervision relay 2 Sets 2 Setsb) Tripping relay (1 for main & 1 for backup

protection) 1 Set 1 Set

c) DC supply monitoring relay 1 Set 1 Setd) Local breaker back up relays (breaker failure

protection) 1 No. 1 No.

e) Flag relays, auxiliary relay, timers etc., as per scheme requirement Lot Lot

3 Other devices:a) Test terminal block If required see noteb) PVC circuit labels 2 Nos. 2 Nos. c) One label indicating manufacturers name, P.O.

details, drawing reference number etc 1 No. 1 No.



308 of 409

ANNEXURE – RPP -7 – SAS RELAY & PROTECTION AND METERING PANEL FOR 33 & 11 KV FEEDERS

(TYPE-3L FOR 33 KV FEEDERS)






As per Cl. No. 3.1.1.1 – Over view3.1.1.2 – Control & Selection.3.2 - System level function 3.2.1 - Status supervision.3.2.2 - Measurements.3.2.3 - event & alarm handling.

1 No. 1No.

Note: i. 2 Nos. Numerical non

directional over current IDMT relay with instantaneous element and 1 No. numerical non – directional earth fault IDMT relay with instantaneous element shall be provided in the bay control IED itself.

ii. For 33KV feeders, the features of IED shall be suitable for single bus with SF6 breaker, 2 isolators & CT’s. For 11KV feeders the features of IED shall be suitable for single bus with vacuum circuit breakers.

iii. The status indication of electromechanical 20CR & IEFR provided in the conventional 11KV switchgear is to be included in the IED.

iv. As the number of features of 33KV /11KV feeders is limited, 2 feeders may be accommodated in one bay control IED.


1 No. 1No.

(b) Test Terminal block for TVM 1 No. 1No.B. Back up protection included in the IED

Refer Note (i) Under item A(i)

309 of 409

ANNEXURE – RPP-7 – SAS

RELAY & PROTECTION PANEL FOR 33 KV FEEDERS





Sl. No. PARTICULARS QUANTITIES

1 Auxiliary Relays:a) Trip circuit supervision relay 2 Sets 1 Setb) Tripping relays 1 Set 1 Setc) DC supply monitoring relay 1 Set 1 Setd) Flag relays, auxiliary relay, timers etc., as per scheme

requirement Lot Lot

2 Other devices:a) Test terminal block If required see noteb) PVC circuit labels 2 Nos. 2 Nos. c) One label indicating manufacturers name, P.O.

details, drawing reference number etc 1 No. 1 No.


310 of 409

ANNEXURE –SAS

SCHEDULE OF REQUIREMENT FOR SUB-STATION AUTOMATION SYSTEM IN 220KV SYATIONS

Particulars

1) Station Human Machine Interface2) Hot Stand by Station HMI.3) Redundant managed switched Earth net Local area Network communication infrastructure

including optic fibre cable etc., with hot stand by ( to RCC & RSCC)4) Gate way for remote control via industrial grade hardware through IEC 60870-5-104

protocal.5) Peripheral equipment line printer display unit key Board mouse etc., 6) system software and Hardware for reliable operation of SAS in conformity with Technical

specification.7) Other accessories required for reliable operation of SAS as per Technical specification.

311 of 409

ANNEXURE –RP –GTPSECTION – RELAY AND PROTECTION PANEL

SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS OF CONTROL EQUIPMENT AND RELAYS

Bidder's NameSl. No. Description

A. PANELS :

I Description, Construction & formation details :1 Make and Type reference of manufacturer2 Type i) type of construction or simplex

ii) type of scheme a) for line b) for power transformer3 Thickness of sheet steel (mm): i. Door, Top and Bottom of panel ii. Other4 Tentative overall dimensions (L*B *H) (mm) of each

panel 5 Dead weight of each panel (Kgs)6 Approximate weight of each panel with all components

(Kgs)7 Details of packing for transport8 Overall dimensions of transport package (L*B*H) (mm)

9 Approximate gross weight of transport package (Kgs)10 Exterior paint film thickness (microns) and paint colour11 Interior paint film thickness (microns) and paint colour12 Cubicle Lighting : Volts, wattage, Type of holder and

fitting whether provided with door control switch or not.13 Safety earthing : a. Material of conductor b. Size (W*T) (mm) c. Surface treatment and finish of conductor. d. Type of end connection

14 Panel front/rear component identity board

a. Material b. Size c. Size of lettering and colour d. Method of fixing

Sl. No. Description

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15 Panel wiring : a. Type and material of wire conductors, insulation and

voltage grade. b. Conductor cross sectional area or strands/gauge of

wire and colour scheme adopted for : i. VT secondary circuits and annunciation circuit. ii. Other Circuits. c. Type of wire termination

16 Mimic bus details : a. Type painted / strip fixed b. Width (mm) c. Whether colour scheme specified will be followed d. If not specify deviations.

II. TERMINAL BLOCKS AND CONNECTORS (USED FOR PANEL WIRING)

1 Make and Type reference of manufacturer2 Insulation and voltage grade3 Constructional details4 Current rating of studs, size and material5 Whether shrouding provided or not6 Whether space terminals provided or not7 Literature enclosed.

III. INDICATING LAMPS :1 Wattage and voltage of lamp2 Size of lens and material thereof3 Type of lamp holder4 Whether provided with series resistor? If yes, specify

Ohmic value power lossIV FUSE HOLDERS AND FUSES :

1 Make and Type reference of manufacturer

2 Insulation and voltage grade3 Type of Insulation material4 Type of fuses5 Rating of fuses provided for different circuits6 Literature enclosed.

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Sl. No. DescriptionVI. SELECTOR SWITCHES :1 Make and Type reference of manufacturer2 Type of handle / Switch3 Mounting details4 Number of positions5 Number of contracts available in each position. a. Open b. Close6 Making capacity of contacts7 Breaking capacity of contacts8 Whether locking arrangement is available.9 Whether detailed literature and drawings enclosed.

(YES/NO)VII. PUSH BUTTONS :

1 Make and Type reference of manufacturer2 Mounting details3 Type of contact4 Current and voltage rating5 No. of contacts a. NO b. NC6 Whether shrouding provided to prevent inadvertent

operation (YES/NO)7 Whether provided with integral engraved inscription

plates (YES/NO)VIII AUXILIARY CT's VT'S :

1 Make and Type reference of manufacture2 a. Type b. Ratios available c. Burden V A d. Standard to which it conforms e. Accuracy class f. Short time current / voltage rating g. Temperature rise h. One minute power frequency withstand voltage j. Mounting dimensional details

j. Weight

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Sl. No. Description

k. Panel in which to be provided with quantity thereof and connected ratio

3 For CT's only a. Knee point voltage (KPV) (Volts)

b. Excitation current at KPV and 50% KPV (ma) c. Internal impedance of primary and secondary

windings in ohms4 Literature enclosed.

IX. SPACE HEATERS :1 Make and Type reference of manufacture

2 Type of space heater (Tubular / strip type)3 Rating Wattage4 Whether thermostat provided (YES/NO)II INSTRUMENT TEST TERMINAL BLOCKS :1 Make and Type reference of manufacturer2 Insulation class and rating3 Size and mounting details4 Type of CT terminal shorting mechanism (LINK /

SCREW)5 Type of VT terminal Isolating Mechanism6 Whether detailed literatures enclosed. (YES/NO)C GENERAL PROTECTION RELAYS :I The tenderer shall furnish guaranteed Technical

particulars for all types of relay offered, in the following proforma (separate sheet shall be enclosed for each type of relay :)

1 Manufacturer's name or trade marks2 Type designation3 Size and mounting details (whether in draw out case)

315 of 409

Sl. No. Description4 Rated Values of both input and auxiliary energizing

quantities5 Values of the limits of the operative range(s) of the

auxiliary energising quantity (ies)6 Contacts data, Number and rating of main and auxiliary

contacts7 Rated value or setting range of the characteristic

quantities and or angle8 Limiting short-time thermal withstand values9 Limiting dynamic values.10 i. Burden data ( in case of poly input relays - data shall

be furnished for appropriate set of input terminals). a. At highest tap - AC current / voltage coil

b. At lowest tap - AC current / voltage (coil) ii. DC power consumption.

11 Impulse and dielectric test voltage(s)12 Details of accessories (If essential to the relay

performance)13 Details of accessories (Optional items)14 Whether provided with seal in trip contacts15 a. Type of operating characteristics b. Accuracy of operating characteristics, operating time

with details16 H.F. disturbance test voltage (s)17 Whether literature enclosed18 Type of relay flag indicator and rating of target coilII In addition to the above details, the following details

shall also be furnished for relays specified below :1 DOCR / DEFR : a. Directional sensitivity b.Minimum voltage at which the directional units operate c. Characteristic angle2 OVER FLUXING RELAY : a. Whether provided with timer if so time setting

available for Alarm and delayed trip.3 Distance Protection Scheme for 220KV / 110KV /

66KV Lines:A Type of distance measuring element a. Starting unit i. Type of scheme b, No. of measuring element or comparator with details

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Sl. No. Description c. Setting range of the distance measurement d. No. of zones i. Overall range for all zones. ii. Reach setting range at rated current.

Zone - 1 (forward) - ohms Zone - 2 (forward) - ohms Zone - 3 (forward) - ohms Off set zone 3 reverse - ohms Zone extension (if any) e. Characteristic of each zone Zone - 1 Phase fault unit Earth fault unit Zone - 2 Phase fault unit Earth fault unit Zone - 3 Phase fault unit Earth fault unit Zone - 3 off set Zone -1 in ohms 1. Reach of the relay along with characteristic angle at

rated current and voltage

2. Reach of the relay in resistive direction at rated current & voltage

3. Reach in reactive direction at rated current & voltage Zone - 2 in ohms 1. Reach of the relay along with characteristic angle at

rated current and voltage 2. Reach of the relay in resistive direction at rated

current & voltage 3. Reach in reactive direction at rated current & voltage Zone - 3 in ohms 1. Reach of the relay along with characteristic angle at

rated current and voltage 2. Reach of the relay in resistive direction at rated

current & voltage 3. Reach in reactive direction at rated current & voltage

317 of 409

Sl. No. Description Zone - 3 in Reverse ohms 1. Reach of the relay along with characteristic angle at rated

current and voltage 2. Reach of the relay in resistive direction at rated current &

voltage 3. Reach in reactive direction at rated current & voltage f. Power swing blocking characteristic setting i. Forward reach ii. Reverse reach g. Setting range of residual compensation h. Setting range of mutual compensation i. (i) Operating time Zone - 1 (ii) Time setting range Zone -2 Zone -3 Power swing blocking j. Accuracy Zone - 1 (reach) Zone - 2 (reach) Zone - 3 (forward reach) K. Polarising scheme Zone - 1 Zone - 2 Zone - 3

B. Additional featues provided : a. Fault locator b. Carrier aided tripping scheme c. Power swing blocking d. Broken conductor detection

e. Synchronous check f. Weakend infeed g. Switch on to fault h. Fuse failure supervision

C. Facilities available for Fault Locator a. Name and type reference of manufacturer b. Rating and setting available c. Rated V A burden d. Power consumption voltage and current element

318 of 409

Sl. No.

Description

e. Memory capacity with details f. Triggering method g. Accuracy h. Method of accuracyD Auto Recloser:

a) Reclosing facilities availableb) Single phase/three phase dead time range.c) Reclaim time ranged) No. of modes selectable by selection switche) Provision of Check synchronizing features and its time setting,

range phase angle setting, voltage difference setting.f) Provision of deadline charging set range of voltage.g) Lock out facility.

E Disturbance Recorder:a) No. of event channelsb) No. of analog signals.c) Sampling rated) Recording Band widthe) Over current triggering – range.f) Under current triggering – range.g) Over voltage triggering – range.h) Pre fault time – range.i) Post fault time – range.j) Limit time – range.k) No. of recorded disturbances.l) Total recording time with 8 Analog and 16 event channels

recorder.m) Voltage channels – details.n) Period of built in calendar.o) Current channels – details,

F EVENT RECORDERa) Time tagging resolution.b) Events capacity

i) Max. NO. of events per disturbance report.ii) Max. No. of disturbance reports

c) Time tagging error with synchronization.i) Once in One secondii) Once in ten seconds.iii) Once in sixty seconds

d) Timer tagging error without synchronization. 4 Restricted Earth fault Relay.

a) Manufacturer Type P designationb) Operating time 2 x setting

5 Differential protection scheme : a. No. of restraining coils and operating coils. b. Harmonic restraints provided with details

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c. Rated VA Burden and power consumption of i. Restraining coil ii. Operating coil d. Type of slope setting :

If variable, range of slope setting through fault current stability. Maximum & minimum range of HV / MV / LV current ratio over which the relay can be used.

e. Whether provided with switching inrush current restraint, if so type.6 Trip circuit supervision relay:

a) Name of manufacturer.b) Type & Designation.c) Whether preclosing & post closing supervision provided.d) Time delay

7 High speed trip relaya) Name of manufacturer.b) Type & Designation.c) Contact rating.

Current rating- i) Continuous rating ii) Rating for 5 secs.

d) Break Resistive load inductive load (with L/R = 40 msec.e) Operating time at rated voltage (max).f) Resetting time.g) Whether supervisory relay included.

8 Local breaker back up protection.a) Name of manufacturer.b) Type & Designation.c) Operating timed) Resetting timee) Setting range

i) currentii) time

9 Bus bar protectiona) Name of manufacturer.b) Type & Designation.c) Type of relay (numerical)d) Principle of operation (biased/low impedance)e) Operating timef) Resetting timeg) Setting range.

i) Current ii) time.

h) Whether will it cause tripping for the differential current below the load current of heavily loaded feeder (Bidder shall submit application check for the same).

III The tenderer shall confirm whether the following details will be furnished at the time of approval of drawings:

a. Identification and location of removable parts.

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b. Data of permit suitable connection of the relay (including the polarity)

c. Data concerning the earthing of metallic part

d. To indicate parts of modules which should not be replaced without observing precaution prescribed by the manufacturer.

321 of 409

GUARANTEED TECHNICAL PARTICULARS FOR ELECTRONIC TRIVECTOR METERS

Sl. No. PARTICULARS1 Type of Meter2 Class of Accuracy3 Standard to which the meter conforms

4 Current rating for which accuracy is guaranteed for a. Basic Current (ib) b. Continuous Current overloading capability

c. Short time over current d. Minimum Starting Current5 a)Voltage rating for which accuracy is guaranteed for

b)Over voltage withstand capacity - continuous c)VoltageRange6 Other Parameters for which accuracy is guaranteed

a. Reference Temperature b. Standard Reference Frequency (Hz)

c. Accuracy Guaranteed for d. FrequencyRange e, For single Phase Loads / In- put

f. For two Phase Loads / In - put

g. For In-put / Loads without neutral in -puts unbalanced Voltages

h. TemperatureRange i. P F range j. Time7 Insulation Resistance8 Sampling Plan for measurement of Voltage, Current and Frequency

9 Power Loss in each Current circuit at Basic Current in VA & WATT

10 Power Loss in each Voltage circuit at reference in VA & WATT

11 Display device (Hardware details) a. Type of Display i.e. LCD b. Character size of display digits c. No. of Display digits used

1. For data 2. For parameter identification d. Life of display unit (Guaranteed)

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e. Method adopted for digit over flow12 Display details (Software)13 a. Non-volatile memory retention time in absence of power

b. Non - volatile memory capacity in KB.

c. RAM Capacity d. Maximum number of Parameters which can be stored in non-

volatile Memory at each half an hour intervals for Six Months.14 Maximum demand a. Parameters that can be dynamically selected

b. IntegrationPeriodRange c. Provision for Automatic Rest

d. Type of MD Computation

323 of 409

Sl. No. Description15 Communication Inter-phase available - for calibration - for data transfer

16 Electro magnetic interference / Electro magnetic comparativity level

17 Mounting arrangement18 Meter sealing arrangement a. Meter body b. Meter terminal block c. MD reset bush button d. Battery unit

19 Degree of protection against moisture etc.,20 a. Provision for real time clock b. Real time clock accuracy c. Life of real time clock (Guaranteed)

21 Power Supply backup22 Measuring principle employed for a. KWH b. KVAH c. RKVAH d. Maximum demand parameters e. PF

NOTE 1. Measuring principle adopted for each of the items above should be specified.

2. Measurement logic employed in case of Harmonics and contents up to which meter recognizes for measurement shall be furnished.

23 Abnormal conditions that will be identified with limiting values

24 Guarantee period offered for a. Performance and accuracy b. Components not covered under guarantee

25 Micro processor a. Address in bits b. Sampling rate

26 Compatibility of the software for the following a. For generation of consumer bill directly with the

existing KPTCL billing software b. Compatibility of software provided for MRI, down

loading from earlier version already supplied to KPTCL c. Compatibility of software for generation of report for

earlier versions

324 of 409

Sl. No. Description27 Additional features available

28 Agreement to furnish protocol details for development of required software through third party

29 Platform on which the meter communicates30 Levels of security a. For changing real time b. Fir changing display parameters c. For changing Load survey parameters

d. For changing TOD Registers, clock setting e. Measuring principle, computation

31 Specification of reference standard offered32 Specification of Lapatop Computer offered33 Specification of MRI kit offered34 Specification of equipment offered for checking

communication capability through RS232/RS485 port

325 of 409

SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS OF SUB-STATION AUTOMATION

GUARANTEED TECHNICAL PARTICULARSSl.No. Particulars

A SUBSTATION AUTOMATION SYSTEM MASTER CONTROL UNIT OF HMI

a) Name and Country of Manufacture.b) Manufactures type and designationc) Memory capacity

i) Hard Diskii) RAMOperating system software type

d) Type of drives providedi) 3.5” Floppy & MG drive.ii) Magnetic optical drive (rewritable)

e) Update time ofi) digital inputii) Analog Input

f) Response time for i) Alarm Functionii) Control Function

g) Response time fori) Alarm functionii) Control function

h) Whether semi of fully colour graphic typei) Total number of bay units which can be connected

without effecting the response/update time of the system

j) Whether facility and hardware for transfer of data to remote sub-station motorized.

k) Communication protocol adopted fori) Bay unitii) RSCC/LDC

l) Applicable standardm) Type of auxiliary supply requiredn) Speed of data processing in instruction per sec.o) List of manufacture whose bay units can be

connected to master unit without additional.p) Whether equipment offered is of industrial gradeq) All necessary software provided for proper

functioning of the system as a whole.r) List of all software provideds) Max. Possible distance return bay unit & master.t) Weight

326 of 409

Sl.No.

Particulars

u) Dimensionsv) Power Consumption

aa) CPUab) Processor speedac) Hard disk

a) Typeb) Capacity

ad) Cache Memorya) On Chipb) On Board

ae) CommunicationPortaf) VDU

a) Screen sizeb) Resolution

B BAY CONTROL UNITa) Name of Country of Manufactureb) Manufacturers type and designationc) Type of Mountingd) No. of bay control units offerede) Memory capacityf) Data Storage capacityg) Standard applicableh) Rated auxiliary voltage i) Rated frequencyj) No. of binary inputsk) No. of outputsl) Languagem) Type of Communication protocol n) No. & type of communication porto) Operation temperature rangep) System response timeq) (i) Exchange of displayii) Presentation of binary changeiii) Presentation of analog changeiv) Order to process outputv) Order to update displayvi) Report generationvii) Max. temperature Max. Humidity

r) Whether data is received on failure of unit. If yes, indicate the duration

327 of 409

Sl.No.

Particulars

s) Speed of transmission between bay and Master control unit

t) No. of inputs it can accommodate (specify voltage & current separately)a) Digital b) Analog

u) Resolution for digital inputsv) Update time of

a) analog inputsb) digital inputs

w) Whether data processing is done in bay unit or master control unit.

x) Power concentrationy) Humidityz) DimensionsC) KEYBOARD

i) Name &county of Manufactureii) Manufactures type & designation

a) Operationb) Engineers.

iii) Whether standard or the numerical keyboard included in the programming terminal.

D) Local Area Network LAN1) Standard2) Protocol3) Communication Medium4) Speed5) Maximum distance

E) Network Operating system F) SCADA Software

1) Supplies2) Operating system3) Facilities Provided (Full details to be enclosed in

separate sheet)

328 of 409

Sl.No.

Particulars

G) Printer1) Colour Printer2) Manufacturer name3) Country of Manufacture4) Model type5) A3 and A4 size paper supplied6) Throughput rate7) Resolution8) Available data interface9) Print colour10) Max. Temperature11) Max. Humidity.

G(b) Alarm/Event Printer1) Manufacturer name2) Country of Manufacture3) Model type4) Paper Size5) Paper Loading Facility6) Print head7) Throughput8) Resolution9) Available Data Interface10) Print Colour11) Max. temperature12) Max. Humidity (Rh.)

329 of 409

Sl.No.

Particulars

G(c) SCANNER1) Manufacturer name2) Country of Manufacture3) Model type4) Paper Size5) Resolution6) Available Data interface

H Following information is attached separately with the bid a) Type, Make and Model No. for each item/sub-item with relevant catalogues / descriptive information

Yes/No

b) List of installation of similar Equipment now in service with contact

Yes/No

Persons name and address Yes/NoDetailed drawing with dimensions of each equipment panel and interfaces

Yes/No

Full functional description specific to project along with proposed Architecture/scheme enclosed

Yes/No

I SYSTEM SOFTWARE1) Multitasking operating system2) Background executive3) File handling utility4) Magnetic tape/disk data transfer utility 5) Online debugger6) Object Module library utility7) Report generator utility for display & Print8) Communication utility9) Graphic display generation utility10) Online system backup capability11) Test and Maintenance Programs (Diagnostic

software)12) System generation at site13) Data base utility14) Data acquisition, processing and alarm

monitoring/reporting15) Communication16) Operator interface (MMI)17) Network Operating system18) Utilities like debugging and software downloading19) Mathematical and logic function

330 of 409

Sl.No.

Particulars

II PROCESS SOFTWARE1) Plant data base2) Control software3) Graphic display with points assignment4) Logs or reports with points assignment5) Software for communication with external computer

system6) Relay setting software7) Any other software.

Note: Bidder shall supplement information in this Data Sheet with a write up on each topicCPU Processing capacityWorld LengthProgrammable real time clock Yes/No.Watch dog timer Yes/No.Auto Restart Yes/NoTime synchronization Yes/NoPROCESS INPUT SYSTEMNo. of high resolution inputs

331 of 409

SECTION –10.0TECHNICAL SPECIFICATION

PLCC EQUIPMENTS

PLEASE FIND UPLOADED THE SPECIFICATIONS OF PLCC EQUIPMENTS AS A SEPARATE FILE WHICH SHALL BE READ UNDER THIS SECTION

332 of 409


FURNITURE

333 of 409


SECTION 11.0 FURNITURE

CLAUSE PARTICAULARSNO.

1.0 GENERAL2.0 QUALIFIYING REQUIREMENTS3.0 STANDARDS4.0 STEEL ALMIRAH(61/2)5.0 OFFICIER’S TABLE.6.0 STEEL SLOTTED ANGLE RACK (BIG)7.0 STEEL SLOTTED ANGLE RACK (SMALL)8.0 STEEL DUST BIN9.0 EXECUTIVE REVOLVING CAHIR WITH FULL HIGH BACK WITH

HEAD REST. 10.0 “S” TYPE CONTINUOUS ARM CHAIR WITH CUSHION SEAT AND

BACK.11.0 STEEL FOLDING CHAIR Wt 3.7 Kb (91.45)

ESTABLISHING TYPE OF BRANDS.

334 of 409

VOLUME IIA

SECTION 11. 0 - FURNITURE

1.0 GENERAL:

This specification covers design, engineering, manufacturing, testing and delivery at site of furniture required for 220 k, 110 kV & 66 kV stations.

2.0 QUALIFIYING REQUIREMENTS:

Please refer volume - 1, section - IFB

3.0 STANDARDS:

Equipments offered shall confirm to relevant Indian standards equivalent or Higher International standards

4.0 STEEL ALMIRAH (6 1/2):

Size H 1.83 m x W 0.915 m x D 0.48 m (excluding leg of 15.24 cm) fitted, with four fixed shelves making five compartments double door with three way locking device and duplicate keys, all joints outside and inside should be spot or arc welded and neatly finished by grinding. The edges of doors and shelves should be properly bent to U-shape of 25 mm width to ensure good strength and the cuter edge of U-bent of the door lengthwise should be double folded and neatly finished, the shelves front side should be bent to U-shape neatly and finished to avoid any possible cuts to fingers and hand when handled. Longitudinal ) of 15-24 cm Wide including bent to required shape should be provided and fixed to each door at the centre. The breath of the shelf in the Almirah should be to the entire width leaving about 12mm up from the shutter when it is closed.

4.1 LOCKING DEVICE:

Three way locking device with 10 guage M.S. sheet for lockine and level olate and with locking rod of 10 mm dia with strong bracket at top and bottom to hold the locking rodWith six lever lock should be provided. 65 mm size lever strong locks to be fixed. Handle should be made out of brass cast alloy with ru'ck-Je chrome plated Lock should be fixed. Handle should be made out of brass cast alloy with nickle chrome plated, Lock should be similar to Godrej type.

4.02 STEEL ALMIRAH WITH GLASS PANE DOORS:

Size H 1.83 m x W 0.915 m x D 0.48 m (excluding leg of 15.24 cm) fitted with four fixed shelves making five compartments doubled door with three way locking device and duplicate keys, all joints outside and inside should be spot or arc welded and neatly finished by grinding. The outside comer should be rounded off to give good appearance. The edges of doors and shelves should properly bent to U-shape of 25mm width to ensure good strength and outer edge of U-bent of the door length wise should be double folded and neatly finished. The shelves front side should be bent to U-shape neatly and finished to avoid any possible cuts to fingers and hand when handled. Longitudinal rilb of 15.24 cm wide including bent to required shape should be provided and fixed to each door at the centre.

335 of 409

The breath of the shelf in the Almirah should be to the entire width leaving about 12mrn gap from the shutter when it is closed. But with glass door fitted with four fixed shelves nuking five compartments. Two-way locking systems with 100 x 37-min brass six ]ever locks to be provided. The glass panels for doors shall be 4mm thick clear glass should be provided. The glass panels should be fixed with fully covered plate around both inside and outside. Handle should be made out of brass cast alloy. Locks should be similar to Godrej type with suitable locking device.

5.0 OFFICER'S TABLE:

Have overall size 1.93 m W x 0.786 m H With laminated top. There shall be three drawers with automatic locking device on the night side and a cupboard with a shelf on the left side with square legs of section 25 mm x 25 mm 16 G. The top shall be of 20-m thick laminated block board with 32mm thick V-shape teakwood internal beading nicely polished with two coats of colourless polish- The table shall be confirmed to Godrej T - 102/D. The table shall be derusted. Premier coated and painted With enamel paint as per indentors choice. All components shall be made out of NIS sheet of 20G.

6.0 STEEL SLOTTED ANGLE RACK (BIG):

Size 1.80 m x 00.9m x 0.375 m overall with four upright and five panels, the uprights shall be slotted angle of section 40x40x.2 mm and the panels of size 900 m x 375 m x 20. The panels should be fixed to the upright by naeans; of-GI. Bolts of size 8mm-x 16 nun by providing 16 nos. Standard gussets at

The rack shall be painted as per indentors choice.

7.0 STEEL SLOTTED ANGLE RACK (SIMALL):

Size 0.90 m x 0.9m x 0.375 m overall with four upnights and 3 panels. The uprights shall be slotted angles of section 40 x 40 x 2 nun and the panels of size 900mm x 375 mm x 20 G. The panel should be fixed to the uprights by means of GI bolts of size 0.079 mm x 0. 158 mm, by providing 16 nos, standard gussets at comers. The rack shall be painted as per indentors choice.

8.0 STEEL DUST BIN:

Made out of 22G MS sheet. The size of the dust-bin shall be 27.94 cm square at the top and 20.32 cm square at the bottom with a height of 30.48 cm. A sheet leg shall be provided for a height of 5cm. The dust bin shall derusted primer, coatedand painted with synthetic enamel paint as peridentors choice.

9.0 EXECUTIVE REVOLVING CHAIR WITH FULL HIGH BACK WITHHEAD REST:

Executive revolving chair with tilting and revolving arrangement of standard size 12.7 cm thick foam for the seat and 10.2 cm thick foam for the back covered with feather touch Bohr Rexin. The chair shall be with full high back with head rest and to be fitted on the M.S.(tubular ) revolving base with 5 frongs fitted with ball casters. The colour and shade of rexin cloth as per the indentors choice.

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10.0 'S' TYPE CONTINUOUS ARM CHAIR WITH CUSHION SEAT & BACK:

The name shall be made from MS tubular pipe of 16 gauge and with 25-mm outer dia- The head of the chair frame shall be 89-cm height 51 cm depth 53 cm width properly bent to its required shape and neatly ruickled chrome plated or powder coated of approved colour. The seat and back shall be 50-mm thick foamcushioned on teak-wood frame and neatly upholstered with Bohr Rexin. The armrest also shall be cushioned and upholstered. Tour rubber shoes shall be provided at the bottom of the chair frame.

11.0 STEEL FOLDING CRAIR Wt 3.7 kg (91.45):

Tubular frame sizes helaht 94 cm when folded seat sizes 39.3 cm deep and 45.7 cm Hip-h from the floor. Rack rest about 20.3 cm wide. The tabular frame should be 22mm OD (18 gauage) ERW or gas welded steel tube and cross pipe of 16mm OD (20 gauge) steel tubes. The cross pipes are fixed to the leg pipes by strong rivets. 22 G CRCA steel should be used for the seat and back plate is neatly pressed to the required contour with rounded comers and fixed on the tabular frame by self tapping screws in such a way that the chair could be folded and opened easily. Connecting 4 lever plates 89 mm x 20 trim 10 gauge thick to be fixed at the top Junction of the front and rear legs and top end of rear legs. Hard plastic shoes should be provided at the bottom of the front and rear legs and top end of rear le s. The chairs are finished by spray or stove enamel in standard 9 colours.

12.0 Establishing type of brands Godrej / Chandan / Featherlite.

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EARTHMAT

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SECTION 12.0- Earthmat

Caluse No. Particulars

1.0 Scope 2.0 Design of Earthmat3.0 Laying Earth Mat4.0 Earth Connections5.0 Power Cables6.0 Outgoing 11KV Feeders7.0 Sub-Station Fencing 8.0 Crushed Rock Surface Layer 9.0 Separation Between Cast iron Pipe Electrodes 10.0 Power Cables & Control Cables11.0 Labeling of Pipe Electrodes12.0 MS Flat 13.0 Execution Payment.

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SECTION - 12EARTHMAT

TECHNICAL SPECIFICATIONS FOR DESIGN AND LAYING OF EARTHMAT

1.0 Scope

1.1 This specification calls for measurement of soil resistivity,Design of earthmat, laying of earthmat and connectingequipments to the earthmat, in accordance with IS 3043 &IEEE-80.

2.0 Design of earthmat

2.1 Various factors that are to be considered for the design ofearthmat are as follows:

i) The fault levels at the 220 KV sub-station at Pavagada are as follows.

220 KV sub-station Voltage class of switchyard

3 phase to ground(MVA)

Single phase to ground(MVA)

220 KV Please refer uploaded scanned copy of EARTHMAT drawing66 KV

ii) Oil resistivity of sub-station area shall be less than one Ohm metre after laying of earthmat.

ii) The touch potential and step potential shall be within permissible limits.

iii) In case of non uniformity of soil resistivity, or to achieve permissible step and touch potentials, it may be necessary, to embed the normal electrodes or deep Bore electrodes at the peripheral of the earthmat.

iv) In case of hard soil/dry fissured rock/hard rock, treatment with Bentomite clay, may be necessary.

2.2 The design calculations and drawings are to be got approved by the owner before taking up the work for execution.

3.0 LAYING OF EARTHMAT:

3.1 I. While installing the earthmat, the rows and columns shall be interleaved like a woven mat to obtain better mechanical strength and electrical continuity.

MS Flat of the designed cross section shall be laid at the designed depth of (around 0.9 Mtr.) and spacing duly straightening and removing any bends.

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3.2 As the standard length of flats available in the market isaround 6 meter in length for continuous running ofearthmat, straight through joints are required. When such traightjoints are made, a minimum overlap equal to the width of theflat shall be maintained.

3.3 The overlap portion shall be welded on all four sides bycontinuous welding. To facilitate welding on all four sides,welding work shall be done on the natural ground surfaceand then laid in the trench.

3.4 A thick coat of Anti-corrosive bituminous paint shall beapplied at the welded joints duly removing the depositedweld flux and any burrs.

3.5 After laying the flats in the trench and. interleaving, all theperpendicular crossings of flats shall be welded and applieda thick coat of ACB paint as above. The ACB paint shall beapplied only to the welded portion.

3.6 Projections of flat at the periphery of the earthmat should beavoided and the overlap shall be in flush with the edge of theperipheral flat of earthmat. At these joints the welding shallbe continues on all the three sides.

3.7 The peripheral MS round rods of length 1050 mm 25mm diashall be driven into the ground at locations shown in theearthmat drawing. Before driving these rods the top 50mmportion of the rod shall be flattened and bent and thenwelded properly to the MS flat of earthmat firmly. The otherend of the rod shall be sharpened for easy driving.

3.8 When hard soils such as fissured rock/ gravel, laterite etc.,are encountered at the sub-station site during excavation forlaying the earth mat, Bentonite clay or soft soil or tank clayshall be used for back filling in trenches of earth mat to aheight of 0.3 mtr.

4.0 EARTH CONNECTIONS

4.1 All earth connections from equipment/cast iron pipeelectrode to the earthmat shall be made using Galvanisediron flats of cross section equal to the MS flat of earthmat.

All earth connections are to be made only by welding.Suitable laps and bends shall be formed while making earthconnections from equipment to the earthmat.

4.2 POWER TRANSFORMER NETURAL

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Two distinct continuous earth conductors (GI flats without any joints) shall be run in opposite directions from the power transformer neutral to the cast iron pipe electrodes provided for the purpose by welding. Further, these cast iron pipe electrodes shall be connected to the earth mat by welding using GI flats.

4.3 LIGHTNING ARRESTERS:

Each phase of the lightning arrester base shall be connected to the cast iron pipe electrodes provided for the phase by running GI flat from the base terminal. The cast iron pipe in turn shall be connected to the earthmat by welding using GI flats. A flexible braided earth bond shall be made firmly between the base terminal and the GI flat. The length of the earth connection shall be as minimum as practicable.

4.4 OUTDOOR SWITCHGEAR AND CONTROL ROOM

A minimum of three-cast iron pipe electrodes are to be provided around both the outdoor switchgear and the control room. The opposite ends and mid points of the earth bus of these panels are to be connected to the earthmat through these cast iron pipe electrodes using GI flats.

If the earth bus provided in the panels are not continuous, a separate earth bus of GI flats shall be connected to this bus which in turn should be connected to the earthmat through the cast iron pipe electrodes.

.4.5 NON CURRENT CARRYING METAL PARTS

All non current carrying metal parts such as transformer body, circuit breaker body, instrument transformer body, outdoor structures and isolator structure are to be directly connected to the earthmat using GI flats with two distinct connections run in opposite directions.

The operating handles of isolators are to be connected to the earth conductor (GI flat) using braided flexible earth bonds.

5.0 POWER CABLES

5.1 THREE CORE CABLES:

The sheath of the cables are to be directly earthed at their terminations and joints, i.e., at the both switchgear and terminating pot heads (cable sealing end).

5.2 Sheath on single core cable shall be earthed at only one end.

6.0 OUTGOING 11 KV FEEDERS

6.1 When the feeders are erected within the substation fence

The cable end leads sheath is to be earthed and connected to the earthmat through independent cast iron pipe electrode by running 50 x 6 mm GI flat along the structure from the cable end to CI

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electrodes. In turn these C I electrodes are to be connected to the earth mat. All these connections shall be made by welding.

6.2 When the feeders are erected out side the sub-station fence.

The lead sheath of the cable end shall be connected to CI pipe electrode of the feeders as mentioned in clause 4.1. further MS Flat of 50 x 6 mm shall be run at a depth of 0.5 mtr and all the CI pipe electrodes of 11 KV feeders shall be connected to this buried MS flats by welding using GI Flats. This system shall be not be connected to the station earthmat and should a1ways be isolated from the station earth.

7.0 SUB-STATION FENCING:

7.1 Fence earthing shall be isolated from the main earthing ofthe sub-station.

7.2 The sub-station earthmat i.e, the last conductor of the earthmat shall be at a distance of 1.5 meter away from the sub-station fence.

7.3 A separate earthing conductor of size 50 x 6 mm MS Flatshould be run along the perimeter of the fence at a depth of0.9 mtr below the ground surface.

7.4 The perimeter of the fence is to be connected to this MS Flatthrough independent vertical electrodes (C I pipe electrodes)using GI Flat of 50 x 6 mm. The connections are to be madeby welding.

7.5 The C1 pipe electrode shall be provided at comers and midpoints of the fence if the perimeter is more than 200mtr,otherwise CI pipe electrodes may be provided only at thecomers or midpoints.

7.6 The fence earth and station earthmat shall not have anyelectrical tie.

8.0 CRUSHED ROCK SURFACE LAYER:

20mm metal (baby granite jelly) to a height of 100mm shall be provided over the total area of the sub-station as mentioned in the SECTION 8- CIVIL WORKS

9.0 SEPARATION BETWEEN CAST IRON PIPE ELECTRODES:

9.1 The separation between any two C I pipe electrodes in thesub-station yard has to be maintained equal to twice thelength of the C I pipe electrode. This is very important due to

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the fact that any lesser electrode intervals will increase the earth resistance due to mutual interference

9.2 The location of cast iron pipe electrodes shall be plannedearlier keeping in view the following

1. The C I pipe electrode for lightning arrester and powertransformer neutral shall be as near as practicable tothe respective equipment.

2. The distance between any two C I pipe electrodesshould not less than twice the length of the C I pipeelectrode.

3. The lightning arrester earth connection should not berun over the ground surface. They should be buried at the mat depth and connected to the earthmat at the nearest point.

10.0 POWER CABLES & CONTROL CABLES

The power cables and control cables shall be laid in a separate concrete duct. A clearance of minimum of 0.6 mtr shall be maintained between any earthmat conductor and the power/control cables. Parallelism of power/control cables with earthmat conductor should be avoided.

11.0 LABELING OF PIPE ELECTRODES:

The individual pipe electrodes shall be labeled for proper identification.

12.0 The transformer plinth, control room & out door switchgear shall be surrounded by MS Flat of designed cross section at the designed depth and the earthmat conductor shall be terminated on this surrounding MS Flat by welding.

12.1 The earthmat shall be run below the concrete cable duct whenever the mat encounter path of the cable ducts.

12.2 When structures come in the way of earthmat conductor, one or two conductors may be slightly shifted. However, the designed spacing must be maintained for other earthmat conductors.

13.0 Execution

13.1 The soil resistivity and other parameters after the installation of the earthmat will be measured by KPTCL (Research wing) to check the values arrived in the approved designs. In caseof non achieving of values, the contractor will have to execute the measures suggested by KPTCL (Research wing).

14.0 Payment

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The bidder has to asses the quantities of earthmat materials and indicate in the bid proposal sheets. Payment will be made for the quantities indicated by the bidder OR actual quantities arrived consequent to finalization of designs and actually executed, WHICHEVER is LOWER.

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11KV SWITCH GEAR

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VOLUME –IIA


SECTION-13 11KV CLASS METAL CLAD SWITCHGEAR

1.0 SCOPE

The scope of this specifications is for design, manufacture, testing and supply of outdoor 11KV - class metal clad switchgear suitable for installation for the use in a 3-phase 50Hz. 11KV solidly earthed system. The switchgear assembly shall consist of incomer transformer VCB panels, outgoing VCB feeder panels, bus coupler panel, central annunciator cum remote operation (trip / close) panel wherever required and shall be complete with all components such as circuit breakers, control gear, instruments, meters, relays, switches, indicating lamps, test blocks, current transformers, voltage transformers, etc., which are required in each panel for satisfactory and efficient performance of the switchgear. The switchgear shall suit outdoor installation.

Note: The 11KV Switchgear shall be compatible with Bay level intelligence Electronic device unit of Substation Automation.

2.0 APPLICABLE STANDARDS:

The switchgear shall conform to the following standards namely BIS - Bureau of Indian Standards and IEC International Electro Technical Commission.

1 . IS : 5 Paints, finishing exterior

2. IS : 513 Cold rolled low carbon steelsheets and strips

3. IS : 641 Paints, finishing interior White

4. IS : 722 AC Electricity meters

5. IS : 722 Direct acting indicatingParts (1) to (5) analogue electrical measuring (7) to (10) instruments and their accessories

6. IS : 1730 Steel sheet and strip dimensions

7. IS :1951 PVC sleeving for electrical purpose

8. IS : 2419 Dimensions for panel mountedindicating and electricalrecoding instruments

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9. IS : 13118 Specification for alternatingcurrent Breakers

10. IS : 2705 Current TransformersParts I to IV

11. IS: 2959 AC & DC Contactors

12. IS: 3156 Voltage Transformers

13. IS: 3231 Electrical relays for powersystem protection

14. IS : 3427 Metal enclosed switchgear andcontrol gear for voltage above1000V but not exceeding 11000V

15. IS: 3842 Application guide for ElectricalParts I to XII relays for protection and other

Relays

16. IS: 4146 Application guide for voltagetransformers

17. IS : 4201 Application guide for currenttransformers

18. IS : 4777 Performance tests for protectiveschemes used in protective of lightgauge steel against corrosion

19. IS : 4794 Push button switchesParts I & II

20. IS : 5608 PVC wires, and sheathsParts I to IV

21. IS : 6236 Direct recording electrical measuring instruments

22. IS: 6875 Control Switches

23. IS: 7118 Recommendation for direction movement for control devices/ operating electrical devices.

24. IS : 8130 Conductors for insulated Electric cables

25. IS : 8197 Terminal markings of Electrical measuring instruments And accessories

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26. IS: 8686 Static protective relays

27. IS: 9224 Pictorial surface preparationParts I & II standards for painting of steel Surfaces

28. IS: 9954, Code of practice for installation of switchgear29. IS: 10118 Code of practice for installation

(Part III) of switchgear

30. IS : 10276 Edison screw lamp holders(Part I & II)

31. IS: 11431 Code of practice for packagingof Electrical indicating and recording instruments

32 IEC: 56 High voltage alternating current circuit breakers - 1987

33. IEC: 694 Common clauses for high voltage switchgear and control gear standards.

34. IEC 687 Static watt-hour meters for class 0.25 and 0.55

35. IS 14697 (3) Static transformer operated watt-hour and VAR hour meters class 0.25 and 0.55

3.0 NORMAL SERVICE CONDITIONS:

Generally as per (1) clause 2.1 of IS 13118.

4.0 DEFINTIONS AND TERMINOLOGY:

As per

i) IS: 3427 Clause (2) and sub-class thereoffor switchgear

ii) IEC: 56 Clause (3) and sub-clauses thereoffor circuit breakers

iii) IS: 13118 Clause 3.0 & sub-clauses thereoffor circuit breakers

iv) IS : 2705 (Part I to IV) clauses (2) and sub- clauses thereof for current transformers

v) IS: 3516 Part - I Clauses (2) and sub- clauses thereof for voltagetransformers

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5.0 DESIGN AND CONSITRUCTION:

5.1 GENERAL:

5.1.1 As per IS 3427 Clause 3.1

5.1.2 The type of construction shall be welded sheet steel. The minimum thickness of the sheet steel shall not be less than 3mm for the base and load bearing members and not less than 2.5 mm for the top cover, side sheets, doors and partitions. Sheet steel shall be cold rolled conforming to IS-513. The panel door shall be provided with louvers and with translucent plastic covered windows directly opposite the close/open indicating lamps and spring status indicator. The panel door shall be hinged, swing door provided with pad locking facility. Rear door shall also be hinged on one side and bolted on the other side.

5.1.3 The design and construction shall be with the following features:

a) Compact and robust constructionb) Easily extensible on both sidesc) Dust protected and vermin proofd) Fully compartmentalized.e) Horizontal draw out typef) Safe and positive interlocksg) Automatic safety shutters. FRP flap or safety shutters shall be installed so as to

prevent accessibility/ exposure for all the HV live parts.h) Easy interchangeability of identically rated components including breakers.i) Extremely reliable operationj) Integral base channel to be fixed below ground level.k) Test facility with the truck in the test position and it shall be possible for closing the

door in test position.l) All relays, instruments, and switches mounted on the instruments panel shall be

accommodated at a height in between 0.5 to 2.0 meters from ground level in the outdoor control panel.

5.1.4 The size of the base channel for cable entry type switchgear shall not be less than 75mm.

5.2 ENCLOSURES:

Generally as per clauses 3.2. 1 of IS 3427.

5.3 COVERS:

Generally as per clause 3.2.2 of IS 3427.

5.4 PARTITIONS:

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5.5 SHUTTERS:


5.6 VENTILATING OPENINGS, VENTS OUTLETS:


5.7 INSPECTION WINDOWS:


5.8 AUXILIARY DEVICES AND CIRCUITS:


5.9 INTERLOCKS

Generally as per clause 3.4 (e) with mechanical interlocks of IS 3427.

5.10 EARTHING:

Generally as per 3.5 of IS 3427, however the earthing conductor shall be of copper flat shall not be less than 25 x 6 mm. 2 Nos. each of M12 size earthing bolts shall be provided at either ends of the switch gears assembly to receive 50 x 6 mm G.1 flat of station earthing system. Earthing of all metallic parts relays covers etc., which are not electrically alive shall be done with stranded insulated copper wire. The earth connections for individual equipment shall be of size not less than 15 Sq. mm and Main earth connection shall be not less than 70 Sq. mm.

6.0 SWITCHGEAR COMPONENTS:

6.1 COMMON COMPONENTS:

The following shall be common components in all the incomer, outgoing and bus inter-connection panels.

a) Vertical / Horizontal isolation and horizontal draw out truck type circuit breaker.

b) Current Transformerc) Instruments and Protective relays and selector switches.d) Copper bus bars.e) Cable termination boxes in the incomer and outgoing.

Incomer shall suit to receive 6 runs/3 runs of Single Core cable 1000 sq. mm and outgoing feeder panel shall be suitable to receive 1 run of 240/400 Sq. mm 3 core cable and suitable cable glands with gland plates and cable support clamp shall be

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provided. Gland plates shall be easily removable type, even when the cable termination kit is in fixed position.

A caution board "Ensure fixing of gland plate before energising of cable" should be provided at a conspicuous place in the cable chamber.

A caution board 'Ensure transformer breaker is off for access to cable chamber" is to be provided on front portion of cable chamber of incomer.

Control switches, indicating lamps, contactors and test terminal blocks.

6.2 ADDITIONAL COMPONENTS:

These are required panel wise as follows

a) Voltage transformer in the incomer panels. If space constraint is there in the incomer panel, separate VT panel adjacent to incoming panel is acceptable.

6.3 COMPARTMENTALIZATION

6.3.1 The various switchgear components shall be housed in separate compartments as follows:

a. Circuit breaker compartment should be located at the bottom portion of the switchgear.

b. Bus bar compartment.

c. CT compartment

d. Cable compartment

e. PT compartment either at bottom or at top or in a separate panel.

f. Relay and control compartment.

6.3.2 It shall not be possible to approach any part of circuit breaker during its service/ test /isolation.

6.4 STANDARD FITTINGS AND ACCESSORIES :

The following shall be provided in each panel as applicable.

a. Cubicle space heater with thermostat.b. View glass for breaker position indication.c. Name plates on front and rear sides of switch boards.d. Danger board on front and rear switch boarde. One set of racking handle per switch board.f. One set of spring charging handle per switch board

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9. Control cable duct and supporting clampsh. Mimic busi Test/ service/ isolated positions for the breakers.j. Operation counter for the breakerk One set of ramp for withdrawal of breakers.

7.0 GENERAL ARRANGEMENT OF THE SWITCH GEAR PANELS:

7.1 the switchgear assembly consisting of the incomer panels, outgoing feeder panels and Bus Inter connector panel being installed side by side in a straight-line formation. Provision shall be made for future extension of the switchgear board.

7.2 All the outdoor panels shall be provided with a lean to drain rainwater to the rear of the panel. The roof shall be projecting on all sides so that rainwater shall not enter into the body of the panels.

7.3 The central annunciator panel shall be suitable for mounting indoor. Remote close/ Trip facility shall be provided on this panel itself for remote closing /opening of individual breakers.

7.4 The line up of the panels shall be as indicated below:

Feeders, Incomer, bus coupler, Incomer and feeders.

8.0 SWITCHGEAR RATINGS

8.0.1 CHARACTERISTICS :

a) Rated voltage as per clauses 4.2 of IS 3427 for nominal system voltage of 11KV.b) Rated insulation level 28 KV/ 75 KV Peak- for 11 KV nominal system voltage.

c) Rated Frequency - 50 Hz.

d) Rated normal current -800A/ 1250A/ 1600 Amps.

e) Rated short - time current : 20KA for 800A Switchgears and 25KA for 1250A Switchgears

f) Rated peak short - time current. As per clause 4.7 of IS-3427 and in conjunction with sub-clauses (e) supra.

g) Degrees of protection. Corresponding to IP 55 of IS : 12063.

h) The temperature rise limits for the various materials shall be as per table V of IEC 694.

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9.0 SWITCH GEAR COMPONENTS:

Rated values of the components forming part of the main enclosed switchgear and control gear are detailed here below individually against each component

9.1.1 Circuit Breakers:

a) Type: vacuum

b) Rated voltage 11 KV r m s

c) Highest system voltage 12 KV r m s.

d) Frequency 50 HZ

e) Number of poles - three

f) Class - outdoor

g) Power frequency withstand voltage: 28 KV r m s,

h) Impulse Withstand Voltage - 75 KVp.

i) Rated normal current 800 or 1250 or 1600 Amps as per requirements.

For 1250 Amps switch gear, the rated current of incomer breaker shall be 1600 Amps and 1250 Amps for feeder breakers. For 800 Amps switchgear, the rated currents of incomer/feeder shall be 1250A & 800A respectively.

j) Rated symmetrical Breaking current : 20 KA or 25KA as per requirements.

k) Rated transient recovery voltage : as per clauses 4.102.2, 4.102.3 of IEC 56, Table - IIA for 12KV rated voltage.

l) Rated making current peak: 50 KA or 62.5 KA as per lots.

m) Short time withstand current - 20 KA for 3 seconds or 25KA for 3 seconds as per lots.

n) Operating sequence : As per clause 4.104 (a) of IEC-56 : O- 0.3sec - CO-3min-CO.

o) Rated supply voltage of opening /closing devices with operating limits.i) Closing Coil – 220V or 110V DC to operate satifactiroly between 85 to 100%

of rated voltage.ii) Opening coil (shunt trip coil) - 220V or 110V DC to operate satisfactorily

between 70 to 110% of rated voltage as the case may be. The DC control voltage will be 220V DC for 220KV stations and 1 10V in other stations

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p) Rated voltage of auxiliary supplies.

i. Space heater - AC 230V, Single Ph, 50Hz

ii. Spring charging motor - AC 230V, Single Ph, 50Hz

iii. Cubicle illumination - AC 230V, Single Ph, 50 Hz

q) Method of closing and opening - The breaker shall be capable of being closed by discharging the energy stored in springs. These springs should be capable of being compressed or charged by an AC motor. It should also be possible to charge the springs manually by means of a spring charging handle or lever. During manual charging of the springs an electromechanical device shall be provided to prevent charging of the same by the motor. The springs should also be capable of being charged even with the breaker in the closed position so as to restore tension in the springs. Besides, there should be provision to automatically cut - off power supply to the motor when the springs are fully charged and also to automatically switch - on the power supply to the motor when the springs are fully discharged. There shall also be provision to indicate spring status namely “FREE" / "Charged," by means of a mechanical lever at the panel. This shall be arranged through potential free auxiliary contacts or limit switches. The mechanism shall be "Trip Free Mechanism" providing priority for "tripping" over "closing". The mechanism shall be provided with an anti-pumping device to prevent closing impulses from being transmitted, to the closing coil when the breaker is in the closed position.

r) Auxiliary Contacts : 8 NO + 8 NC conforming to clause 5.4 of IEC 694.

s) Name Plates - As per clause 5.9 of IEC 56.

t) Requirements for simultaneity of poles - As per clause 5. 101 of IEC 56.

9.2 CURRENT TRANSFOREMRS:

9.2.1 The current transformer to be mounted in the incomer panels and outgoing panels shall conform in all respects to IS-2705 parts I to IV. CTs are required in Bus-Coupler Panel also.

9.2.2 The CTs shall be of the cast resin double bar type with a single CT having multiple cores for each phase. Alternatively, they can be of the ring type with separate cores for each function. They shall be located in separate compartment next to the cable termination end box.

9.2.3 CT ratio changing is preferred on secondary side.

Rating Characteristics :

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a. Nominal voltage 11KV r m s.b. Highest system voltage 12 KV r m s.c. Frequency 50 Hz.d. i. The Insulation class of CTs shall be suitable for higher voltage

class of 15KVii. Power frequency

withstand voltage 35 KV rmsiii. Impulse Withstand

Voltage 95KVp

e. Ratio and coresi. Incomer panel-3 cores 1200-800/1-1-1A for

1250 A rating or 800-400/ 1-1-1A for 800A as the case may be

ii. Bus Coupler panel-2cores 1200-800/ 1 - 1A for1250A rating

OR800-400/ 1-1A for800 A rating as the case may be

iii. Outgoing panel-2cores 400-200/ 1-1A for25KA breakers &200-100/ 1-1Afor 20KA Breakers

f. Accuracy class /burden

i. Incomer panel

Core 1 (Metering) 0. 5/ 15VACore 2 (OC, EF & REF Protection) 5P20/15VACore 3 (differential Protection) PS/Vk min 300V

ii. Bus coupler panel

Core 1(Metering) 0. 5/ 15VACore 2 (OC protection) 5P 20/15VA

iii. Out going panel

Core 1 (Metering) 0.5 / 15VACore 2 (OC, EF Protection) 5P 10/ 15VA

g. Instrument security factor 5 at all ratios

h. Earthing As per clause 4.3 ofIS 2705 (Par-t-1)

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i. Short time current rating

i. Thermal rating 25KA for 1 second for 1250A/20KA for 1 second for 800Arespectively as the case may be

ii. Dynamic rating As per 5.6.2 of IS 2705, Part -I

j. Terminal Marking As per Clause 6.2 ofIS 2705 Part -I

k. Rating plate As per IS 2705 Part-IClause 6.1 & 7.1

l. The minimum creepage distance of insulator shall not be less than 250mm.

9.3 VOLTAGE TRANSFORMERS:

9.3.1 The voltage transformers in case of cable entry type switchgear, are to be mounted in the incomer panels only and shall conform to IS-3156 parts (I to III). They shall be of the cast resin type and shall be connected on the incoming side of the cables in a separate compartments so as to give a positive indication of the supply conditions, even with the incomer breaker in the "open" position. The. VTs shall be three phase or 3 single phase Star connected on the primary and secondary sides and provided with HRC fuses on HV side.

9.3.2 RATING AND CHARACTERISTICS:

a. Nominal Voltage - 11 KV rms.b. Highest system voltage - 12KV rms.c. Frequency - 50 Hzd. i. The Insulation class of VTs shall be suitable for higher voltage

class of 15KVii. Power frequency

withstand voltage - 35 KV rmsiii. Impulse Withstand Voltage- 95KVp

e. Ratio & Core : 11000V/√3 / 110V/√3 – 110V/√3

Core-1 Connected in starCore-2 Connected in star

f. Accuracy class/ BurdenCore-1 : 0.5/ 100VA (Metering)Core-2 : 3P/50VA (Protection)

g. Earthing As per clause 4.3 of IS 3156 (Part- I)

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h. Rated voltage factor 1. 2Continuous and 1. 5 for As per clause 5.6 of IS 3156 (Part- I) 30 seconds

i. Limits of Temperature Rise As per Clause 6.2 of IS 3156 (part -I)

j. Terminal Markings As per Clause 7.2 of IS 3156 (Part -I)

k. The minimum creepage distance between the line terminal of 11KV PT and the metallic base plate shall not be less than 250mm. The overall mounting height of the PT i.e., vertical clearance shall be minimum 200mm.

9.3.3 The secondary of PTs shall be such that the potential of various meters, relays etc., change-over to second set of PTs located in INCOMER-2, if breaker for INCOMER-1 is opened out. However, under normal condition each set of PTs shall feed potentials to half number of feeder circuits, (one third in case of 3 incomers) and auto-change over as described earlier, should take place when one of the breakers is opened out for maintenance and bus coupler is closed. The PT secondary shall not be paralleled under any circumstance. PT selection shall be carried out through auxiliary contact of breakers.

9.4 BUS BARS AND BUS BAR ARRANGEMENT:

9.4.1 The main Bus Bars shall be of EC grade copper flats in two lams with suitable spacers between lams for aeration, for the continuous current rating of 1250 Amps or 2000 amps as the case may be as per lots as noted below.

Switchgear Bus Bar Rating Size of Bus bars800 A 1250 A 50 mm x 10 mm x 2Lams or equivalent1250 A 2000 A 60 mm x 10 mm x 2Lams or equivalent

9.4.2 All bus bars shall be coated with non-inflammable bus bar paint. The material of bus bars shall be EC grade copper conforming to space VDE 0201 code ECVF 30 IS : 8084.

9.4.3 The Bus-bar risers, connectors and tees shall be of EC grade copper flats for the continuous rating of 1250A for 800A panels and 2000A for 1250A panels

9.4.4 Bus bar arrangement arranged in a staggered vertical formation.

9.4.5 Bus bar supports-porcelain bus supports shall be used. However epoxy insulators, reputed make with rain-shed type and adequate creepage distance acceptable.

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9.4.6 Bus bar joints : All riser, bus bar joints shall be lap bolted joints. All straight joints in the run of the bus shall be butt joints with double cover plates of adequate current carrying capacity. All butt joints shall be provided with expansion spaces at the butt point. The cover plates shall be of the same material as that of the bus bars. All bolts and nuts used in the joints shall be of brass and adequate in number and liberal in current rating.

9.4.7 CLEARANCES:

i) Between Phases Not less than 120mmii). Between Phase to Earth Not less than 120mm

9.5 INSTRUMENTS:

9.5.1 Meters to be mounted shall conform with IS 1248 Parts (I to IX)and dimension shall conform to IS-2419.

9.5.2 All meters shall be CT/VT Secondary operated instruments and shall be flush mounted with only the bezels projection. All meters shall be wired at the back and shall be provided with tropicalised dials, to ensure freedom from warping, discoloration or fading. The lettering/ Numbering on dials shall be in bold black on white dial background.

9.5.3 All meters shall be magnetically shielded.

9.5.4 All indicating analog meters shall be provided with a screw type zero adjuster for the needle with facility to operate from the front of the panel without having to remove the cover of the meter.

9.5.5 All meters shall be wired through test terminal blocks to provide for independent calibration of meters.

9.5.6 TYPE RATING AND CHARACTERISTICS:

A) AMMETER:

a. One No. to be provided in all the panels. Each ammeter shall be provided with a selector switch to read the current in each of the phases.

b. Type - Moving Iron

c. Size - 96 x 96 mm

d. Accuracy - 1.0e. Scale - 90 º

f. Range i. 0-800-1200 Amps for,ammeter in the incomer/

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Buscoupler panel for CTR 800-1200/ 1A.

ii. 0-400-800Amps for Ammeters in the incomer/ Bus coupler panels for CTR 400-800/ 1A

iii. 0-200-400 Amps for ammeters inthe feeder panels for CTR 200-400/ 1A

iv. 0- 100-200 Amps for ammeters inthe feeder panels for CTR 100-200/ 1A

B) VOLTMETERS:

a. One No. to be provided in the incomer panel with a selector switch to read voltage between phases.

b. Type - Moving Iron

c. Size - 96 x 96 mm

d. Accuracy 1.0

e. Range - 0 to 15 KV

f, Scale - 90º and end zero suppressed

C) WATTMETERS:a. One number to be provided in all panels except bus coupler.

b. Type- 3-Phase 3-Wire, Two-element dynamometer.

c. Size- 96 X 96 mm.

d. Accuracy - 1. 5

e. Range - i. 0-12-24MW/0-8-16MW Suitable for PTR of 11000V/√3 / 110V/√3 and CTR 800-1200 /1A or CTR 400-800/1A as the case may be.

ii. 0-4-8 MW suitable for PTR of 11000V/√3 / 110V/√3 and CTR 200-400/1A.

iii. 0-2-4MW suitable for PTR of 11000V/√3 / 110V/√3 & CTR 100-200/1A.

f. Scale 90 deg and end zero suppressed.

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D) VARMETER

a. One number to be provided in all incomer panelsb. Type - 3 Phase 3 - Wire. Two - element dynamometerc. Size - 96 x 96 sq. mmd. Accuracy - 1. 5e. Range - i. Incomer Panel:

800A. Panel 1250A. Panel0-15 MVAR 0-15 MVARsuitable for CTR of 800/ 1A suitable for CTR of 1200/ 1A && PTR of 11000V/√3/ 110V/√3 11000V/√3 / 110V/√3

f. Scale 90 deg and end zero suppressed.

E) ELECTRONIC TRIVECTOR METER – 0.2 Accuracy class.

The Scope of Supply of ETV meters for Incomer & Outgoing Feeders is included in the scope of Relay & Protection panel and Substation automation supplier. For details refer Specification & Bill of materials of Relay & Protection Panel and Substation Automation.

a) One No. of Trivector meter be provided in all panels except Bus coupler panel.

b) It shall be of static type 3 phase. 2 element trivector meter suitable for 1 Amp. CT and 110 Volts phase to phase VT secondaries. It must be flush mounted type and tropicalised. It shall have separate registers for recording KWh and KVARh consumption separately and also demands with automatic resetting at the end of the month.

c) The meter should be of 0.2 accuracy class.

d) The meter shall have legible LED / LCD minimum 6 digits auto cycle display. The meter shall have non-volatile memory requiring no battery back up.

e) The meter shall be capable of storing half an hour demand data and all other relevant data required for energy management for at least last 35 days.

f) The meter shall have a galvanically isolated optical communication port so that it can be easily connected to DCD (data collection device)/MRI (meter reading instrument).

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g) The meter shall have self diagnostic feature, to check its circuits for any malfunctioning.

h) The Parameters of display and printout of station meters shall be as follows.

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I PARAMETER FOR DISPLAY OF STATION METERS1. Time and date.

2. Anomaly indications

3. Cumulative consumption KW h a) Importb) Export

4. Cumulative consumption KV Ah a) Importb) Export

5. Hourly Consumption KW h a) Export 1)(Previous 3 Hours) 2)

3)6. Hourly consumption RKV Ah a) Export 1)

(Previous 3 Hours) 2)3)

7. Hourly consumption KVAh a) Export 1)(Previous 3 Hours) 2)

3)8. Daily consumption KVAh a) Export 1)

(Previous 3 days) 2)3)

9. Daily consumption RKVAh a) Export 1)(Previous 3 days) (Lag) 2)

3)(Lead) 1)

2)3)

10. Daily consumption KVAh a) Export 1)(Previous 3 days) (Lag) 2)

3)11. Monthly Consumption details KW h a) Export

(Previous month)

12. Monthly consumption details a) ExportRKV Ah (Previous Month)

13. Monthly Consumption details a) ExportKVAh ( previous Month)

14. Instataneous values a) Voltage R&B Phaseb) Current R&B Phasec) Frequencyd) Power factore) KWf) KVA

15. High Resolution a) Kwhb) KVAh

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II DETAILS OF PRINT OUT OF PARAMETERS FOR STATION METERS

1. Load survey at 30 Mintues interval a)KWh 1) Importfor 35 days (with first in and first 2) Exportout facility)

b)RKVAh 1) Export (Lag)c)RVAh 1) Export

(Lead)d) KVAH 1) Export

2. Daily Consumption details for 35 a)KWh 1) Exportdays (with first in and first out facility) b)RKVAh 1) Export

(Lag)c)RKVAh 1) Export


3. Monthly Consumption Details for 12 a)KWh 1) ExportMonths (with first in and first out Facility) b)RKVAh 1) Export

(Lag)c)RKVAh 1) Export


4. Meter Identification in respect of equipment to which it is metered.

5. Snap shot of instantaneous values.

6. Tamper details

9.6 PROTECTION RELAY'S

9.6.1 GENERAL,

The relays to be mounted in front of panels shall be three single pole, horizontally mounted, housed in a common case, electromagnetic, drawout type suitable for 50 Hz, 1 Amps CT secondary currents, 110V PT secondary phase to phase voltages and 220V DC auxiliary. All OCR, DOCR, EFR, DEFR shall have 3 seconds. IDMT characteristics. The current setting range in variable steps shall be as follows:

OCR/DOCR 50 TO 200 %

EFR 20 TO 80%

Instantaneous highest elements for relays outgoing panels only and shall be as follows:

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OCR/DOCR 400 TO 1600 %

EFR 100 TO 400%

Only OCR relays are required in the bus coupler panels. The relays shall be tropicalized and housed in dust, vermin, waterproof cases and with similar type covers. All relays flag indications shall be capable of being reset from the front of the panel without having to open out the relay covers. All wiring shall be done at the rear side of the relay cover. Suitable terminals with studs shall be provided at the rear of the relay cover all relays shall have a auxiliary contacts to facilitate remote indication and annunciation.

9.6.1.1 Tripping Relay:

Each panel shall be provided with high speed DC operated tripping relay. The relay shall have adequate number of normally open and normally close hand reset contacts to meet the requirement of scheme. The maximum operating time of the relay shall not exceed ten milliseconds and reset within 20 milliseconds.

9.6.1.2 Tripping Circuit Supervision Relay.

a) Each trip coil of circuit breaker shall be provided with an independent trip circuit supervision relay. These relays shall be mounted in the control panel associated with the circuit breakers.

b) These relays shall monitor the whole of the trip circuit while the breaker is in open or closed position and give an alarm for the loss of battery supply or for faults in the trip coil or for faults in the trip circuit such as leads, auxiliary contacts. The relay shall have a time delay on drop off of not less than 200 milliseconds and be provided with operation indication.

c) Trip supervision relay shall be located in the control panel.

9.6.1.3 DC Supply monitoring relay:

The relay shall be capable of monitoring the failure of DC supply to which it is connected. Separate DC supply monitoring relay shall be provided for DC main circuit, control circuit of tripping relay and protection circuit of each panel. It shall have adequate potential free contact to meet the scheme requirement. The relay shall have a time delay on drop off of not less than 100msecs and be provided with operation indicator/flag. Indicating lamp and separate alarm for DC fail shall be provided and shall be operated by 230V AC single phase supply. Push buttons for test and accept shall be provided.

9.6.2 SCHEDULE OF REQUIREMENTS OF RELAYS:

a) Over current relays with instantaneous elements 2 Nos. in each outgoing feeder panel.

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b) Over current relays without instantaneous elements 2 Nos. in each incomer panel.

c) Earth fault relays with instantaneous element - one No. in each outgoing feeder panel.

d) Earth fault relays without instantaneous element - one No. in each incomer panel.

e) Directional OCR-Three Nos. in each incomer panel.

f) Over current relays without instantaneous elements in each bus coupler.

g) Trip circuit supervision relay - One No. in each incomer, bus coupler and outgoing panel (This relay shall detect failure of DC in the breaker closed as well as in open position. A flag indication and auxiliary contact for audible annunciation shall be provided).

h) Master trip relay – One No. in each incomer, bus coupler & outgoing panel.i) DC supervision relay – One No. in each incomer, bus coupler & Outgoing

panel.

9.6.3 In addition to Electromechanical OCR/EFR relay provided in the Switchgear additional numerical OCR/EFR relay will be provided in the bay control IED panel by the Relay panel & Substation Automation supplier.

9.7 CONTROL SWITCHES:

9.7.1 GENERAL:

The Control switch shall contain two electrically independent double break contacts and shall be moulded in a self extinguishing plastic compound with inherent arc - quenching and high insulating property enclosed moulding giving a high degree of dust protection. The back of control switch is to be shrouded in transparent cover automatic spring return to neutral switch type to be provided. The switches shall be suitable for 20 Amps continuous rating and 110KV DC or 220KV DC as the case may be.

9.7.2 REQUIREMENT:

a. One No. in each outgoing / incomer and bus coupler panel.b. One No for each incomer/ outgoing breaker in the annunciator panel for

remote operation.

9.8 SELECTOR SWITCHES

9.8.1 GENERAL:

These shall be slow - break, quick make, rotary type, stay put switches, and shall. be suitable for flush mounting. These switches shall be suitable for being operated

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by flush mounting. These switches shall be suitable for being operated by a knob from the front face of the panel. They shall be suitable for 10 Amps continuous rating and 415 V AC.

9.8.1.1 a) Requirement of selector switch is one No. in eachoutgoing, incomer and bus coupler for local & SCADA selection.

b) VOID

9.9 INDICATION LAMPS:

9.9.1 Indicator lamps shall be integral LED module type 0.5 watts suitable for 110V or 220V DC and these shall be integral self contained LED indicator units which can be directly mounted in the panel. The rated in put voltage can be directly applied to the module input as all the controlling circuitry is built into the module body it self. These modules shall be suitable for panel cutouts of size 22.5 mm dia with the use of Crome plated standard mounting bezel / adopter sets and of colors, red, Green, Amber/ Yellow, white and blue. The axial light intensity should be min 40 milliCandella.

9.9.2 COLOUR CODE FOR LAMPS;

Breaker open - GreenBreaker closed - RedAuto trip - AmberSpring charged - Violet/ BlueTrip Circuit Healthy - White

9.9.3 REQUIREMENT LAMPS:

a. One set of green amber and red lamps in each incomer bus coupler and outgoing panels along with spring status violet, blue and trip circuit healthy white on command.

b. One set of green, red, amber violet / blue and white lamps for indicating the status of each incomer, bus coupler and outgoing breakers in the remote indoor annunciation panel.

9.9.4 10% of the total of integral LED module type lamps for each panel shall be supplied as spare without extra cost.

9.10 FUSES

9.10.1 GENERAL:

All fuses shall be moulded Bakelite complete with fuse bases, fuse carriage and HRC cartridge fuses. All fuse fittings should be labeled by etching on an anodized plate with details of the fuse rating and the circuit for which the fuse is provided.

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9.10.2

a. RATING:

i. AC 415 V for all supply fuses

ii. DC 110V / 220V as the case may be, for all DC supply fuses

b. Rated current: As per clause 5.3 of IS 9224 (part - I) 1979 (preferred value of rated current 32 Amps.)

9.10.3 REQUIREMENTS:

All AC and DC circuits shall be provided with suitable fuses and fuse links for each phase /pole.

9.10.4 10% of the H.R.C fuse cartridge shall be supplied as spares without Extra cost.

9.11 MIMIC DIAGRAM:

6 mm wide mimic bus shall be painted on each panel. The colour shall be signal Red, conforming to IS- 120-1962 shade No. 537. Mimic bus shall also be provided on the remote indoor control panel.

9.12 WIRING:

9.12.1 GENERAL:

The wiring shall be done by using PVC - insulated 660V annealed, stranded copper wire. The wires shall run straight and shall be given right angle bends wherever necessary so as to give a pleasing appearance. The size of wiring indifferent circuits shall not be less than the sizes specified below:

a. Metering and Relay circuits : 2.5 Sq. mm connection from CT's and VT's.

b. All terminal connections to the equipments and terminal blocks shall be done by using Tin coated copper lugs. All the outgoing wiring from the panel shall be terminated on the terminal block mounted in the front of the panel with suitable provision for connection to the interconnecting control cable. The wiring shall conform to IS 375 with latest amendments if any.

c. All wiring shall be provided with alphanumeric ferules at either ends as per the wiring schedule.

d. All terminals shall be nut and stub type of brass coated with Nickle of size M6.

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Note: Sufficient no. of terminals shall be provided for wiring of metering circuit & additional protection circuit to the Bay Control IED & Numerical relays.

9.13 a. TEST TERMINAL BLOCKS:

The test terminal blocks required are for testing while in service and shall be of the 3 phase 4 wire, front adjustable, link type, projected, mounted with screwed cover and wired at the rear, rated for 10 Amps. The wiring shall be so as to short circuit the CT phase to the star point and it shall be possible to calibrate through external injection.

b. For circuits, disconnecting type terminals shall be used to enable measurements of current.

9.14 a. PAINTING AND FINISHING:

The frame work and surface of the steel panels shall be sand blasted to remove rust and scales. The pre-painting procedures shall include cleaning, de-rusting, phosphating and priming of the panels in accordance with IS 6005 1970. The base channel shall be painted with Two coats of anti - corrosive black paints. The outdoor panel exterior and interiors shall be painted with Admiralty Grey Epoxy Paint conforming to shade No. 631 of IS - 5. However, pre-paintings procedures by chemical treatment are also acceptable.

b. Block No. shall be assigned for each compartment and the same shall be stencilised in white paint on the inside of panel.

9.15 TERMINAL PAD / CONNECTORS:

The terminal pads at cable termination points and CT junctions to have minimum two bolt connections in case of feeders nad 4 bolt connections in case of incomers.

9.16 FOUNDATION BOLTS:

Foundation bolts with 10% spares are in the scope of supply of the supplier.

9.17 AUXILARY DC SUPPLY:

For the switchgear will be arranged from station battery panel.

9.18 AUXILIARY AC:

Will be arranged from owner's panel.

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9.19 INDOOR TYPE COMBINED REMOTE -CONTROL AND ANNUNCIATOR PANEL.

a. General: Sloping desk type / free standing panel, with audio visual annunciator facia windows on the inclined slope along with annunciator lamp test, accept and reset push buttons. All control switches in the run of the mimic bus with indicating lamps mounted on the horizontal desk. The base of the desk shall be provided with vermin – proof sheet metal cover and cable gland, to receive the control cables from the outdoor panels. The annunciator shall be electromechanical. Paint shade of annunciator panel shall be No. 275 of IS : 5 i.e, opaline green

b. Wiring : All wiring from the outdoor panel shall be terminated on the terminal blocks inside the cubicle. The terminal block shall be Brass stud and nut type of size M6. The terminal blocks shall be of moulded resin type provided with plastic shrouds. Sufficient spare terminals shall be provided on the terminal blocks.

c. Annunciation facia windows - shall be with plastic facia sheet engraved with letters of 5mm size. The inscriptions shall be visible only when the facia is lighted. The lamps shall be suitable for 110V / 220V DC with an in-built resistor. The initiation of annunciation shall be through NO-NC contacts of the relay.

A hooter suitable for 110V / 220V DC shall be installed in the annunciator panel for alarms.

d. Requirement and engraving in the annunciator desk

A. OUTGOING PANELS.

i. No. of windows 5OCR R Phase operated 1 |OCR B Phase operated 1 |Trip alarmEFR operated 1 |

DC fuse failure 1 > Non tripNo. of windows spare 1Trip Circuit supervision 1Indication lamp

ii. Breaker open indication lamp 1

iii. Breaker close indication lamp 1

iv. Spring free / chargedindication lamp 2

v. Breaker auto trip indication lamp 1vi. Trip / Neutral /Close switch 1

B. INCOMER PANEL:

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i. No. of windows 10OCR R Phase operated 1 |OCR B Phase operated 1 |EFR operated 1 | DOCR R phase operated 1 | Trip alarmDOCR Y phase operated 1 |DOCR B phase operated 1 |

DC fuse failure 1 > Non trip alarmNo. of windows spare 2Trip Circuit supervision 1 Non trip alarm

ii. Breaker open indication lamp 1iii. Breaker close indication lamp 1

iv. Spring free / chargedindication lamps 2

v. Breaker auto trip indication lamp 1

vi. Trip / Neutral /Close switch 1

C. BUS COUPLER PANEL:

i. Breaker open indication lamp 1

ii. Breaker close indication lamp 1

iii. Spring free / chargedindication lamp 2

iv. Breaker auto trip indication lamp 1

v. Trip / Neutral /Close switch 1Trip circuit healthy indication lamp 1

vi. FaciaNo. of windows 5OCR 'R' Ph- 1 |OCR 'Y' Ph- 1 |Trip alarmOCR 'B' Ph- 1 |Spare windows 2

10.0 TESTS

10.1 TESTS ON SWITCH GEAR:

10.1.1 Type Tests as per clause 8. 1. 1 - (a) to (e) and (h) and j) of IS : 3427 -1969.

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10.1.2 Routine tests - as per clause 8.12 - (1), (b)) & (e) of IS-3427-1969.

10.2 TESTS ON CIRCUIT BREAKERS:

10-2.1 Type tests as per clause 6.0 of IS 13118.

10.2.2 Routine test - as per clause 7.0 of IS 13118.

10.3 TEST ON CURRENT TRANSFORMERS

10.3.1 Type test : As per clause 7. 1. 1 (a) to (h) of IS 2705 (Part- 1) 1981, clause 8.1 of IS-2705 (Part-II). 1981, clause 8.2 of IS : 2705 (Part - III)-1981, clause 8.3 of IS-2705 (Part-Ill)-1981 and clause 6 of IS 2705 (Part -IV).

10.4 TEST ON VOLTAGE TRANSFORMERS;

10.4.1 Type tests: As per clause 6. 1. 1 of IS 3156 (Part -I)- 1978, clause 8.1 of IS 3156 (part-II), 1978 and clause 9.1 of IS 3156 (Part - III) - 1978.

10.4.2 Routine Tests : As per clause 8.1.2 of IS 3156 (part - 1)-1978,clause 8.2 of IS 3156 (Part-11), 1978 and clause 9.2 of IS : 3156 (part - III) - 1978.

10.5 TESTS ON RELAYS:

10.5.1 Type tests and routine tests as per IS. 3231 and IEC 255.

10.6 GENERAL:

10.6.1 TYPE TESTS:

The tests reports of all the tests as stipulated in IS 3427 and other tests conducted shall be supplied. Three copies of the test certificates of the type tests shall be furnished along with the bid without which the offer is liable to be overlooked. Further, type test certificates furnished shall pertain to tests carried out not older than 5 years from the date of notification of the bid. It is left to the discretion of the owner to waive the type tests and to accept the type test certificates finished along with bids.

10.6.2 All routine tests shall be carried out in the presence of owner's representative for which the contracts shall give sufficient advance intimation.

10.6.3 All rests certificates shall be duly approved by the owners without which no dispatches can be effected.

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11.0 Marking and name plates:

11.1.0 As per clause 7.1 of IS 3427-1969.

11.2.0 The above markings shall be in addition to the individual nameplates at their rear and shall be supplied separately as disassembled components.

11.3.0 All instruments, relay and other components shall be provided with nameplates at their rear and shall be supplied separately as disassembled components.

12.0 DOCUMENTS AND DRAWINGS:

12.1 BID DOCUMENTS:

The following drawings, literature and test certificates in duplicate shall accompany the bid.

a. Principal layout drawings for the switchgear panels and indoor annunciator panel.

b. Dimensional arrangements of the switch board in accordance with arrangements proposed by the owner as per clause 5.0 of this specification.

c. Front and rear views of the switch board and annunciator panel with instrument and device positions marked.

d. Pictorial view of the control switches, terminal blocks, indicating instruments, test blocks and exploded views of drawout type instruments etc.,

e. Cross-section drawing of incomer, bus coupler and out going panels indicating bus bar clearances and risers in between phase to ground.

f. Schematic and wiring diagrams for the various circuits.

g. Illustrative descriptive, literature, general technical data and specification of all devices and components.

h. Type and Routine test certificates.

12.2 CONTRACT DRAWINGS:

12.2.1 The contractor shall submit the following contract drawings in triplicate for approval by the owner within 3 weeks from the date of order. The owner will convey approval to the drawings after the receipt of contract drawing.

12.2.2 CONTRACT DRAWINGS FOR APPROVAL:

a) i) Drawings under item No. 12.1.1(a), (b), (c) and (f)mentioned above.

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ii) Foundation drawings indicating the details of foundation, foundation bolts, cable entries and trenches etc.

b) Cabling and wiring diagram of the switchgear and annunciator panel. Ferrule numbers, device numbers, grouping of cables etc., shall be distinctly shown.

c) Inter-connection diagram between switchgear panel and indoor annunciator panel.

d) Elementary diagrams of all controls, metering, protection, annunciations and other circuits panel wise. All devices shall be numbered as ASA code.

e) Individual internal wiring diagram of the devices, test blocks, terminal blocks etc.

f) Construction details of the switches, terminal blocks and test blocks.

12.3.0 DESPATCHE DRAWINGS:

12.3.1 Four copies of the approved drawings and detailed literature shall be directly sent to the consignees.

12.3.2 Four copies of the approved drawings and detailed literature shall be submitted to the Chief Engineer Electy., T&P, KPTCL, Bangalore.

13.0 Requirements of relays, meters, lamps etc., in each switchgear panel.

13.1 INCOMER PANELSl No.

1250 A panels 800 A panels Quantity

1 Ammeter 0-800-1200 A 0-400-800 A 1 No.

2 Voltmeter 0 to 15 KV 0 to 15 KV 1 No.3 MW Meter 0-12-24 MW 0-8-16 MW 1 No.4 VAR Meter 0 to 15 MVAR 0 to 20 MVAR 1 No.5 Electronic

trivectormeterAccuracy Class 0.2

Accuracy Class 0.2

1 No.

13.1.2 Common for each 1250A & 800A Panels

a. Over current - relay -electromechanical -2 Nos.(without instantaneous elements)

b. Earth fault relay without inst. Element-(EM) - 1 No,

c. Directional over current relay (EM) - 3 Nos.

d. Trip circuit supervision relay - 1 No.

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e. Master trip relay -1 No.

f. DC Supervision relay -1 No.

13.1.3 Common for 1250A & 800A panels

a. Control switch for breaker - 1 No.b. Selector Switch Local/Remote/SCADAc. VOIDd. VOIDe. Fuses, terminal blocks and test terminal blocks. - As required.

13.2 OUTGOING PANEL:

13.2.1

Sl No.

1250 A panels 800 A panels Quantity

1 Ammeter 0-200-400 A 0-100-200 A 1 No.2 MW Meter 0-4-8 MW 0-2-4 MW 1 No.3 Electronic

trivectormeterAccuracy Class 0.2

Accuracy Class 0.2

1 No.

13.2.2 Common for each 1250A & 800A Panels.

a. Over current - relay -electromechanical -1 No.(with instantaneous elements)

b. Earth fault relay with inst. Element-(EM) - 1 No.

c. Trip circuit supervision relay - 1 No.

d. Master Trip relay -1 No.

e. DC Supervision relay -1 No.

13.2.3 Common for each 1250A & 80OPanels

a. Control switch for breaker - 1 No.b. Selector Switch – Local/Remote/SCADAc. VOIDd. VOID

13.3 BUSCOUPLER PANEL COMMON FOR BOTH 1250A & 800A

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PANELS

a. Ammeter (0-1000-2000A or 0-400-800A as the case may be) - 1 No.

b. Over current relay (electromechanical)(without instantaneous element) - 3 Nos.

c. Trip circuit supervision relay - 1 No.

d. Master trip relay - 1 No.

e. DC Supervision relay - 1 No.

f. Control switch for breaker - 1 No.

g. Selector Switch – Local/Remote/SCADA- 1 No.

h. Indicating lamps Green, Red, Amber - 1 No. eachBlue, white

i. Fuses, terminal blocks & test terminal blocks - As required

13.4 INDOOR COMBINED ANNUNCIATOR AND REMOTE CONTROLPANELS

a. Control switch - One No. for each breaker

b. Indicating lamps - One set of the following for each breakeri) Greenii) Rediii) Amberiv) Violet/ Bluev) Whitevi) Yellow

c. Annunciator windows - as per clause 9.19

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d. Fuse - As Required

e. Bell - I No.

f. Hooter - 1 No.

g. Push button

i. Accept 1 No.ii, Reset 1 No.iii. Lamp test 1 No.iv. Hooter test 1 No.

h. Electro-mechanical annunciator relay - As required

13.5 MISCELLANEOUS:

a. A ramp or trolley shall be supplied two per set of switchgear panels for easy withdraw and insertion of the breaker truck.

b. One set of test jacks for testing the breaker in the breaker withdraw position.

c. One set of relay test jacks with accessories.

14.0 The schedule of requirement is as per Annexure enclosed.

15.0 SPARES

a. Bank CTs. 1 No.b. Closing Coil 2 No.C. Trip coil 2 Nos.

16.0 SCHEDULES:

The tenderer shall fill in the following schedule which form a part of the tender specification and offer. If the schedules are not furnished duly filled in with the offer, the offer shall be liable for rejection.

Schedule ‘A’ - Prices and DeliverySchedule ‘B’ - Guaranteed Technical Particulars.Schedule ‘C’ - Schedule of Deviations.Schedule ‘D’ - Tenderer’s experience.

17.0 DEVIATION FROM TECHNICAL SPECIFICATION:

The Tenderer shall furnish the details of deviation/ modification proposed by him to improve overall performance of the system. The deviation shall be brought in the tender clause by clause as per annexure.,

18.0 PERFORMANCE GUARANTEE:

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The equipment offered shall be guaranteed for satisfactory performances for a period of 18 months from the date of satisfactory commissioning of equipment. The equipment found defective/failed within the above guarantee period shall be replaced or repaired by the supplier free of cost within one month from receipt of intimation. If the defective/failed transformers are not replaced/repaired as per the above guarantee clause, the KPTCL shall recover an equivalent amount plus 15% supervision charges from any of the supplier’s bills.

19.0 MINIMUM EXPERIENCE FOR QUALIFYING AS BIDDER:The bidders shall have a minimum experience of five years in the design, manufacture, testing and commissioning of 11KV Metal clad Switch gear similar to the type specified in the present enquiry. At least 50% of the quantity of similar type of 11KV Metal clad Switch gear called for in the present enquiry shall be in successful operation for a minimum period of two years. The tenderer shall also furnish the details of similar 11KV Metal clad switch gear supplied by them so far giving order reference, name and address of the customer etc., also indicating the period of commissioning. The tenderer shall also furnish performance certificates for a period of minimum two years of similar 11KV Metal clad Switch gear in proof of the satisfactory operation of 11KV Metal clad Switch gear.

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SCHEDULE – B

GUARANTEED TECHNICAL PARTICULARS OF I I KV SWITCHGEARCOMPONENTS

I AMMETERS:

1. Type of Instrument

2. Size

3. Whether magnetically shielded or not

4. Scale length & range

5. Whether tropicalised

6. Short time overload capacity

7. VA burden current coil

8. Power consumption of current coil

9. ISS grade of accuracy

10. Description leaflet

11. Temperature at which instrument calibrated

II VOLTMETER

1 . Type of instrument

2. Size


4. Scale length and range



7. VA burden of potential coil

8. Power consumption of potential coil

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10, Description leaflet

11. Temperature at which instrument calibrated.

III MW METER

1. Type of instrument

2. Size






8. VA burden - potential coil

9. Power consumption

i) Current coil

ii) Potential coil

10. Temperaturr, at which instrument calibrated.



IV VARMETER

1. Type of instrument

2. Size




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7. VA burden - potential coil

8. Power consumption

i) Current coil

ii) Potential coil

10. Temperature at which instrument calibrated.



V ELECTRONIC TRIVECTOR METER

1 . Type & Rating

2. Size

3. Whether Magnetically shielded are not

4. Whether troplicalised

5. Rated VA burden - current coil

- Potential coil

6. Continuous over load rating - current coil

- Potential coil

7. Accuracy class and grade

8. Adjustments provided

9. Limits of error at UPF and at 125%,

25% and 10% of rated current

10. Limits of error 0.5 PF and at 125%,

25% and 10% of rated current

11. Type of Registering Mechanism

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12. Display sequence

13. Details of display

a. Parameters that can be measured Refer Cl. 9.5.6 E

1). Details of print out parameters

14. Whether the meter can be used to

get demand details

15. Whether optical readout facility provided.

16. Whether detailed literatures enclosed

17. Additional features provided

VI ANNUNCIATOR :

1. a. Type & particulars of windowsb. Whether the annunciator is electro mechanical type yes/ No

1. Particulars of wiring

2. Rated voltage

3. Power Consumption

4. Instantaneous making capacity of contacts.

5. Breaking capacity

6. Overall. dimensions of annunciator group

7. Descriptive leaflet of schematic diagram.

VII (A) GENERAL PROTECTION RELAY

I The tenderer shall furnish guaranteed Technical particulars for all types of meters offered, in the following proforma (separate sheet shall be enclosed for each type of relay :)

1 Manufacturer's name or trade marks2 Type designation3 Size and mounting details (whether in draw out case)4 Rated Values of both input and auxiliary energizing

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quantities5 Values of the limits of the operative range(s) of the

auxiliary energising quantity (ies)6 Contacts data, Number and rating of main and auxiliary

contacts7 Rated value or setting range of the characteristic

quantities and or angle8 Limiting short-time thermal withstand values9 Limiting dynamic values.10 i. Burden data ( in case of poly input relays - data shall

be furnished for appropriate set of input terminals).

a. At highest tap - AC current / voltage coil

b. At lowest tap - AC current / voltage (coil) ii. DC power consumption.

11 Impulse and dielectric test voltage(s)12 Details of accessories (If essential to the relay

performance)13 Details of accessories (Optional items)14 Whether provided with seal in trip contacts

15 a. Type of operating characteristics b. Accuracy of operating characteristics, operating time

with details16 H.F. disturbance test voltage (s)17 Whether literature enclosed18 Type of relay flag indicator and rating of target coil

VII (B) PROTECTIVE RELAYS

1. Non- directional IDMT/Inst. OCR/ EFR Relays.

a) Type

b) Current coil rating

c) VA burden

1) Highest tap

2) Lowest tap.

d) Tap range

e) Power consumption

1) Highest tap

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2) Lowest tap

f) Time of operation at maximum dial Setting at:

1) 5 times tap setting current


g) Type of characteristics

h) Whether drawout type or not

i) Trip contact rating amps.

j). Whether seal in contacts provided or not.

2. DIRECTIONAL OVER CURRENT RELAY

a) Type

b) Current coil rating

c) VA burden

i. Highest tap

ii. Lowest tap.

d) Tap range

e) Power consumption

1) Highest tap

2) Lowest tap

f) Time of operation at maximum dial Setting at:



g) Type of characteristics

h) Whether draw out type or not

i) Trip contact rating amps.

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j) Whether seal in contacts provided or not.

k) Minimum voltage at which relay operates

VIII CIRCUIT BREAKER:

1. RATING

a. No. of poles

b, Rated voltage

c. Rated normal current

d. Rated frequency

e. Making capacity in peak kA

f. Breaking capacity :

i) Symmetrical in KA and MVA

i) Assymmetrical

ii) The maximum Capacity of theCapacitor bank for whichthe breaker is designed to open

g. Short time current in kA

h, Operating duty

2. DETAILS OF SHORT CIRCUIT

TYPE TEST CERTIFICATES

3. CONSTRUCTIONAL PARTICULARS:

a. No. of breaks in series per pole

b. Total length of breaks per pole

c. Type of main contacts

d. Type of arcing contacts

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e. Type arc control device

f. Min. clearance in air

a. Between live partsb. Between live parts and earth

g. minimum clearance in VCB

h. Mechanical endurancei. Electrical endurance

j. Method of closing mechanism

i) Type of operating mechanism

ii) Whether hand or power or both

iii) Whether the circuit breaker is designed to close and latch onmaking or is fitted with a makingcurrent release.

iv) Whether the circuit breaker istrip free.

v) Time required to charge the spring.

vi) Details of spring charging motor powerrequired at designed normal voltage

k. Normal voltage of shunt trip coil

l. Power required at normal voltage in VA

4. OPERATING PARTICULARS

a. Opening time

a) With no current

b) At rated breaking current

b. Closing arc duration at

a) 10% SC breaking currentb) 60% SC breaking current

C) 80% SC breaking current

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d) 100% SC breaking current

C. Speed of Break at -

a) 10% SC breaking current

b) 60% SC breaking current

c) 80% SC breaking current

d) 100% SC breaking current

IX CURRENT TRANSFORMER:

a) Make

b) Type

C) Ratio

d) Burden

e) Accuracy class as per ISS

x POTENTIAL TRANSFORMERS

a) Make

b) Type

c) Ratio

d) Burden

e) Accuracy class

XI AUXILARY TRANSFORMER

a) Make

b) Type

C) Ratio

d) Details of OFF load taps

XII BUSBARS:

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1. size

2. Material

3. Whether insulated

4. Make/ type of busbar insulator

5. Creepage distance of busbar insulator

6. Clearance between phase to phase }}For main bus bars / risers/

7. Clearance between phase to earth. } connectors / ties.

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Schedule –C

SCHEDULE OF

DEVIATIONS FROM SPECIFICATION

All deviation from this specification, shall be set out by the bidder, clause by clause, in this schedule, unless specifically mentioned in this schedule the bidder shall be deemed to conform to the owner’s specification.

Sl. Details of deviationNo. Clause No. with justification

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SCHEDULE - DSchedule of Tenderer’s Experience

1. Name of the Manufacturer :

2. Standing of the Firm as manufacturer of

Equipment:

3. Testing Facility at manufacturer’s work. :

4. If the Manufacturer is having collaboration With

another Firm, details regarding standing of

parent Firm, Period of collaboration

:

5. Description of equipment similar to that quoted,

supplied and installed during the last 3 years

with names of parties to whom the supplies are

made along with the names of persons to whom

a reference may be made by purchaser in case

the considers such a reference necessary

:Shall be furnished in the

Form indicated below

Sl. No.

Description Value of Work

Place Where

installed

Period of Execution

& date

Client Persons to whom reference can be

made(a) (b) (c) (d) (e) (g) (h)

Signature :…………………………

Designation:……………………….

Company:………………………….

Date :………………………………

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SECTION-14.0TECHNICAL SPECFICATION

CAPACITOR BANKS

Please refer the Technical Specifications for Capacitor Banks uploaded separately

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11KV SPECIAL GOS

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VOLUME-IIA

TECHNICAL SPECIFICATIONSection 15.0 –11 KV Special GOS

Clause No. Particualrs1.0 Scope2.0 Switches3.0 Construction 4.0 Testing and Test Certificates5.0 Other Details

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VOLUME IIASECTION 15.0 - 11 KV SPECIAL GOS

TECHNICAL SPECIFICATION FOR 11 KV, 400 A, SPECIAL (ROSTERING)G.O.S FOR RURAL LOADS

1.0 SCOPE:

This specification covers the manufacture, testing at manufacture's work and supply of 11 KV switches of single break- 400 Amps capacity complete with accessories such as operating pipes, connecting pipes and guides, supporting insulators, link work and locking arrangements etc., complete

The equipment offered shall conform to IS 1818 : 1972 and latest amendments these of eof. The switches shall be suitable for horizontal upright mounting.

3.0 CONSTRUCTION

The base shall be made of robust rolled M.S channel section of size 75 x 40 mm. All ferrous parts shall be hot dip galvanised and all copper parts shall be tinned. The rotating parts shall be fitted with suitable bearing.

3.1 The blades and contacts- shall be of best quality electrolytic copper and shall be capable of carrying rated current of 400 A without exceeding the temperature limits specified in IS 1818 - 1972.

3.2 a) The insulators shall be of post type brown glazed porcelain stacking, type design E.22 as per IS 5350 (part- 111) 1971 with capscrews and spring washers and to technical specification enclosed conforniing to IS – 2544 ,1973 with amendments thereof.

b. The operating pipes shall be of 25 mm dia "B" CLASS G I. Pipes. The GIPipes used Shall conform to IS 1239 part- I 3rnm thick 1979 with amendment of January ' 81 and any further amendment thereof The operating mechanism shall be as shown in the drawing,

c Bimetallic P.G. clamps suitable for terminating ACSR conductors shall be provided.

d. All the parts shall be hot dip galvanised and shall conform to the following ISS.

IS 200 - 1960 for quality of Zinc for galvanisation.

IS - 2620 - 1960 for hot dip galvanisation of iron and steel.iu . IS-2633-1972 testing of Zinc coating on galvanised parts.

iv. IS 6759- 1966 hot dip %zalvanised coating on structural steel.

v IS 5358 - 1960 hot dip galvanised coating on fasteners.

vi IS 6745 - 1972 determination of welizzlit of 21ric coating on galvanised iron and steel parts (With amendments No. 1) with latest amendments there of if any to the above.

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3.3 ARCING HORNS

The switches shall be supplied with hot dip galvanised arcing horns so that while not closing or opening the switches arcing takes place between the arcing horns and between the main contacts.

3.4 LOCKING ARRANGEMENTS:

Suitable locking arrangements shall be provided for the operating handle. The locking devices shall be supplied with duplicate keys along with the switches.

3.5 The switches shall be designed to withstand the test voltage as per IS 1818. 1972 or its latest revision thereof. The switches shall be designed to have a continuous current capacity of 400A

4.0 TESTING AND TEST CERTIFICATES:

4.1 ROUTINE TESTS -.

The routine tests as per IS 1818 1972 shall be conducted on each switch

TYPE TESTS

The following type tests on one switch specified in the IS 1818 1972- shall be conducted in a recognised laboratory, and the test certificate along with the drawing attested by the concerned laboratory shall be submitted.

1. Impulse voltage dry test as per clause 11-1-3 IS 1818/1972

2. Power frequency voltage dry test as perclause 11 .1 .4

3. Power frequency voltage wet 11 - 1 .5

4. Temperature rise test as per clause 11.1.7. 1

5. Measurements of resistance as per clause 11.1.8

6. Test for rated per short Circuit current as per clause

7. Operation test as per clause 11.1.11

8. Mechanical endurance test as per clause 11. 1. 12

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4.4 NAME PLATE

The switch assembly shall be provided with the name plate legibly and indelibly marked with the following information.

a) Name of materialb) Name of manufactuer and trade mark.c) Name of the purchaser the letters K. P. T.C.d) Purchase order number and date.e) Type - desimiation and serial number0 Rated current.9) Rated voltageh) IS specification

5.0 All other details as per enclosed drawing.

6. Creeping distance 230 mm

7. Failing load as per IS 5350 part ITU1971

a) Upright 9000 Nb) Underhung 4500 Nc) Tension 20,000 Nd) Compression 40.000 Ne) Torsion 680 NM

8 Height of insulator (Min) 254 mm

9. Insulating pan dia 202 mm

10. Top metal fitting pitch 57 mmcircle dia

11. Bottom metal fitting pitch 57 mincircle dia

12. a) No. of bolts 4 Nos.

b) Bolts holes dia 10 mm tapped holes at the top 12 plain holes atthe bottom.

c) Nominal dia ofmounting face not to exceed 85 mm

3.0 MARKING:

Each insulator shall be legibly and indelible marked with the following:

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a) Name or trade mark of the manufactureb) Month and year of manufacturec) Country of manufactured) ISI certificate mark if anye) Letter " K-PT C"

Marking shall be durable and shall be painted by the transfer process before fining.

NOTE:Manufacturer's test certificate and type test certificate conducted on similar sample insulator shall be submitted.

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SECTION –16.0


TESTING & COMISSIONING

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Section 16.0 - Testing and Commissioning


1.0 General2.0 Other checks3.0 PowerTransformers4.0 Circuit Breakers-Pre commissioning checks5.0 Disconnects- Pre commissioning checks6.0 Current Transformer Pre Commissioning Checks

Voltage Transformers - Pre Commissioning Checks9.0 Station Earthing10.0 Drake ACSR Stringing Work, Tubular Bus Work and

Power Connectors:11.0 Aluminium Tube Welding12.0 Insulators13.0 Cables14.0 Motor15.0 Commissioning Check List for Control & Relay Panels16.0 Commissioning Check List for RelaysITO Commissioning Check List for Meters18.0 Other Equipments: Battery & Battery Charger, 415V, L.T.

A.C. Panels, Diesel Generator, Distribution Transformers19.0 Commissioning Check List for Electrical Installation

General

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VOLUME IIA

SECTION 16.0 - TESTING & COMMISSIONING

TESTING AND COMMISSIONING PROCEDURES

1.0 GENERAL:

1.1 The contractor shall submit a field quality plan consisting of following:

a) Receipt, storage, pre-erection inspection of all materials in the scope of contractor

b) Structural work erection

c) Civil works

d) Welding procedure for aluminium pipe bus and earth mat system.

e) Cabling

f) Pre-commissioning tests.

g) Commissioning.

1.2 An indicative list of pre-commissioning and commissioning is given below. Contractor shall perform any additional test based on specialties of the items asper the field Q.P. /instructions of the equipment supplier or owner without any extra cost to the owner. The contractor shall arrange all instruments requiredfor -conducting these tests along with calibration certificates and shall furnish the list of instruments to the owner for approval.

2.0 GENERAL CHECKS:

2.1 Check for physical damage.

2.2 Visual examination of zinc coatings/ plating

2.3 Check from nameplate that ail items are as per order/ specification

2.4 Check tightness of all bolts, clamps and connecting terminals using torque wrenches.

2.5 For oil filled equipment check for oil leakage, if any.Also check oil level and top up wherever necessary.

2.6 Check ground connections for quality of weld and application of zinc rich paint over weld joint of galvanised suxfaces.

2.7 Check cleanliness of insulator and bushings.

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2.8 All checks and tests specified by the manufacturer in the drawings and manuals as well as all tests specified

2.9 Check for surface finish of grading rings (corona. control rings).

2.10 Pressure tests on all pneumatic lines at 1.5 times the rated pressure shall be conducted.

2.11 Proper lubrication of all moving parts.

2.12 Check space heaters.

3.0 POWER TRANSFORMER

3.1.0 PRE-COMMISSIONING TESTS:

3.1.1 Drying out by using streamline oil filter, vacuum pump, centrifuge and heater set.

3.1.2 Dielectric strength of oil both main and OLTC chamber.

3.1.3 Insulation resistance of windings.

3.1.4 Checking of phase sequence test.

3.1.5 Continuity test.

3.1.6 No load voltage ratio, at all tap positions.

3.1.7 Checking of vector group, polarity and miter phase connections.

3.1.8 Tap changer operation check (Mechanical & Electrical local, remote, group and solo) including indication and alarm circuits.

3. 1. 9 Magnetizing current check at 415V, 3-Phase, 50 cycles supply for all the three phases.

3.1.10 Measurement of winding resistance.

3.1.11 Breather (check, for silica gel)

3.1.12 Buchholtz's relay operation.

3.1.13 Low oil level for main tank/OLTC chamber.

3.1.14 Physical line connections as per phasing diagram.

3.1.15 Natural connection to earth effectivity.

3.1-15.1 Calibration of different temperature indicators, relays, switches.

3.1.16 Cooler control operational check both from local and remote.

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3.1.17 Check all fans and oil pumps.

3.1.18 COMMISSIONING:

After obtaining approval from the purchaser and supplier the contractor shall proceed to commission the transformer.

3.2.0 GENERAL CHECKS TO BE DONE BEFOPE/AFTERCOMMISSIONING

3.2.1 All off valves are in correct positions, closed or opened as required.

3.2.2 All air pockets are filled with oil.

3.2.3 Thermometer pockets are filled with oil.

3.2.4 Oil is at correct levels in the bushings, conservator, diverter switch tank; etc.

3.2.5 Earthing connects are done.

3.2.6 The condition of silica gel in the breathers.

3.2.7 Arcing horn gaps on bushings are properly adjusted.

3.2.8 Heaters in cubicles, conservator etc., where provided should be checked.

3.2.9 Any other alarm / trip contacts of flow meters differential pressure gauges etc.

3.3.0 If all t1ie above tests/checks are found satisfactory, a time of at least 24 hours for setting of oil shall be allowed and air released from all points. Thetransformer shall be energized after setting the protective relays to the minimum extent possible. Wherever possible the voltage shall be built up in steps. Any abnormality during commissioning such as vibration of radiator parts, hum etc., should be observed. After a few hours of energisation at no load, the transformer shall be switched off. The Buchholtz relay should be checked for collection of air/ clyas. Abnormalities noticed shall be corrected. All protective relavs should be reset to normal values. Transformer shall be reenergised and loaded gradually.

After commission the contractor shall fu the test results and all relevant details, drawings of erection testing and commissioning of the Purchaser all properly bound With plastic jackets.

4.0 CIRCUIT BREAKER - PRE COMMISSIONING CHECKS:

4.1 Insulation resistance of each pole.

4.2 Check adjustments, if any, suggested by manufacturer.

4.3 Breaker closing and tripping time, pole discrepancy etc.

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4.4 Slow and power closing operation and opening.

4.5 Minimum pick up voltages of trip and close coils.

4.6 Contact resistance.

4.7 Functional checking of compressed air plant and all accessories including adequacy of the air receiving for design set of operations.

4.8 Functional checking of control circuits, interlocks, tripping through protective relaysand reclose operation.

4.9 Insulation resistances of control circuits, motor, etc.

4.10 Resisting of closing and tripping coils.

4.11 Check on simultaneous closing of all three poles, three- phase/single phase auto reclosures.

4.12 Blocking of operation at low pressure.

4.13 Checking of electrical & mechanical interlocks.

5.0 DISCONNSECTS - PRE COMMISSIONING CHECKS:

5.1 Insulation resistance of each pole.

5.2 Manual and electrical operation and interlocks.

5.3 Insulation resistance of control circuits and motors.

5.4 Ground connections of structures & operating handle.

5.5 Contact resistance 'of each pole per gap between male and female contacts.

5.6 Proper alignment so as to minimise to the extend possible the vibration during operation.

5.7 Measurement of operating Torque for Isolator and Earth switch.

5.8 Resistance of operating and interlocking coils.

5.9 Manual and Electrical -interlocks.

5.10 Clearances in op.-In & closed operations.

6.0 CURRENT TRANSFORMER - PRE COMMISSIONING CHECKS:

6.1 Insulating Resistance test.

6.2 Polarity test.

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6.3 Ratio identification test - checkng of all ratios on all cores by primary injection of current.

6.4 Dielectric test of oil (wherever applicable).

6.5 Magnetising characteristics test.

6.6 Checkng of earth connection at only one point.

6.7 Shorting of spare C.T. cores.

6.8 Dielectric tests (wherever applicable).

6.9 Checking gas pressure wherever required.

7.0 VOIAPAGE TRANSFORMERS - PRE COMMISSIONING CHECKS

7.1 Insulation Resistance Test

7.2 Polarity test oil all windings

7.3 Patio test of all windings

7.4 Dielectric test of oil (wherever applicable)

7.5 Open delta test with low voltage (wherever applicable)

7.6 Capacitance and tan delta measurement.

7.7 Checking gas pressure measurement where required.

8.0 LIGHTNING ARRESTOR.

8.1 Grading leak-age current

8.2 Resistance of ground connection.

9.0 STATION EARTHING:

9-1 Check oil resistivity

9.2 Check continuity of grid wires

9.13 Check earth resistance of the entire grid as well as various sections of the same.

9.4 Check for weld joint and application of zinc rich paint on galvanised surfaces.

9.5 Dip test on earth conductor prior to use.

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10.0 DRAKE ACSR STRINGING WORK TUBULAR BUSWORK AND POWER CONNECTORS:

10.1 Physical check for finish

10.2 Electrical clearance check

10.3 Testing of torque wrenches on all bus bar powerconnectors and other accessories.

10.4 Millivolt drop test on all power connectors.

10. 0 Sag and tension check on conductors.

11.0 ALUMINIUM TUBE WELDING:

11.1 Physical check

11.2 Millivolt drop test on all joints.

11.3 Die penetration test/Radiography test on 10% samplebasis on weld joints.

11.4 Test check on 5% sample Joints after cutting the weld piece to observe any voids, etc.

12.0 INSULATORS:

12.1 Visual examination for finish damage, creepage distance etc.

13.0 CABLES:

13.1.0 PRELIMINARY CHECKS:

13.1.1 Check details as per specification-

13.1.2 Check for physical damage.

13.2.0 COMMISSIONING CHECKS:

13.2.1 Megger test between each core & armour/sheath.

13.2.2 Continuity check.

13.2.3 Connections.

13.2.4 And all other checks as specified by equipment manufacturers/ Engineer.

14.0 MOTOR

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14.1.1 Check name plate details according to specification.

14.1.2 Check tightness of all bolts, clamps and connecting terminals.

14.1.3 Check ground connections.

14.1.4 Bearing lubrication.

14.1.5 Check clearance inside terminal box.


14.2.1 Megger testing of motor vymidings and cables.

14.2.2 Motor Widings, control and power cables continuity check.

14.2.3 Resistance of motor windings in case of large motors.

14.2.4 Control and interlocks.

14.2.5 Overload and short circuit relay tests and settings.

14.2.6 Phase sequence and rotation.

14.2.7 Operating of timer in case of star-delta starting.

14.2.8 Starting and no load current.

14.2.9 No. of load operation (observe vibrations, temperatures of bearings and body of the motor)

14.2.10 On load operation, starting and running currents (observe vibrations, temperatures of bearings and body).

14.2.11 In case of close loop arrangement for cooling the windings of the motor, inlet and outlet temperature of the cooling air.

14.2.12 And all other checks as specified by equipment manufacturers/ Engineer.

15.0 COMMISSIONING CHECK LIST FOR CONTROLS:

RELAY PANELS:


15.1.1 Check name plate details of every associated equipment according to specifications

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15.1.2 Check for physical. dam age of various meter and relays.

15.1-3 Check tightness of all bolts and nuts and wiring terminals.

15.1.4 Check earthing


15.2.1 Switch developments.

15.2.2 Each vaire shall be traced by continuity tests and it should be made sure that the wiring is as per relevant drawings. All inter connections between panels/ equipment shall be similarly checked.

15.2.3 All the wining shall be meggered.

15.2.4 Checks on relays.

15.2.5 Checks on meters.

15.2.6 Settings of relays, other alarm, tripping de ice, and inter locks as per schemes.

15.2.7 Phase angle checks - Measurement of magnitude and phase angle of current transformer secondary currents and potential transformer secondary voltages.

15.2.8 Punctional checking of all control circuitry - viz., closing, tripping, control, inter lock, supervision and alarm circuits including proper functioning of thecomponent equipment.

16.0 COMMISSIONING CHECK LIST FOR RELAYS:

16. Check name plate details according, To specifications.

16.2 Check for any physical damage.

16.3 Check internal wiring

16.4 MEGGER:a) All terminals to body.b) A.C. to D.C. terminals.

16.5 Check operating characteristics by secondary injection.

16.6 Check minimum pick up voltage of D.C. coils.

16.7 Check operation of electrical mechanical targets.

16.8 Relay settings.

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16.9 Check C.T. and V.T. connections, with particular reference to their polarities for directional distance type relays.

17.0 COMMISSIONING CHECK LIST FOR METERS:

17.1 Check

17.2 Check for physical damage.

17.3 Check calibration by comparing with sub standard.

17.4 Megger all insulated portions.

17.5 Check C.T. and V.T. connections with particular reference to their polarities for Power type meters.

18.0 OTHER EQUIPMENTS : BATTERY & BATTERY CHARGER, 415V, L.T. A.C. PANELS, DIESEL GENERATOR, DISTRIBUTION TRANSFORMERS:

18.1 The pre-commissioning/commissioning checks and dried out in accordance with the tests shall be car manufacturer's instruction manual and instructions of the owner. The charge /discharge cycle of battery shall be strictly followed.

19.0 COMMISSIONING CHECK LIST FOR ELECTRICAL INSTALLATION GENERAL:

19.1.0 Phasing out.

19.1.1 By means of phasing rods, if available or by measuring voltages on voltages transformer secondary.

19.2.0 FUNCTIONAL CHECKING:

19.2.1 Checking all closing, tripping, super-vision and interlock of control devices.

19.2.2 Check operation of all alarm circuits.

19.3.0 CABLE TESTING:

19.3.1 All I IKV, 415 and 230V power cables are to meggered with suitable meggers to check the insulation resistance.

19.4.0 EARTHING:

19.4.1 Measure resistance of each earth well/rod by isolated the same from station grid as well as from other car wells/rods and then measure resistance of two card at a time by D.C. drop method.

19.4.2 Check continuity, of grid conductor and wires.

19.4.3 Soil resistivity tests.

19.5.0 In addition to the above, any other tests specified manufacturers shall be carried out as the manufacturer's instructions.

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19.6.0 Test fire detection system if provided.Check operation of protective relays by putting short circuit bar at different location, conduct system stability test by primary injection test method.

---------------------------------------END HERE-------------------------------------------

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