SECURITY PAPER MILL, HOSHANGABAD-461005(M.P.

)
(A unit of Security Printing & Minting Corporation of India Ltd.) Wholly owned by Government of India

TENDER DOCUMENT FOR AUGMENTATION OF 33/11KV SUBSTATION, CONSTRUCTION OF 11/0.415 KV SUBSTATION ALONG WITH SWITCHGEARS, CABLING, GROUNDING, LIGHTNING PROTECTION SYSTEM AND CIVIL WORK -DESIGN, SUPPLY, INSTALLATION & COMMISSIOING ON TURNKEY BASIS

Not Transferable Security Classification: Non-Security Item TENDER DOCUMENT FOR AUGMENTATION OF 33/11KV SUBSTATION, CONSTRUCTION OF 11/0.415 KV SUBSTATION ALONG WITH SWITCHGEARS, CABLING, GROUNDING, LIGHTNING PROTECTION SYSTEM AND CIVIL WORK.-DESIGN, SUPPLY, INSTALLATION & COMMISSIOING ON TURNKEY BASIS

Tender No. 14(35)/33-11-0.415KV/Vol.III/Adv. No.125/3225 This Tender Document Contains 559 Pages. Tender Documents is sold to:

Dated 05.03.2012

M/s _______________________ Address

Details of Contact person in SPM regarding this tender:

Name, Designation Address

: :

Shri. Rajkumar R Officer Materials Security Paper Mill Hoshangabad M.P-461005

07574-279847

Phone Fax Email

: : :

07574-255170 gm_spm@yahoo.co.in

CONTENTS
SECTION Section I Section II Section III Section IV Section V Section VI Section VII Section VIII Section IX Section X Section XI Section XII Section XIII Section XIV Section XV Section XVI Section XVII Section XVIII Section XIX Section XX DESCRIPTION Notice Inviting Tender (NIT) General Instruction to Tenderers (GIT) Special Instruction to Tenderers (SIT) General Conditions of Contract (GCC) Special Conditions of Contract (SCC) List of Requirements(LR) Technical Specifications(TS) Quality Control Requirements(QCR) Qualification / Eligibility Criteria Tender Form(TF) Price Schedule(PS) Questionnaire Bank Guarantee Form for EMD Manufacturers Authorization Form Bank Guarantee Form for Performance Security Contract Form Letter of Authority for attending a Bid Opening Shipping Arrangements for Liner Cargoes Performa of Bills for Payments Drawings Appendix - E Page No. 2 32 03 28 05 10 273 06 01 01 02 01 01 01 01 02 01 01 01 55 93

(Section I)

NOTICE INVITING TENDER (NIT)

Tender No. 14(35)/33-11-0.415KV/Vol.III/Adv.No.125/3225 Dated: 05.03.2012

1. Sealed tenders are invited from eligible and qualified tenderers for s u p p l y of following g o o d s & S e r vi ce s: Schedule No. Brief Description of Goods/ Services AUGMENTATION OF 33/11KV SUBSTATION, CONSTRUCTION OF 11/0.415 KV SUBSTATION ALONG WITH SWITCHGEARS, CABLING, GROUNDING, LIGHTNING PROTECTION SYSTEM AND CIVIL WORK - DESIGN, SUPPLY, INSTALLATION & COMMISSIOING ON TURNKEY BASIS as per List of Requirement section VI on turnkey basis Quantity (with unit) Earnest Money (in Rs.)

1.

As per List of Requirements Section VI of this tender document

Rs. 12,75,000/(Rupees Twelve Lakhs Seventy Five Thousand Only)

Type Of Tender Tender Cost Date and time of Pre-bid conference Place of Pre-bid conference Closing date and time for receipt of tenders Place of receipt of tenders Time and date of opening of tenders Place of opening of tenders Nominated Person/ Designation for receive bulky tenders

Single stage (three packet), NCB Rs. 5000/- (Rs. Five Thousand Only) 05.04.2012 at 11.00 AM Security Paper Mill, Hoshangabad Up to 14.00 Hrs till 27.04.2012 Security Paper Mill, Hoshangabad 15.00 Hrs On 27.04.2012 Security Paper Mill, Hoshangabad Officer Materials

2. Interested tenderers may obtain further information about this requirement from the above Office selling the tender document. They may also visit our website mentioned above for further details.
3

3. Tender documents may be purchased on payment of non-refundable fee of Rs.5000/- per set in the form of account payee demand draft/ cashiers cheque/ certified cheque, drawn on a scheduled commercial bank in India, in favour of The General Manager, Security Paper Mill payable at Hoshangabad. 4. If requested, the tender documents will be mailed by registered post/speed post to the domestic Tenderers, for which extra expenditure per set will be Rs. 100/- (Rupees Hundred) for domestic post. The tenderer is to add the applicable postage cost in the non-refundable fee mentioned in para 3 above. 5. Tenderers may also download the tender documents from the web site http://spmhoshangabad.spmcil.com and submit its tender by utilizing the downloaded document along with the required non-refundable fee as mentioned in Para 3 above. 6. Tenderers shall ensure that their tenders, duly sealed and signed, complete in all respects as per instructions contained in the Tender Documents, are dropped in the tender box located at the address given below on or before the closing date and time indicated in the para 1 above, failing which the tenders will be treated as late and rejected. ADDRESS The General Manager, Security Paper Mill, Hoshangabad - 461 005 (M.P.) India. 7. In the event of any of the above mentioned dates being declared as a holiday/ closed day for the purchase organization, the tenders will be sold/ received/ opened on the next working day at the appointed time. 8. The tender documents are not transferable.

(Rajkumar. R) Officer Materials Security Paper Mill, Hoshangabad, M.P-461 005 Ph.No: 07574-279847, 07574-279791 Fax No: 07574-255170 For and on behalf of The General Manager

(Section II)

GENERAL INSTRUCTIONS TO TENDERERS (GIT)

Kindly refer http://spmhoshangabad.spmcil.com/spmcil/uploaddocument/GIT.pdf for further details. (GIT contains 32 Pages)

(Section III)

SPECIAL INSTRUCTION TO TENDERER

The following special instructions to tenderers will apply for this purchase these special instructions will modify/ substitute/ supplement the corresponding General Instructions to Tenderers (GIT) incorporated in Section II. The corresponding GIT clause numbers have also been indicated in the text below. In case of any conflict between the provision in the GIT and that in the SIT, the provision contained in the SIT shall prevail. Sl. No. 1. 2. 3. 4. 5. 6. 7. 8 GIT Clause No. 8 18 19 21 43 33 21.1, 24.1 Topic Pre Bid Conference Earnest Money Deposit (EMD) Tender validity Submission of Tenders Parallel Contracts Evaluation Criteria Corrections in GIT Clauses Coordination with Statuary outside Agencies SIT Provision 1. 2. 3. 4. 5. 6. 7. 8

Bodies

&

1.

PRE-BID CONFERENCE Pre-bid conference will be held on 05.04.2012 at 11 AM for this tender at SPM Hoshangabad.

2.

EARNEST MONEYDEPOSIT (EMD) Tender should be accompanied with Earnest Money Deposit (Non-interest bearing) of Rs.12, 75,000/- (Rupees Twelve Lakhs Seventy Five Thousand Only) in the forms as given below. a) Account Payee Demand Draft or b) Fixed Deposit Receipt or c) Bankers cheque The demand draft, fixed deposit receipt or bankers cheque shall be drawn on any scheduled commercial bank in India, in favor of Account specified in the Clause 3 of NIT. The earnest money shall be valid for a period of forty five days beyond the validity period of the tender.

3. 3.1 3.2

TENDER VALIDITY The tender shall remain valid for acceptance for a period of 165 days after the date of tender opening prescribed in the tender document. Any tender valid for a shorter period shall be treated as unresponsive & rejected. In exceptional cases, the tenderers may be requested by SPM to extend the validity of their tenders up to a specified period. Such request(s) and responses thereto shall be conveyed by surface mail/E-mail/Telex/Cable followed by surface mail. The tenderers, who agree to extend the tender validity, are to extend the same without any change or modification of their original tender and they are also to extend the validity period of the EMD accordingly.
6

3.3 3.4

In case the day up to which the tenders are to remain valid falls on/ subsequently declared a holiday or closed day for SPM, the tender validity shall be extended up to the next working day. Compliance with the clauses of this Tender document: Tenderer must comply with all the clauses of this tender document. No deviations with any of the clauses of this tender are permitted to the bidder.

4. SUBMISSION OF TENDERS: Pre-Qualification bid, Technical bid and financial bid are to be submitted in three separate doubled sealed envelopes on or before the due date of submission of tenders. It may be noted that the price is not to be quoted either in the pre-qualification or in technical bid. It shall only be quoted in price bid. Non-adherence to this shall make tender liable for rejection. The envelopes containing bids shall be superscribed Pre-qualification bid, Technical bid, Price bid, as the case may be, for Tender Document for augmentation of 33/11KV substation, construction of 11/0.415 KV substation along with switchgears, cabling, grounding, lightning protection system and civil work-design, supply, installation &commissioning on turnkey basis. The sealed envelopes shall be again be put in another sealed cover and should be superscribed Tender Document for augmentation of 33/11KV substation, construction of 11/0.415 KV substation along with switchgears, cabling, grounding, lightning protection system and civil workdesign, supply, installation & commissioning on turnkey basis due on 27.04.2012 up to 14.00 Hrs (IST). Late tenders shall not be accepted. Tenderers shall submit their offers only on prescribed forms. Tender by Telegram/Fax/E-mail shall not be accepted. Tender by Post/Hand/courier received on or before the due date and time shall be accepted. Postal delay/ delay by courier service etc. shall not be condoned. 4.1 Tenders shall be submitted in parts as below:PART I PRE-QUALIFICATION BID i) Containing un-priced tender consisting of complete Qualification/ Eligibility of the tenderer as per the format specified under Section I X in this document. ii) One original and one duplicate copy shall be submitted. It should not have any price aspects. iii) Earnest Money Deposit. iv) Power of Attorney/authorization with the seal of the company of person signing the tender documents. v) Tender document fee Rs.5,000/PART II - TECHNO-COMMERCIAL BID i) The tenderer shall submit detailed technical offer as per Technical Specifications as per Section VII of this tender document. ii) The tenderer has to submit acceptance of all sections of this tender document (GIT, SIT, SCC, Quality control requirements, Tender form, Questionairre, etc.,) iii) One original and one duplicate copy shall be submitted. iv) Containing un-priced tender consisting commercial package including all terms and conditions. No price details to be given in this tender. v) Containing Blank price Bid (No price details to be given in this tender.) PART- III - PRICE BID: The tenderers shall quote the prices as per the proforma given in Section XI of the tender document. Insertion, post script, addition and alteration shall not be recognized unless confirmed by the tenderers. 5 PARALLEL CONTRACTS No parallel contracts shall be awarded for this tender.
7

EVALUATION CRITERIA FOR L1 BIDDER The pre-qualification bids are to be opened in the first instance, at the prescribed time and date. These bids shall be scrutinized and evaluated by the competent committee/ authority with reference to the parameters prescribed in the eligibility criteria. Thereafter, in the second stage, the technical bids of only pre-qualified bidders (as decided in the first stage) shall be opened at a later date and time for further scrutiny and further evaluation. These bids shall be scrutinized and evaluated by the competent committee/ authority with reference to the parameters prescribed in the tender document. Subsequently, in the third stage the financial bids of only the technically acceptable offers (as decided in the second stage shall be opened for further scrutiny and evaluation. Intimation regarding to opening of technical and financial bids shall be given to acceptable Tenderers to enable them to attend the technical and financial bid opening, if they so desire. The method of evaluation of L1 bidder for awarding the Contract shall be on consolidated grand total offer by the bidder and will be decided taking into consideration of the total offered price including Parts(A+B+C) as per Section-XI (Price schedule)of this tender document.

CORRECTIONS in GIT Clauses GIT CLAUSE 21.1 21.1 24.1 WRITTEN AS IN GIT CORRECTED AS IN SIT In 3rd line of procurement manual the Para 1 of NIT words Para 11 of NIT In 6th line of procurement manual the Clause 1 of NIT words Clause 11 of NIT In 2nd line of procurement manual the Clause 1 of NIT words Clause 11 of NIT

8. CO-ORDINATION WITH STATUTORY BODIES AND OUTSIDE AGENCIES The Contractor shall be fully responsible for carrying out all co-ordination & liaison work as may be required with Electrical Inspector, Factory Inspector & other statutory bodies for implementation of the work. The application on behalf of the Owner for submission to the Electrical Inspector & other statutory bodies along with copies of drawings complete in all respects shall be done by the Contractor & approval/certificates taken well ahead of time so that the actual commissioning of equipment is not delayed for want of inspection and approval by the Inspector & statutory bodies. The actual inspection work by the Electrical Inspector shall be arranged by the Contractor. However, official fees paid to Electrical Inspector/ statutory bodies, etc. in this regard shall be borne by the Owner.

(Section IV)

GENERAL CONDITIONS OF CONTRACT (GCC)

Kindly refer http://spmhoshangabad.spmcil.com/spmcil/uploaddocument/GCC.pdf for further details. (GCC contains 28 Pages)

(Section V)

SPECIAL CONDITIONS OF CONTRACT (SCC)

The following Special Conditions of Contract (SCC) will apply for this purchase. The corresponding clauses of General Conditions of Contract (GCC) relating to the SCC stipulations have also been incorporated below. These Special Conditions will modify/ substitute/ supplement the corresponding (GCC) clauses. Whenever there is any conflict between the provision in the GCC and that in the SCC, the provision contained in the SCC shall prevail. Sl. No GCC Clause No. 1 2 3 4 5 6 7 8 9 10 1. 1 9 11.2 12 14 16 21.2 22 Topic Abbreviations in conjunction with GCC Inspection and Quality Control Transportation of Domestic Goods Insurance Incidental Services Warranty Taxes and Duties Terms and Mode of Payment Security Rules Compliance with contract labour Act SCC Provision 1 2 3 4 5 6 7 8 9 10

2.

Abbreviations SPM/OWNER/PURHCASER means Security Paper Mill, Hoshangabad. SPMCIL means Security Printing and Minting Corporation of India Limited DCPL means Development Consultants Private Limited, Kolkata BIDDER/TENDERER/CONTRACTOR means the individual/firm who quotes against this tender enquiry . Inspection and Quality Control

2.1 SPM and/ DCPL or its nominated representative(s) will, without any extra cost to SPM, inspect and/ or test the ordered work and the related services to confirm their conformity to the contract specifications and other quality control details incorporated in the contract. SPM shall inform the contractor in advance, in writing, SPM's programme for such inspection and, also the identity of the officials to be deputed for this purpose. 2.2 The Technical Specification and Quality Control Requirements incorporated in the contract shall specify what inspections and tests are to be carried out and, also, where and how they are to be conducted. If such inspections and tests are conducted in the premises of the contractor, all reasonable facilities and assistance, including access to relevant drawings, design details and production data, shall be furnished by the supplier to SPM's inspector at no charge to SPM. 2.3 If during such inspections and tests the contracted work fail to conform to the required specifications and standards, the inspector may reject them and the contractor shall either replace the rejected work or make all alterations necessary to meet the
10

specifications and standards, as required within the original delivery period and as specified in the contract free of cost to SPM and resubmit the same to the inspector for conducting the inspections and tests again. 2.4 In case the contract stipulates pre-despatch inspection of the ordered work at contractor s premises, the contractor shall put up the work for such inspection to SPMs or DCPLs inspector well ahead of the contractual delivery period, so that the inspector is able to complete the inspection within the contractual delivery period. 2.5 If the contractor tenders the goods to the inspector for inspection at the last moment without providing reasonable time to the inspector for completing the inspection within the contractual delivery period, the inspector may carry out the inspection and complete the formality beyond the contractual delivery period at the risk and expense of the contractor. The fact that the goods have been inspected after the contractual delivery period will not have the effect of keeping the contract alive and this will be without any prejudice to the legal rights and remedies available to SPM under the terms & conditions of the contract. 2.6 Work accepted by SPM and/ or its inspector at initial inspection and in final inspection in terms of the contract shall in no way dilute SPM's right to reject the same later, if found deficient in terms of the warranty clause of the contract, as incorporated under GCC Clause. 2.7 Travelling expenses, Lodging and boarding charges of SPM officer for pre-shipment inspection shall be borne by SPM. 3. Transportation of Domestic Goods The supplier shall arrange transportation of the ordered goods up to the SPM and further transportation up to the Project site. 4. Insurance 4.1 The Supplier shall arrange for insuring the goods the goods against loss or damage incidental to manufacture or acquisition, transportation, storage and delivery in the following manner: 4.2 The supplier shall be responsible till the entire stores contracted for arrive in good condition at destination. The transit risk in this respect shall be covered by the Supplier by getting the stores duly insured. The insurance cover shall be obtained by the Supplier in its own name and not in the name of SPM or its Consignee. 4.3 Insurance in respect of damages to persons and property during equipment erection: 4.3.1 The Contractor shall be responsible for all injury or damage to persons, animals or things and for all damage to property which may arise from any factor omission on the part of the CONTRACTOR or any of their employees. The liability under this clause shall cover also inter-alia any damage to structures, whether immediately adjacent to the works or otherwise, any damage to roads, streets, footpaths, bridges as well as damage caused to the building and other structures and works forming the subject matter of this contract. The Contractor shall also be responsible for any damage caused to the buildings and other structures and works forming the subject matter of this contract due to rain, wind, frost or other inclemency of weather. The Contractor shall indemnify and keep indemnified the SPM and hold him harmless in respect of all and any loss and expenses arising from any such injury or damage to persons or property as aforesaid and also against any claim made in respect of injury or damage, whether under any statute or otherwise and also in respect of any award
11

or compensation or damage consequent upon such claims. The Contractor shall, at his own expense, effect and maintain till issue of the virtual completion certificate under this contract, with an insurance company approved by the SPM, an All Risks Policy for Insurance for the full amount of the contract including earth quake risk in the joint names of the SPM and the Contractor (the name of the former being placed first in the policy) against all risks as per the standard all risk policy for Contractors and deposit such policy or policies with the Owner before commencing the works. 4.3.2 The Contractor shall reinstate all damage of every sort mentioned in this clause so as to do delivery of the whole of the works complete and perfect in every respect and so as to make good or otherwise satisfy all claims for damage to property or third parties. The Contractor shall also indemnify and keep indemnified the SPM against all claims which may be made against the SPM by any person in respect of anything which may arise in respect of the works or in consequence thereof and shall at his own expense, effect and maintain until the virtual completion of the contract, with an Insurance Company approved by the SPM a policy of Insurance in the joint names of the SPM and the Contractor (name of the former being placed first in the policy) against such risks and deposit such policy or policies before commencement of the works. The minimum limit of the coverage under the policy shall be Rs.2 Lakhs per person for any one accident or occurrence and Rs.5 Lakhs in respect of damage to property for any one accident or occurrence. The Contractor shall also indemnify the SPM against all claims which may be made upon the Owner, whether under the Workmens Compensation Act or any other statute in force, during the currency of this contract or at Common Law in respect of any employee of the Contractor and shall be at his own expense, effect and maintain until the Virtual Completion of the Contract with an Insurance Company approved by the SPM a policy of Insurance against such risks and deposit such policy or policies with the SPM from time to time during the currency of this contract. In default of the Contractor insuring as provided above, the SPM may so insure and may deduct the premiums paid from any money due or which may become due to the Contractor. The Contractor shall be responsible for any liability which may not be covered by the insurance policies referred to above and also for all other damages to any person, animal or defective carrying out of this contract, whatever, may be the reasons due to which the damage shall have been caused. The Contractor shall also indemnify and keep indemnified the SPM against all and any costs, charges or expenses arising out of any claim or proceedings relating to the works and also in respect of any award of damage or compensation arising there from. Without prejudice to the other rights of the SPM against Contractors in respect of such default, the SPM shall be entitled to deduct from any sums payable to the Contractor the amount of any damages, compensation costs, charges and other expenses paid by the Owner and which are payable by the Contractor under this clause.
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4.3.3

4.3.4

4.4

4.4.1

4.4.2

4.4.3

4.4.4

4.4.5

The Contractor shall upon settlement by the insurer of any claim made against the insurer pursuant to a policy taken under this clause, proceed with due diligence to rebuild or repair the works destroyed or damaged. In this event all the money received from the insurer in respect of such damage shall be paid to the Contractor and the Contractor shall not be entitled to any further payment in respect of the expenditure incurred for rebuilding or repairing of the materials or goods destroyed or damaged. The Contractor, in case of re-building or reinstatement after damage shall be entitled to such extension of time for completion as the SPM and/ or DCPL may deem fit, but shall, however, not be entitled to reimbursement by the SPM of any shortfall or deficiency in the amount finally paid by the insurer in settlement of any claim arising as set out herein.

4.4.6

5. Incidental Services 5.1 Subject to the stipulation in the Technical Specification (Section - VII), the supplier shall be required to perform any or all of the following services. a) Providing required jigs and tools for assembly, start-up and maintenance of the goods b) Supplying required number of operation & maintenance manual for the goods c) Installation and commissioning of the goods d) Training of SPMs operators for operating and maintaining the goods e) Providing after sales service during the tenure of the contract f) Providing maintenance service after expiry of the warranty period of the goods if so incorporated in the contract 5.2 Prices to be paid to the supplier by SPM for any of the required incidental services, if not already included in the contract price during the placement of the contract, shall be settled and decided in advance by SPM and the supplier. However, such prices shall not exceed the contemporary rates charged by the supplier to other customers for similar services. 6. Warranty 6.1 The supplier warrants that the goods supplied under the contract is new, unused and incorporate all recent improvements in design and materials unless prescribed otherwise by SPM in the contract. The supplier further warrants that the goods supplied under the contract shall have no defect arising from design, materials (except when the design adopted and / or the material used are as per SPM's specifications) or workmanship or from any act or omission of the supplier, that may develop under normal use of the supplied goods under the conditions prevailing in India. 6.2 This warranty shall remain valid for twelve months after the goods or any portion thereof as the case may be, have been delivered to the final destination and installed and commissioned at the final destination and accepted by SPM in terms of the contract or for eighteen months from the date of despatch from the supplier's premises whichever is later. 6.3 In case of any claim arising out of this warranty, SPM shall promptly notify the same in writing to the supplier. 6.4 Upon receipt of such notice, the supplier shall, with all reasonable speed and time, repair or replace the defective goods or parts thereof, free of cost, at the ultimate destination. The supplier shall take over the replaced parts/ goods after providing their
13

replacements and no claim, whatsoever shall lie on SPM for such replaced parts/ goods thereafter. 6.5 In the event of any rectification of a defect or replacement of any defective goods during the warranty period, the warranty for the rectified/ replaced goods shall be extended to a further period of twelve months from the date such rectified / replaced goods starts functioning to the satisfaction of SPM. 6.6 If the supplier, having been notified, fails to rectify/ replace the defect(s) within a delivery period, SPM may proceed to take such remedial action(s) as deemed fit by SPM, at the risk and expense of the supplier and without prejudice to other contractual rights and remedies, which SPM may have against the supplier. 7. TAXES and DUTIES: TDS or any other applicable taxes shall be deducted from the firms bill. 8. TERMS AND MODE OF PAYMENT

a. 80% payment of the value of goods as per PART A of section XI of this tender
document shall be made on receipt and acceptance of goods by the consignee at destination and on production of all required documents by the supplier. b. 20% payment of the value of goods as per PART A of section XI of this tender document shall be made on successful installation, commissioning, charging the installation after getting the clearance from Central Electrical Inspector and other related Statutory Bodies, successful load trial of the installation and acceptance by the consignee. c. 100% payment of the value of civil works as per PART B of section XI of this tender document shall be made after successful completion of civil works and acceptance by consignee. d. 100% payment of the value of installation and commissioning as per PART C of section XI of this tender document shall be made on successful installation and commissioning, charging the installation after getting the clearance from Central Electrical Inspector and other related Statutory Bodies, successful load trial of the installation and acceptance by the consignee. 9. SECURITY RULES

9.1 The Contractor shall strictly abide by the security rules and regulations enforced by the SPM from time to time. The Contractor shall provide proper identity cards, badges etc., to his employees whenever directed by the DCPL/SPM. 9.2 The Contractor shall arrange for police verification certificates for all his employees/worker/supervisor and the contractor and submit it to CISF(SPM) before starting of the work to obtain the gate pass of the concerned person. 10. COMPLIANCE WITH CONTRACT LABOUR ACT The contractor shall comply with all the provisions of the EPF rules, Workmen Compensation Act 1923, Minimum Wages Act, 1948, and Contract Labour (Regulation and Abolition) Act, 1970 amended from time to time and rules framed there under. The provision of building and other Construction Workers Regulation of Employment & Condition of Service Act, 1996 amended from time to time and rules framed therein to be followed.
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(Section VI)

LIST OF REQUIREMENTS
Schedule No. Brief description of work and services (Related specifications etc. are in Section-VII)

Accounting unit

Quantity

Amount of Earnest Money

1.

Design, Engineering, Manufacture, assembly/ pre-assembly, tests at manufacturers works, insulation work, shop painting, delivery properly packed for transport, supply, complete erection, final checkup, testing at site, successful commissioning, conducting performance and acceptance tests at SPM site of AUGMENTATION OF 33 / 11KV SUBSTATION, CONSTRUCTION OF 11/0.415 KV SUBSTATION ALONG WITH SWITCHGEARS, CABLING, GROUNDING, LIGHTNING PROTECTION SYSTEM AND CIVIL WORK.-DESIGN, SUPPLY, INSTALLATION & COMMISSIOING ON TURNKEY BASIS. as per detail list of requirement A,B,C given below and specified under Section VII of this tender document complete with all accessories. On Turnkey basis

As per detail list of requirement A, B, C given below and specified under Section VII of this tender document complete with all accessories. On Turnkey basis

As per detail list of requirement A, B, C given below and specified under Section VII of this tender document complete with all accessories. On Turnkey basis

Rs. 12,75,000/(Rupees Twelve Lakhs Seventy Five Thousand Only)

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LIST OF REQUIREMENT A S.No. 1 2 3 4 5 6 7 8 9 10 11 DESCRIPTION Material as per SUB SEC-II OF TECHNICAL SPECIFICATION SECVII of this Tender Document Material as per SUB SEC-III OF TECHNICAL SPECIFICATION SECVII of this Tender Document Material as per SUB SEC-IV OF TECHNICAL SPECIFICATION SECVII of this Tender Document Material as per SUB SEC-V OF TECHINCAL SPECIFICATION SECVII of this Tender Document Material as per SUB SEC-VI OF TECHNICAL SPECIFICATION SECVII of this Tender Document Material as per SUB SEC-VII OF TECHNICAL SPECIFICATION SECVII of this Tender Document Material as per SUB SEC-VIII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-IX OF TECHNICAL SPECIFICATION SECVII of this Tender Document Material as per SUB SEC-X OF TECHNICAL SPECIFICATION SECVII of this Tender Document Material as per SUB SEC-XI OF TECHNICAL SPECIFICATION SECVII of this Tender Document Material as per SUB SEC-XII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document UNIT LOT LOT LOT LOT LOT LOT LOT LOT LOT LOT LOT QTY 1 1 1 1 1 1 1 1 1 1 1

LIST OF REQUIREMENT B S.No. 1 DESCRIPTION CIVIL WORK as per SUB SEC-XIII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document. UNIT LOT QTY 1

LIST OF REQUIREMENT C S.No DESCRPTION SERVICES (Installation & Commissioning) 1 Complete Erection, Testing, Start Up, & Commissioning fulfilment of guaranteed performance obligation including training of Purchasers operation and maintenance staff. LOT 1 UNIT QTY

Required Completion Schedule : Twelve (12) months from the date of issue of Notification of Award of contract or Purchase Order whichever is earlier. (Including Supply, Erection & Commissioning) Detail Schedule of completion as Time schedule (D) below.
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1. TIME SCHEDULE D 1.1 TIME SCHEDULE 1.1.1 1.1.2 The work shall be executed strictly as per the time schedule given below. The Bidder shall furnish a proposed time schedule by CPM/bar-chart along with his quotation. The time schedule should indicate the details considering the date of intimation of award of contract as the zero date and should show completion of various activities there from. The time schedule shall clearly include all important events regarding engineering, procurement, construction, testing and handing over for each area, commensurate with the overall time schedule. The time schedule shall form a part of the Contract Document. BI-WEEKLY Progress reporting shall be done by the Contractor for engineering, procurement and construction activities on mutually agreed formats. Reports on such formats will be sent regularly in soft copies with six (6) copies of print as per frequency / periodicity agreed upon from time to time.

1.1.3 1.1.4 1.1.5

1.2

DETAIL TIME SCHEDULE A. Substation drawings Weeks from issue of Notification of Award of contract or Purchase Order (D)

Electrical & Mechanical 1. Key Single line diagram & vendor list 2. Electrical Layout Plan & Elevation, Clearance diagram 3. Sag tension calculation 4. Short circuit force & Spacer span calculation 5. Equipment short circuit & Post Insulator span calculation 6. Direct Stroke Lightning protection calculation 7. Switchyard Structural layout 8. Control building equipment layout 9. Grounding design 10. Grounding layout 11. Cable trench layout 12. Control building cable trench layout 13. DC System design & drawings 14. AC System design & drawings 15. Switchyard Erection drawing, list of hardware Erection sag chart Civil & Structural 1. Design & drawing of Gantry Structure 2. Civil design & drawing of existing Control building 3. Design & drawing of Switchyard 4. Design & drawing of Switchyard Equipment structure 5. Design & drawings of Equipment foundation 6. Design & drawing of Cable Trench outdoor area
17

D+3 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+5 D+5 D+7

D+4 D+6 D+5 D+6 D+7 D+8

7. Design & drawing of Transformer foundation 8. Design & drawing of Switchyard Roads, Drains, fence, gate B. Manufacturers Drawings, Data, Manuals 1. Technical Particulars 2. GA and Part List 3. Schematic drawing with Terminal numbers 4. QAP, Test Schedule 5. Spares list 6. Installation, Commissioning & Operating Manuals D+6

D+8 D+8

D+9

C.

Manufacturers Drawings, Data, Manuals for Substation Control, Protection and Management System 1. Technical Particulars & system write-up 2. Schematic drawing with Terminal numbers 3. QAP, Test Schedule 4. Spares list 5. Installation, Commissioning & Operating Manuals 6. Protection settings D. cable Schedule & Interconnection E. PROJECT MILE STONES i) Supply & Installation of 11/.415 KV Distribution System along with the all the necessary requirement for completion of erection ,commissioning & charging the substation (i.e. 3 MVA transformer 3nos., Switchgear,415 PCC,PMCC, Non segregated 3 phase Sandwich Bus duct etc) D+8 Months D+7 D+8 D+6 D+8 D+9 D+8 D+8

ii) Supply & Installation of 33/11 KV in Main Receiving Substation System along with the all the necessary requirement for completion of erection ,commissioning & charging the substation (i.e. 2 nos. of 10 MVA transformer ,cable trench,HV Switchgear, etc)

D+10 Months

iii) Project completion & handing over in all respect

D+12 Months

Required Terms of Delivery Preferred Mode of Transportation

: F.O.R SPM Hoshangabad : Road

18

LIST OF SAFETY AND HEALTH INSTRUCTIONS TO BE COMPLIED BY CONTRACTOR 2. SAFETY AND HEALTH INSTRUCTIONS FOR COMPLIANCE BY THE CONTRACTOR AS BELOW During installation, the Contractor shall follow all the Safety Policy and Plant Safety rules of SPM and also the various provisions of M.P. Factories Rules, 1962 made under Factories Act, 1948. This instruction gives broad guidelines to be followed by the Contractor for ensuring safe working conditions in and around the site. 2.1 SAFETY ORGANISATION Contractor at site shall organize a Safety Group headed by a Safety Officer who shall be responsible for providing, supervising and monitoring safe working conditions at all times for their workers. The Safety Officer shall be experienced in maintaining safe conditions for workers at site and shall be responsible for and shall have authority to enforce safe conditions for the workers. The Contractor shall have a declared Safety Policy and shall get the same approved by the SPM and/or DCPL. The approved Safety Policy shall be displayed prominently in the Contractors site office. The Contractor shall take active interest and participate in the development and operation of safety programs at site. His responsibility does not cease with establishment of Safety Group and approval of its various activities. He shall demonstrate his involvement by regular participation in safety meetings, review of safety records and taking corrective action where required, introduction of safety promoting bulletins, posters, suggestions and awards and by setting example by strictly observing safety rules. The Contractor shall remove all waste material and debris from and around the work area and properly clean up the area at the end of each day before leaving the work site. The Contractor shall take all necessary precautions not only for safe working of his own workmen but also deploy all precautions to ensure safety of structures, equipment and workmen of other agencies in and around his work site. The Contractor shall ensure that his workmen do not trespass into prohibited areas. The SPM and/or DCPL shall have the right to inspect at any time, all items of machinery or equipment brought to site by the Contractor, his agents or workmen and to prohibit the use on the site of any item, which in the opinion of the SPM and/or DCPL is or may be detrimental to the safety of the site. The exercise of such right or the omission to exercise it in any particular case shall not absolve the Contractor or his agents or workmen of their responsibility of adhering to the safe working practices. The Contractor shall execute the work in a manner causing the least possible interference with the business of the SPM and/or DCPL, or with the work of any other Contractor who may be engaged on the premises and shall at all times cooperate with the other Contractors working at site. The Contractor shall obtain work permit from the SPM and/or DCPL before starting any work at site. The work permits are issued to prevent the Contractor from working in un-authorized areas and shall be valid for specific area for a stipulated period The Contractor shall ensure at all times that his workers do not lie down or sleep under or around any machine, equipment, vessel, vehicle or structures in his work area.

19

2.2

RESPONSIBILITIES OF THE CONTRACTORS SAFETY OFFICER He is responsible and accountable for: a) Preventing injury to personnel, damage to plant and equipment and fires. b) Instituting ways to improve existing work methods from safety point of view. c) Legal and contractual requirements affecting safety, health, and welfare of his workmen d) Provision and use of protective clothing and equipment and use of firefighting equipment e) Suitability of new and hired equipment from a safety viewpoint f) Identifying potential hazards. g) Changes in safety requirements and fire precautions h) Carrying out site surveys to see that only safe work methods are in operation, health and safety requirements are being observed and welfare and first aid facilities are adequate and properly maintained. i) Determining the cause of an accident or dangerous occurrence and recommend means of preventing recurrence. j) Supervising the recording and analysis of information on injuries, damage and production loss. Assess accident trends and review overall safety performance. k) Assisting with training of employees at all levels. Organizing periodic demonstration of practicing safe working conditions by experienced safety instructors. l) Taking part in discussions on injury, damage and loss control. m) Keeping up-do-date with recommended codes of practice and safety literature. Circulating information applicable to each level of employees. n) Fostering within the company an understanding that injury prevention and damage control are an integral part of business and operational efficiency. o) Attending job progress meetings where safety is an item on the agenda. Report on job safety performance. The Safety Officer shall inspect and ensure the following: a) All electrical equipment are securely earthed. b) Standard access platforms and ladders are provided for inspection, operation and maintenance of equipment. c) The equipment are periodically inspected for their condition, maintained d) Properly and operated by trained personnel at design speeds and loads.

2.3

WORKING AT HEIGHTS For carrying out work at heights exceeding 2 meters or near openings in floors and roofs etc. precautions as given in following paras shall be taken. Adequate safety precautions like use of safety belts, crawling-ladders, safety nets etc. shall be taken. The workers shall wear safety belts with hook properly fastened. All workmen engaged on work at heights shall be experienced in such work. Written permission of the SPM and/or DCPL shall be obtained before undertaking work on roofs. Wherever possible, steel staging or platform shall be erected. Staging with toe guards shall be provided with simple safety rails or ropes at waist height throughout its length on all open sides. Staging supports shall be All Purpose Scaffolding (APS) steel tubes scaffolding, safety secured and supported on firm level footings or slung from overhead beams. The supports shall be situated at maximum distance of 2.5 metres apart and the staging shall be secured to each support.
20

Wherever it is not possible to put up staging and/or use of safety belts, safety nets shall be slung beneath the place of work for safety. When working over open process vessels or tanks, safety belts and safety nets shall always be used whether or not staging and scaffolding is provided. Safe access to all points of works shall be provided in the form of suitable ladders and stairways etc. Area around the work place shall be barricaded suitably or fenced off to avoid injuries to personnel passing by. Suitable warning boards and signs shall be put up. 2.4 LIFTING GEAR The Contractor shall submit a valid Test Certificate to the SPM and/or DCPL, from approved certifying authorities for all of his lifting gear and hoists, slings, chains, wire ropes, hooks, chain-pulley blocks, winches, hoists and cranes etc. before commencing work. These certificates shall be available at site in the Contractors office for inspection as and when required. 2.5 PRESSURE AND LEAK TESTING Pressure and leak testing of equipment shall be carried out hydraulically. However, in special cases where pneumatic testing is specified, written approval shall be obtained from the SPM and/or DCPL before starting work. Under no circumstance gases other than nitrogen, carbon dioxide, air or steam shall be used for testing. In case nitrogen or carbon dioxide is used for testing, the equipment shall be adequately ventilated and gas tested to ensure oxygen content of 21% before permitting a worker to enter the equipment. 2.6 WORK INSIDE AN EQUIPMENT OR DRAINAGE SYSTEM All equipment and associated piping shall be isolated, completely drained, purged and well ventilated before entry of a worker. The atmosphere inside the vessel or equipment shall be tested to ensure absence of toxic and flammable gases. Toxic and flammable liquids and gases in the equipment shall be safely disposed off as per the statutory requirements to the satisfaction of the SPM and/or DCPL. Workers carrying out drainage, purging and testing operations shall wear gas masks and other protective gear appropriate to the material being handled. While a worker has entered equipment or a drainage system, another worker shall be present outside at all times to assist the worker inside in the event of an emergency. 2.7 ELECTRICAL Portable power tools rated for above 50 V supply and hand lamps rated for above 24 V supply shall not be used at site. An armored cable with a 3 pin Reyrolle type plug, properly earthed shall be provided between the Contractors DG set and step down transformer. All power supply and distribution boards shall have canopy for protection and all the distribution boards shall be earthed securely. All supply points shall have proper plug and socket. The Contractor shall check tightness of connection of cable terminations and joints before starting the work. 2.8 WELDING Only qualified welders shall be employed at the work site. The Contractor shall organize the qualifying test at site for his welders and the SPM and/or DCPL shall approve the welders. All welders shall have to undergo qualifying test and only on passing the test, they shall be allowed to work at site.
21

For all welding work at site, generator sets shall be used instead of AC transformer sets. AC transformer sets are banned for welding jobs inside vessels (both open and closed top type). The Contractor shall get his welding sets certified by the SPM and/or DCPL before starting work. These certificates shall have to be renewed every two months. A copy of the certificates shall be displayed on respective welding sets. Only cables in good condition and insulated holders shall be used. The length of supply cable to welding site shall not exceed 8 meters and the welding set body shall be properly earthed. A charged fire extinguisher of CO2 type shall be carried with each welding set. The Contractor shall keep Halon or equivalent type fire extinguishers near hot jobs like cutting oil lines. The welder shall not use a building structure, pipeline or railway track etc. as a return path of the current. Adequately rated circuit breaker shall be provided in the power circuit for human protection on all power supply points. 2.9 HOT WORK Before starting any hot work like gas cutting, welding and grinding etc., the Contractor shall obtain hot work permit from the SPM and/or DCPL. The permit shall be renewed on day-to-day basis. The Contractor shall ensure purging of piping and equipment to make it totally safe before carrying out any hot work. Smoking is strictly prohibited in work areas inside the SPM premises No combustible material shall be stored on or near any source of heat like hot pipes, welding or gas. Before leaving the place of work or the Contractors sheds, the Contractors workmen shall ensure that no material or item that could start a fire is left at site. Special attention shall be paid to collection and disposal of oil soaked cotton waste or rags. On no account are these to be dropped into corners, pushed below equipment or left hanging on pipes. Gas cylinders shall be used in a safe manner. These shall not be dropped from heights or dragged on the floor. Trolley with rubber rimmed wheels shall be used for transporting gas cylinders within the site. Acetylene cylinders shall be kept in upright position. Oxygen cylinders shall not be kept near inflammable materials like oil etc. Tarpaulins shall not be used in the vicinity of welding and gas cutting jobs. The Contractors supervisor of the rank of a foreman or equivalent shall examine the arrangements made for hot work before commencement of work and shall satisfy himself that all reasonable safety precautions have been taken. The Contractor shall return the hot work permit after completion of welding work. 2.10 PERSONAL PROTECTIVE EQUIPMENT Workmen at site shall wear protective clothing, head, leg and eye protection safety equipment at all times as per the job requirements. These are to be supplied and provided by the Contractor. Adequate number of IS approved safety helmets shall be available at site. Welders shall wear good quality insulated welding gloves, goggles, face shield, shoes and overalls while at work. 2.11 ACCIDENTS In case of injury or serious illness of a worker, the CONSULTANT or OWNER shall be notified immediately. All accidents shall be recorded by filling in the Accident Report form, which shall be kept in easy accessible location in the site office of the Contractor. Any Near Miss incident shall also be reported by the Contractor and recorded.
22

2.12

INSURANCE All the Contractors workmen shall be covered under the Employees State Insurance Scheme, Medi-Claim Policy or any other scheme which may be specified by the Statutory Authorities from time to time.

2.13

REVIEW MEETING The SPM and/or DCPL shall conduct fortnightly Safety Review Meeting to review the safety conditions practiced at work areas by the Contractor.

2.14

WORK AFTER NORMAL WORKING HOURS Extra care shall be taken for jobs to be carried out after normal working hours with due revalidated work permit and supervised by the Contractors site in-charge. The site-in-charge shall make available his residential address and telephone number to the SPM and/or DCPL so that he can be contacted in case of an emergency. Proper lighting shall be ensured at the workplace for any work carried out after the normal working hours.

2.15

CONVEYANCE FOR EMERGENCY The Contractor shall ensure that conveyance and person with driving license is available at site at all times of work execution so that in case of an accident, the victim can be rushed to nearest medical Centre.

2.16

SAFETY PRACTICES Avoid working under un-insulated live conductors or working on freshly painted steel, which is still wet. Stairs and railing shall be in place as long as necessary. Ladders shall be periodically checked for any defects. Ladders shall be securely fastened to prevent movement while in use. The Contractor shall advise his workmen to take the following precautions while using ladders: a) While ascending or descending, face the ladder. Use both hands for holding. b) Do not climb higher than the third rung from top on straight or extension-ladders and second rung from top on set ladders. c) Step-ladders shall be fully open before use. d) Sliding down a ladder shall be prohibited. e) Make shift ladders such as clear fastened across a single rail and short ladders spliced together shall never be used. f) Ladders shall be kept free from dirt and grease. g) Defective ladders shall be removed from use. h) Ladders shall not be left un-attended unless these are securely anchored at top and bottom. i) While using ladders, shoes shall not be greasy, muddy or otherwise slippery. j) Ladder shall not be used during severe windy conditions. Lumber shall be piled out of the work area. Nails shall be removed or bent while handling lumber to avoid injury to workmen. While tearing down plaster or brickwork, dust shall be controlled with water. Walls shall not be subjected to lateral pressure or impact from materials stored or falling materials. The safety valves for boilers shall be set by trained personnel and shall be sealed or padlocked at safe working pressure. Only authorized person shall change the setting
23

of safety valves. The safety valve relieving pressures shall be checked as recommended by the manufacturer and applicable codes. Blow down valves shall be operated strictly as per instructions. If blow cock is not marked with an arrow to show open and close position, the same shall be marked at site. Safety slogans and safety instructions shall be prominently displayed in English, Hindi and local language at strategic locations. 2.17 EMERGENCY PROCEDURES The Contractor shall familiarize himself with the emergency procedures, which apply to plants and areas in which his men are working. First Aid Box shall be kept in the Contractors site office. The Contractors site-incharge and his key supervisors shall be trained in administering first aid, preliminary treatment for electrical shocks, fall from height and burns etc. When an emergency condition exists or on hearing the Stop Work Alarm every supervisor shall ensure: a) All work is stopped at once. b) All equipment is shutdown. c) All men are evacuated to a pre-determined assembly point. d) A roll call is taken and every man is accounted for. e) No one shall be permitted to return to work until notification has been received from a responsible authorized agency that it is safe to do so. 2.18 REPONSIBILITY OF THE CONTRACTORS SITE IN CHARGE His primary responsibility is safety of personnel and equipment. He shall: Understand the companys policy on maintaining safe working environment and appreciate the responsibility allocated to each grade of supervision. Know the safety requirements and relevant Government Regulations, and ensure their implementation. Ensure that sound, safe working methods and reasonable welfare facilities are provided for workers. Determine at the planning stage the following: 2.18.1 The most appropriate order and method of working 2.18.2 Allocation of responsibilities to supervisors 2.18.3 Storage areas and access etc. 2.18.4 Hazards which may arise from overhead or underground services 2.18.5 Facilities for welfare, first aid and sanitation 2.18.6 Work permit procedures and requirements 2.18.7 Basic fire precautions 2.18.8 Provide written instructions to establish work methods, to explain the sequence of operations, to outline potential hazards at each stage and to indicate precautions to be adopted.

24

(Section VII)

TECHNICAL SPECIFICATIONS
OVERALL CONTENTS

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SL.NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00

DESCRIPTION GENERAL ELECTRICAL SPECIFICATION 10 MVA POWER TRANSFORMER LT AUX. TRANSFORMER NEUTRAL GROUNDING RESISTOR 11 KV HV SWITCHGEAR 415 V PCC/PMCC/MCC, 415V AC AND 220V DC DB /FB, 220V DC STARTER AND 415 V NON-SEGREGATED PHASE SANDWICH TYPE BUSDUCT BATTERY & BATTERY CHARGE 33 KV OUTDOOR SWITCHYARD 415 V EMERGENCY DIESEL GENERATOR POWER & CONTROL CABLES ELECTRICAL INSTALLATION CABLING & GROUNDING CIVIL WORKS

SUB-SECTION SUB-SECTION-I SUB-SECTION-II SUB-SECTION-III SUB-SECTION-IV SUB-SECTION-V SUB-SECTION-VI

7.00.00 8.00.00 9.00.00 10.00.00 11.00.00 12.00.00 13.00.00

SUB-SECTION-VII SUB-SECTION-VIII SUB-SECTION-IX SUB-SECTION-X SUB-SECTION-XI SUB-SECTION-XII SUB-SECTION-XIII

25

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION - I GENERAL ELECTRICAL SPECIFICATION

26

SUB-SECTION - I GENERAL ELECTRICAL SPECIFICATION CONTENTS CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 8.00.00 9.00.00 DESCRIPTION INTENT OF SPECIFICATION SCOPE OF WORK GENERAL REQUIREMENT SITE CONDITION CO-ORDINATION WITH STATUTORY BODIES AND OUTSIDE AGENCIES FACILITIES TO BE ARRANGED BY CONTRACTOR CO-ORDINATION WITH OTHER CONTRACTORS AND OWNERS SYSTEM DRAWINGS, DATA AND MANUALS PREFFERRED MAKE LIST ATTACHMENTS ANNEXURE - A ANNEXURE - B SYSTEM DETAILS LIST OF TENDER DRAWINGS 12 14 PAGE NO. 1 2 7 9 9 9 10 10 11

27

GENERAL ELECTRICAL SPECIFICATION

1.00.00 INTENT OF SPECIFICATION

1.01.00

This specification is intended to cover complete design, engineering, manufacture, assembly, testing at manufacturer's works, supply and delivery, properly packed for transportation F.O.R. SPM,Hoshangabad of all equipment and accessories, steel structures including complete erection, testing, commissioning & putting into successful commercial operation of Plant Electrical system inclusive of supply of all labour; supervision, tools, implements and supplies as required for new PM-5 and Up gradation project of SECURITY PAPER MILL, Hoshangabad, India on turnkey basis. All items of equipment and system covered under this specification shall be complete in all respect and any item of equipment or accessory not specifically mentioned in this specification but considered essential for efficient and satisfactory operation of individual equipment and system as a whole shall be included in the offer. Specification of equipment / system as well as drawings enclosed herewith shall be read in conjunction with this section of specification and rating/quantity/system/design shall be finalized and substantiated accordingly. Any conflict/discrepancy shall be brought to the notice of Client/Consultant by Bidder for resolution during bidding stage. Any such issue not raised at bidding stage but raised after award of contract, decision of Client/Consultant shall be binding on successful Bidder. The equipment shall conform in all respect to high standards of engineering design and workmanship and should be capable of performing continuous commercial operation within the parameters guaranteed. Standard designs are preferred, provided they meet the requirements of this Specification, and serve the intended purpose. Alternative design may be offered if the same provide substantial technical improvements or economic advantages. However, it will be at the discretion of the Owner to accept such alternative proposed design. All equipment are intended for continuous duty at the specified ratings without forced cooling under the specified climatic conditions, unless else specified. All material and equipment supplied under this specification shall be new and unused. The work is subject to all the terms and conditions detailed in the documents listed below, which shall form part of this specification as if bound together. a. b. c. Tender Notice Instruction to Bidders General conditions of contract for supply, delivery & installation of plant and materials.

1.02.00

1.03.00

1.04.00

1.05.00 1.06.00

1.07.00

In the event of any discrepancy with listed documents, the most stringent one shall govern.

28

1.08.00

Before bid submission, Bidder is advised to visit existing plant & substation to acquaint himself with the detailed technical requirement, terminal points, facilities available, space & layout etc. for consideration in Bid accordingly. Failure to do so by Bidder shall not be a reason for Owner to accept any additional commercial implication of successful Bidder for interfacing with existing system. SCOPE OF WORK SCOPE OF SUPPLY Broad scope of electrical works under this package is outlined below. Items that are not specifically mentioned but are required to make the system complete in all respect shall be deemed to be included in the scope without any extra cost implication. The scope of supply includes involves timely procurement of items based on design guidelines as per this specifications subsections, delivery to site, storing at site as detailed in the respective specifications of those stated in the following table: i) ii) iii) iv) vi) 33/11 KV 10 MVA Power Transformers 3 MVA, 11KV/ 415V LT Aux. Transformers Neutral Grounding Resistors 11 KV HV Switchgear 415V LT Switchgear with APFC controllers with harmonic tuner, Power cum motor control centers(PMCC), Motor Control Centers (MCC), AC Dist. Boards & Fuse boards, DC Dist. Boards &Fuse boards and 415 V Non segregated phase sandwich type bus duct . Local control boards/panels, Local isolating switch units, Local push button stations Battery and battery chargers 33 KV Outdoor switchyard equipment and accessories. 415 V Emergency Diesel Generator Power and Control Cable Associated Civil work for 33KV Substation and outdoor cable trench/ Cable tray work from 33 KV MRSS to PM#5 Mill Building Substation. Erection - cabling, grounding and lightning protection system. Erection indoor and outdoor electrical equipment.

2.00.00 2.01.00 2.01.01

vii) viii) ix) x) xi) xii) xiii) xiv)

29

2.02.00 2.02.01

SCOPE OF INSTALLATION The scope of installation work includes erection, testing, commissioning and putting into successful commercial operation of all concerned equipments, grounding system and cabling work, lightning protection system as detailed in accompanying specifications described above including supply of all labor, materials, tools, tackles etc. Installation work shall be in conjunction with/not limited to the followings and the requirements of the attachments, drawings and Bill of Materials issued along with this specification. a. Installation work shall be carried out in accordance with good engineering practices and also manufacturers instructions/ recommendations where the same are available. b. Equipment shall be installed in a neat workmanlike manner so that it is level, plumb, square and properly aligned and oriented. c. The equipment shall be furnished in disassembled condition as received at site. Bidder shall assemble all those parts, mount and wire-up loose equipment, fittings and accessories and complete all connections. d. The equipment will be generally supplied with base frame. All bolts, nuts, anchors etc. shall be supplied to complete the installation. e. All erection work shall be carried out in strict compliance with manufacturers instructions and shall include all necessary adjustments, checks and measurements. f. All internal wiring of the equipment which has been left incomplete because of shipping split or which requires minor modifications shall be carried out by the contractor.

2.02.02

g. The contractor shall record results of all erection tests and measurements. The contractor shall submit copies of those test results to the Owner for his reference and record. h. Boards etc. will be split up in sections for ease of transportation and handling. All bus wires, relays, meters and control switches etc. supplied loose to be mounted and connected at site. i. Base frames shall be properly anchored with foundation. Inter-shipping section connections shall be made. If any civil modification work is required, same shall be done by the Bidder. All connections in the Cabinets, distribution boards etc. shall be completed, checked and adjusted to ensure safety and satisfactory operation of the equipment. In some cases, modifications may have to be carried out at site in the wiring of an equipment to meet the requirements of the desired control scheme.

j.

k. Bidder shall follow all standard safety regulations and site specific procedures to adopt effective safe working practices to ensure safety of personnel with an objective of zero fatalities and zero lost time due to injuries.
30

l.

Steel Fabrication Installation, fabrication and painting with one coat of anti-rust primer and two finished coats of approved synthetic enamel paint on structural steel for mounting of various equipments and for cable tray supporting arrangement. Contractor shall use all existing available steel structures, cable rack supports, hangers and brackets as per as possible. Additional racks, supports, hangers and brackets wherever necessary shall be supplied and fabricated by the contractor. Steel for fabrication shall be straightened and cleaned of rust and grease. All fabrication shall be free of sharp edges. GA drawing and related technical particulars shall be furnished by Owner/Consultants review. m. Miscellaneous items
The contractor shall install miscellaneous items such as local starters, fuse boards, start-stop push button station, ventilation fan etc. as required.

These equipment will be generally wall or column mounted excepting a few which may be floor mounted. The exact locations will be as decided by the Owner's Engineer at site and as shown in the final drawings. All welding, cutting, chipping and grouting as and when necessary shall be carried out by the Contractor at no extra cost. 2.02.03 Providing all equipments / instruments / materials / components required at site for entire scope of services under this specification including handling, protection, testing, oil filtration, welding, cutting, bending, pulling, civil & structural work etc. shall be under scope of Bidder, including but not limited to the followings in the indicative list: a) Stream line filter machine for adequate capacity suitable for filtration of oil of transformers of various ratings mentioned in the specification, along with power supply equipments and accessories Test kit for transformer oil (BDV etc.) Hi-pot test kit (AC & DC) Primary & secondary injection test kit Phase sequence meter Ratio tester for transformer Welding machine Crimping tools for various sizes of cables Erection crane

b) c) d) e) f) g) h) i)

31

2.03.00 2.03.01

SCOPE OF SERVICES Furnishing all labor, skilled & unskilled, supervisory personnel, erection tools & tackles, testing equipment, implements, supplies and transport for timely and efficient execution of the erection work. Scope of service shall include supply, erection, installation, testing and commissioning of all Electrical Equipments and accessories as mentioned in clause no.2.01.01 above. The items of work to be included under the scope of services of the contractor as specified below: a) Erection, Testing & Commissioning of all equipments with all fittings and accessories supplied under this contract b) Laying, termination, testing & commissioning of Power and Control Cable supplied under this Contract. c) Installation, testing & commissioning of grounding and lightning protection materials for grounding of all equipments, cable trench/tray, gantry, structure, fencing etc. d) Erection, testing & commissioning of pre-fabricated cable trays with all accessories supplied under this contract. e) Fabrication & Installation of fence supports, fence, etc. supplied under this Contract. f) Laying of earth material and equipment including Risers,. Earthing of all equipment & Numerical relays, Bay Controllers by using separate electronic Earth pits.

2.03.02

2.03.03

g) Dismantling and removal of following equipments from 33KV MRSS i) Two (2) nos. 33KV /11 KV 3MVA, Power Transformers. ii) Eight (8) nos. 33KV Disc. Switches. iii) Six(6) nos. 33KV Lightning Arrestors iv) Two(2) nos. 33KV, 1250A VCBs v) Six(6) nos. CTS. vi) 33KV bus bars and conductors. vii) Misc. items such as existing structures, transformer foundation etc. xv) Two(2) nos. 33KV Transformer control panels. 2.03.04 Proper storing arrangement and protection of equipment and materials at site at Contractors expense. The Contractor shall be held responsible for any loss or damage until the work is fully and finally accepted. All testing equipment as required for testing & commissioning of equipment/system shall be arranged by the bidder. The contractor shall also carry out the following services but not be limited to: a) Taking delivery of the owner supplied equipment and materials from the Owners stores, if any, and safe transportation up to the place of erection and excess material back to Owners store.
32

2.03.05 2.03.06

b)

Opening of Packing Cases and inspecting the equipment and materials at site and reporting damages or any discrepancy thereof, if and observed immediately after opening, to the Owner. Supervision of civil work for major electrical equipments. Repair of all minor damages such as removal of paint, loosening of components of the assembly etc. Complete assembly, erection and commissioning. Pre-commissioning checkup to ensure correctness of erection as per actual manufacturer instructions. Testing and commissioning in presence of Owners engineers. Obtaining Engineers approval and written acceptance of satisfactory operation. Handing over of installation for commercial operations. Preparation and submission of drawings & job compliance report and obtaining drawing approval and charging permission from the electrical inspectorate for the project

c) d). e) f) g) h) i) j)

2.04.00

SCOPE OF DESIGN WORK The scope of design work shall include detail design for construction and installation of entire electrical system of the Plant.

2.04.01

Design Work - Electrical o o o o o o o o O Design Memorandum for various Equipment & Systems Design Calculation, Bill of Material Electrical Single Line Diagrams. Electrical layouts, showing equipment location, cable trays/ trenches, overhead cable routes, etc. Control, metering, protection equipment and the system. and signaling scheme of each

Cable schedule and interconnection charts. List of equipment and respective ratings. Cabling and cable tray system. Grounding and lightning protection system including underground grounding mat, over ground grounding grid, air terminal network, lightning mast, Earth Pits.

33

O o 3.00.00 3.01.00 3.01.01

Relay co-ordination and recommended co-ordination, sag-tension curves.

settings,

insulation

Preparation of installation, commissioning, operation and maintenance manuals.

GENERAL REQUIREMENT CODES & STANDARDS All electrical equipment and materials shall conform to latest applicable standard publications of International Electro-technical Commission (IEC) or equivalent standards published by the Bureau of Indian Standards (BIS) and other standards mentioned in the various volumes of sections of this specification. In case of a conflict between IEC and other standards, the requirement of IEC shall govern. The provisions of tender specifications (except the clauses of codes and standards of individual specifications) shall however have precedence over all other standards The electrical installation shall meet the requirements of Indian Electricity Rules as amended up-to-date, relevant IS code of Practice for respective equipment and National Electrical code of India. In addition, other rules & regulations applicable to the work shall be followed. In case of discrepancies, most restrictive rules shall be binding. COMPLETENESS OF SUPPLY & INSTALLATION It is not the intent to specify completely herein all details of the equipment & installation. Nevertheless, the equipment & installation shall be complete & operative in all aspects and shall conform to highest standard of engineering, design & workmanship. Any material or accessory which may not have been specifically mentioned but which is necessary or usual for satisfactory & trouble free operation & maintenance of the equipment shall be furnished without any extra charge. The Contractor shall supply all brand new equipment & accessories as specified herein with such modification and alteration as agreed upon in writing & after mutual discussion. PROPOSAL DATA The proposal data sheets annexed to this specification shall be filled in without any ambiguity by typing in appropriate place on each page. These pages must be properly signed by authorized representative of the Bidder as verification of the data and submitted along with the bid to form part of the Bidder's formal proposal.

3.01.02

3.02.00 3.02.01

3.02.02

3.02.03

3.03.00

3.04.00

PERFORMANCE The performance figures quoted in Technical Particular sheets shall be complied within the tolerance permitted by relevant standards. In case of failure of the equipment, the equipment may be liable for rejection.

34

3.05.00 3.05.01 3.05.02

DRAWING APPROVAL Before starting manufacture of any equipment, the Contractor shall have to take approval of relevant drawings and data from SPM/ DCPL in writing. Any manufacture done prior to the approval of drawings/data shall be rectified in accordance with the approved drawings/data by the Contractor at his own cost and the equipment shall be supplied within the stipulated period. QUALITY ASSURANCE Contractor shall follow his standard procedures for quality assurance and control. However, said standard procedures shall be submitted to the SPM/ DCPL for review and approval. The procedures shall be in such a form as to clearly delineate the manufacturing sequence and major inspection points and to reference Bidder's test and inspection procedures. The SPM/ DCPL will inform the Contractor as to which of the inspection points and tests will be witnessed. As a minimum, a final inspection of the equipment will be made prior to shipment. Manufacturing and quality control procedures shall be available for audit to the SPM/ DCPL and/or its representative at the place of manufacture. The SPM/ DCPL and/or its representative reserves the right to inspect the equipment at the point of manufacture and witness factory and other such tests as may be necessary to ensure conformance to the specification. The SPM/ DCPL and/or its representative may inspect the Contractor's facilities prior to award of contract. The SPM/ DCPL and/or its representative may witness any or all of the tests described. The SPM/ DCPL and/or its representative may conduct surveillance of the Contractor's facilities for compliance to his standard procedures of quality assurance and quality control while work on the specified equipment is in progress. SITE CONDITION The plant is located in SPM, Hoshangabadin the state of MP. The site is approachable from Mumbai by the state highway. The nearest broad gauge rail link is at Hoshangabad, and the nearest airport is at Raja Bhoj Airport, Bhopal. The apparatus shall be suitable for satisfactory operation in the following environment:Altitude Design Ambient Temperature Relative humidity
35

3.06.00 3.06.01

3.06.02

3.06.03

3.06.04 3.06.05

3.06.06 3.06.07 3.06.08

4.00.00

: : :

302 m above MSL 500 C max. / 3.30 C min. 91% max.

Basic wind speed as per IS: 802 Seismic zone as per IS: 1893 Pollution level according to IEC60815 Isoceraunic level Switchyard formation level Equipment & Tower foundation plinth level Bay control room / Main control building Plinth level Substation road level 5.00.00 5.01.01 5.01.02

2.1 m /sec III (heavy) As per IS: 2309 Bidder to submit 300 mm (above formation level) 500 mm (above formation level) 200 mm (above formation level)

FACILITIES TO BE ARRANGED BY CONTRACTOR The Contractor will be given a plot of land at site for building his site office stores for construction activity only. Electricity will be provided at one point only. It will be the responsibility of the contractor to arrange for further distribution. The contractor shall also arrange for storing of materials with weather protection wherever necessary & proper security arrangement till the installation. CO-ORDINATION WITH OTHER CONTRACTORS & OWNERS SYSTEM The Contractor shall be fully responsible for carrying out all co-ordination work required with other contractors as well as with Purchaser & Owners System for execution & completion of his work.

6.00.00

7.00.00 7.01.00

DRAWINGS, DATA & MANUALS Drawings, Data and Manuals shall be submitted in four (4) nos. of copies with the bid and in quantities and procedures as specified in General Conditions on Contract and/or elsewhere in this specification for approval and subsequent distribution after the issue of Notification of Award of

contract or Purchase Order

7.02.00 7.02.01 7.02.02 7.02.03 7.03.00

To be submitted with the Bid Typical general arrangement drawings of the equipment indicating space requirement, etc. Proposal Technical Particulars, leaflets on equipment and special tools explaining construction features, principle of operation, special features etc. Type test certificate of the offered model of the for the specified type tests. To be submitted for SPM/ DCPL Approval and Distribution after issue of Notification of Award of contract or Purchase Order (A) : Approval Category (R) : Reference Category
36

Quantities: Hard Copy: 3 Initial submissions, 6 Final approved copies Soft copy Auto Cad Version: Initial & Final 7.03.01 7.03.02 7.03.03 7.03.04 7.03.05 7.03.06 7.03.07 7.03.08 7.03.09 Guaranteed Technical Particulars (A) & Quality assurance plan.(R) Dimensional general arrangement drawing showing disposition of various fittings, (A) Structure Plan with details and loading. (R) Foundation loadings for all equipment and supporting structure ( R) Assembly drawing for erection at site with part numbers and schedule of materials Transport/shipping dimensions with weights (R) Control schematic (A) and wiring diagrams (R). Grounding arrangement and ground bus details (A) including Manufacturers recommendation on Grounding of reinforcement bars of Column foundation. Any other relevant drawing or data necessary for satisfactory installation, operation and maintenance. Instruction manuals on all HT & LT Equipments and its accessories (R) The manual shall clearly indicate method of installation, checkups and tests to be carried out before commissioning of the equipment. 7.04.00 The drawings and documents marked with (A) above are of Approval category and are subject to review by SPM/ DCPL. Those marked (R) are for reference category. The Owner may review the documents marked (R) if thought necessary. The contractor shall note that the approval of drawings & documents by the Owner does not relieve him of his contractual obligation. 7.05.00 The bidder may note that the drawings, data and manuals listed herein are minimum requirement only. The bidder shall ensure that all other necessary write-up, curves, etc require to fully describe the equipment are to be submitted with the bid. All drawings shall be prepared by using AutoCAD and documents shall be generated using Electronic version. The paper copy of the drawings & document shall be submitted for approval & reference. All final drawings and documents shall be submitted in CD in AutoCAD 2000 and MS office format as applicable for Owners future reference. Also AutoCAD version of Main GA drawings is to be submitted for Owners layout finalization.

7.06.00

37

8.00.00

MAKE LIST: Bidder has to consider following make list of major electrical Equipment:I) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) 33KV vacuum circuit breaker ABB, Siemens, CGL, BHEL, AREVA 33/11KV ,10 MVA power transformer - ABB, Siemens, CGL, BHEL, AREVA Neutral grounding resistor RSI Switchgear,RESITECH,NARKHEDE 11KV switchgear BHEL, Siemens, ABB, CGL,AREVA LT Switchgear &MCC L&T, Siemens, SCHNEIDER,ABB 415V Sandwich Bus ductABB, L&T, Siemens 11/0.415 KV 3MVA LT Transformer ABB, BHEL, CGL, AREVA Battery & Battery Charger Exide, Amaron, AMCO HT & LT Power Cable Finolex,Universal, POLYCAB , Fort Gloster, Numerical Relays ABB, Siemens, AREVA ACB ABB, Siemens, L&T DG Set Cummins, Kirloskar, Crompton Greave

38

ANNEXURE-A SYSTEM DETAILS EHV / HV System 1.0 2.0 3.0 4.0 Rated Voltage Frequency Phase System Neutral : : : : 33KV 33KV 11KV 11KV

-----50 Hz +3% to -3%------------------3-----------------Effectively Earthed Non-Effectively Earthed thru resistance.

5.0 6.0 6.1 6.2 7.0 8.0

Fault Level (Sym) rms : Insulation Level Basic Insulation level Switching Impulse level Power Frequency withstand voltage dry/wet KVrms

-----31.5KA for 1 sec.-----

650 KVp

170KVp

230KV

70KV

Maximum radio Interference voltage level between 0.5 and 2 MHz at 320KV rms phase to ground (Voltage in micro-volts) Minimum Visual Corona Extinction Voltage (KV rms) Minimum Clearance Phase to Phase (mm) (Rod-Conductor) (Cond.-Cond.) Phase to Earth Safety Clearances Sectional Clearance (mm) Height of the lowest live point on the insulator from the ground Minimum creepage distance (mm)

--------------

9.0 10.0 10.1 10.2 11.0 11.1 11.2 12.0

1300 1300

320 320

4000

2800

-------------2440----------------------------31mm / KV-----------

(mm)

39

13.0 13.1 13.2 14.0. 15.0 15.1 15.2 15.3 16.0 17.1 17.2 17.3

Auxiliary Power Supply A.C. Supply D.C. Supply Bus Configuration Conductor Main Bus Equipment Interconnection Phase to phase equipment spacing Bus Height Main Bus (mm) Equipment Connection Jack Bus 5500 4000 8500 Dog Type ACSR 3.0 IPS Al tube 2750 : : 415V 10%, 3phase, 50Hz 3% 4 wire, effectively earthed system. Fault level 50 KA r.m.s. symm. 110V + 10%, - 15%, 2 W, ungrounded system. Fault level 15 KA. 1M+1T

Note: The above figures are for general guidance only. The switchyard layout shall meet the requirements of CBIP standards and IE rules.

40

ANNEXURE-B LIST OF TENDER DRAWINGS

SL.NO.

DRAWING NO.

TITLE / DESCRIPTION

1. 2. 3. 4. 5. 6. 7. 8. 10. 11.

11P01-DWG-E-100, Rev-e 11P01-DWG-M-111-050.01, Rev 2 11P01-DWG-E-111-050.01, Rev 0 A- SPM PM5 BUILDING, Rev.0 1327-001377 Sht.1 of 2 1327-001377 Sht.2 of 2 1002-0000110350, Rev.1.0 (4 Sheets) 11P01-DWG-E-40-ND-400 (14 Sheets) 11P01-DWG-E-53-2341 (28 Sheets) Part List TPE1/TPE2/TPE3 (3 Sheets)

Key Single line diagram Plot Plan 33KV Switchyard Layout Single Line Diagram Earthing Layout Basement Level PM5 Earthing Layout Machine Level PM5 Typical Grounding Details for PM5 Building General Arrangement of cable tray, Trench & support details Grounding notes and details Bidders Scope of Supply

41

SPECIFICATION NO. : 11P01-SPC-E-291-53.02 SUB-SECTION: II 10 MVA POWER TRANSFORMERS

42

SUB-SECTION: II

10 MVA POWER TRANSFORMER

CONTENTS
CLAUSE NO 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 DESCRIPTION CODES AND STANDARDS SCOPE OF WORK DESIGN CRITERIA SPECIFIC REQUIREMENTS TESTS SPECIAL TOOLS & TACKLES INSTALLATION REQUIREMENTS PAGE NO. 1 1 2 3 8 10 10

ATTACHMENTS
ANNEXURE - A ANNEXURE - B ANNEXURE C RATINGS AND REQUIREMENT FITTINGS AND ACCESSORIES AUXILIARY EQUIPMENT 11 14 16

43

10 MVA POWER TRANSFORMERS

1.00.00 1.01.00 CODES & STANDARDS All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification. The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed. Accountability of transformer loss Transformer losses will be taken into account during bid evaluation. The loss figures quoted shall be guaranteed under penalty. The test values for losses will be compared with the corresponding guaranteed figures subject to I.S/IEC. Tolerances for computation of penalties. SCOPE OF WORK SCOPE OF SUPPLY Type, rating and connections of the equipment listed below are detailed in the Annexure A. The equipment shall be offered in strict compliance with the same. 2.01.01 2.01.02 Copper Wound 33KV/11 KV, 10 MVA HT Transformers: Each transformer shall be furnished complete with :a. b. c. 2.01.03 2.01.04 2.02.00 Fittings and accessories Auxiliary equipment First filling of oil including 10% extra Two (2) Nos.

1.02.00

1.03.00 1.03.01 1.03.02

2.00.00 2.01.00

One (1) set of special tools and tackles All relevant drawings, data and instruction manuals. SCOPE OF SERVICES The services of supervisor must have supervisory license from State Electricity licensing authority / Qualified Electrical Engineer, experienced in the erection and commissioning of the equipment of similar type and rating on per diem basis. The work includes but not limited to: -

2.02.01 2.02.02 2.02.03

Complete checking of materials at site and advising the Owner/Purchaser any discrepancy thereof. Advice on procedure of erection to be followed. Regular supervision and following up of erection work done by others.
44

2.02.04 2.03.00 2.03.01

Testing, commissioning and putting the equipment into successful commercial operation. DELIVERY SCHEDULE The delivery period shall be as mentioned in the delivery Time Schedule (D)from the date of issue of Notification of Award of contract or

Purchase Order

2.03.02 2.03.03 2.03.04 3.00.00 3.01.00 3.02.00

Delivery period shall be inclusive of the time to be allowed for approval of drawings & test certificates and shall include transportation time to site. Delivery date shall be reckoned as the date of receipt of the complete equipment & materials at site. Mandatory spares, special tools and tackles shall be supplied with the first consignment. DESIGN CRITERIA The transformer will be used to supply power for SECURITY PAPER MILL, HOSHANGABAD-461005(M.P.) The transformer will be installed in hot, humid and tropical atmosphere. All equipment, accessories and wiring shall be provided with tropical finish to prevent fungus growth. The transformer shall be capable of continuous operation at rated output under the following condition: a. b. c. Voltage variation Frequency variation Combined voltage and frequency variation (absolute sum) : 33KV 5% : 50Hz 3% : 8%

3.03.00

3.04.00

The transformer shall be capable of withstanding the short circuit stresses due to a terminal fault on one winding with full voltage maintained on the other winding for minimum period of two (2) seconds. The transformer shall be free from annoying hum or vibration. The design shall be such as not to cause any undesirable interference with radio or communication circuits. The transformer shall be so designed that it is capable of operation at 125% rated voltage for a period of one minute and 140% rated voltage for a period of five seconds due to sudden load throw off. The noise level shall be limited to the value specified by NEMA Standard Publication No. TR-1-1993 when measured in accordance with conditions outlines in ANSI/IEEE C57.12.90-1999/IS13964/CBIP publication.

3.05.00

3.06.00

3.07.00

45

4.00.00 4.01.00 4.01.01 4.01.02

SPECIFIC REQUIREMENTS TANKS The tank shall be fabricated from good commercial grade low carbon steel of suitable thickness to the project.. The tank wall shall be reinforced by stiffener to ensure rigidity so that it can withstand without any deformation (a) mechanical shock during transportation, (b) oil filling by vacuum, (c) Short circuit forces and (d) continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure of oil. All removable covers shall be provided with weatherproof, hot oil resistant, resilient gaskets. The design shall be such as to prevent any ingress of water into or oil from the tank. The tank shall be provided with one set of bi-directional flanged wheels for rolling the transformer parallel to either center line over 1676 mm rail gauge. In case more than two rails are required to be provided the rail gauge of 1676 mm shall be maintained between two adjacent rails. Jacking pads, lifting eyes and pulling lugs shall be provided to facilitate movement of the transformer. All heavy removal parts shall be provided with eyebolt for ease of handling. Manholes / hand-holes of sufficient size shall be provided for access to leads, windings, bottom terminals of bushings and taps. Suitable guide shall be provided in the tank for positioning the core and coil assembly. Inside of tank shall be painted with varnish/hot oil resistant paint. The top cover of the tank shall be slightly sloping to drain rain water. CORE & COILS The core shall be built up with high grade, non-aging, low loss, high permeability, grain oriented, cold-rolled silicon steel laminations especially suitable for core material. They should be bolted together and to the frames firmly to prevent vibration or noise. The coils shall be manufactured from electrolytic copper conductor and fully insulated for rated voltage. However, HV winding shall be non-uniformly graded for voltage class above about 33KV. Insulation shall be of Class A. Insulating material shall be of proven design. Coils shall be so insulated that impulse and power frequency voltage stresses are minimum. Coil assembly shall be suitably supported between adjacent sections by insulating spacers and barriers. Bracing and other insulation used in assembly of the winding shall be arranged to ensure a free circulation of the oil and to reduce the hot spot of the winding.

4.01.03

4.01.04

4.01.05

4.01.06 4.01.07 4.01.08 4.02.00 4.02.01

4.02.02

4.02.03 4.02.04

4.02.05

All leads from the windings to the terminal board and bushings shall be
46

rigidly supported to prevent injury from vibration or short circuit stresses. Guide tube shall be used where practicable. 4.02.06 The core and coil assembly shall be securely fixed in position so that no shifting or deformation occurs during movement of transformer or under short circuit stresses. The value of the maximum flux density allowed in the design and grade of lamination used shall be clearly mentioned in the offer. The transformers core shall be suitable for over fluxing (due to combined effect of voltage and frequency) up to 12.5% without injurious heating at full load conditions and shall not get saturated. TAPINGS Off circuit tap changer (OCTC) as specified in the Annexure-A shall be provided on the high voltage winding. The transformer shall be capable of operation at its rated KVA on any tap provided the voltage does not vary by more than 10% of the rated voltage corresponding to the tap. The winding including the tapping arrangement shall be designed to maintain electromagnetic balance between HV and LV windings at all voltage ratios. Off Circuit TAP CHANGER (OCTC) The OCTC switch contacts shall be located in a separate oil-filled chamber complete with its own oil preservation system, Oil Surge relay, shut-off valves, oil level gauge, gas vent etc. OCTC mechanism and associated controls shall be housed in an outdoor weather-proof cabinet (IP 55 minimum). Internal illumination lamp and thermostat controlled space heater shall be provided in the cabinet. The tap change equipment shall be so designed that if the mechanism is stuck in an intermediate position, the transformer shall be capable of delivering full load without any injury. The OCTC gear shall be suitable For local manual control. Further, there shall be provision of automatic operation through voltage sensing relay wherever specified. The hand cranking arrangement shall be such that it can be operated at standing height from ground level. Further the mechanism shall be provided with a tap position indicator and an operation counter. Interlock shall be provided to ensure the following:a. Positive completion of tap changing step once initiated. b. Blocking of reverse tap change command during a forward tap change already in progress until the mechanism rests and vice-versa. c. Cutting out of electrical circuit during manual operation.
47

4.02.07

4.03.00 4.03.01 4.03.02

4.03.03

4.04.00 4.04.01

4.04.02

4.04.03

4.04.04

4.04.05

4.04.06

4.04.07

The tap changing gear shall have local selector switches with RTCC-LocalTest-Central positions. Provisions of various modes of operation of the tap changers of transformers, like individual operation (Master / follower operation for 3 off 1- Ph. Bank), remote/local operation; operation from voltage regulating relays(where specified), etc. and for various interlocks shall be kept in the Remote Tap Changer Cubicle (RTCC) as well as local OCTC cabinet. Necessary equipment switches, relays, etc., shall be provided in these panels. The following minimum components shall be provided in the RTCC panel. Any other feature desired for proper and safe operation of equipment shall be provided. All indicating lamps shall be LED type. a) b) c) d) e) f) g) h) i) Voltage regulating relay for auto operation where specified. Auto-manual selector switch where auto operation specified Selector switch for master follower solo operation. Raise-Lower control switch Necessary relays and accessories. Tap position indicator Indication lamps for Tap change in Progress and Control supply healthy. Red lamp to indicate master position Annunciations for : Tap position in progress Mechanism stuck Control supply failure Tap changer A.C. supply failure Oil surge relay operated

4.04.08 4.04.09 4.05.00 4.05.01 4.05.02

Provisions shall be kept in the RTCC for control from DCS. The construction and other details of the RTCC shall be similar to those described elsewhere in this specification. INSULATING OIL The transformer shall be filled with mineral insulating oil of adequate voltage grade suitably inhibited to prevent sludging. First filling of oil along with 10% excess shall be furnished for each transformer. Oil shall be supplied in non-returnable containers suitable for outdoor storage. Oil preservation shall be by means of bellows / diaphragm sealed conservator tank with silica gel breather to avoid direct connection between atmosphere and transformer oil. It shall be complete with level gauges, pipes, drain valve etc. The level gauges shall be so placed that same can be readable standing from ground. Necessary device shall be kept to provide annunciation in the event of rupturing of bellow.
48

4.05.03

Diaphragm seal type constant oil pressure system shall have following system: a) Contact of the oil with atmosphere is prohibited by using a flexible urethane or nitride rubber reinforced with nylon cloth air cell. b) Diaphragm shall be suitable for 100deg C temp continuous operation c) The connection of air cell at the top of the reservoir is by air proof seal permitting entrance of air into the cell only. d) Diaphragm shall with stand vacuum during instillation/ maintenance; otherwise provision shall be made to isolate conservator from main tank during vacuum by providing vacuum sealing valve in the pipe connecting main tank with conservator. 4.06.00 4.06.01 BUSHING Bushing rated 52 KV class and above shall be oil impregnated paper condenser bushings. Bushing rated below 52 KV voltage class shall be solid porcelain or oil communicating type. Condenser type bushing shall be provided with oil level gauge, bottom drain plug and test terminal for measurement of loss factor (tan-delta) and capacitance. Bushings shall be provided with terminal connectors of approved type and size. Arcing horns shall be provided on HV bushings. Bushing location shall provide adequate phase and ground clearances as per relevant IS and CBIP recommendation. TERMINAL ARRANGEMENTS The physical position of the terminals and the markings shall be as per relevant IS/IEC unless otherwise shown in the enclosed drawing. High voltage terminals shall be brought out through top cover mounted bushings for connection to overhead ACSR/AAAC/Al tube conductors . Low voltage terminals shall be brought out through top cover mounted bushings with matching flanges around each bushing for connection cable as specified in Annexure. A detachable type cable end-box with disconnect link shall be furnished. Low voltage winding neutral shall be brought out through side wall mounted bushing to a detachable cable end-box with disconnect link for connection to neutral grounding resistor through copper cable.. The LV cable-end box shall be self-supporting, air filled type complete with all hardware such as gland plate, brass glands, tinned copper lugs, armour clamps etc. Supports shall be provided for all vertically rising cables Cable shall be terminated using stress relieving plug in elbow connectors In general, the arrangement shall be such as to permit removal of transformer without dismantling the cable connection.
49

4.06.02

4.06.03 4.06.04 4.07.00 4.07.01 4.07.02 4.07.03

4.07.04

4.07.05

4.07.06

4.08.00 4.08.01

COOLING SYSTEM The transformer cooling system (ONAN only) and number of cooling banks and capacity of each bank shall be as specified in the annexure. The cooling system shall comprise number of cooling units each complete with its radiator banks and other accessories. The radiators shall be detachable type with top and bottom isolation valves to permit the removal of the same without drainage of oil from the tank. MARSHALLING BOX A sheet steel, weatherproof, IPW55, marshaling box shall be provided for the transformer. The box shall contain all auxiliary devices except those which must be located directly on the transformer.
All terminal blocks for Owner/Purchaser's cable connection shall be located in this box.

4.08.02

4.09.00 4.09.01

4.09.02

4.09.03 4.10.00 4.10.01 4.10.02

The marshaling box shall be provided with cubicle lamp with door switch, space heater with thermostat and removable cable gland plate. WIRING All control, alarm and indication devices provided with the transformer shall be wired upto the terminal blocks. Wiring shall be done with flexible, 1100V / 650V grade PVC insulated copper wires in conduit or PVC armored cable. Minimum wire size shall be 2.5 mm2 copper. Not more than two wires shall be connected to a terminal. 10% spare terminals shall be provided. Multi-way terminal block complete with mounting channel, binding screws and washers for wire connections and marking strip for circuit identification shall be provided for terminating the panel wiring. Terminals shall be stud type, suitable for terminating 2 nos. 2.5 mm2 stranded copper conductor and provided with acrylic insulating cover. Terminals for C.T. secondary leads shall have provision for shorting and grounding. All devices and terminal blocks shall be identified by symbols corresponding to those used in applicable schematic or wiring diagram. Each wire shall be identified, at both ends, with interlocking type permanent markers bearing wire numbers as per Contractor's Wiring Diagrams. AC / DC wiring shall have separate color-coding. Wire termination shall be made with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals. GROUNDING The grounding pads, located on the opposite sides of the tank, shall be provided for connection to station ground mat. Grounding pad shall have clean buffed surface with two tapped holes, M10 G.I. bolts and spring washers for connection to 50x6 mm Cu. flat.
50

4.10.03

4.10.04

4.10.05 4.11.00 4.11.01 4.11.02

4.11.03 4.11.04

Ground terminals shall be also provided on marshaling box to ensure its effective earthing. For continuity of earth connection, all gasketted joints shall be provided with braided copper wire jumpers. AUXILIARY SUPPLY A.C. supply will be made available to each transformer by two separate feeders one normal and the other standby. Isolating switch fuse unit shall be provided for each of the incoming supply along with automatic changeover scheme to switch on to the standby source in case of failure of the normal supply. AUXILIARY EQUIPMENT Neutral bushing current transformers and phase bushing transformers shall be furnished when specified in the annexure. current

4.12.00 4.12.01

4.12.02

4.13.00 4.13.01 4.13.02 4.13.03 4.14.00 4.14.01

The arrangement shall be such that the C.T. can be removed from the transformer without removing the tank cover. CT secondary leads shall be wired upto the terminal blocks. PAINTING All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents as required, to produce a smooth surface free of scales, grease and rust.
The internal surfaces in contact with insulating oil shall be painted with heat resistant insulating varnish which shall not react with and be soluble in the insulating liquid used.

4.14.02

4.14.03 4.14.04 4.14.05

The external surfaces, after cleaning, shall be given a coat of high quality red oxide or yellow chromate primer followed by filler coats. The transformer shall be finished with two coats of battle ship grey (IS Shade # 632).synthetic enamel paint. The paints shall be carefully selected to withstand tropical heat, rain etc. The paint shall not scale off or crinkle or be removed by abrasion due to normal handling. Sufficient quantity of touch up paint shall be furnished for application after installation at site. If it is considered necessary, the transformer may be given a further coating at site by the Owner/Purchaser. The Bidder shall therefore indicate the type and quality of the paint with full specification for this purpose. All supporting structures and hardware shall be hot dip galvanized. TRANSPORTATION
51

4.14.06 4.14.07

4.14.08 4.15.00

4.15.01

Transformer tank shall be dispatched filled with oil and transformer should be filled with nitrogen. In case the tank is filled with oil, sufficient space is left above the oil to take care of the expansion of the oil. The space is filled with pure dry air or inert gas under atmospheric pressure. TESTS ROUTINE TESTS
During manufacture and on completion, all transformers shall be subjected to the routine tests in accordance with latest IEC 60076 and its different parts. In addition, the following tests shall be performed on each transformer:

5.00.00 5.01.00

5.01.01

Transformer tank with coolers shall be tested for leaks with normal head of oil plus 35 KN/m2 for a period of 8 hours. If any leak occurs, the test shall be conducted again after all leaks have been repaired. During fabrication stage, the tank shall be pressure tested with air at a pressure corresponding to twice the normal head of oil or normal pressure plus 35KN/m2 whichever is lower for a period of one hour. Also the tank designed for full vacuum shall be tested for maximum internal pressure of 3.33KN/m2 for one hour. The permanent deflection of flat plates shall not exceed CBIP specified figures on release of excess pressure of pressure test and on release of vacuum. After assembly, each core shall be pressure tested for one minute at 2KV (r.m.s.) A.C. between all bolts, side plates, structural steel works and the core. The wiring for auxiliary power and control circuitry shall be subjected to withstand one minute power frequency test with 2.0KV (r.m.s.) to earth Dielectric special tests as per IEC60076-3 Determination of capacitances windings-to-earth and between windings Frequency Response Analysis test (This test shall also be undertaken by the manufacturer at site after transformer is installed.) Measurement of acoustic sound level Measurement of power consumption of fans Measurement of zero sequence impedance(s) on three-phase unit Measurement of dissipation factor (tan delta) of insulation system capacitances TYPE TESTS Following type tests shall be performed on one transformer in accordance with relevant standard: a. Dielectric type test (IEC60076-3) b. Temperature rise test. Cost of such tests, if extra, shall be quoted separately by the Bidder.
52

5.01.02

5.01.03

5.01.04 5.01.05 5.01.06 5.01.07 5.01.08 5.01.09 5.01.10 5.01.11 5.02.00

5.03.00

MISCELLANEOUS All component parts and auxiliary equipment such as oil, bushings, C.Ts etc. shall be routine tested as per relevant Indian Standards.

5.04.00

TEST WITNESS Tests shall be performed in presence of Owner/Consultant representative if so desired by the Owner/Consultant. The Contractor shall give at least seven (7) days' advance notice of the date when the tests are to be carried out

5.05.00 5.05.01
5.05.02

TEST CERTIFICATES Certified reports of all the tests carried out at the works shall be furnished in six (6) copies for approval of the Owner/Consultant.
The equipment shall be dispatched from works Owner/Consultant's written approval of the test reports. only after receipt of

5.05.03 6.00.00 6.01.00

Type test certificates on any equipment, if so desired by the Owner/Consultant, shall be furnished. Otherwise the equipment shall have to be type tested, free of charge, to prove the design. SPECIAL TOOLS & TACKLES A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied. The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended. INSTALLATION REQUIREMENTS The Contractor shall perform erection, testing and commissioning along with oil filtration & dissolved gas analysis test but excluding the construction of foundation. Job includes safe storage at place of installation, unpacking, positioning in place, site assembly of loosely furnished accessories, connection & assembly of loose supply items, auxiliary circuits, topping up with oil and testing of oil with Contractor's own test equipment, including Erection of MB, fixing of nuts and bolts etc., including all labour and materials, as per approved drawings, specifications of this tender and directions of Engineer-in-Charge/Manufacturer's supervisor. The contractor shall place the transformer on its foundation, assemble parts and erect the sheet steel chamber with danger plate fixed on the same. The storage and installation of transformer shall be carried out in strict compliance with manufacturer's instruction.

6.02.00 7.00.00 7.01.00

7.02.00 7.03.00

53

ANNEXURE-A RATINGS AND REQUIREMENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 10.1 10.2 11.0 11.1 11.2 Application Service Winding Type Environment Reference standard Rated power Rated voltage ratio (line to line) No. of phases Rated frequency Cooling system Type of Cooling Nos. of cooling units & each capacity Temperature rise Design ambient temperature Temperature rise above design ambient temperature. a) b) 12.0 in oil by thermometer in winding by resistance : : 40 oC 45 oC : 50 degree Centigrade : : ONAN 2X 50% : Outdoor type
: Outdoor, step down, two (2)

nos. Cu Winding.

: Oil immersed : Highly Humid : : : : : IS 2026 & IEC 60076 10MVA 33 / 11 KV 3 50 Hz

Insulation level (SI: Switching Impulse Voltage, LI: Lightning Impulse Voltage, AC: Short duration induced & separate source AC withstand Voltage) E.HV- (SI/Li/AC) HV(LI/AC) : : 170KVp / 70 KV rms 75 KVp / 28 KV rms

13.0

Vector group
54

Dyn 11

14.0 14.1 15.0 16.0 16.1 16.2 TC 16.3

Short-circuit impedance at 75C at principal tap Short circuit withstand time Parallel operation of transformer Type of taps provided Taps provided on Range of taps Method of Tap charge controla) b) c) d) Manual local Electrical local Electrical Remote Automatic : : : : : : :

: 10 % on base MVA : : 2 Sec. Yes, momentary

on load, full capacity H.V. winding +10% @ 1.25% OC

YES YES YES NO

17.0

System earthing 33 KV SIDE 11 KV SIDE through : : Solidly earth Non-effectively earthed

resistance to limit the fault current to 300 A

18.0

Terminal arrangement 33 KV SIDE 11 KV SIDE : : : KV (r.m.s.) : : mm : : : ACSR/ Al tube Cu XLPE cable 33KV 36 LV/LV-N 12

19.0 19.1 19.2 19.3 19.4 19.5 20.0

Transformer bushing Voltage class Material Min. Creepage distance Min. Ph-Ph clearance mm Min. Ph-Gr clearance mm System fault Level 33 KV Side 11KV Side

Solid Porcelain 31mm per KV HV LV As per CBIP As per CBIP

: :

31.5 KA (rms.) 40 KA (rms.)

21.0

Max. Flux density in any part of core & Yoke under any tap position
55

1.7 Tesla

at 110% rated voltage 22.0 23.0 Max. Noise level in accordance with Conditions specified in NEMA Std. TR-1 Auxiliary supply (AC) DC wire : : : 65 dB 415/230V, 3 ph., 50 Hz 110V +10%, -15% 2

24.0 No Load Loss Load Loss

Maximum guaranteed losses at principal tap at full load and 75 Deg Centigrade must not exceed the following values : .KW (to be filled by bidder) : .KW (to be filled by bidder)

Above losses are subject to the IS tolerance.

56

ANNEXURE - B FITTINGS AND ACCESSORIES Transformer shall be equipped with fittings and accessories as listed below:1. 2. 3. 4. Rubber back type oil conservator with filler cap, drain plug, plain oil level gauge and alarm contacts for rupturing of bellows/diaphragm. Rubber back type oil preservation system complete with accessories. Air release plugs of adequate no over tank cover and one no over each radiator tube link Pressure release device with alarm/trip contacts. Explosion vent, if provided, should be double diaphragm type with a gauge glass in intermediate chamber. Equalizer pipe connection with conservator if explosion vent is provided. 250 mm dial magnetic oil level gauge with low level alarm contacts 150 mm dial oil temperature indicator with maximum reading pointer and electrically separate contacts for trip and alarm and embedded temperature detectors (PT-100) with suitable output for remote indication (data logging). 150 mm dial winding temperature indicator with maximum reading pointer and electrically separate sets of contacts for trip, alarm and cooler control and embedded temperature detectors (PT-100) with suitable output for remote indication (data logging).Winding temperature detector shall be 3 Wire duplex type. Remote winding temperature indicator for mounting on remote control panel with a separate detector element. Separate CTs and temperature detector element- One each for local indicating temp and remote winding temp. Thermometer pockets. Double float Buchholz relay with gas release cock, shut-off valve on either sides with separate sets of contacts for trip and alarm. Filter valve with threaded adopter (top and bottom). Drain valve with threaded adopter. Sampling valve.

5. 6. 7.

8.

9. 10. 11. 12. 13. 14. 15

Necessary valves for detachable cooler units. 16. Jacking pads, handling and lifting lugs.
57

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Cover lifting eyes. Bi-directional flanged wheels and skids for rolling transformer over a 1676 rail gauge. Clamping device with bolts & nuts. Man-hole of sufficient size for access to interior of the tank. Two-grounding pads. Ladder with safety device for access to the top of transformer tank. Weather proof marshaling box for housing control equipment and terminal connections. H.V. and L.V. bushing terminal connectors. Rating and terminal marking plates. Cooler units complete with valves(isolation valves shall be provide at both end of each cooler bank ) Tap-changing gear complete with tap position indicator, operation counters etc. For OCTC gear (where specified), oil surge relay (OSL) with shut-off valve, Local control cabinet and Remote (RTCC) panel Prismatic oil level gauge (required no to cover entire depth of conservator) All indication, alarm, trip contacts provided shall be rated for 2A at 110 V D.C. and 5A at 230 V A.C.

28. Note

58

ANNEXURE-C

AUXILIARY EQUIPMENT Transformer shall be provided with phase (where specified) and neutral bushing current transformers as specified as indicated below:Phase CT Application Current Ratio Class Burden Knee point voltage Excitation current at Vk/2 Secondary resistance at 75oC Rated frequency Voltage class : : : : : : 30 VA V .. mA PS 5P10 Neutral CT

: : :

...ohm 50 HZ (max) 12 KV

59

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION: III LT AUX. TRANSFORMER

60

SUB-SECTION: III LT AUX. TRANSFORMER CONTENTS

CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 DESCRIPTION CODES AND STANDARDS SCOPE OF WORK DESIGN CRITERIA SPECIFIC REQUIREMENTS TESTS SPECIAL TOOLS AND TACKLES INSTALLATION REQUIREMENTS 7 PAGE NO. 1 1 2 2 6

ATTACHMENTS
ANNEXURE A ANNEXURE B RATINGS AND REQUIREMENT FITTINGS AND ACCESSORIES 8 9

61

LT AUX. TRANSFORMER
1.00.00 1.01.00 CODES AND STANDARDS All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification. The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed. Accountability of transformer loss Transformer losses will be taken into account during bid evaluation. The loss figures quoted shall be guaranteed under penalty. The test values for losses will be compared with the corresponding guaranteed figures subject to I.S/IEC. Tolerances for computation of penalties. SCOPE OF WORK SCOPE OF SUPPLY Type, rating and connections of the equipment listed below are detailed in the Annexure A. The equipment shall be offered in strict compliance with the same. i) Copper Wound Three (3) nos. 3000KVA, 11KV/415 V oil filled ONAN transformers. 2.01.02 Each transformer shall be furnished complete with:a. b. c. 2.01.03 2.01.04 2.02.00 2.02.01 Fittings and accessories Auxiliary equipment First filling of oil including 10% extra

1.02.00

1.03.00 1.03.01 1.03.02

2.00.0 2.01.00 2.01.01

One set of special tools and tackles All relevant drawings, data and instruction manuals. SCOPE OF SERVICES The services of supervisor must have supervisory license from State Electricity licensing authority / Qualified Electrical Engineer, experienced in the erection and commissioning of the equipment of similar type and rating on per diem basis. The work includes but not limited to:Visiting site prior to dispatch of equipment to check readiness of foundation, and survey access to site. Providing labor, equipment and specialized services for unloading the transformer and placing the same on foundation.
62

2.02.02

2.02.03 2.02.04 2.02.05 2.02.06

Complete checking of materials at site and advising the Owner/Purchaser any discrepancy thereof. Advice on procedure of erection to be followed. Regular supervision and following up of erection work done by others. Supervision of testing, commissioning and putting the equipment into successful commercial operation.

2.03.0
2.03.01

DELIVERY SCHEDULE
The delivery period shall be as mentioned in the delivery Time Schedule D from the date of issue of Notification of Award of

contract or Purchase Order

2.03.02

Delivery period shall be inclusive of the time to be allowed for approval of drawings & test certificates and shall include transportation time to site. Delivery date shall be reckoned as the date of receipt of the complete equipment & materials at site.

2.03.03

2.03.04
3.00.00 3.01.00

Mandatory spares, special tools and tackles shall be supplied with the first consignment.
DESIGN CRITERIA These transformers will be used for supply of power to various 415V PCC s / MCC s for SECURITY PAPER MILL, HOSHANGABAD-461005(M.P)The high voltage winding (11 kV) will be connected to new 11KV HT Switchgear which will be located in existing 33KV MRSS. The 415 V winding will be connected to respective 415 V PCC/MCC in the Mill building. The transformer will be installed in hot, humid and tropical atmosphere. All equipment, accessories and wiring shall be provided with tropical finish to prevent fungus growth. The transformer shall be capable of continuous operation at rated output under the following condition: a. b. c. Voltage variation Frequency variation Combined voltage and
frequency variation : 8%

3.02.00

3.03.00

: :

5% 3%

3.04.00

The transformer shall be capable of withstanding the short circuit stresses due to terminal fault on one winding with full voltage maintained on the other winding for minimum period of two (2) seconds. The transformer shall be free from annoying hum or vibration. The design shall be such as not to cause any undesirable interference with radio or communication circuits.

3.05.00

63

4.00.00 4.01.00
4.01.01

SPECIFIC REQUIREMENT Tanks

Tanks shall be of all welded construction and fabricated from good commercial grade low carbon steel of adequate thickness. All seams shall be double welded. All welding shall be stress relieved. The tank wall shall be reinforced by stiffener to ensure rigidity so that it can withstand without any deformation (a) mechanical shock during transportation and (b) oil filling by vacuum. All removable covers shall be provided with weatherproof, hot oil resistant, resilient gaskets. The design shall be such as to prevent any leakage of water into or oil from the tank. Each transformer tank shall be provided with one set of bi-directional rollers for rolling the transformer parallel to either centre line. Jacking pads, lifting eyes and pulling lugs shall be provided to facilitate movement of the transformer. All heavy removal parts shall be provided with eye bolt for ease of handling. windings, bottom terminals of bushings and taps.

4.01.02

4.01.03

4.01.04 4.01.05

4.01.06 Manholes/hand holes of sufficient size shall be provided for access to leads, 4.01.07 Suitable guide shall be provided in the tank for positioning the core and coil assembly.

4.02.00
4.02.01

Core & Coils

The transformer may be of core or shell type. The core shall be built up with high grade, non-aging, low loss, high permeability grain oriented cold-rolled silicon steel laminations specially suitable for core material. The coils shall be manufactured from electrolytic copper conductor and fully insulated for rated voltage. The core and coil assembly shall be securely fixed in position so that no shifting or deformation occurs during movement of transformer or under short circuit stresses.

4.02.02 4.02.03

4.02.04 4.02.05

Insulating material shall be of proven design. Coils shall be so insulated that impulse and power frequency voltage stresses are minimum. Coil assembly shall be suitably supported between adjacent sections by insulating spacers and barriers. Bracing and other insulation used in assembly of the winding shall be arranged to ensure a free circulation of the oil and to reduce the hot spot of the winding. All leads from the windings to the terminal board and bushings shall be rigidly supported to prevent injury from vibration or short circuit stresses. Guide tube shall be used where practicable. Tappings

4.02.06

4.03.00

4.03.01 Off-circuit taps as specified shall be provided on the high voltage winding. 4.03.02 4.03.03 The transformer shall be capable of operation at its rated KVA on any tap provided the voltage does not vary by more than 5% of the rated voltage corresponding to the tap. The winding including the tapping arrangement shall be designed to maintain electromagnetic balance between HV and LV windings at all voltage ratios.

4.04.00

Off-Circuit Tap Changer (OCTC)

64

4.04.01

The off-circuit tap changing will be effected by a 3-phase gang operated switch. Arrangement shall be such that switch can be operated at standing eight from ground level. The operating handle can be padlocked at any tap position. The design shall be such that the lock cannot be inserted unless the contacts are correctly engaged. The mechanism shall be provided with a mechanical tap position indicator and an operation counter. All contacts shall be silver plated and held in position under strong contact pressure to ensure low contact drop and avoid pitting.

4.04.02

4.04.03 4.04.04

4.05.00 4.05.01 4.05.02

Insulating Oil The transformer shall be filled with mineral insulating oil (as per IS:335) suitably inhibited to prevent slugging. First filling of oil along with 10% excess shall be furnished for each transformer. Oil shall be supplied in non-returnable containers suitable for outdoor storage. Oil preservation shall be by means of conservator tank complete with silica gel breather and oil seal. Bushing Bushing rated 52 KV class and above shall be oil impregnated paper condenser bushings. Bushing rated below 52KV voltage class shall be solid porcelain or oil communicating type. Condenser type bushing shall be provided with oil level gauge, bottom drain plug and test terminal for measurement of loss factor (tan-delta) and capacitance. Bushings shall be provided with terminal connectors of approved type and size. Bushing location shall provide adequate phase and ground clearances. Terminal Arrangements
Terminals for bus duct connection shall be brought out through top-cover mounted bushings with matching flange.

4.05.03 4.06.00 4.06.01

4.06.02

4.06.03 4.06.04 4.07.00

4.07.01

4.07.02

Terminals for cable connection shall be brought out through top cover/side wall mounted bushings to a detachable cable-end box with disconnect links. Cable-end box shall be self-supporting, weatherproof, air filled type with sufficient space inside for termination and connection of cables. In general, the arrangement shall be such as to permit removal of the transformer without dismantling the bus duct/cable installation. A separate L.V. neutral bushing shall be provided for connection to station
65

4.07.03

4.07.04 4.07.05

ground mat (50 x 6 Cu flat). 4.08.00 4.08.01 Marshaling Box A sheet steel, weatherproof, IPW55 marshaling box shall be provided for each transformer. The box shall contain all auxiliary devices except those which must be located directly on the transformer. All terminal blocks for auxiliary cable connection shall be located in this box. The marshaling box shall be provided with cubicle lamp with door switch, space heater with thermostat and removable cable gland plate. Wiring All control, alarm and indication devices provided with the transformer shall be wired upto the terminal blocks. Wiring shall be done with PVC Insulated Copper wires in conduit or PVC armored cable. Minimum wire size shall be 2.5 mm2 copper. Not more than two wires shall be connected to a terminal. 10% spare terminals shall be provided. All devices and terminal blocks within the marshaling box shall be identified by symbols corresponding to those used in applicable schematic or wiring diagram. Grounding
Two grounding pads, located on the opposite sides of the tank, shall have clean buffed surface with two tapped holes, M10 G.I. bolts and spring washers for connection to 50 x 6 mm Cu flat. Marshaling box shall also be grounded effectively. For continuity of earth connection, all gasketted joints shall be provided with braided copper wire jumpers.

4.08.02 4.08.03 4.09.00 4.09.01 4.09.02

4.09.03

4.10.00
4.10.01

4.10.02 4.10.03

4.11.00
4.11.01

Auxiliary Equipment
Neutral bushing current transformers shall be furnished where required by the specified protection scheme. The arrangement shall be such that the C.T. can be removed from the transformer without removing the tank cover.

4.11.02

C.T. secondary leads shall be wired upto the terminal blocks. The terminals for C.T. secondary leads shall have provision for shorting. Painting
All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents, as required, to produce a smooth surface free of scales, grease and rust.

4.12.00
4.12.01

4.12.02

The internal surfaces in contact with insulating oil shall be painted with heat resistant insulating varnish which shall not react with and be soluble in the insulating liquid used. 66

4.12.03

The external surfaces, after cleaning, shall be given a coat of high quality red oxide or yellow chromate primer followed by filler coats. The transformer shall be finished with two coats of battle ship grey (IS Shade # 632) synthetic enamel paint. The paints shall be carefully selected to withstand tropical heat, rain and the highly corrosive atmosphere prevailing at site.

4.12.04

4.12.05

4.13.00 4.13.01 4.13.02

Auxiliary Supply A.C. supply will be made available to each transformer by two separate feeders one normal and the other standby. Isolating switch fuse unit shall be provided for each of the incoming supply along with automatic changeover scheme to switch on to the standby source in case of failure of the normal supply. TESTS Routine Tests
During manufacture and on completion, all transformer shall be subjected to the IS routine tests. In addition, the following tests shall be performed on each transformer:

5.00.00 5.01.00

5.01.01

During fabrication stage, the tank shall be pressure tested with air at a pressure corresponding to twice the normal head of oil or normal pressure plus 35KN/m2 whichever is lower for a period of one hour. Also the tank designed for full vacuum shall be tested for maximum internal pressure of 3.33KN/m2 for one hour. The permanent deflection of flat plates shall not exceed CBIP specified figures on release of excess pressure of pressure test and on release of vacuum. After assembly, each core shall be pressure tested for one minute at 2KV (r.m.s.) A.C. between all bolts, side plates, structural steel works and the core. The wiring for auxiliary power and control circuitry shall be subjected to withstand one minute power frequency test with 2.0KV (r.m.s.) to earth Dielectric special tests as per IEC60076-3 Measurement of acoustic sound level

5.01.02

5.01.03 5.01.04 5.01.05

5.01.06 Measurement of zero sequence impedance(s) on three-phase unit

5.02.00 5.02.01

Type Tests Following type tests shall be performed on one transformer in accordance with relevant standard: a) Dielectric type test (IEC60076-3) b) Temperature rise test Cost of such tests shall be quoted separately by the Bidder as an optional item.
67

5.02.02

Type and special tests as per requirements of the IEC standards shall be carried out with the exception of short circuit test. A type test certificate on an identical transformer and confirmation that the cable boxes have been designed to the short circuit levels specified is acceptable. SPECIAL TOOLS & TACKLES A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied. The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended. INSTALLATION REQUIREMENTS The Contractor shall perform erection, testing and commissioning along with oil filtration & dissolved gas analysis test but excluding the construction of foundation. Job includes safe storage at place of installation, unpacking, positioning in place, site assembly of loosely furnished accessories, connection & assembly of loose supply items, auxiliary circuits, topping up with oil and testing of oil with Contractor's own test equipment, including Erection of MB, fixing of nuts and bolts etc., including all labour and materials, as per approved drawings, specifications of this tender and directions of Engineer-inCharge/Manufacturer's supervisor. The contractor shall place the transformer on its foundation, assemble parts and erect the sheet steel chamber with danger plate fixed on the same. The storage and installation of transformer shall be carried out in strict compliance with manufacturer's instruction.

6.00.00 6.01.00

6.02.00 7.00.00 7.01.00

7.02.00 7.03.00

68

ANNEXURE A RATINGS AND REQUIREMENT 1.0 2.0 4.0 4.0 5.0 6.0 7.0 8.0 9.0 Application Service Type Rated output Cooling Rated voltage (line - line) Number of phases Rated frequency Temperature rise above 50oC a. in oil by thermometer b. in winding by resistance 10.0 Insulation level H.V. L.V. 11.0 12.0 14.0 14.0 15.0 16.0 17.0 Vector group Parallel operation of transformer Type of taps provided Taps provided on Range of taps : : : : : 50 oC 55 oC 75../28.. KV (peak/rms) 3/2. KV (peak/rms) : L.T. Aux. Transformer

: Outdoor, step-down : : : : : : Oil immersed 3000 KVA ONAN 11kV/415 V 3 50 Hz

: Dyn11 : Yes, momentary

: OCTC : H.V. winding + 2.x 2.5% _ : 7%

Percentage impedance at 75 oC Terminal arrangement: H.V. L.V. & N L.V. Neutral

: : :

H. V. Cable ( 1/C-500mm min.) Sandwich Bus duct 50x6 Cu flat

18.

Maximum guaranteed losses at principal tap at full load and 75 Deg Centigrade must not exceed the following values No Load Loss Load Loss : ..KW (to be filled by Bidder) : ..KW(to be filled by Bidder) Above losses are subjected to the IS tolerance.
69

ANNEXURE-B FITTINGS AND ACCESSORIES Each transformer shall be equipped with fittings and accessories as listed below :o o o o o o o o o o o o o o o o o o o o o Oil conservator with filler cap, drain plug and plain oil level gauge. Oil preservation system complete with accessories. Silica gel breather with connecting pipe and oil seal. Air release plugs. Pressure release device. Explosion vent, if provided, should be double diaphragm type. 150mm dial magnetic oil level gauge with low level alarm contacts. 150 mm dial oil temperature indicator with maximum reading pointer and electrically separate contacts for trip and alarm. 150 mm dial winding temperature indicator with maximum reading pointer and electrically separate sets of contacts for trip and alarm. Thermometer pockets. Double float Buchholz relay with gas release cock, shut-off valve on either side and separate sets of contacts for trip and alarm. Filter valve with threaded adopter (top and bottom). Drain valve with threaded adopter. Sampling valve. Jacking pads, handling and lifting lugs. Cover lifting eyes. Bi-directional rollers and skids. Handhole of sufficient size for access to interior of the tank. Two-grounding pads. Weatherproof marshaling box for housing control equipment and terminal connections. Rating and terminal marking plates. Cooler banks (if applicable) complete with isolation valve at both ends for each bank.

70

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION-IV NEUTRAL GROUNDING RESISTOR

71

SUB-SECTION-IV NEUTRAL GROUNDING RESISTOR CONTENTS

CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00

DESCRIPTION SCOPE OF SUPPLY CODES AND STANDARDS DESIGN CRITERIA SPECIFIC REQUIREMENTS TESTS SPECIAL TOOLS & TACKLES INSTALLATION REQUIREMENTS ATTACHMENT

PAGE NO. 1 1 1 2 3 4 4

ANNEXURE-A

RATINGS AND REQUIREMENTS

72

NEUTRAL GROUNDING RESISTOR

1.00.00
1.01.00

SCOPE OF SUPPLY
Type, rating and connection of the equipment listed below are detailed in the Annexures. The equipment shall be offered in strict compliance with the same.

1.02.00
1.03.00

Two (2) nos. 21.17 Ohms, 11500 Volts, 300 Amps for 10 seconds Neutral Grounding Resistor as required.
Each Resistor shall be furnished complete with :

a) b) b) 1.04.00 1.07.00 2.00.00 2.01.01

Fittings and accessories. Auxiliary Equipment All supporting steel work and hardwares.

One set of Special Tools and Tackles. All relevant drawings, data and instruction manuals. CODES AND STANDARDS All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification. The electrical installation shall meet the requirements of Indian Electricity Rules as amended up to date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed. DESIGN CRITERIA
The Neutral Grounding Resistor (NGR) shall be used for non-effective grounding of 11000 volt System of the plant and will be connected to LV-N of the 10 MVA Power transformers.

2.01.02

3.00.00
3.01.00

3.02.00

Neutral Grounding Resistor shall be used to limit the magnitude of earth fault current so that damage of electrical equipment is reduced, safety of personnel is increased and sensitive, selective earth fault protection can be provided. The NGR will be installed in dust prone, hot, humid and tropical atmosphere. All equipment, accessories and wiring shall be provided with tropical finish to prevent fungus growth. The Resistor unit shall be air-cooled type suitable for installation at outdoor locations. The resistor enclosure shall be made of sheet steel and shall have minimum thickness of 2 mm.

3.03.00 3.04.00 3.05.00

73

4.00.00 4.01.00 4.01.01

SPECIFIC REQUIREMENTS Resistor The resistor element shall be made of non-aging stainless steel or equivalent corrosion resistant material having high Electrical Resistivity and low temperature co-efficient of resistant.
The resistor unit shall consist of a no. of elements. All the elements shall be mounted inside the cubicle so as to ensure ease of inspection and replacement of individual element.

4.01.02

4.01.03

Each Resistor element shall possess a balanced combination of both Mechanical and Electrical properties over the entire intended operating temperature range without any harmful effect on the elements and their accessories. All the resistor elements constituting the NGR shall be assembled and supported inside the cubicle in such a way that no distortion or breakage will occur during the passage of through fault current to earth. All element connections shall be bolted type to ensure stable resistance value throughout the working life of the unit. Wet process type brown glaze porcelain insulators shall be used for supporting resistor elements. Porcelain insulators shall have high creepage value suitable for heavily polluted atmosphere charged with dust particles. Enclosure Each neutral grounding resistor shall have structural steel work enclosed on all sides and also on top by sheet steel having a minimum thickness of 2 mm. Suitable ventilating louvers shall be provided on sides to ensure proper ventilation. The louvers shall be provided with fire wire mesh to make it vermin proof. Each enclosure shall be self-supporting, weather proof type suitable for outdoor mounting having a protection class as indicated in annexure. Each cubicle shall be complete with a front access door with handles, lock and also a removable bolted cover. All doors and removable covers shall be properly gasket with neoprene rubber gaskets. All cubicle door hinges shall be concealed type. Each cubicle shall be complete with a suitably mounted cable end box fitted with removable gland plate for fixing cable gland. The cable size shall be as indicated in the annexure. Double compression cable glands and tinned copper lugs shall be provided. Each cubicle shall be provided with suitable base channels for direct bolting to the foundation at site. All necessary galvanized bolts, nuts, washers etc. shall be supplied by the Tenderer for installation of Cubicle at site.

4.01.04

4.01.05 4.01.06

4.02.00 4.02.01

4.02.02 4.02.03

4.02.04

4.02.05

74

4.03.00
4.03.01

Cubicle lamp and sockets

Each cubicle shall be provided with 5A, 3 pin plug socket and door-switch controlled cubicle illumination lamp.

4.03.02 4.04.00
4.04.01

Two pole switch fuse unit shall be provided for receiving 240 V single phase AC supply for cubicle lamp and illumination circuit. Wiring
All internal wiring between equipment and terminal block shall be carried out by PVC insulated 650 V grade 2.5 Sq.mm Stranded copper conductor wires.

4.04.02 4.04.03

All wiring shall be suitably ferruled with corresponding wiring identification marks used in the Schematic/wiring diagrams. All devices and terminal blocks within the terminal box shall be clearly identified by symbol corresponding to those used on applicable schematic/wiring diagram. 20% spare terminals shall be provided in terminal block. Grounding All parts of enclosure, supporting structures, equipment frames etc. shall be properly grounded at two points separately.
Each cubicle shall be completed with two (2) nos. ground pads, tapped holes and bolts suitable for connection of 50 x 6 mm Cu flats.

4.05.00 4.05.01
4.05.02

4.06.00 4.06.01 4.06.02 4.06.03 4.06.04 5.00.00 5.01.00

Painting All surfaces shall be sand blasted, pickled and grounded as required to produce a smooth, clean surface free of scale, grease & rust. After cleaning, the surfaces shall be given a phosphate coating followed by 2 coats of high quality primer and stoved after each coat. The equipment shall be finished with two coats of approved shade as stated in the annexure. Sufficient quantity of touch-up paint shall be furnished for application at site. TESTS Routine Tests Each equipment shall be completely assembled, wired, adjusted and routine tested as per relevant standards at manufacturer's works. The tests shall include :

5.01.01 5.01.02 5.01.03 5.01.04

Resistance measurement Voltage measurement Insulation resistance measurement Dielectric test

75

5.02.00
5.02.01

Type Test
Temperature test ( on one unit of each rating)

5.03.00 5.03.01
5.03.02

Test Witness All tests shall be performed in presence of Owner/Consultant's representative, if so desired by the Purchaser.
The Contractor shall give at least seven (7) days advance notice of shop tests.

5.04.00 5.04.01 5.04.02 5.04.03

Test Certificates Certified copies of all tests carried out at works and at site shall be furnished in six (6) copies for approval of the Owner/Consultant. Equipment shall be dispatched from works only Owner/Consultant's written approval of shop test reports. after receipt of

Type test certificate on equipment, shall be furnished along with the tender. In case the Type Test Certificates of identical equipment of the offered items are not submitted, the bidders shall have to conduct the Type test on the offered equipment before delivery free of charge to the Purchaser. Type test performed beyond years (5) time are not acceptable. SPECIAL TOOLS & TACKLES A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied. The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended. INSTALLATION REQUIREMENTS The Contractor shall perform erection, testing and commissioning of complete NGR but excluding the construction of foundation. Job includes safe storage at place of installation, unpacking, positioning in place, site assembly of loosely furnished accessories, connection & assembly of loose supply items, auxiliary circuits, including erection of MB, fixing of nuts and bolts etc., including all labour and materials, as per approved drawings, specifications of this tender and directions of Engineer-in-Charge/Manufacturer's supervisor. The contractor shall place the NGR on its foundation, assemble parts and erect the sheet steel chamber with danger plate fixed on the same. The storage and installation of NGR shall be carried out in strict compliance with manufacturer's instruction.

6.00.00 6.01.00

6.02.00 7.00.00 7.01.00

7.02.00 7.03.00

76

ANNEXURE-A

RATINGS AND REQUIREMENTS

1.0 1.1 1.3 1.4
1.4 2.0

General Applicable Standard Service Rated system voltage

Rated frequency and allowable variation Rating

: : :
:

IEEE-32 Outdoor, free standing 11KV + 10%

50Hz3%

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

Rated Voltage Rated current at rated time duration Rated time duration Resistance in design ambient temp. Allowable Tolerance in resistance value Design ambient Temperature Temperature rise of resistor Temp rise of Enclosure Insulation class of insulating material Basic Insulation level and system insulation class a) System insulation class for line end & ground end Insulation level(applied 1min. power frequency potential)

KV

12KV 300 10 21.17 10 50 350 30 Over 220C Class C

Amp : Sec. : Ohm : % C C C : : : : :

KVrms :

75/28KV (peak/r.m.s) 75/28KV (peak/r.m.s) 11KV

b)

KVrms :

3.0 3.1

NGR & NGR Cubicle Materials of resistor :

------ Non-aging, ---punched ------ Stainless steel.-------

3.2 3.3

Resistor element combination Enclosure material

77

: :

-- Series-parallel (6 X6) --------- Sheet steel ------

3.4 3.5 3.6

Min.Thickness of aluminum sheet Enclosure protection class Finish paint of interior & exterior a) b) shade as per IS-5 Base

mm

: :

-----------

2 IP33

-----------

: : : : -----Through cable------

3.7 3.8 4.0 4.1 4.2 4.3 4.4

Terminal arrangement Type & size of cable to be terminated Insulator Type Materials Bushing rating Creepage distance

-- 2-1/C-70sq. mm XLPE -

: : KVrms : mm :

------ Support insulator --------- Porcelain 12 KV ----------

3.6 KV 31 MM/KV --------

78

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION-V HT SWITCHGEAR

79

SUB-SECTION-V HT SWITCHGEAR
CONTENTS CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 DESCRIPTION CODES & STANDARDS SCOPE OF WORK DESIGN CRITERIA SPECIFIC REQUIREMENTS TESTS SPECIAL TOOLS & TACKLES INSTALLATION REQUIREMENT PAGE NO. 1 1 2 2 12 13 14

ATTACHMENTS ANNEXURE- A ANNEXURE - B ANNEXURE C RATINGS AND REQUIREMENTS PROTECTIONS TYPICAL LIST OF DIGITAL I/O AND ANALOG SIGNALS 15 19 22

80

HT SWITCHGEAR
1.00.00 1.01.00 CODES & STANDARDS All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification. Equipment and material conforming to any other standard which ensures equal or better quality, may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid. The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed. SCOPE OF WORK Scope of Supply Type and rating of the equipment listed below are detailed in the annexure. The equipment shall be offered in strict compliance with the same. 2.01.01 One( 1) sets of 11000V switchgears as detailed below :a. Two(2) nos. 1250 A incomers VCB b. One (1) no. 1250 A VCB Bus coupler c. Three(3) nos. 1250A outgoing VCB for 3 MVA Transformers. 2.01.02 2.01.03 Base channel frame of the switchgear with hardware, if called for in panel design. Set of accessories as detailed below :Earthing equipment suitable for earthing the bus/cables. 2.01.04 2.01.05 2.02.00 Special tools and tackles. : : As required. As required

1.02.00

1.03.00

2.00.00 2.01.00

All relevant drawings, data and instruction manuals. Scope of Services The services of supervisor must have supervisory license from State Electricity licensing authority / Qualified Electrical Engineer,, experienced in the erection and commissioning of the equipment of similar type and rating on manday basis. The work includes but not limited to :-

2.02.01 2.02.02 2.02.03 2.02.04

Complete checking of materials at site and advising the Owner / Consultant of any discrepancy thereof. Advice on procedure of erection to be followed. Regular supervision and following up of erection work done by others. Testing, commissioning and putting the equipment into successful commercial operation.
81

2.04.00 2.04.01

Delivery Schedule The delivery period shall be as mentioned in the delivery Time Schedule D from the date of issue of Notification of Award of contract or

Purchase Order

2.04.02 2.04.03 2.04.04

Delivery period shall be inclusive of the time to be allowed for approval of drawings & test certificates and shall include transportation time to site. Delivery date shall be reckoned as the date of receipt of the complete equipment & materials at site. Auxiliary equipment, mandatory spares, recommended spares, special tools and tackles shall be supplied with the first consignment. DESIGN CRITERIA The switchgear shall be used to supply power to 3MVA Transformers for Security paper plant. The switchgear shall be located in a clean but hot, humid and tropical atmosphere. Switchgear ratings and quantities are detailed in the enclosed drawings and annexure. Equipment shall be furnished in strict accordance with the same. For continuous operation at specified ratings, temperature rise of the various switchgear components shall be limited to the permissible values stipulated in the relevant standards and/or this specification. The Switchgear and components thereof shall be capable of withstanding the mechanical forces and thermal stresses of the short circuit current listed in the annexure without any damage or deterioration of material. Circuit breaker shall not produce any harmful over-voltage during switching off induction motors, unloaded lines and unloaded transformers. If required, surge protective device shall be provided in the scope of supply to limit overvoltage. to 2.2 times the peak value of rated phase to neutral voltage. SPECIFIC REQUIREMENT Construction The switchgear shall be indoor, metal-clad, floor mounted, self standing, dust proof construction, draw out type. Design and construction shall be such as to allow extension at either end The Switchgear, where specified in the annexure, shall be internal arc tested and shall conform to partition guideline as per latest edition of relevant IEC.

3.00.00 3.01.00 3.02.00 3.03.00 3.05.00

3.06.00

3.07.00

4.00.00 4.01.00 4.01.01

4.01.02

The switchgear enclosure shall conform to the degree of protection IP-4X. The minimum thickness of CRCA sheet steel used shall be 2 mm.

82

4.01.03

The switchgear assembly shall comprise a continuous, dead-front, line-up of free standing, vertical cubicles. Each cubicle shall have a front hinged door with latches and a removable back cover. All covers and doors shall be provided with neoprene gaskets. Switchgear cubicle shall be so sized as to permit closing of the front access door when the breaker is pulled out to TEST position. The working zone shall be restricted within 750 mm to 1800 mm from floor level. Circuit breakers, instrument transformers, bus-bars, cable compartment etc., shall be housed in separate compartments within the cubicle. The design shall be such that failure of one equipment shall not affect the adjacent units and the design should conform to the stipulation of Loss of Service Continuity and Partition guideline as per the latest edition of relevant IEC. The sides of the Switchgear & Control gear, which are accessible according to the testing arrangement, shall be specially designed to withstand internal explosions to prevent personnel injury.

4.01.04

4.01.05

4.01.06

Pressure relief device (at the option of Owner/Purchaser) shall be provided in each panel and shall prevent the possibility of spreading the fault to other compartments and panels. The pressure relief device shall not be deterrent to achieving the degree of protection of Switchgear Panel. All panels shall come fitted with infrared inspection windows along with the removable plate for measuring the temperature of joints/hotspots during charged condition. The plate shall be removable from outside the panel, exposing the termination joint for scanning by Infra red Camera. All relays, multifunctional meter (at the option of Owner/Purchaser), breaker control switches, selector switches and indicating lamps shall be flush mounted on the respective cubicle door or on control cabinet built on the front of the cubicle. AC/DC auxiliary supply switches / isolation switches for cubicle space heater, cubicle lamp, spring charging motor circuit shall be located inside metering compartment Dummy panel shall be provided in the switchgear line up, if required, for easy termination access of power and control cables. Dummy panel / bus trunking panel shall be of full cubicle with closed roof and rear door similar to enclosures for active cubicles. Bus and Bus Taps The main buses and connections shall be of high conductivity copper and may be bare or coated and sized for specified current ratings with maximum temperature at the connection point limited to the following : a. b, c. For bolted joints (Bare) For bolted joints (Tin coated) For bolted joints (Silver coated) : : : 90oC 105oC 115oC

4.01.07

4.01.08

4.01.09

4.02.00 4.02.01

4.02.02

Bus bars shall be of same size for the entire length of the switchgear. Continuous current rating of bus connections / dropper shall be same as that of continuous in panel current rating of associated breaker.

83

4.02.03

Adequate contact pressure shall be ensured by means of two bolts connection with plain and spring washers and locknuts. Bimetallic connectors shall be furnished for connections between dissimilar metals. Bus bars and connection shall be fully insulated for maximum system voltage with adequate phase/ground clearances. Insulating sleeves for bus bars and cast-resin shrouds for joints shall be provided, suitable for maximum temperature rise of bus bars corresponding to maximum system voltage. Bus support insulator shall be flame-retardant, track resistant type with creepage distance suitable for heavily polluted atmosphere. All buses and connections shall be supported and braced to withstand stresses due to maximum short circuit current and also to take care of any thermal expansion. Bus bars shall be color 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 front of the switch-gear assembly. Circuit Breaker Circuit breaker shall be triple pole, single throw Vacuum type. Ratings of circuit breakers shall be as per enclosed single line diagram mentioned in Section XX. The continuous ratings specified shall be achieved under installation conditions i.e. specified ambient temperature when installed within the breaker cubicle and without use of cooling fans. Circuit breakers shall be horizontal isolation and horizontal draw out type, having SERVICE, TEST and DISCONNECTED positions with positive indication for each position. Circuit breakers of identical rating shall be physically and electrically interchangeable. Circuit breaker shall have motor wound spring charged trip free mechanism with anti pumping-feature and shunt trip. In addition facility for manual charging of spring shall be provided. For motor wound mechanism, spring charging shall take place automatically after each breaker closing operation. One open-close-open operation of the circuit breaker shall be possible after failure of power supply to the motor. Mechanical safety interlock shall be provided to prevent : a. b. c. d. The circuit breaker from being racked in or out of the service position when the breaker is closed. Racking in the circuit breaker unless the control plug is fully engaged. Rack In/Out of the CB from Test to Service and vice versa with cubicle door open. The enclosure cannot be open and the low voltage circuits cannot be disconnected when the withdrawable part is in the service or intermediate position.
84

4.02.04

4.02.05 4.02.06

4.02.07

4.03.00 4.03.01

4.03.02

4.03.03 4.03.04

4.03.05

4.03.06

4.03.07 4.03.08

Automatic safety shutters shall be provided to fully cover the female primary disconnects when the breaker is withdrawn. Each breaker shall be provided with an emergency manual trip, mechanical ON-OFF, indication, an operation counter and mechanism charge/discharge indicator. Each breaker shall be provided with following : a. b. c. Auxiliary switch, with 6 NO + 6 NC contacts, mounted on the draw out portion of the switchgear. Position/cell switch with 3 NO + 1 NC contacts, one each for TEST and SERVICE position. Auxiliary switch, with 4 NO + 4 NC contacts, mounted on the stationary portion of the switchgear and operated mechanically by a sliding lever from the breaker in SERVICE position.

4.03.09

4.03.10 4.04.00

Switch contact shall be rated 10 A AC. and 2A DC at their respective operating voltage. Control & Indication The circuit breaker shall be wired up for local & remote operation. Each breaker cubicle shall be equipped with following :-

4.04.01 4.04.02 4.04.03

One (1) TEST-NORMAL-TRIAL selector switch stay put type with pistol grip handle and key interlock. Two (2) heavy-duty oil tight, push buttons for TRIP & CLOSE. Three (3) indicating lights on front of compartments:GREEN RED AMBER : : : Breaker Open and Spring Charged Breaker Closed Trip/Trip circuit trouble

4.04.04

Lamps shall be clustered type LED module pilot lights in thermoplastic enclosure with polycarbonate lens and diffuser. LED shall be protected by inbuilt fuse with surge suppressor and leakage voltage glow protection. Lamp and lens shall be replaceable from front. Current Transformer Current transformers shall be cast resin type. All secondary connections shall be brought out to terminal blocks where wye or delta connection shall be made. The Current Transformers shall be capable of withstanding the stresses arising out of making, breaking and symmetrical short circuit currents for the specified durations as mentioned in the annexure. For Switchgear of 3 Sec. short circuit rating, CT s for outgoing motor feeders and transformer feeders may be provided with 1 Sec. rating.
85

4.05.00 4.05.01

4.05.02

4.05.03

Accuracy class of the Current Transformers shall be:a. b. c. d. Class PS for differential relaying (or as required depending on the type of relay selected). Class 5P20 (5P15 or 5P10, if specified in the drawing) for other relaying. Class 1.0 and ISF <=10 for metering. Class 0.5 or better and ISF <=2 for performance / precision metering.

4.05.04 4.05.05

Current transformer secondary shall be rated for 1A or 5A, depending on requirement. CT ratio, accuracy, VA burden, knee point voltage, magnetizing current, saturation factor, etc. of the CTs to be provided shall be compatible with the requirement. Voltage Transformer Voltage Transformer (VT) shall be cast-resin, draw out type and shall have an accuracy class of 1.0. Voltage transformer shall be mounted in a separate vertical panel. However, for cassette mounted type breaker arrangement, line VTs mounted below circuit breaker compartment is also acceptable. High voltage windings of voltage transformer shall be protected by current limiting fuses. The voltage transformer and fuses shall be completely disconnected and visibly grounded in fully draw-out position. Low voltage winding of voltage transformer shall have MCB, installed in all ungrounded secondary leads. MCBs shall be suitably located to permit easy replacement while the switchgear is energized. Relays (Numerical) Relays shall be of draw out design with built-in testing facilities and flush mounted at the front of panel. Small auxiliary relays may be in non-draw out execution and mounted within the cubicle. Relays shall be rated for operation on 110V secondary voltage and 1 A secondary current as shown on drawings. Number and rating of relay contacts shall suit the job requirements. Unless mentioned otherwise in the specification, protective relays shall be multifunction type numerical relays. Multifunction numerical relays shall be selected to provide an integrated protection, and monitoring functions. Features such as self-diagnosis and external testing, disturbance recording, sequence of event recording, time stampings shall be available with the relay. Relevant data shall be possible to be stored in non-volatile memory backed up by battery. The relay shall have multiple setting groups, optically isolated input / output, front LCD display and menus, fixed function and programmable LEDs, keypad and password protection. All functions including protection, automation, communication, LEDs, input / output shall be programmable and can be modified, if required,
86

4.06.00 4.06.01

4.06.02

4.06.03

4.07.00 4.07.01

4.07.02

4.07.03 4.07.04

using the front panel user interface. Communication port for local and remote (with suitable protocol) communication shall be located in the front and rear part of the relay. A laptop loaded with support software (complete version) shall be supplied for local off line programming, measurements, extracting and viewing of events, disturbance etc. Protection relay communication protocol shall be compliant with IEC 61850. The relay shall be housed in dust tight enclosure, suitable for IP 52 degree of protection. In addition to achieving the functions as described above, continuous measurement of various electrical parameters shall also be possible with an accuracy class of either 0.5 or 1.0 subject to Owner/Purchasers requirement. Separate multifunction meter shall be provided in the event of said accuracy class cannot be met by the numerical protection relay. Multifunction meter shall be communicable type and be compliant with IEC 61850. 4.07.05 The Contractor shall furnish, install & co-ordinate all relays to suit the requirements of protection, interlock schemes as broadly indicated in the annexure and drawings. Meter Indicating instruments (96 x 96 mm) shall be switchboard type, with 240 degree scale, anti-glare glass and accuracy class of 2% full scale. Each meter shall have zero adjuster on the front. Motor ammeter shall have extended suppressed end-scale range to indicate starting current (6-8 times full load). Energy meter shall be three phase multifunction, digital type with communication port for DCS interface. Energy accounting and audit meters The energy accounting and audit meters shall be suitable for measurement, recording and display of cumulative active energy with date and time. The meter shall have accuracy class of 0.2S The energy accounting and audit meters shall have the facility to measure, record and display one or more of the following parameters depending upon the energy accounting and audit requirement. All parameters excluding instantaneous electrical parameters shall also be stored in memory. 4.08.04.03 Apparent power Phase wise kilowatt at peak KVA Phase wise KVA (reactive) at peak KVA Phase wise voltage at peak KVA Power down time Average power factor Line currents Phase voltages Date and time Tamper events

4.08.00 4.08.01

4.08.02 4.08.03 4.08.04 4.08.04.01

4.08.04.02

The energy accounting and audit meter shall have data storage capacity for at least 35 days in a non-volatile memory.

87

4.08.04.04

Energy accounting and audit meters shall have facility to download the parameters through meter reading instruments as well as remote transmission of data over communication network. Multi Function Meter The multifunction power meter shall be digital type with communication port and suitable for display the following parameters on selection basis. The meter shall have accuracy class of 0.5S. Bidder shall get approved the make of MFM from Owner/Purchaser before providing the MFM. Voltage L-L Voltage L-N per phase Current per phase Neutral Current Frequency Power Factor Active Power Reactive Power

4.08.05

4.08.06

Transducer Transducers shall be provided for conversion of AC electrical quantities such as voltage, current and power. Transducers shall be of low burden type having 4 20 mA DC linear galvanically isolated output compatible with secondary indicating instrument. Transducer shall be dual channel type.

4.09.00 4.09.01

Switch Switches shall be dust protected, heavy duty, switchboard type complete with escutcheon plate. Contacts shall be silver surfaced, rated 10A at operating voltage. Lockable stay-put type switchgear / field / remote selector switch shall be provided as per requirement and mounted on switchgear cubicle. Meter selector switches shall be maintained contact, stay put type with knob handle. Ammeter& voltmeter selector switches shall be four position type. Ammeter selector switches shall have make before break feature to prevent open circuiting of CT secondary. Breaker control switch shall be multistage, spring return to normal, with lost motion device and pistol grip handle. Fuse & MCB Fuses shall be HRC, link type, with minimum interrupting capacity equal to the listed short circuit current. Fuses shall be furnished complete with fuse bases and fittings. Visible indication shall be provided on blowing of the fuse. MCBs, if used, shall be three/four pole, trip free, with manual close / open mechanism. Automatic tripping provision for over load and short circuit shall also be provided. MCBs shall be rated for full fault level of the system. MCB shall be provided with required number of auxiliary contacts as per circuit requirement.

4.09.02 4.09.03

4.09.04 4.10.00 4.10.01

4.10.02

88

4.11.00 4.11.01

MCCB MCCB shall be triple pole, air break, single throw type having trip free mechanism with quick make, quick break contacts. The MCCB shall have current limiting feature. Motors duty MCCB shall be capable of safely making and breaking the locked rotor current of the associated motor circuit including number of starts.

4.11.02 4.11.03

Molded case circuit breakers of identical rating shall be physically and electrically interchangeable. The compartment door shall be interlocked mechanically with the MCCB such that the door cannot be opened unless the MCCB is in OFF position. Further, the compartment door can only be closed when the MCCB is in service position. Short circuit protection shall be provided with the MCCB. All incoming and outgoing feeders shall be provided with bolted disconnect link for isolation of neutral, if necessary. Molded case circuit breaker shall be provided with 1 NO and 1 NC electrically separate auxiliary contact. Push Button Push button shall be heavy duty, shrouded, push to actuate type with colored button and inscription plate. Each push button shall have 2 NO + 2 NC contacts, rated 10A and 0.5A at their respective AC and DC operating voltage.

4.11.04 4.11.05 4.11.06 4.12.00

4.13.00 4.13.01 4.13.02

Secondary Wiring The switchgear shall be fully wired at the factory to ensure proper functioning of control, protection, transfer and interlocking schemes. Fuse, links and MCB shall be provided to permit individual circuit isolation from bus wires without disturbing other circuits. All spare contacts of relays, switches and other devices shall be wired upto terminal blocks. Wiring shall be done with flexible, 1100V grade, PVC insulated, FRLS type switchboard wires with stranded copper conductors of 2.5 mm2 for current circuits and 1.5 mm2 for control and voltage circuits. Each wire shall be identified, at both ends, with interlocking type permanent markers bearing wire numbers as per Contractor's Wiring Diagrams. AC / DC wiring shall have separate color-coding. Wire termination shall be made with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals. All spare contacts of relays, timers, auxiliary switches shall be wired up to the terminal block.

4.13.03

4.13.04

4.13.05 4.13.06

89

4.14.00 4.14.01

Terminal Block 1100V grade, multi way terminal block complete with mounting channel, binding screws and washers for wire connections and marking strip for circuit identification shall be provided for terminating the panel wiring. Terminals shall be stud type, suitable for terminating 2 nos. 2.5 mm2 stranded copper conductor and provided with acrylic insulating cover. Terminals for C.T. secondary leads shall have provision for shorting and grounding. Not more than two wires shall be connected to any terminal. Spare terminals equal in number to 20% active terminals shall be furnished. Separate terminal blocks shall be used for AC/ DC wiring termination. Terminal 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. Terminal blocks used for interface with DCS / PMS / PLC via termination cabinet shall be suitably sized to facilitate proper termination of interconnecting cables. Cable Termination Switchgear shall be designed for cable entry from bottom, as specified. Sufficient space shall be provided for ease of termination and connection. All provisions and accessories shall be furnished for termination and connection of cables, including removable gland plates, cables supports, crimp type tinned copper/ aluminum lugs, brass compression glands with tapered washer (Power cables only) and terminal blocks. Gland plates shall be minimum 3 mm thick. The gland plate and supporting arrangement for 1/C power cables shall be of aluminum. Sufficient space shall be provided between the power cable termination and gland plate. Core balance CTs wherever specified, shall be accommodated within this space, inside the cubicle. Ground Bus A ground bus, rated to carry maximum fault current, shall extend for the full length of the switchgear. The ground bus shall be provided with two-bolt drilling with G.I. bolts and nuts at each end to receive 50 x 6 mm Cu flat. Each stationary unit shall be connected directly to the ground bus. The frame of each circuit breaker and draw out VT unit shall be grounded through heavy multiple contacts at all times except when the primary disconnecting devices are separated by a safe distance. Wherever, the schematic diagrams indicate a definite ground at the switchgear, a single wire for each circuit thus grounded shall be run independently to the ground bus and connected thereto. CT and VT secondary neutrals shall be earthed through removable links so that earth of one circuit may be removed without disturbing other.
90

4.14.02

4.14.03

4.14.04

4.15.00 4.15.01 4.15.02

4.15.03 4.15.04

4.16.00 4.16.01 4.16.02 4.16.03

4.16.04

4.16.05

4.17.00

Earthing Truck Earthing trucks shall be provided for earthing the switchgear bus bars or outgoing cables. The trucks shall have a voltage transformer and an interlock to prevent earthing of any live connection. The trucks shall have audio-visual annunciation to warn the operator against earthing of live connections. It shall not be possible to use bus-earthing truck for cable earthing& vice versa. Earthing truck shall be non- fault making type. Circuit breakers provided with integral earth switch, as an alternative, is to be provided wherever specified. Nameplate Nameplates of approved design shall be furnished at each cubicle (one no. each at front as well as at backside of cubicle) and at each instruments & device mounted on or inside the cubicle. The material shall be lamicoid or approved equal, 3 mm thick with white letter on black back ground. The nameplate shall be held by self-tapping screws. Nameplate size shall be minimum 20 x 75mm for instrument/device and 40 x 150mm for panels. Caution notice on suitable metal plate shall be affixed at the back of each vertical panel. Space heaters and Plug socket Each cubicle shall be provided with thermostat controlled space heaters and 5A, 3 pin plug socket. In addition, motor feeder cubicle shall be wired-up for feeding the motor space heater through suitable rated breaker auxiliary NC contact and/or contactor. Cubicle heater, Motor heater, Plug/socket circuits shall have individual switch fuse units. A.C/D.C Power Supply The following power supplies shall be made available to each switchgear: A.C. supply D.C. supply : : Single Feeder Double Feeder

4.18.00 4.18.01

4.18.02 4.18.03 4.18.04 4.19.00 4.19.01 4.19.02

4.19.03 4.20.00 4.20.01

4.20.02

Isolating switch fuse units shall be provided at each switchgear for the incoming supplies, 4-pole, single throw for A.C. and 2-pole, double throw for D.C. Molded case circuit breaker (MCCB) shall also be accepted as an alternative. Bus-wires of adequate capacity shall be provided to distribute the incoming supplies to different cubicles. Isolating switch fuse units / MCCB shall be provided at each cubicle for A.C/D.C. supplies. A.C. load shall be so distributed as to present a balance loading on threephase supply system. Redundant DC control supply shall be designed for auto/manual changeover to alternate back up DC supply.
91

4.20.03

4.20.04 4.20.05

4.21.00 4.21.01 4.21.02 4.22.00 4.22.01 4.22.02 4.22.03 4.22.04 4.23.00

Tropical Protection All equipment, accessories and wiring shall have fungus protection, involving special treatment of insulation and metal against fungus, insects & corrosion. Screens of corrosion resistant material shall be furnished on all ventilating louvers to prevent the entrance of insects. Painting All surfaces shall be sand blasted, pickled and grounded as required to produce a smooth, clean surface free of scale, grease and rust. After cleaning, the surfaces shall be given a phosphate coating followed by 2 coats of high quality primer and stoved after each coat. The switchgear shall be finished in light gray color with two coats of powder paint. The coating shall be done electro statically followed by stoving. Sufficient quantity of touch-up paint shall be furnished for application at site. Accessories Following accessories shall be furnished along with the Switchgear : a. b. Earthing equipment suitable for earthing the bus. Earthing equipment suitable for earthing the outgoing cable.

5.00.00 5.01.00 5.02.00

TESTS The switchgear shall be completely assembled, wired, adjusted and tested at the factory as per the relevant standards. Routine Test The tests shall include but not necessarily limited to the following : a. Operation under simulated service condition to ensure accuracy of wiring, correctness of control scheme & proper functioning of the equipment. All wiring and current carrying part shall be given appropriate High Voltage test. Primary current and voltage shall be applied to all instrument transformers. Routine test shall be carried out on all equipment such as circuit breakers, instrument transformers, relays, meters etc. as per relevant standard.

b. c. d.

92

5.03.00

Type Test Following minimum tests shall be performed on a typical section of the bus assembly : a. b. c. d. Impulse Test Temperature rise Test Short circuit Test Internal Arc Test

The cost of such tests, if any, shall be quoted separately. 5.04.00 Test Witness All tests shall be performed in presence of Owner / Consultant's representatives, if so desired by the Owner / Purchaser. The Contractor shall give at least seven (7) days advance notice of the date when tests are to be carried out. 5.05.00 5.05.01 5.05.02 5.05.03 Test Certificate Certified reports of all the tests carried out at the works shall be furnished in six (6) copies for approval of the Owner / Consultant. The equipment shall be dispatched from works only after receipt of Owner / Consultant's written approval of the test reports. Type test certificate on any equipment, if so desired by the Owner / Consultant, shall be furnished. Otherwise the equipment shall have to be type tested, free of charge, to prove the design. SPECIAL TOOLS & TACKLES A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied. The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended. INSTALLATION REQUIREMENTS The Contractor shall perform erection, testing and commissioning of complete switchgear but excluding the construction of foundation. Job includes safe storage at place of installation, unpacking, positioning in place, site assembly of loosely furnished accessories, connection & assembly of loose supply items, auxiliary circuits, fixing of nuts and bolts etc., including all labour and materials, as per approved drawings, specifications of this tender and directions of Engineer-in-Charge/Manufacturer's supervisor. The contractor shall place the switchgear on its foundation, assemble parts and erect the sheet steel chamber with danger plate fixed on the same. The storage and installation of switchgear shall be carried out in strict compliance with manufacturer's instruction.
93

6.00.00 6.01.00

6.02.00 7.00.00 7.01.00

7.02.00 7.03.00

ANNEXURE-A RATINGS AND REQUIREMENTS 1.0 1.1 SWITCHGEAR General Type Service Enclosure Reference Standard Internal Arc Classification IAC Test Current & Duration Loss Of Service Continuity & Partition Class 1.2 System Rated Voltage Phase Rated Frequency System grounding 1.3 1.4 Design ambient temperature Rated Current inside the cubicle and at design ambient temperature of 50oC Bus bar Circuit breaker In Panel Rating 1.5 Short Circuit Rating Rated short time withstand current Duration Rated peak withstand current 1.6 Insulation level Rated lightning impulse withstand voltage
94

: : : : : : :

Metal-clad, draw out Indoor / Outdoor IP 4X IEC-62271-200 IAC AFLR --- kA, 0.5 Sec LSC 2B PM

KV rms

: : : : :

11 10% Three 50 Hz 3% Resistance grounding 50 oC

: : : 2000 A 1250 A

: : : : :

40KA 3 Sec. 2.5 x rated short time current

75KV ( peak)

ANNEXURE-A Rated one minute power frequency : withstand voltage 1.7 AC/DC Power Supply Control voltage Service voltage 1.8 Termination details Incomer/ Tie feeder : : :

28 KV ( r.m.s)

110V DC 240V 10%, 1 Ph, 50 Hz 3%

Through side / top entry bus duct or side / top / bottom entry cable, depending on requirement. Through side / top / bottom entry cable as per requirement. Yes (test submitted) certificates to be

Outgoing feeder

1.10 1.11

Type test required Painting requirement a) b) c) Finish paint Paint base Paint shade

: : :

Powder coating Epoxy / poly-urethane 631 as per IS-5

2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7

CIRCUIT BREAKER Type No. of poles Rated Voltage Rated Frequency KV rms Hz : : : : Vacuum :Three 11 10% 50 3% 1250/630 :IEC-62271-100,

Rated normal current at site condition Amps Reference Standard Rated Insulation Level Lightning Impulse withstand voltage KV peak

75

95

ANNEXURE-A Rated one minute power frequency withstand voltage KV rms 2.11 Rated Making & Breaking Capacity Rated Short-circuit breaking current (Symmetrical) KA rms Percentage DC component Rated short-circuit making current KA peak Rated peak withstand current KA peak Rated short time withstand current for rated duration of 1sec. KA rms Rated Out of phase breaking current In % of rated Short Ckt. Rated Out of phase making current In % of rated Short Ckt. Breaking current Rated cable charging breaking current Rated capacitor bank breaking current KA peak Rated capacitor bank inrush making current KA peak Inductive current breaking capability without exceeding over voltage by 2.2 pu. 2.12 2.13 2.14 2.15 First pole to clear factor Rated Operating Sequence Operating mechanism Operating time Opening time (ms) Closing time (ms) : : Not more than 60 Not more than 100 : : O - 3m - CO - 3m - CO Motor wound Spring charging Refer APPENDIX - E : 28

96

ANNEXURE-A 2.16 Number of trip coils For 33 KV breakers For all other breakers 2.17 Rated Supply Voltage and frequency for Closing Tripping Spring Charge Motor Heater/Lamp/Socket : : : : 110 V DC, 2W (85% to 110%) 110 V DC, 2W ( 70% to 110%) 110 V DC, 2W ( 85% to 110%) 240V, 1 Ph, 2W : : Two One

97

ANNEXURE-B PROTECTIONS 1.0 Minimum protections to be provided for different type of circuits are listed below A. Transformer : a. Incomer b. c. . d. e. f. g. h. i. IDMTL over current (51/51) for phase fault IDMTL over current ( 50 N / 51N) for earth fault IDMTL over current (51SN) for stand by earth fault (for incomer from transformer only). Restricted E/F (64) (for incomer from transformer only) Differential Relay (87T) (for incomer from transformer rated 5 MVA & above) Under voltage with time delay (27) VT fuse failure Circuit breaker failure Auxiliary relays for Transformer Protection like Buchholz Relay Alarm & Trip, Oil Temperature Alarm & Trip, Winding Temperature Alarm & Trip, OLTC Buchholz Alarm & Trip, Oil Pressure level and Pressure relief device operated Alarm. IDMTL over current ( 50/51) for phase fault IDMTL over current (50N/51N) for earth fault Under voltage with time delay (27) VT fuse failure Circuit breaker failure IDMTL over current ( 50/51) for phase fault IDMTL over current ( 50N/51N) for earth fault Under voltage with time delay (27) VT fuse failure Circuit breaker failure Synchronizing check relay, if applicable, complete with guard relay

B.

Feeder Incomer

: a. b. c. d. e.

C.

Tie feeder

: a. b. c. d. e. f.

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ANNEXURE-B D. Auxiliary : a. IDMTL over current (50/51) with high set instantaneous units Transformer for phase faults b. Definite time O/C (50G) for earth fault (through CBCT) c. Differential protection (for transformers rated 5MVA and above) d. Auxiliary relays for Transformer Protection like Buchholz Relay Alarm & Trip, Oil Temperature Alarm & Trip, Winding Temperature Alarm & Trip, OLTC Buchholz Alarm & Trip, Oil Pressure level and Pressure relief device operated Alarm. e. Circuit breaker failure.

E.

Bus-coupler : a. IDMTL over current (51) for phase fault. b. IDMTL over current (51N) for earth fault. c. Circuit breaker failure. d. Partial differential scheme shall be provided, wherever applicable.

2.0 3.0 4.0

In case any trip function is not available in a single relay, separate numerical relays shall be provided to achieve the requirement. All protective relays shall be provided with self reset type of contacts. Apart from protection relays, each breaker shall be provided with separate discrete auxiliary relays for anti-pumping (94), trip annunciation (30), trip supervision/Alarm relay (74), electrically reset type breaker contact multiplication (52X) and lockout (86) functions. Lockout relay shall be hand reset type. For multifunction relays however, trip circuit supervision function as an integral feature of the relay is acceptable. Individual trip circuit supervision function shall be provided with respect to each trip coil of circuit breaker. Numerical under voltage relays (27) with time delay relay including VT fuse failure relay shall be provided for Bus VTs. One no. DC supply supervision relay (80) shall be provided for each panel of the switchboard. One no. DC supply failure annunciation relay shall be provided for each incoming DC supply to the switchboard. Auxiliary relays (hand reset type) with flag indications shall be provided for each type of transformer fault. IDMTL relay version shall be decided as per system requirement and the same shall be finalized during detail engineering. Zero-sequence CT and associated relay combination shall be such as to ensure a pick-up sensitivity of 10A primary ground fault current (for transformer and motor feeder only).
99

5.0 6.0 7.0 8.0 9.0 10.0

ANNEXURE-C TYPICAL LIST OF DIGITAL I/O AND ANALOG SIGNALS FOR DCS A. DIGITAL INPUT/OUTPUT SIGNALS Applicable for Breakers pertaining to Switchboard. Close Trip Status of Circuit Breaker (On / Off / Trip) Status of Earth Switch. Circuit Breaker Failure. Trip Coil Unhealthy. Lock Out Relay Operated. Breaker Test Position Breaker Service Position Local Selection Remote Selection

Applicable for Incomer Breaker to Switchgear Incomer Trip selection. Synchronizing Check Relay (On). Momentary Paralleling of Supplies. Bus Differential relay Operated (optional) Phase Fault Relay (51) Operated. Earth Fault Relay (51N) Operated Stand By Earth Fault Relay (51SN) Operated.

Applicable for HT Transformers. Restricted Earth Fault Relay Operated. Differential Relay Operated. OTI Alarm OTI Trip. WTI Alarm. WTI Trip. Buchholz Alarm. Buchholz Trip. Rupturing of Bellows Alarm. Pressure Relieve Device Operated. OLTC Buchholz Alarm. OLTC Buchholz Trip. Lockout Switch Operated. Tap change in Progress. Tap change not completed. Oil Level Gauge Alarm.
100

ANNEXURE C Applicable for LT Distribution Transformer (ONAN). Oil temperature Indicator Alarm. Oil temperature Indicator Trip. Winding temperature Indicator Alarm. Winding temperature Indicator Trip. Buchholz Alarm. Buchholz Trip. Oil Level Gauge Alarm. Phase Fault Relay Operated. Earth Fault Relay Operated. Back Up Phase Fault Relay Operated. Lock Out Switch Operated.

Applicable for Line PT. Fuse Fail. Under Voltage Relay Operated.

Applicable for Bus PT. Under Voltage Relay 20% Operated. Under Voltage Relay 80% Healthy. Fuse Fail for Under Voltage Relay 20%. Fuse for Under Voltage Relay 80%.

Applicable for Bus Coupler. Auto Changeover Completed. Phase Fault Relay Operated. Earth Fault Relay Operated. Auto changeover blocked. Bus Coupler Trip Selection Synchronizing Check Relay (On). Momentary Paralleling of Supplies.

B. TYPICAL LIST OF ANALOG SIGNALS (All are the Part of MFM) INCOMER Line current R phase, Y phase, B phase. Power Factor KW KVAR KVA KVAH KWH
101

ANNEXURE C LV TRANSFORMER FEEDER BUS PT LINE PT

NOTE:-

Line current R phase, Y phase, B phase. KWH.

Voltage R Y phase, Y-B phase, B-R phase.

Voltage R Y phase, Y-B phase, B-R phase.

Signal List as indicated above are indicative only. Vendor shall finalize the input/output list as required during detail engineering.

102

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION- VI

415 V PCC/PMCC/MCC, 415 V AC AND 110 V DC DB/ FB&415 V NON-SEGREGATED PHASES SANDWICH BUSDUCT

103

SUB-SECTION- VI 415 V PCC/PMCC/MCC, 415V AC AND 110V DC DB/FB & 415 V NON-SEGREGATED PHASE SANDWICH BUSDUCT CONTENTS

CLAUSE NO.

DESCRIPTION

PAGE NO.

1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00

CODES AND STANDARDS SCOPE OF WORK DESIGN CRITERIA SPECIFIC REQUIREMENTS TESTS SPECIAL TOOLS AND TACKLES INSTALLATION REQUIREMENTS

1 1 2 3 18 19 19

ATTACHMENTS ANNEXURE-A ANNEXURE-B ANNEXURE-C ANNEXURE-D RATINGS AND REQUIREMENTS PROTECTIONS 415V NON-SEGREGATED PHASE BUSDUCT RATINGS AND REQUIREMENTS FOR 415 V NON-SEGREGATED PHASE SANDWICH BUSDUCT LIST OF 415V PCCs/PMCCs/MCCs/ DBs MODULE SELECTION LOAD LIST 21 23 25 29

ANNEXURE-E ANNEXURE-F ANNEXURE-G

30 31 32

104

415 V PCC/PMCC/MCC, 415V AC AND 220V DC DB/FB AND 415 V NON-SEGREGATED PHASE SANDWICH BUSDUCT
1.00.00 1.01.00 CODES AND STANDARDS All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification. The electrical installation shall meet the requirements of Indian Electricity Rules as amended up to date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed. SCOPE OF SUPPLY The following equipment shall be furnished complete with all accessories: a) b) c) d) 415V Power Control Centers 3 nos. 415V Miscellaneous ServiceMotor Control Centers 2 nos. 415V Distribution Boards and Fuse Boards As required 415V Non- segregated phase sandwich type electro tinned, electrolytic copper bus trucking (bidder to decide the bus trucking system capacity) 3 sets system

1.02.00

2.00.00 2.01.00

A list of various 415V boards that have been envisaged to be supplied under the main plant package is given in Annexure - E. This list is only for general guidance of the Tenderers and the exact numbers shall be finalised by them. 2.02.00 2.03.00 Base channel frame of all boards along with necessary mounting hardware. Set of accessories as listed below : a) b) c) d) 2.04.00 2.05.00 Breaker lifting and handling trolley Test cabinet with coupling cables for testing the breaker in drawout position. : Racking in/out handle for breakers Racking in/out handle for drawout MCC modules

: :

All relevant drawings, data and instruction manuals. GENERAL NOTES In the context of the specification, the following definitions shall apply.

2.05.01

POWER CONTROL CENTER, hereinafter referred to as PCC, shall mean a continuous line-up of breaker panels, used to feed Motor Control Centers and
105

motors rated 110 KW upto and including 160 KW. All PCCs shall have duplicate incomers and a bus-section. Incomers, bus-section, and all outgoing feeders of a PCC shall be breaker controlled. Distribution of outgoing feeders shall be such as to ensure uniform loading on each section of the PCC. 2.05.02 MOTOR CONTROL CENTER, hereinafter referred to as MCC, shall mean a continuous line-up of vertical sections housing breaker panels, switch fuse, contactor operated modules. All MCCs except D.G. plant auxiliary MCC, emergency MCCs and ventilation MCCs shall have duplicate incomers and a bus-section. D.G. Plant Auxiliary MCC may have duplicate incomers and ventilation MCCs may have single incomers. Emergency MCCs shall have four incomers, two each from emergency PCC and respective unit PCC. All incomers and Bus-sections shall be breaker controlled except few, which are castle key inter-locked. Whenever bus-sections are provided, all outgoing feeders shall be breaker/ switch fuse controlled, or contactor operated depending upon the rating and application. Distribution of outgoing feeders shall be such as to ensure uniform loading on each section of the MCC. DISTRIBUTION BOARD, hereinafter referred to as DB, shall mean a continuous line-up of vertical sections housing switch fuse modules only. ACDBs shall have duplicate incomers and a bus- section. Power house main DCDBs shall have two incomers from its associated battery charger with bus sectionalized. Wherever bus-sections are provided, distribution of outgoing feeders shall be such as to ensure uniform loading on each section of DB. FUSE BOARD, hereinafter referred to as FB, shall mean a continuous line-up of vertical sections housing switch fuse only. FBs Boards may be fed from DBs and may have one incomer. ACFBs Boards shall be of two types - one with 415V, 4-wire, triple pole- and-neutral (TPN) outgoing feeders and the other with 240V, 2- wire, single-pole-and-neutral outgoing feeders. The incomers in either case shall be 415V, 4-wire, TPN type. Incomers and outgoing feeders of DCFBs shall be 220V, 2-wire type. DESIGN CRITERIA
415V power distribution within the paper plant shall be by mean of PCCs, DBs, and FBs. MCCs,

2.05.03

2.05.04

3.00.00
3.01.00 3.02.00

Three(3) PCCs shall be used to supply auxiliary power for normal and start up operation of new PM-5 paper plant.

The MCCs/DBs /FBs shall be used to provide power, control, and protection for A.C. and D.C. auxiliary services (motors and feeders) . 3.03.00 3.04.00 The equipment will be located in a hot, humid, and tropical atmosphere, heavily polluted at places with coal dust and/or fly ash. Duty involves direct-on-line starting of large induction motors and also under certain emergency conditions, automatic transfer of loads from one source of supply to other. Motor starting current varies from 6 to 8 times of full load current.
3.05.00 Busbars of PCCs shall be sized to carry continuously the associated transformer secondary current plus a 20% margin.

Busbars of MCCs/DBs/ FBs shall be sized to carry continuously the total

106

running load of the MCC/DB/ FB (including anticipated future load, wherever applicable) plus a 20% margin. All busbars shall be capable of withstanding the mechanical forces and thermal stresses due to maximum short circuit current. 3.06.00
3.07.00

In-cubicle ratings of incomer and bus-section breakers/switches shall be identical to the associated busbar rating.
Incomers rated up to and including 400 A, shall all incomers shall be breaker controlled. be MCCB controlled. Above 400 A,

3.08.00

PCCs shall be used to feed Paper machine MCCs and motors rated 110 KW up to and including 200 KW. All motors rated 110 kW up to and including 200 KW shall be breaker controlled. For motors rated 110 kW up to and including 200 KW, breaker shall be given with motor protection relay.
Motors rated below 110 KW shall be contactor operated and shall be fed from MCCs. For all motors below 45 kW, MCCB/switch fuse shall be given. For motors between 45 kW to below 75 kW, MCCB/ switch fuse with SPPR protection should be used. For motors between 75KW to below 110KW motor protection relay should be used. For continuous operation at specified ratings, the temperature rise of various equipment/components shall be limited to the permissible values specified in relevant standards and/or this specification. Circuit breakers shall not produce any harmful over voltage during switching off of induction motors. If required, surge protective devices shall be included in the scope of supply to limit over voltages.

3.09.00

3.10.00

3.11.00

3.12.00

Incomer and Bus-sections of all MCC shall have provisions for remote operation from the respective control room through electrical control desk /CRT monitor. SPECIFIC REQUIREMENTS Construction
PCCs/ MCCs/DBs /FBs shall be indoor, air insulated, and metal-clad type.

4.00.00 4.01.00
4.01.01

The design construction shall be such as to permit extension at either end. 4.01.02
4.01.03

PCCs /MCCs shall be drawout type. DBs/FBs shall be fixed type.

PCCs/ MCCs/DBS shall be suitable for floor-mounting and FBs Boards shall be suitable for wall-mounting.

4.01.04 4.01.05

Generally, PCCs/DBs shall be of single-front construction and MCCs shall be of double-front construction. In switchgear room and control room, all PCC /MCC/DB /FB enclosures shall conform to the degree of protection IP-54. For ampere rating up to 2000A degree of protection of PCC /MCC shall be IP-54 and above 2000A the degree of protection will be IP-42. Minimum thickness of sheet metal used shall be 1.6mm for non load bearing end and 2mm for load bearing end.
The design shall be such that the specified degree of protection is achieved even 107

after a breaker control module has been taken out of the panel. 4.01.06 PCC assemblies shall comprise of a continuous line-up of single/ multi-tier cubicles. Installation of circuit breakers shall however be limited to the bottom two tiers only. Not more than two breakers shall be accommodated in one vertical section.

MCC/DB assemblies shall comprise of a continuous line-up of dead-front, free-standing vertical sections, housing the control modules in multi-tier formation. 4.01.07 PCCs/ MCCs/ DBs shall be fully compartmentalised with metal/ insulating partitions between compartments. FBs Boards shall be non-compartmentalised. Working height shall be limited between 450mm and 1800mm from floor level.
4.01.08 Each breaker/control module shall be housed in a separate cubicle, complete with an individual front access door having sufficient opening with concealed type hinges.

Each vertical section shall have a removable back cover. All doors and covers shall be gasketted. 4.01.09 Breaker cubicles shall be so sized as to permit closing of the front access door when the breaker is pulled out to ISOLATED position. The breaker can be operated both in service & test position with the door closed.
For breaker panels, all switches, lamps, and indicating instruments shall be flush mounted on the respective compartment door whereas relays and other auxiliary devices shall be mounted in a separate compartment.

4.01.10

For MCC/DB modules, all push-buttons, lamps, and indicating instruments shall be flush/semi-flush mounted on respective module compartment. 4.01.11 For single-front assemblies, a full-height vertical cable alley with cable supports shall be provided in each section to facilitate unit wiring. The alley shall be liberally sized to accommodate all cables as per cable schedule and shall have removable cover at the front for access. 4.01.12 Wherever two breaker compartments are provided in the same vertical section, insulating barriers and shrouds shall be provided in the rear cable compartment to avoid accidental touch with the live parts of one circuit while working on the other. A horizontal wire way extending the entire length of the assembly shall be provided of the top for inter-panel wiring. Incomers shall be provided at the ends of an assembly and bus section, wherever required, shall be provided at the middle of the assembly. Four (4) Nos. lifting lugs shall be for each section, two (2) nos. on either end of the section.
108

4.01.13

4.01.14 4.01.15

4.01.16

PCCs /MCCs/DBs shall be supplied with base frames made out of structural steel sections along with all necessary mounting hardware required for bolting/welding the base frames to the foundation.

FBs Boards shall be supplied along with necessary hardware for mounting against wall.
4.01.17 After isolation of power and control circuit connections, it shall be possible safely carry out maintenance in a compartment with the busbar and adjacent circuit live. Necessary shrouding arrangement shall be provided for this purpose over the cable terminations located in cable alley. The minimum clearance in air between phases and between phases and earth for the entire run of horizontal and vertical busbars shall be 25mm. For all other components, the clearance between two live parts, a live part and an earthed part, and isolating distance shall be at least 10mm throughout. Wherever it is not possible to maintain these clearances, insulation shall be provided by barriers. However, for horizontal and vertical busbars, the clearances mentioned above should be maintained even when these are sleeved or insulated. All connections from busbars up to fuses shall be fully shrouded to minimize the risk of phase to phase and phase to earth shorts. Unless otherwise stated, equipment rating and module size shall be as per Annexure - G. Module selection chart is specified for guidance of Bidder in respect to requirement of module space and component rating.

4.01.18

4.01.19

4.02.00 4.02.01

Bus and Bus Taps All PCCs/ MCCs/ACDBs/ ACFBs provided with three phase busbars and neutral busbar. All DCDBs and DCFBs shall be provided with two busbars. All busbar compartments shall be completely enclosed.

4.02.02

Horizontal and vertical busbars and bus connections shall be of high conductivity copper. The maximum temperature of busbars and bus connections shall be limited to 85oC i.e. 35oC rise over 50oC ambient. No diversity factor shall be allowed for temperature rise.

4.02.03 4.02.04
4.02.05 4.02.06

Vertical busbars shall be designed as per technical requirement. All bus connections shall be provided with anti-oxide grease. Adequate contact pressure shall be ensured by means of two-bolt connection with plain and spring washers and locknuts.
Bimetallic connectors shall be provided for connections between dissimilar metals.

All bus bars and bus connections shall be fully insulated for working voltage. Insulating heat shrinkable sleeves shall be provided for all bus bars. All joints and tap-off points shall be shrouded.

4.02.07

Bus insulators shall be non-hygroscopic, flame retardant, track resistant, high

109

strength, sheet molded compound or equivalent polyester fibreglass molded type. Separate supports shall be provided for each phase and neutral bus bar. 4.02.08 Cross-section of the bus bars shall be uniform throughout the length of the assembly. All bus bars and bus connections shall be supported and braced to withstand the stresses due to maximum short circuit current and also to take care of any thermal expansion. 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. Bolted disconnecting links shall be provided for all incoming and outgoing feeders for isolation of neutral, if necessary. MCC/ DB Modules MCC modules shall have self-aligning power/control disconnects. All disconnects shall be silver-plated to ensure good contacts.
Modules of same size and type shall be physically and electrically interchangeable.

4.02.09

4.02.10 4.03.00 4.03.01

4.03.02

4.03.03 4.03.04

The design of drawout modules shall be such as to permit easy withdrawal/re-insertion of the unit with guide rails to ensure correct alignment. Various module sizes should be multiples of one basic unit to facilitate modifications at site. Suitable provision for this purpose should also be incorporated in the vertical busbars.
Drawout modules shall have three distinct positions, namely, SERVICE, TEST and ISOLATED.

4.03.05

In the SERVICE position, both power and control circuits shall be engaged. It shall not be possible to open the module door when the module is in SERVICE position.

In the TEST position, the power circuits shall be disengaged but the control circuits shall be engaged. It shall be possible to close the module door when the module is in TEST position. Keeping the front access door of module in closed condition, the Breaker can be placed in ISOLATED, TEST or SERVICE position from outside. In the ISOLATED position, both power and control circuits shall be disengaged. 4.03.06 Modules shall house the control components for a circuit such as switch, fuse, contactors, relays, push-buttons, lamps, meters, etc. only the push-button actuators, lens' of indicating lamps, and transparent windows for meters shall
110

be mounted on module door such that when the module is withdrawn, the cubicle door shall provide specified IP-54 degree of protection when the module door is closed. 4.03.07 Breaker operated incomes and bus sections shall be provided with one (1) TEST-NORMAL selector switch.
Contactor operated motor feeder modules shall be provide with one (1) LOCAL-REMOTE selector switch.

These selector switches shall be lockable type and shall be mounted inside the panel. 4.03.08 4.04.00 4.04.01
4.04.02

The equipment layout shall provide sufficient working space in between the components. Circuit Breaker Circuit Breakers shall be three pole, single throw, air break type with stored energy, trip free mechanism and shunt trip coil.
Circuit breakers shall be drawout type, having SERVICE, TEST & ISOLATED positions with positive indication for each position.

4.04.03
4.04.04

Circuit breakers of identical rating shall be physically and electrically interchangeable.

All incomer breakers, bus-section breakers, and motor feeder breakers shall have motor wound spring charging mechanism. All other outgoing feeders shall generally have hand-operated spring charging mechanism. Each breaker operated feeder shall be provided with protective devices as specified in Annexure-B.

4.04.05

4.04.06 4.04.07

All breakers with motor wound spring charging mechanism shall have facility of manual spring charging also. For motor wound mechanism, spring charging shall take place automatically after each breaker closing operation. One open- close-open operation of the circuit breaker shall be possible after failure of power supply to the motor. Mechanical safety interlock shall be provided to prevent the circuit breaker from being racked in or out of the service position when the breaker is closed.
Automatic safety shutters shall be provided to fully cover the female primary disconnects when the breaker is withdrawn.

4.04.08
4.04.09

4.04.10

Each breaker shall be provided with an emergency manual trip, mechanical ON-OFF indicator, an operation counter, mechanism charge/discharge indicator, and electrical anti-pumping feature.

111

4.04.11

In addition to the auxiliary contacts required for normal breaker operation and indication, each breaker shall be provided with the following for interlocking purpose :

a) b)

Position/cell switch with minimum 4NO + 4NC contacts. Auxiliary switch, with minimum 6NO +6NC contacts, mounted on the stationary portion of the breaker panel and operated mechanically by a sliding level from the breaker in SERVICE position.

Alternatively, electrically reset-latching relay may be used for the purpose. The exact requirement contacts of the position/cells switch, limit switch, auxiliary switch and latching relay shall be decided by the Tenderers taking into account the scheme requirements spares. Limit/auxiliary switches shall be convertible type, that is, suitable for changing N.O. contact to N.C. and vice-versa.

4.04.12

Spring charge limit switch shall be provided for breakers with motor wound spring charging mechanism. These limit switches shall be provided with minimum 2NO + 2NC contact. Limit/auxiliary switches shall be convertible type, that is, suitable for changing N.O. contact to N.C. and vice-versa. Switches Switches shall be triple/double pole, air break type and designed for duties as specified in Annexure A. Motor duty switches shall be capable of safely making and breaking the locked rotor current of the associated motor circuit. The switch shall have a quick-make, quick-break mechanism operated by a suitable external handle, complete with position indicator. This handle shall have provision for padlocking in ON and OFF position.
The compartment door shall be interlocked mechanically with the switch such that the door cannot be opened unless the switch is in OFF position. Means shall be provided for releasing this interlock at any time.

4.04.13 4.05.00 4.05.01

4.05.02

4.05.03

4.05.04

Switches shall be capable of withstanding the let-through fault current of back-up fuses or circuit breakers. Wherever two incoming switches and one bus-section switch/breaker are provided for an assembly, these shall be mechanically/key interlocked to ensure that only two out of the three can be closed at time.
Wherever two incoming switches are provided for an assembly, these shall be mechanically/key interlocked to ensure that one of the two can be closed at time.

4.05.05

4.06.00
4.06.01

Fuses
Fuses shall be HRC, preferably link type, with a minimum interrupting capacity equal to the short circuit current of the LT system. Fuses shall be furnished complete with fuse bases and fittings of such design as to permit easy and safe replacement of fuse element.

4.06.02

112

Visible indication shall be provided on blowing of the fuse. 4.06.03 Motor fuse characteristics and ratings shall be chosen to ride over starting period without blowing. The fuse on incoming feeder wherever provided, shall be chosen to provide discrimination with motor/feeder fuses. A.C. Starter Contactors a) The contactors shall be three pole, air break type with non-bouncing silver/silver alloy contacts. The contactor shall be designed for duty as per Annexure-A attached.

4.07.00 4.07.01

b) Each contactor shall be provided with minimum (2) normally open and two (2) normally closed auxiliary contacts rated 10A at 240V A.C. The exact requirement of contacts shall be decided by the tenderer taking into account the scheme requirements and spares. c) Contactors for forward and reverse direction of reversible drives shall preferably be both electrically and mechanically interlocked. d) Delayed dropout contactors, if required and provided for some essential auxiliaries, shall not dropout on power failure if the voltage is restored within three seconds e) Contactor starters shall comply with the requirements of IS-8544 (Part-1) in respect of co-ordination of the characteristics of contactor, overload relay, and fuse. The type of co- ordination shall be Type-C as per IS-8544.

4.07.02

Thermal Overload a) b)
c)

Thermal overload relays shall be three elements, positive acting, ambient temperature compensated with adjustable settings. Single phasing preventer shall be provided as an inbuilt feature of the thermal overload relay.
Relays shall be manual reset type with changeover contacts; Resetting of relays shall be possible with compartment door closed. Colour of the resetting button shall be BLACK.

d) Relays for fan motors having long starting time shall be suitable case C.T operated. 4.08.00
4.08.01

Control and Indication

Circuit breakers shall be wired up for local and remote operation. Each breaker cubicle shall be equipped with the following :

i)

One(1) TEST-NORMAL-TRIAL selector switch with pistol grip handle and key interlock for breakers with motor wound spring charging mechanism.
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ii) iii)

Two(2) push buttons for TRIP and CLOSE Three(3) indicating lamps on the front of the compartment : Breaker open & Mechanism charged Breaker closed Breaker tripped/trip circuit faulty GREEN RED AMBER

4.08.02

The general scheme of connections for control, interlock, and protection is shown in the enclosed drawings. Detailed requirements of individual circuits shall be developed by the Tenderers. Push buttons shall be heavy duty, oil tight, push to actuate type with integral escutcheon plate marked with its function. Each push-button shall have minimum two (2) NO and two (2) NC contacts rated 10A at 240 V A.C.
Selectors switches shall be stay-put; rotary type with escutcheon plates marked to indicate the function and positions, and shall be lockable in each position. Selector switch contacts shall be rated for 10A at 240 V A.C.

4.08.03 4.08.04
4.08.05

4.08.06

Selector switches shall be provided with minimum three (3) contact blocks of 1 NO + 1 NC each. The exact requirements contacts shall be decided by the Tenderers taking into account the scheme requirement and spares.

4.08.07

Lamps shall be LED type. LED lamp shall be made in accordance with InP Technology (Aluminum Indium Gallium Phosphide Technology). The body shall be made of Poly Carbonate Unbreakable Lens. LED shall be protected by inbuilt fuse with surge suppressor or leakage voltage glow protection. LED circuit shall be PCB mounted. Intensity shall be greater than 200 mcd. All Push Button lamp shall be as per LED indicating lamp. For control supply, two (2) nos. adequately rated 415/240V control transformers with necessary taps shall be provided. Auxiliary bus bars shall be used to distribute 240V AC control supply. The control supply of different modules shall be tapped individually from the auxiliary bus bars. Transformer ratings shall be so selected to facilitate 100% standby arrangement with adequate spare capacity.

4.08.08

4.08.09 4.09.00
4.09.01

DCDBs shall be provided with indication to monitor healthiness of the incoming DC supplies. Meters and Meter Selector Switches
All indicating instruments (96 x 96 mm) shall be switchboard types, with 240 Deg. scale, anti-glare glass and accuracy class of 2% full scale. Each meter shall have zero adjuster on the front.

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4.09.02

Motor ammeters shall have an extended suppressed end-scale range to starting current (6 to 8 times full-load current).

indicate

4.09.03

All breaker operated incomers and motor feeders above 30 KW upto 160 KW shall be provided with 3-phase electronic energy meter with pulse output for interfacing with DCS. Meter selector switches shall be maintained contact, stay-put type, with knob handle. Ammeter and voltmeter selector switches shall be four position type. Ammeter selector switches shall have made before break contacts, to prevent open circuiting of CT secondary.

4.09.04

4.09.05 4.10.00 4.10.01 4.10.02

Energy meters suitable shall be provided as per Meters for Energy Accounting & Audit (MEEA) confirming to latest CEAs regulations Current Transformer Current Transformers shall be cast-resin type. All secondary connections shall be brought out to terminal blocks where wye or delta connection will be made. Motor feeders rated 30 KW to below 75KW, shall be provided with CTs for metering. Motor feeders rated 75KW and above , separate CTs shall be provided for metering and protection. Accuracy class of the current transformers shall be : a) b) c) Class PS for differential Class 5P20 for other relaying Class 1.0 ISF < 5 for metering other than MEAA metering

4.10.03

4.10.04

Other CT particulars like ratio, burden knee-point voltage, excitation current and secondary resistance shall be decided by the Tenderers.

4.10.05

Feeders requiring remote metering and/or current monitoring shall be provided with current transducers with calibration for full scale reading. The output shall be 4-20 mA DC of which shall correspond to the normal range. CT secondary shall be rated for 1 A for metering and either 5 A or 1 A for protection. Voltage Transformer
Voltage transformers shall be cast-resin and shall have an accuracy class of 1.0. Voltage transformer mounted on breaker carriage is not acceptable.

4.10.06

4.11.00
4.11.01

4.11.02 4.11.03

High voltage windings of voltage transformer shall be protected by current limiting fuses. Low voltage fuses, sized to prevent overload shall be installed in all ungrounded secondary leads. Fuses shall be suitably located to permit easy replacement while the switchgear is energised.
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4.12.00

Relays I. General-A
a) All relays & timers in the protection circuit shall be flush mounted with connection from inside. They shall have transparent, dust tight covers, removable from the front. They shall have built-in testing facilities. Except small auxiliary relays and timers all relays shall be drawout type.

b)

Relays shall be rated for operation on 1A or 5A secondary current and 110V secondary voltage to be decided by the bidder. Number and rating of relay contacts shall suit the job requirements. The Bidder shall furnish, install & co-ordinate all relays to suit the requirements of protection, interlock and bus transfer schemes as broadly indicated in the annexures and drawings. Application check shall be made on all motor protection relay motor characteristics furnished by the Owner. The result of such check shall be furnished for approval. It shall be the responsibility of the Bidder to fully co-ordinate the overload and short circuit tripping of the circuit breakers with the upstream and downstream circuit breakers / motor starters to provide satisfactory discrimination. All setting devices shall be accessible after removing the front cover. No relay shall be mounted on the rear side of PCC / PMCC panel. All relay coils and their auxiliary contacts (including un-enabled relays in Composite Numerical Relays, if any), including spare contacts will be wired up to the terminal blocks of respective panels for wiring to DCS & SCADA and for future use. Parameterization and loading and downloading of data shall be possible from local HMI and as well as from DCS / SCADA. All numerical relays shall have front communication port for parameterization, loading and downloading of data thru Laptop. All numerical relays and multi-functional meters shall be hooked up and connected with HMI thru Fiber Optic cable.

c)

d)

e)

f)

g) h) i) II.

General-B a) All protective relays shall be of numerical microprocessor based multifunctional type having communication facility for connection to DCS through PC via PLC console. All relays shall conform to the requirements of IS: 3231 / IEC: 60255 standards.
116

b)

c)

Vendor shall ensure availability of spare parts and maintenance support for the equipment for at least 15 years from the date of supply. Any foreign relay manufacturer through his Indian partner or subsidiary company in India shall provide application, testing, commissioning and other necessary support for minimum 15 years. They shall also maintain adequate inventory of each type of relay or spares to meet the requirement arising during project execution and plant operation.

d)

III.

Technical Requirement a) Auxiliary Power Supply Unless otherwise specified, relay shall be suitable to accept both AC / DC supplies with range 110V to 240V with tolerance of 20%. The auxiliary power supply shall preferably be site selectable requiring no additional hardware. b) Basic Requirement and Constructional Requirement i) Relays shall be suitable for flush mounting on the front with connections from the rear. The enclosure shall be dust tight having degree of protection minimum as IP: 5X. Relay shall have draw out feature with plug in type PCB for easy replacement. In case of fixed type relay, the terminals shall be easily accessible for testing and commissioning. Relay shall have self-diagnostic feature with indication of relay failure on relay front. However, while diagnostic circuit runs, it must not interfere in the main protective relay circuit and allow working of main protective circuit continuously. Relay faults (self diagnostic) shall be communicated and annunciated to HMI. Design of the relay shall be such that it must operate selectively and with proper discrimination. It must be immune to any kind of electromagnetic interference. Vendor to submit all related type test reports for the offered model along with the offer.

ii)

iii)

iv)

c)

Display & Indication i) All numerical relays shall have keypad / keys to allow relay settings from relay front. In addition, relay shall have front port for downloading / uploading of relay settings from the PC / Laptop. All hand-reset relays shall have reset button on the relay front. Relay to be self or hand reset shall be software selectable. All relays shall have LED / LCD display for settings, status, faults and events. LCD display shall be backlit
117

ii)

and temperature compensated up to 65C for contrast and legibility. iii) As a minimum, the relay shall have LED indicating lamps for fault trip, relay healthy / unhealthy and control supply on. The relay shall have at least 6 programmable LEDs on relay front.

iv) d)

Software Security Relay shall be provided with password protection against unauthorized write access. However, viewing of metering data, settings, and status and event data as read only parameters should be without password protection.

e)

Disturbance, Event Recording & Data Storage Status, disturbance data and events shall be stored in nonvolatile memory or memory backed up by battery. It should be possible to store minimum 50 events with date and time stamp, last 5 fault records and last disturbance record. When auxiliary power fails, it should be possible to see the latest state of display when power is restored. Also, in case of power supply failure lock out status of the relay should be stored and kept in memory to allow the working of interlock logic properly on restoration of the supply.

f)

Trip Circuit Supervision & Lock out function i) Relay shall have built in lockout function. Lock out feature shall be self reset or hand reset and shall be software selectable. Relay shall have built in trip circuit supervision function.

ii) g) h)

Input / Output Interface, Filters and Galvanic Isolation Relay shall have at least 4 NO contacts each shall separately be programmable for either hand reset or self-reset. The contact rating shall be minimum 5A at 250V AC / DC. i) ii) Relay shall be made immune to capacitance effect due to long length cables. All IOs shall have galvanic isolation. Analog inputs shall be protected against switching surges, harmonics etc.

i)

Serial Communication i) Relay shall have RS 485 or FO (Fiber Optic) port for serial communication.
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ii) iii)

All relays should be able to communicate with DCS system. Data shall be available at the DCS on request. Protocol adapted for communication to DCS should facilitate easy interface with world wide used open protocol like Modbus or IEC 103 protocols. It shall be also possible for Relay Parameterization as well Downloading of Disturbance Records from PC provided in Unit & Engineering Workstations located in Switchgear Room of each unit i.e. Unit & Engineering Workstations shall be provided each in four (4) Switchgear Rooms. Necessary software to be provided for this purpose. Communication protocol shall be selected from relay to PC to provide all information. One (1) set of Laptop loaded with common support software should be supplied, which will allow easy settings of relays in addition to uploading of event, fault, disturbance records, measurements from relay front communication port.

iv)

v)

4.13.00
4.13.01

Secondary Wiring
All boards shall be fully wired at the factory to ensure proper functioning of control, protection, transfer and interlocking schemes. Fuse and links shall be provided to permit individual circuit isolation from bus wires without disturbing other circuits. All spare contacts of relays, switches and other devices shall be wired up to terminal blocks.

4.13.02

4.13.03

Wiring shall be done with flexible, 1100 V grade, PVC insulated switchboard wires with stranded copper conductors of 2.5 mm2 for control, current and voltage circuits.
Each wire shall be ferruled by plastic tube with indelible ink print at both end having terminal block no., terminal nos., destination no. as per approved Drawing.

4.13.04

4.13.05 4.14.00 4.14.01

Wire terminations shall be made with crimping type connectors with solder as insulating sleeves. Wires shall not be spliced between terminals. Terminal Blocks Terminal blocks shall be 660V grade box-clamp type 10 mm2 minimum with marking strips. Terminals for C.T. secondary leads shall have provision for shorting.
Terminal blocks used for interface with DCS via termination cabinet shall be suitably sized to facilitate proper termination of interconnecting cables.

4.14.02

4.14.03

Not more than two wires shall be connected to any terminal. Spare terminals equal in number to 20% active terminals shall be furnished.

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4.14.04

Terminal 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.

4.15.00
4.15.01

Cable Termination
Generally, all assemblies shall be designed for cable entry from the bottom. Sufficient space shall be provided for all the cables as per cable schedule, for ease of termination and connection.

4.15.02

All provisions and accessories shall be furnished for termination and connection of cables as per cable schedule, including removable gland plates, cable support, crimp type tinned copper/aluminium lugs, double compression brass glands with tapered washer (Power cable only) and terminal blocks. Gland plates shall be minimum 3 mm thick. The gland plate and supporting arrangement for 1/C power cables shall be non-magnetic type to minimise the flow of eddy current. Bus Duct Connection
Bus duct connection, wherever provided, shall be furnished along with transition panel, if required. Bus duct connections shall be from the top.

4.15.03

4.16.00
4.16.01

4.16.02

All connecting bus work shall have the same continuous rating as associated PCC/PMCC/MCC/DB bus and shall be fully braced for the LT system short circuit current.
All provisions such as matching flanges and other accessories required for proper connection to bus duct shall also be supplied.

4.16.03

4.17.00
4.17.01

Ground Bus
A ground bus, rated to carry maximum fault current, shall be provided which shall extend the full length of the assembly.

4.17.02 4.17.03

The ground bus shall be provided with two-bolt drilling with G.I. bolts and nuts at each end and shall be suitable to receive 50 x 6 mm G.S. flat. All stationary units shall be directly connected to the ground bus for effective grounding.
The frames of all circuit breakers and drawout V.T. units shall be grounded through heavy multiple contracts at all times except when the primary disconnecting devices are separated by a safe distance.

The frames of all other drawout modules shall be grounded at all times except when the power disconnects are separated by a safe distance. 4.17.04 Wherever the schematic diagrams indicate a definite ground at the switchgear; a single wire for each circuit thus grounded shall be run independently to the ground bus and connected thereto.

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4.17.05 4.17.06 4.18.00

4.18.01

C.T. & V.T. secondary neutrals shall be earthed through removable links so that earth of one circuit may be removed without disturbing others. All hinged doors shall be earthed by flexible copper braid. Nameplates
Nameplates of approved design shall be provided on each cubicle, at the top of the assembly and on each instrument & device mounted on or inside the cubicle.

4.18.02
4.18.03

The material shall be lamicoid or approved equal. 3 mm thick with white letters on black background.
The name plates shall be held by self-tapping screws. Nameplate size shall be minimum 20 x 75 mm for instrument/devices & 40 x 150 mm for panels.

4.18.04 4.19.00
4.19.01

Caution notice on suitable metal plate shall be affixed both at the front and back of each vertical panel. Space Heaters and Plug Sockets
Each vertical section shall be provided with thermostat controlled space heater and 5A, 3 pin plug socket.

4.19.02

In addition, motor feeders rated 30 KW and above shall be wired-up for feeding the motor space heater through suitably rated breaker auxiliary NC contact and/or contactor.

4.19.03 4.19.04 4.20.00 4.20.01

Cubicle heater. Motor heater and Plug-socket circuit shall have individual switch fuse units. Two nos. 5KVA space heater transformer shall be provided for bus section- A & B for catering space heater supply to respective bus. A.C./D.C. Power Supplies Necessary 415V AC and 110V DC power supplies as required for control and service, shall be arranged by the contractor. Single feeder shall be arranged for A.C. supply and duplicate feeder shall be arranged for D.C. supply. Isolating switch fuse units shall be provided for the incoming supplies. These shall be 4-pole, single throw for 415V AC and 2- pole double throw without off position for 110V DC.
Bus-wires of adequate capacity shall be provided to distribute the incoming supplies for different cubicles. Isolating switch- fuse units shall be provided at each cubicle for A.C./D.C. supplies.

4.20.02

4.20.03

4.20.04

A.C. load shall be so distributed as to present a balanced loading on three-phase supply system.

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4.21.00 4.21.01 4.21.02 4.22.00

4.22.01

Tropical Protection All equipment, accessories and wiring shall have fungus protection, involving special treatment of insulation and metal against fungus, insects & corrosion. Screens of corrosion resistant material shall be furnished on all ventilating louvers to prevent entry of insects. Painting
All assemblies shall be finished with two coats of RAL7032 paint.

4.23.00
4.23.01

Miniature Circuit Breaker

MCB shall be suitable for manual closing and opening and also automatic trip on overload and short circuit.

5.00.00
5.01.00

TESTS
The switchgear shall be completely assembled, wired, adjusted and tested at the factory as per the relevant standards.

5.02.00

Routine Tests The tests shall include but not necessarily limited to the followings : a) Operation under simulated service condition to ensure accuracy of wiring, correctness of control scheme & proper functioning of the equipment. All wiring and current carrying parts shall be subjected to appropriate High Voltage Test.
Primary current & voltage shall be applied to all instrument transformers.

b)
c)

d)

Routine test shall be carried out on all equipment such as circuit breakers, instrument transformers, relays, meters, contactors, switch-fuses, etc.

5.03.00

Type Tests The following type tests shall be performed on a representative sample of the LV Switchgear assembly, even if type test certificates of these tests are submitted by the Bidder for Purchaser's approval : a) b) Temperature rise Test Short circuit test should be performed so that one complete (longest) span of insulator supports of main busbars are covered in the S.C path thereby subjected to dynamic forces developed.

122

Short circuit test shall be performed in the following section of the busbar:Circuit Breaker Panel: In the main horizontal busbar and vertical bus bar with ACB replaced by shorting link. Motor Control Centre / Distribution Boards:Main horizontal busbar, Vertical busbar. c) Degree of protection of enclosure IP-54.

Charges for each of the above tests shall be indicated separately. 5.04.00 Type test certificates of any equipment shall be furnished if so desired by the Purchaser. Otherwise, the equipment shall have to be type tested, free of charge, to prove the design. Type tests performed before five (5) years are not acceptable. SPECIAL TOOLS & TACKLES A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied. The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended. INSTALLATION REQUIREMENTS All busbars, relays, meters and control switches will be supplied loose to be mounted and connected at site as per the relevant drawings which shall be supplies to the Contractor for necessary mounting, wiring and connection work at site. All alignment, leveling, grouting, anchoring, tack welding, adjustments and oil conditioning shall be carried out in accordance with manufacturer's instructions and/or as directed by the Engineer. All connections in the extension/dummy panels of switchgears shall be completed, checked and adjusted to ensure safety and satisfactory operation of the equipment. In some cases, some modifications may have to be carried out at site in the wiring of a equipment to meet the requirements of the desired control scheme and the contractor shall have to do same at no extra cost. Schedule of work for LT switchgear shall include erection, testing and commissioning of all panels as listed in Bill of Materials

6.00.00 6.01.00

6.02.00

7.00.00 7.01.00

7.02.00

7.03.00

7.04.00

7.05.00

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ANNEXURE-A RATINGS & REQUIREMENTS 1.0 GENERAL

Type : Metal-clad, drawout (PCC/ MCC) Metal-clad, fixed (DB)

Service
Enclosure

:
:

Indoor
For ampere rating up to 2000A degree of protection of PCC/PMCC/MCC shall be IP-54 and above 2000A the degree of protection will be IP-42.

1.1

System Voltage Phase Frequency Combined voltage and frequency variation System grounding : : : : :

AC 415V 10% 3-phase and neutral 50 Hz 3% 10% (absolute sum) Solidly grounded

DC 110V 10% Ungrounded

1.2

Rated Current at 50oC ambient Busbar Circuit breaker Switches : : : AC : 50 KA 50 KA 2.5 KV To be decided by the Tenderers - Do 16A to 630A DC 25* KA 25* KA 1.5 KV

1.3

Short Circuit Rating Interrupting

Short Time for 1 second : 1.4Hipot for 1 minute (min.) * :

Indicative only; the actual value will be decided by the Bidder, after substantiating the same by calculation.

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1.5

A.C./D.C. Power Supply Control Voltage for Circuit breaker Control voltage for MCC modules Service voltage : : : 110V DC 10% 240V AC 10%, 1 Ph, 50 Hz 3% 240V AC 10%, 1 Ph, 50 Hz 3%

2.0 2.1 2.2

CIRCUIT BREAKER Duty Cycle Breaking Current A.C. Symmetrical : : 50 KA 105 KA Peak : 0-3'-CO-3'-CO

2.3 2.4

Making Current Auxiliary Voltage

Closing

110V D.C. (85 - 110%)

Tripping Spring Charging 3.0 CONTACTOR DUTY :

: :

110V D.C. (70 - 110%) 110V D.C. (85 - 110%) AC DC Class I Category DC2

Class III-Category AC3 for unidirectional drives and AC4 for bi-directional/inching duty drives

4.0

SWITCH DUTY Motor feeders Other feeders : : AC23 AC22 DC22 DC22

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ANNEXURE-B PROTECTIONS 1.0 The minimum protections to be provided for circuit breaker controlled feeders are listed below : a) Incoming Feeders : 3-Inverse time O/C relays (51) for phase faults & Instantaneous O/C(50) with timer

1-Inverse time O/C relay (51N) for Earth faults Under Voltage relay (27) with Timer(2) b) Motor Feeders : Microprocessor based Numerical Protection for LT Motor above 75KW

Bidder shall quote suitable digital/microprocessor based numerical relay for motor protection with following minimum facility as indicated below : Thermal model based with RTD feedback and negative sequence current.

Voltage compensated acceleration. Under voltage, over voltage protection. Overload protection. Short circuit & SC back-up. Current unbalance. Ground fault. Temperature monitoring (stator, bearing etc.). Phase reversal. Locked rotor protection

Apart from above suitable provision for metering and monitoring such as voltage, current, power factor, watt-hr, event record etc. shall be provided.

The relay shall have facility for user interface capability, character display, keypad, LED indicator and communication port along with licensed version software.

c)

Lighting transformer

3-inverse time O/C relays with feeders high set instantaneous unit (50/51) for phase faults 126

1-inverse time O/C relay (51N) for earth fault d) Outgoing Feeders : - 2-Inverse time O/C relay (51) for phase fault

- 1-Inverse time O/C relay (51N) for Earth fault

All inverse time O/C relay shall be 1.3 sec version.

2.0

Apart from protection relays, each electrically operated breaker shall be provided with anti-pumping (94), trip annunciation (30), lockout (86) and trip circuit supervision (74) relays. Lockout relay shall be hand reset type. Fuse failure relay shall be provided on the secondary side of voltage transformer to monitor H.V. & L.V. fuses.

3.0

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ANNEXURE-C

415 V NON-SEGREGATED BUS TRUNKING SYSTEM

1.1.0 1.1.1 General The bus Trucking will serve as interconnection between L.V. terminals of Auxiliary L.T. Transformers to their respective PCC and also for trucking connection between each set of PCC, if required.
The busduct shall be non-segregated type, self-cooled sandwich type. The cooling medium shall be air.

1.1.2

1.1.3
1.1.4

The busduct will be installed in a hot, humid and tropical atmosphere.

It shall be capable of withstanding the mechanical forces and thermal stresses of the specified short-circuit currents without any damage or deterioration of material.

1.1.5 1.1.6 1.1.7 1.1.8 1.1.9

Same phase disposition shall be maintained throughout the run of the bus duct. Phase cross-over units, if required, shall also be provided. The connection flanges shall be sufficiently stiffened so as not to bend while tightening the bolts. The conductor shall be of high conductivity electrolytic copper sized for the same rating as associated PCC bus/Transformer. The ends of the Bus bar shall be electro tinned to avoid corrosion and to ensure proper conductivity. The bus bars should be suitably braced with non-hygroscopic SMC supports to provide a through fault withstands capacity of 85 KA(r m s) symmetrical for one second. The insulation class of said support should be class H.
The trunking system shall be so design that close proximity of bus bar does not allow mutual inductance between phases yielding low reactance, low impedance, low voltage drop and low power loss.

1.1.10

1.1.11 All supporting structures required for hanging and/or supporting the complete busduct shall be furnished. These include all members, indoor/outdoor posts, bolts, shims, base plates, beams, hangers, brackets, bracings and hardware. 1.1.12 All buses shall be adequately supported and braced to successfully withstand normal operation, vibration, thermal expansion, short circuit forces, and all specified design loads. 1.1.13 All steel members shall be hot-dip galvanised after fabrication. All hardware shall be of high strength steel with weather resistant finish. 1.1.14 The distance between L.V. terminals of Auxiliary L.T. Transformers to their respective PCC and also for trucking connection between each set of PCC will be consider as running meter cost.
128

1.1.15 All matching flanges, gaskets, fittings, hardware, and supports required for termination of the busduct at PCC, transformer, and any other equipment shall be supplied. All hardware used at conductor points shall be of non-magnetic, high tensile material. 2.0.0 TESTS
The busduct shall be completely assembled and checked at the factory for correctness of alignment.

2.1.0

Routine Tests: Busduct shall be subjected to the following tests: a) b) c) d) e) Visual inspection and verification of dimensions. Dry power frequency voltage withstand test for 1-min. Insulation resistance measurement. Mili-volt drop test. Water tightness test.

2.2.0

Type Tests The following type tests shall be performed on a representative section of bus assembly: a) b) c) Impulse voltage withstand test. Heat run test. Short circuit test.

129

ANNEXURE-D RATINGS AND REQUIREMENTS FOR 415V NON-SEGREGATED PHASE BUSDUCT 1.0 General Type Service Applicable Standard Enclosure material Conductor 2.0 System Voltage Phase Frequency Combined voltage and
Frequency variation : 10% (absolute sum)

: : : : :

Non-segregated sandwich type Indoor/Outdoor IEC60439(1&2) & IS 8623(1&2) steel(16 SWG GI as min.) Copper

: : :

415V AC+ 10% _ 3-Phase and neutral 50 HZ+ 5% _

4.0 5.0 6.0 7.0 8.0

Rated current at 50C ambient Short time current rating for one (1) second Rated impulse withstand voltage Degree of protection Busbar Insulation

shall be suitable for 3000KVA,11/433V Transformer (To be decided by the Bidder). 85 KA 12 KV (1.2/50 s)

: :

: IP 65 : Multi-layer insulation

130

ANNEXURE-E INDICATIVE LIST OF 415V PCCS/MCCS/PMCCS/DBS A. PCC/PMCC/MCC i) ii) 415 V Station PCC : with one(1) 6000A ACB incoming feeder and outgoing feeders as per Drg. 11P01-DWG-E-291-100.01_Rev.E 415 V MCC (for supplying misc. loads) : with two (2) 1000 A ACB incoming feeder outgoing feeders as per Drg. 11P01-DWG-E-291-100.01_Rev.E 3 nos. 2 nos.

B.

415V ACDBS
i) Station ACDB : : : : 1 no. 4 nos. 3 nos. 4 nos.

ii) Main Lighting distribution Board iv) Lighting Distribution Board v) Welding Transformer Board In PM#5

C.

110V DCDBS i) DCDBS : 2 nos.

Three (3) sets.

D.

415V Non Segregated Phase sandwich type Bus Duct :

NOTE: THIS LIST IS AN INDICATIVE ONE, BASED ON INFORMATION AVAILABLE FOR EXISTING PLANT. THE DISTANCE BETWEEN LT TRANSFORMERS TO PCC WILL BE CONSIDERED AS METER RUNNING COST.

131

ANNEXURE-F MODULE SELECTION

MOTOR FEEDER

Type AU/AR BU/BR CU DU EU FU NOTE: 1. 2. 3.

Motor Rating 0 - 5.5 KW 5.6 - 11 KW 11.1 - 22 KW 22.1 - 50 KW 50.1 - 75 KW 75.1 - 109KW

Switch Fuse Rating 32A 63A 63A 100A 200A 400A

Contactor 16A 32A 63A 100A 160A 300A

Cable size 3/c 2.5 Sq.mm - Cu 3/c - 16 Sq.mm - Cu 3/c - 35 Sq.mm - Cu 3/c - 95 Sq.mm -Cul 3/c - 185 Sq.mm - Cu 2 x 3/c - 185 Sq.mm - Cu

Switch Fuse, thermal overload relay, Contractor are to be co-ordinated (Type-2) with motor rating by the Contractor. U stands for Unidirectional and R for Reversible drives. Switch Fuse with SPPR protection to be considered for motors between 45KW to 75KW.

132

OUTGOING FEEDER Type AF BF CF DF EF MODULE SELECTION Switch Fuse Rating 32A 63A 100A 200A 400A Cable Size 4/c 16 Sq.mm - Cu 4/c 35 Sq.mm - Cu 3.1/2 95 Sq.mm - Cu 3.1/2 300 Sq.mm - Cu 4 x 1/c 630 Sq.mm - Cu

Type Switch Rating Fuse Rating Cable Size ___________________________________________________________________________ DAU DAF DBF DCF DDF 16A 32A 63A 100A 200A 16A 32A 63A 100A 200A 2/C-2.5 Sq.mm. Cu. 2/C-2.5 Sq.mm. Cu. 2 x 2/C-16 Sq.mm - Cu 4/C-35 Sq.mm - Cu 2 x 4/C-35 Sq.mm - Cu

DEF 400A 400A 2 x 1/C-630 Sq.mm -Cul ___________________________________________________________________________

133

ANNEXURE-G LIST OF OUTGOING FEEDERS FROM 415V STATION MCC FOR SUPPLYING MISCELLANEOUS LOADS (1) Ventilation System: (a) 4 nos. LSCP for 4 nos. AWU (100kW each x 3 nos. & 30kW x 1 no.) (b) 6 nos. roof extractors LSP x 6 nos. (c) 1 no. ceiling heating fan 1 no. x LSP (d) Other fans 24 nos. (e) Switches for single phase fans 20 nos. (2) Cranes: (a) 125A 1 no. feeder (3 ph., 4 wire) (b) 150A 1 no. feeder (3 ph., 4 wire) (c) 200A 1 no. feeder (3 ph., 4 wire) (3) Elevators: (a) 3 nos. feeders of 125A each (3 ph., 4 wire) (4) Fire-fighting: (a) 1 no. feeder for Fire water pump (7.5kW) (b) 1 no. feeder for Jockey pump (5kW) (5) Sump pumps: (a) 4 nos. feeders of 100A each

134

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION-VII 110V BATTERY AND BATTERY CHARGERS

135

SUB-SECTION-VII
110V BATTERY AND BATTERY CHARGERS

CONTENTS
CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 DESCRIPTION CODES AND STANDARDS SCOPE OF WORK DESIGN CRITERIA SPECIFIC REQUIREMENTS TESTS SPECIAL TOOLS & TACKELS INSTALLATION REQUIREMENTS ATTACHMENTS ANNEXURE-A ANNEXURE-B RATINGS AND REQUIREMENTS FITTING & ACCESSORIES 14 17 PAGE NO. 1 1 2 3 12 13 13

136

110V BATTERY AND BATTERY CHARGERS

1.00.00 3.01.01 CODES AND STANDARDS All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification. Equipment and material conforming to any other standard which ensures equal or better quality, may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid. The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed. SCOPE OF WORK Scope of Supply Type, ratings, requirements, fittings and accessories listed below are further detailed in Annexure- A & B. Equipment shall be offered in strict compliance with the same. 2.01.01 600 AH, 110V High discharge Pocket Plate Nickel-Cadmium type Battery Bank for the new Paper Plant : One (1) no. 110 V Battery Charger, each comprising of one (1) Float Charger and one (1) Float-cum-Boost Charger: One (1) no. 2.01.02
2.01.03 2.01.04

3.01.02

3.01.03

2.00.00 2.01.00

One (1) no. Battery Impedance Tester.

One (1) no. Battery Earth Fault Locator. One (1) no. Battery Discharge Resistor Unit suitable for continuous 150 A.

2.01.06 2.01.08 2.03.00 2.03.01

One set of Special Tools and Tackle. All relevant drawings, data and instruction manuals. Completeness of Supply 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, design and workmanship. Any material or accessory which may not have been specifically mentioned but which is necessary or usual for satisfactory and trouble-free operation and maintenance of the equipment shall be furnished without any extra charge. 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.
137

2.03.02

2.03.03

2.03.04

Make of brought-out items are subject to Owner/Purchasers approval. The contractor shall furnish relevant details to the Owner/Purchaser for his concurrence before procurement. DESIGN CRITERIA Design Basis D.C. system provides reliable sources of D.C. power for control, indication, protection and annunciation of all electrical equipment related to the new paper plant. In addition, it provides power supply for emergency lighting. The batteries and chargers will be installed indoor in a dusty, hot, humid and tropical atmosphere. The battery and charger combination shall be such as to ensure continuity of DC supply at load terminals at all times without even momentary interruption.
The battery shall be sized to meet emergency load duty cycle requirements for at least four (4) hours. However, the minimum rating of battery bank shall be 600AH. While estimating battery capacities, aging margin as per relevant standard, temperature correction factor as per manufacturers standard and a design margin of 10% shall be considered. For the purpose of estimating battery capacities, the maximum and minimum temperatures shall be considered as 50C and 5C respectively. All momentary loads shall be treated as one-minute loads. The procedure for estimating battery capacities shall be as per guidelines stipulated in IEEE Std. 1115-1992. The battery will be sized such that the voltage at any time during the duty cycle shall not be less than 1 Volt per cell.

3.00.00 3.01.00 3.01.01

3.01.02 3.01.03
3.01.04 3.01.05

3.01.06 3.01.07 3.01.08

3.01.09

3.01.10

The Float charger shall be sized to carry the total load as indicated in clause no. 4.01.01 and the trickle charging current of the battery plus a 25% margin. The output voltage of the float charger shall be adjustable between 110-120V. The charger shall also be capable of delivering the rated load even under the specified voltage and frequency variations. Minimum Charger current shall be 150A.
The Float-cum-Boost charger shall be sized to restore the fully discharged battery to full charge condition in five (5) hours with 25% margin over maximum charging rate or to operate as a float charger with duty requirement as indicated against cl. No. 4.01.10 whichever is greater.

3.01.11

3.01.12

For continuous operation at specified ratings, temperature rise of the various components of battery & battery charger shall be limited to the permissible values stipulated in the relevant standards and/or this specification. The batteries & chargers shall be so designed that the maximum fault level on DCDB is limited to 15KA (Indicative only: the actual value will be decided by the Bidder after substantiating the same by calculation).

3.01.13

138

3.02.00 3.02.01
3.02.02

System Concept The basic system configuration is broadly outlined below.

The float charger will be normally ON, supplying the D.C load current and at the same time trickle charging the battery.

3.02.03 3.02.04

The characteristics shall be such that if load is high and exceeds the charger capacity then the excess load will be supplied by the battery. The float-cum-boost charger will be normally in stand-by (auto float / charge) mode and will cut into the circuit automatically a) to provide occasional equalizing charge as required, b) to make over the functions of float charger in case of its failure, c) to boost charge the battery upto 1.53 Volts per cell. The float-cum-boost charger shall also have provision for float, equalizing and boost charging the battery through manual selection. On failure of station A.C. supply both float and float-cum-boost chargers will go out of service and battery will take over to supply emergency loads without any interruption. Interlock shall be provided to ensure that the battery can be taken to boost mode only if the float charger is healthy and running. Interlock defeat arrangement shall also be provided for initial charging of battery. SPECIFIC REQUIREMENTS Layout The battery & battery charger will be located indoor. The Bidder shall also indicate his recommendation for battery room ventilation. Sufficient clear space shall be provided for attending individual cells. Sufficient clear space shall be kept in the battery room to accommodate a battery of identical capacity in future. Battery General i) The battery shall be stationary High discharge Nickel Cadmium pocket plate type and shall be suitable for operating satisfactorily in humid and corrosive atmosphere. ii) The equipment shall comply with the requirement of latest revision of following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified:

3.02.04 3.02.05

3.02.06

4.00.00 4.01.00 4.01.01 4.01.02 4.01.03 4.01.04 4.02.00 4.02.01

139

IS: 10918 Cadmium batteries.

Specification for vented type Nickel

Incase Indian Standards are not available for any equipment, Standards issued by IEC/BS/VDE/IEEE/NEMA or equivalent shall be applicable. 4.02.02 Technical Requirement i) The High discharge pocket plate Nickel Cadmium cell/battery shall be heavy duty high discharge type suitable for power plant duty with float duty operation at constant voltage permanently applied to its terminals which is sufficient to maintain it in state close to full charge and shall be designed to supply the load in the event of normal power supply failure. The rated ampere-hour capacity of the cell/battery shall be at reference temperature of 27C, constant current discharge at 5 hours rate (C5) and end cell voltage of 1 V/Cell. The battery shall be suitable for being boost charged to fully charged condition from fully discharged condition within 5 hours. Battery assembly shall be supplied in dry and uncharged with dry alkaline powder with 10% extra. Each battery set shall consist of a group of cell electrically connected in series to attend the nominal voltage level specified on the data sheet. The terminal cells shall be supplied with connectors for termination to the charger. The supplier shall provide inter-cell connectors and related hardware and accessories required for normal operation and maintenance. All cell posts shall be shrouded and connectors insulated. Cell container shall be made of heat resistant, tough translucent polypropylene material to make the cell mechanically sturdy and facilitate visual electrolyte level checks for ease in of maintenance. The terminal posts shall be of Nickel-plated steel. The terminals shall be suitable for short circuit current and specified discharge current without damage to cell as a result of terminal heating. Flame arresting flip-open vent cap shall be provided on the cell to avoid explosion and contamination. The following information shall be permanently marked on the cell: Nominal voltage. Name or manufacturer/model reference. Rated capacity in ampere-hour (Ah) with End Cell Voltage. Voltage for float operation of 27C with tolerance of 1%. Month and year of manufacture.

ii)

iii) iv) v)

vi)

vii)

viii) ix)

140

x)

Battery racks shall be constructed of structural steel frames forming a rigid structure. Rack shall be pretreated and epoxy painted/PVC coated. Cell shall be supported on porcelain insulator fixed on the rack with adequate clearance between adjacent cells. Each set of battery shall be equipped with a battery condition and performance monitoring system. The battery monitoring system shall compare measured figure during a partial discharge against (too high ambient temperature, too high temperature of single cell or block, difference in the voltage across the cell, too high voltage ripple, too high charging current, too many cycles or micro cycles) stored characteristics for the type and capacity of the battery. The system shall be able to test, analyze and predict the battery performance, computing remaining capacity and battery efficiency. The battery monitoring system shall compensate for cell temperature and discharge load current throughout the discharge cycle. The system shall have a programmable event log shall be secured in the event of total power failure for a period upto six month. In addition to local indication and control the battery monitoring system shall include an RS 485 output port to enable battery parameters and alarms to be monitored from Control room.

xi)

4.03.00 4.03.01

Battery Charger General a) b) c) The charger shall be natural air cooled, solid-state type with full wave, fully controlled, bridge configurations. The charger shall be provided with automatic voltage regulation, current limiting circuitry, smoothing filter circuit and soft-start feature. Voltage control shall be step less, smooth and continuous. Voltage control shall be possible either in Auto mode or in Manual mode. An Auto-Manual selector switch shall be provided for this purpose. The charger shall be self-protecting against all AC and DC transients and steady state abnormal currents and voltages. Charger AC input and DC output shall be electrically isolated from each other and also from panel ground. The ripple to DC side or AC side should not exceed 1% (RMS). Isolation shall also be provided between power and control circuits. Each battery charger shall be provided with one (1) no. Voltage transducer and one (1) no. Current transducer for monitoring the D.C. output.

d) e)

f) g)

4.03.02

Construction a) The charger shall comprise a continuous line up of free-standing, floor mounted sheet steel panels, with access from both front and rear.

141

b)

In between the float and float-cum-boost charger panels, a central panel shall be provided. This panel shall house the battery terminals, load terminals, battery blocking diodes, and a few meters, annunciator and indicating lamps. The panels shall conform to the degree of protection IP: 42. Minimum thickness of sheet metal used shall be 2 mm. Access doors shall be with concealed hinges and neoprene gaskets. Ventilating louvers shall be covered with fine wire mesh. Doors over 600 mm width shall be of double-leaf design.

c) d)

e) f)

All equipment within the panels shall be arranged in modular units and laid out with sufficient space for easy maintenance. Switches, meters, relays, etc. shall be flush mounted on the front of the panels. Adequately sized nameplates shall be provided for all circuits and devices both at front & inside of the panel. All busbars and bus connections shall be of high conductivity aluminum/aluminum alloy and adequately sized to limit the maximum temperature rise to 35C under rated load condition. The maximum allowable temperature rise shall be 35C at joints. The ambient temperature in either case shall be 50C. All bus connections shall be silver-plated. Adequate contact pressure shall be ensured by means of two bolt connection with plain and spring washes and locknuts. Heat-shrinkable insulating sleeves shall be provided for busbars. All bus connections shall be shrouded. Busbars shall be colour coded for easy identification.

g)

h)

i)

j)

Busbars shall be supported and braced to withstand the stresses due to maximum short circuit current and also to take care of any thermal expansion.

4.03.03

Charger Equipment a) All power diodes and control rectifiers shall be silicon type. Rectifier transformers shall be vacuum impregnated cast resign dry type, double wound, delta / star, with copper conductor and class- F insulation. The maximum temperature of the class- F insulation shall be limited to that of class-A insulation. Blocking diodes shall be fully rated and redundant so that failure of a single diode shall not incapacitate the system in any way. Isolating switches shall be heavy duty, load break type, operated by an external handle with provision for padlocking in ON and OFF position.

b) c)

142

d)

Changeover switch shall be 3 position, 4 pole, load break type with minimum 2 NO + 2 NC auxiliary contacts. The switch shall be installed in such a manner that the operating handle shall be accessible only after opening the front door. Contactors shall be air-break type. Thermal overload relays shall have in-built single phasing preventer. Fuses shall be HRC type and arranged for easy replacement. Semiconducting device fuses shall be fast-acting. Indicating Lamps shall be LED type. LED lamp shall be made in accordance with InP Technology (Aluminum Indium Gallium Phosphide Technology). The body shall be made of Poly Carbonate Unbreakable Lens. LED shall be protected by inbuilt fuse with surge suppressor or leakage voltage glow protection. LED circuit shall be PCB mounted. Intensity shall be greater than 200 mcd. Meters shall be 96 x 96 mm switchboard type, 90 scales, antiglare glass, +1% accuracy with zero adjuster on the front. _ Rectifier transformer for float-cum-boost charger shall be provided with + 2x2.5% taps on the primary side. _ All power diodes and thyristors shall be designed to withstand 200% continuous load current without exceeding junction temperature of 85C. Charger to be equipped with LCD display, so the system or particular module operations parameters can be locally or remotely reviewed/ monitored. Metering of required parameters, display of alarm, interfacing with serial communication port RS 485, LED/ Indication for alarm with relay operation, reset for fault condition and following input parameters to be displayed: Input AC voltage Input AC Current Charging Voltage Charging Current Load Voltage Load Current Battery Voltage Battery Current

e) f) g)

h) i) j)

k)

l)

In incoming of charger MCCB to be provided (AC side).

143

4.03.04

Alarms a) b) Solid-state, audio-visual annunciation system shall be provided for battery chargers. Annunciation system shall operate on 220 V D.C. One (1) minimum ten-point alarm facia shall be provided on each float charger and float-cum-boost charger panel, complete with proper actuating devices, circuitry, legend, push-buttons (Accept, Reset and Test) and hooter. Each central panel shall be provided with one (1) minimum eight-point alarm facia, complete with proper actuating devices, circuitry, legend, push buttons (Accept, Reset and Test) and hooter. The arrangement shall be such that on occurrence of a fault, the corresponding window will light up and stay lighted until the fault is cleared and the reset button is pressed. Each time a window lights up, a master relay will get energized to provide group alarm signals to remote control panel. The requirements of indications/alarms are given in Annexure-B. Alarms should be compatible to Main DCS.

c)

d)

e) f) g) 4.03.05 Meters a)

Each Float charger panel shall be provided with the following meters: i) ii) One (1) D.C. ammeter (for charger output) One (1) D.C. voltmeter with selector switch (for charger output/battery voltage).

b)

Each Float-cum-Boost charger panel shall be provided with the following meters: i) ii) One (1) D.C. ammeter (for charger output) One (1) D.C. voltmeter with selector switch (for charger output/battery voltage)

c)

Each central panel shall be provided with the following meters: i) ii) One (1) D.C. Ammeter (for load circuit) One (1) A.C. Voltmeter with selector switch (for main A.C. supply)

4.03.06

Controls
The following manual controls shall be provided on the front of each charger panel:

a)

Selection of float, equalizing or boost charge.

144

b)

Voltage setters for setting the output of float/equalizing/ boost charge. Setting shall be independent of each other so that setting of one voltage will not require resetting of the others. Current limit setter.

c) d)

4.03.07

Acknowledge-Reset-Test push buttons for annunciation system. The colour of reset buttons shall be BLACK. Lamp/Space heaters/receptacles a) The charger panels shall be provided with: i) ii) iii) iv) b) Internal illumination lamp with door switch Space heater with thermostat control 3 pin 5A receptacle with plug Communication plug

Lamp, heater and receptacle circuits shall have individual switch fuse units/MCCB.

4.03.08

Wiring/Cabling a) The panels shall be completely wired-up. All wiring shall be routed through wiring troughs. Wires shall be ferruled at both ends for identification. Internal wiring of the panels shall be done with 1100 V grade FRLS PVC insulated cables with stranded copper conductor of minimum size 2.5 Sq.mm. Panels shall have removable gland plates at the bottom for cable entry. All incoming/outgoing cables shall be terminated in suitable terminal blocks. Control terminal blocks shall be box-clamp type, minimum 10 Sq.mm. 20% spare terminals shall be provided.

b)

c)

d) 4.03.09

Grounding a) b) The charger panels shall have fully rated ground bus with two ground terminals, one at each end. Each terminal shall comprise two-bolt drilling with M10 G.I. bolts and nuts and shall be suitable for connecting to 50 x 6 mm G.S. flat.

4.03.10

Tropical protection a) All equipment accessories and wiring shall have fungus protection, involving special treatment of insulation and metal against fungus, insects and corrosion. Screens of corrosion resistant material shall be furnished on all ventilating louvers to prevent entry of insects.
145

b)

4.03.11

Painting
The panels shall be finished in RAL-7032 with two coats of dry powder coated paint. The panels shall have a matt finish to prevent any glare from surface due to illumination. Inside panels painting shall be as per RAL-7032

4.03.12

Name Plate a) b) c) Nameplates shall be provided for each panel and for each equipment/device mounted on it. The material shall be anodized aluminum/lamicoid, 3 mm thick, with white letters on black background. Nameplates shall be held by self-tapping screws. The size of nameplates shall be approximately 20 mm x 75 mm for equipment and 40 mm x 150 mm for panels. Nameplates for panels shall be provided both on the front rear and also inside of the panels. Control and meter selection switches shall have integral nameplates. Nameplates for all other devices shall be located below the respective devices both inside & outside of panel. Instruments and devices mounted on the face of the panels shall also be identified on the rear with the instrument/ device number. The number may be painted on or adjacent to the instrument or device case. Caution notice on suitable metal plate shall be affixed at the back of each panel.

d) e)

f)

g) 4.04.00 4.04.01

Battery Impedance Tester Battery Impedance tester shall have the following features and benefits: Provides excellent data to evaluate critical systems back-up time. On-line testing requires no downtime. Graphical printout aids to quickly determine cell condition to make immediate decisions. Storing of data for on-site review. Requires no battery discharge to save cycle. Built-in printer to leave a record at the site. RS 485 connector for downloading stored data to PC. Testing time shall be less than 30 seconds.
146

Measure Impedance and dc voltage for NI-Cd cells. Directly measures inter-cell connection to eliminate re-torqueing. Upto 1000 sets of readings can be stored in an unlimited number of tests. Custom Lead sets. Suitable for aux. Power supply of 220V, 50 Hz. Backlit LCD panel display with 5 inch (125 mm) viewing area. Voltage Resolution: 0 to 2.5 V DC, 1 mV resolution and 2.5 to 25 V DC, 10 mV resolutions. Impedance Resolution: 0 to 1 m Ohm, 1 micro Ohm resolution and 1 to 10 m Ohm, 10 micro Ohm resolutions. With following additional accessories a) b) c) d) e) f) g) Potential probe extension cable (8 ft.) Extension cable, CT (20 ft.) Clamp-on current sensor, CT, with Inch. Opening. Factory probes, dual-point helical hand spikes. Factory probes, AMP/Burndy lead set Bar code wand with preprinted, laminated code sheet. Bar code label printing software.

4.05.00 4.05.01

Battery Ground-Fault Locator Battery ground fault locator shall have the following features and benefits: Reads resistance directly -1 Ohm to 100 kilo Ohms (Min. range) Locate single or multiple ground faults. Operates on floating or resistance grounded battery system. Operates on live battery systems. Operates in the presence of surge correction capacitors. Fused output leads for maximum user safety. Battery operated with internal automatic charger. Measure capacitance.
147

Lightweight and portable. Tough polyethylene plastic sealed enclosure that provides high shock and vibration resistance. Suitable for Aux. Power supply of 220V, 50 Hz. With following additional accessories : a) b) Mini clamp-on current sensor, 0.5 In. (127 mm) openingmaximum DC current: 5 A. Bus bar clamp-on sensor, 2x4 In. (50 x101 mm) openingmaximum DC current: 50 A.

4.06.00
4.06.01

Battery Discharge Resistor Unit

Battery Discharge Resistor Unit shall be designed to perform period discharge tests on Ni-Cd Batteries. This Resistor Unit shall be made specially to check initial battery performance, guarantee smooth operation of backup system during emergencies and improve overall health and life of Battery system.

4.06.02

Resistor Unit shall be robust assembly consisting of copper-nickel alloy wire grid elements supported by stainless steel tie rods. Castors shall also be provided with this unit for easy mobility. The resistor bank shall have adequate trimming facility (coarse and fine) to maintain a constant current against falling voltage during discharge operation. The Unit shall have the facility for accurately controlling and monitoring the unique rate of discharge. TESTS
All equipment and components thereof shall be subject to shop tests as per relevant IS standards.

5.00.00

5.01.00
5.01.01

The above tests shall include but not be limited to:

Following type tests on two cells of the Battery, even if type test certificates of these tests are submitted by the Bidder for Purchaser /Consultant's approval:

a) b) c) 5.02.00

Test for capacity - test for voltage during discharge Ampere hour & watt hour efficiency test Endurance test.

Tests on battery charger a) b) c) d) Dielectric tests. Voltage regulation check from 0 to 100% load with +10% input voltage _ variation. Ripple content measurement. Functional tests.
148

e) 5.03.00 5.04.00

Heat run test on current limiting value.

Routine tests on component parts a) b) Burning test on PCBS - Assembled PCBS shall be tested at 70C for 72 hours in loaded condition. Rapid temperature cycling test at 70C and 0C for 30 minutes at each temperature - 5 such cycles.

5.05.00

Type test certificates of any equipment shall be furnished, if so desired by the Purchaser. Otherwise, the equipment shall have to be type tested, free of charge, to prove the design. SPECIAL TOOLS & TACKLES A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied. The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended. INSTALLATION REQUIREMENTS The Contractor shall perform erection, testing and commissioning of complete battery and charger but excluding the construction of foundation. Job includes safe storage at place of installation, unpacking, positioning in place, site assembly of loosely furnished accessories, connection & assembly of loose supply items, auxiliary circuits, fixing of nuts and bolts etc., including all labour and materials, as per approved drawings, specifications of this tender and directions of Engineer-in-Charge/Manufacturer's supervisor. The contractor shall place all equipment on its foundation, assemble parts and erect the sheet steel chamber with danger plate fixed on the same. The storage and installation of Battery and charger shall be carried out in strict compliance with manufacturer's instruction.

6.00.00 6.01.00

6.02.00 7.00.00 7.01.00

7.02.00 7.03.00

149

ANNEXURE-A RATINGS & REQUIREMENTS 1.0 1.1 1.2 BATTERY Application Ambient temperature a) b) 1.3 1.4 1.5 1.6 1.7 Type Nos. of Cells per Battery Battery nominal voltage Maximum Minimum : : :
:

Station Battery

50 C 3.3 C Ni-Cad To be confirmed by the Bidder. 110 V 600 AH

Battery capacity in AH at 270C for 5 hr : discharge rate and end cell voltage of 1V/cell Proposed Method of working a) b) c) Float charging (normal) Equalizing Charge (occasional) Boost charging (max.).
(after complete discharge)

: : :

1.40 Volt per cell Bidder to furnish 1.53-1.67 Volt/cell

1.8 1.9

Mounting Intermediate tapping NOTE

: :

Steel racks as required As required

Items 1.4, 1.6 &1.7 a, b & c Bidder to check and provide data, if different from the values specified. 2.0 2.1 2.2 BATTERY CHARGER Charger Type : : Float-cum-boost. Solid-state, full wave, fully controlled, three phase bridge for continuous application. Sheet steel enclosure, IP-42.

2.3 2.4

Enclosure A.C. Input a) Supply

150

415V, 3phase, 50Hz, 4wire.

b) c.) d) e) f) 2.5

Voltage variation Frequency variation Combined volt + frequency variation Short-circuit level System earthing

: : : : :

10% 3%. 10% (absolute sum) 50 KA r.m.s symmetrical Solidly earthed.

D.C. Output a) Float charger : (Continuous D.C. load + float charging battery) plus 25% margin. Minimum Float Charger shall be 150A Output voltage adjustable between 110-120 Volt. Restoring fully discharged battery to full charge condition in 5-hours with 25% margin over maximum charging rate.

b)

Boost charger

2.6

Performance Requirements a) The output voltage of the charger shall be regulated within 1% of the set value for any load variation from 0 to 100% and A.C. input voltage and frequency variations as indicated above in 2.4. The ripple content in 110V charger D-C output shall be limited to 2%.

b)

Specific Requirement a) b) c) The Battery charger shall have isolating transformer to isolate the AC supply from the DC output. The Battery Charger shall be designed to prevent the Battery from discharging back into the charger in case of AC power failure or other charger malfunction. The charger shall have filters or other means to prevent voltage spikes or other distortion being fed back into the AC power supply due to the firing of SCRs or for any other reason. The filter may consist of capacitors or other devices singly or in combination.

2.7

Charger panel a) b) Type Enclosure : : Free standing floor mounting. Sheet steel (min. 2mm thick) enclosure conforming to IP-42 : Dry type, cast resin, double wound, taps 2x2.5% on primary Class- F

2.8

Rectifier transformer a) b) Type Class of insulation

151

: :

c) 2.9

Type of cooling

Naturally air cooled

Max temp rise above 500C ambient a) b) Rectifier transformer SCR : : Restricted to class- B limited to 350C ambient temp 500C rise above

3.0

Controlled rectifier (SCR) a) b) c) Type Surge protection provided? Fast acting HRC fuse provided? : : : Silicon Yes Yes

3.1

Diode Peak Inverse Voltage : 1200V

3.2

Filter Choke Insulation class : Class- F

3.3

Contactor a) b) Type Utilization category : : Air break heavy duty AC-3 (for A.C contactor) DC-3 (for D.C contactor) 96 mm2 1%.

3.4

Meter a) b) Size Accuracy : :

3.5

Changeover switch a) Type : 3 position 4 pole, load break with minimum 2 NO + 2 NC aux. contacts Yes

b) 3.6

Key interlock furnished?

Terminal Connection a) b) A.C Input D.C. output i) ii) To battery To load : : : AYWY cable of adequate size 1/C copper cables of adequate size 1/C AYWY cables of adequate size

152

ANNEXURE-B

FITTINGS & ACCESSORIES

1.0 BATTERY Battery shall furnish the following accessories for each set of battery as applicable: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) NOTE Bidder shall include in their offer all the accessories required, if not shown above, and submit a complete list of accessories for the battery along with their offer. One battery log book Two copies of printed instruction sheet One no. cell testing voltmeter (3-0-3 volts) complete with leads One no. rubber syringe type hydrometer suitable for specific gravity reading Three nos. pocket thermometer One no. thermometer (0 to 100) with specific gravity correction scale One set cell bridging connector Two nos. each Alkali resistant plastic funnels and plastic jug Battery racks suitable for accommodating the cells coated with paint Delrin insulator, rubber pad etc. for rack Two nos. plastic filling bottle for filling up One Set of cell number plates with fixing pins One pair of spanners Requisite quantity of electrolyte with 10% extra in non-returnable containers Two pairs or rubber hand gloves Two nos. cell lifting straps One set of inter cell, inter tie and interbank connectors as required for complete installation.

153

2.0 2.1

LIST OF ALARMS Each Float charger and Float-cum-Boost charger panel shall be provided with one (1) minimum ten-point annunciation facia with repeated relay & SAS alarm. Alarm points shall include: a) b) c) d) e) f) g) h) A.C. supply failure D.C. Voltage low D.C. Voltage high D.C. System ground Charger overload SCR fuse blown Filter fuse blown D.C. output fuse blown

2.2 2.3 2.5

Initiating contacts for all alarm points shall also have electrically separate spare set of contacts wired to the terminal block for future use. All alarm contacts shall be rated 0.5A at 110V D.C. and 5 Amp. at 230V A.C. In addition to the alarm points mentioned above, any other alarm point, if required for battery and charger shall be provided. In addition to above requirement, each section of battery charger shall have atleast two (2) nos. spare annunciation channels and window facia.

3.0 3.1

LIST OF INDICATIONS The indications to be provided on each float charger and float-cum-boost charger panel shall include but shall not be limited to: a) b) c) Charger power supply ON Charger D.C. output healthy Control supply ON

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SPECIFICATION NO. : 11P01-SPC-E-291-53.02 SUB-SECTION-VIII 33KV OUTDOOR SWITCHYARD

155

SUB-SECTION-VIII 33KV OUTDOOR SWITCHYARD CONTENTS CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 DESCRIPTION CODES AND STANDARDS SCOPE OF WORK DESIGN CRITERIA SPECIFIC REQUIREMENTS TESTS SPECIAL TOOLS AND TACKELS INSTALLATION REQUIREMENTS ATTACHMENTS ANNEXURE-A ANNEXURE-B ANNEXURE- C ANNEXURE- D ANNEXURE- E RATINGS AND REQUIREMENTS FITTINGS AND ACCESSORIES ANNUNCIATOR LIST OF PROTECTION INDICATIVE LIST OF ANNUNCIATION TO BE PROVIDED IN CONTRL PANEL 31 36 38 39 40 PAGE NO. 1 1 4 4 28 29 30

156

33KV OUTDOOR SWITCHYARD

1.00.00 1.01.01 CODES AND STANDARDS All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) except where modified and/or supplemented by this specification. Equipment and material conforming to any other standard which ensures equal or better quality may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid. SCOPE OF WORK Scope of Work The scope of work shall include detailed design, engineering, manufacture, testing & supply including transportation, insurance, receiving & unloading, storage, erection, getting approval from Electrical Inspector, testing and commissioning of following equipment and systems required for 33KV switchyard modification work. 2.01.01 Scope of Supply The scope of supply shall include the following A. 33kV System Equipment

1.01.02

2.00.00 2.01.00

Conductors for equipment and bus connection. 3 Pole VCB Circuit Breaker with support structures Two(2) sets Horizontally rotating, end break, mechanically ganged, 3 phase Isolators with earth switch Eight (8) sets. Single phase gapless metal oxide Surge Arrester nine (9) nos. Single phase Electromagnetic Voltage Transformer with 3 secondary windings One (1) set Single phase 3 core Current Transformers six (6) nos. 33KV control and relay panels for 10 MVA Power transformers and 33KV incoming lines All above items in compliance with tender SLD enclosed with this specification. B. Items in Lots

Double tension and single suspension string assembly Spacers, clamps and connectors
157

Bus post insulators Conductor ACSR Zebra for strung bus 3 IPS Aluminum Tube for equipment connection & bus work LT power and control cables of required sizes Galvanized steel ladder and perforated type cable tray, marshaling box, and junction boxes along with supporting arrangement Galvanized tubular/lattice type switchyard equipment support structure including foundation bolt (if required) C. Items as System Direct Stroke Lightning Protection by spike on towers and Lightning Mast. Earthing system with soil resistivity test DC Main & sub distribution board in 2x100% configuration for the entire switchyard 415/240 V AC power supply system for the entire switchyard including AC main & sub distribution boards. Tariff Metering Complete cabling and grounding D. i) ii) iii) iv) v) vi) vii) Civil works Transformers etc as applicable Foundation for lighting poles. Cable trenches with covers. Roads and drainage within the switchyard fence. Modification of existing 11KV switchgear building to accommodate 11KV switchgear, 33KV control panels etc. Anti-weed treatment and gravel surfacing of the substation area. Supply of Materials required for above works

158

2.01.02

Design Work Design calculations for electrical, civil & structural works, bill of materials for all items. Plot plan for the switchyard including line take-off arrangement Layout of the substation including plan, section and clearance diagram Control, metering, protection and signaling scheme of each piece of equipment & system AC & DC auxiliary systems Cable schedule & inter-connections Cabling and cable tray system Grounding and lightning protection system including Earth Pit , above ground, air terminal network. Relay coordination and recommended setting, insulation coordination, sag tension charts Preparation of installation, commissioning, operation and maintenance manuals Any other design work necessary for successful completion of the work.

2.01.03

The scope is further elaborated in the accompanying specifications as listed in overall contents of this specification.

2.01.05 2.01.06

All relevant drawings, data and instruction manuals Scope of Installation Work The scope of installation work includes erection, testing, commissioning and putting into successful commercial operation of all the substation equipment, grounding system, lightning protection system, cabling work, stringing & connections as detailed in the sub specifications detailed above including supply of all labour, materials, tools and tackles. Laying of 100mm thick 20mm Gravel and spray of anti-weed powder/ chemical. Fabrication & Installation of tower, gantry & structure, fence supports, fence, etc. supplied under this Contract Approval of the drawings & documents from Electrical Inspector as per requirement.

159

2.02.00

Terminal Point & Exclusion Stringing from existing 4pole structure of 33KV outdoor switchyard to terminal gantry of 33KV plant switchyard including supply of stringing hardwires. 132KV/33KV switchyard located outside the plant boundary is not in the scope of this package.

3.00.00

DESIGN CRITERIA The existing 33KV switchyard will be modified to accommodate two (2) new 10 MVA Transformers and will be utilized as a new distribution substation (33/11KV) for new paper machine#5. Two 33KV lines will be taken from 132/33 KV switchyard to this 33KV plant switchyard to feed these two (2) 10 MVA, 33/11KV Transformers and three existing(1 X 3MVA & 2 x 6 MVA), 33/11 KV Transformers as shown in enclosed single line diagram. One new 11KV switchgear will be installed in the existing 11KV switchgear building. This 11KV switchgear will receive power from new 10 MVA transformers via cables. The 132KV/33KV Switchyard and 33 KV overhead lines will be under the scope of other contractor.

4.00.00

SPECIFIC REQUIREMENTS Type, rating, connections, etc. of the equipment shall be as detailed in the Annexure-A. All equipment shall be offered in strict compliance with the same. The quantity of each type of equipment shall be offered as per requirement detailed in the General Electrical Specification & relevant sub sections.

4.01.00 4.01.01

Circuit Breaker The 33 KV Circuit Breaker shall be three-pole gang operated VCB type suitable for three phase auto-reclosing type. The Circuit Breaker shall be restrike free as per IEC under all duty conditions and shall be capable of performing its duties without opening resistors. The Circuit-Breaker shall meet the duty requirements for any type of fault at any fault location and also for line charging and line switching off when used on 33 KV effectively grounded system with transmission lines The Circuit Breaker shall perform, make and break operations as per stipulated duty cycles satisfactorily. The Circuit Breaker shall be capable of interrupting the steady and transient magnetizing current corresponding to 33 KV class Transformers. The Circuit Breaker shall be capable of a) Interrupting line-charging current as per Annexure- B without any restrike and preferably without the use of opening resistors as applicable. Clearing short line fault (kilometric faults) of the same magnitude as rated short circuit current.
160

4.01.02

4.01.03

4.01.04

b)

c) i) 4.01.05

Breaking low reactive currents (lagging) without switching over-voltage shall be as per IEC in case of 33 kV system. Breaking 25% of rated fault current at twice rated voltage under phase opposition condition.

Circuit Breaker with multi-break interruptions shall be so designed that the voltage developed across a pole is uniformly distributed over the power breaks. Calculations/test reports in support of the same shall be furnished with the bid. The thermal and voltage withstands of the grading elements shall be adequate for the service conditions and duty specified. The breaker shall satisfactorily withstand the high stresses imposed on them during fault clearing, load rejection and re-energisation of lines with trapped charges. The breaker shall withstand successfully all transient and sustained voltages under various operating conditions. Total Break Time The total break time of circuit breaker as mentioned in Annexure A shall not be exceeded under any condition of operation like combined variation of trip coil voltage (70% to 110%), pneumatic/spring pressure, arc extinguishing medium pressure etc. Further, the total break time shall not be exceeded under any of the following duties: a) Test duties 1,2,3,4,5 (TRV as per IEC-56) b) Short line fault L75, L90 (- do -) Bidder to furnish necessary documents in support of the same. While furnishing the proof of total break time of complete circuit-breaker, the bidder shall also show the effect of non-simultaneous operation of contacts within a pole or in different poles and show how it is covered in the guaranteed total break time. The value guaranteed shall be supported with the type of test reports.

4.01.06

4.01.07

4.01.08

Any device used for voltage gradient to damp oscillations or to prevent restrike prior to the complete interruption of the circuit or to limit over voltages on closing shall have a life expectancy at least equal to that of the breaker as a whole. Constructional Features i) Each circuit breaker shall comprise of three (3) identical poles complete with individual operating mechanism for specified duty. Three poles shall be linked together electrically / pneumatically for simultaneous closing. ii) The circuit breaker shall be single pressure type. The design and construction shall be such that there is minimum possibility of gas leakage and ingress of moisture. Further, the arrangement shall be such that condensation of SF6 gas on the internal insulating surfaces of the circuit breaker must not occur under any condition.
161

4.01.09

iii) Each pole shall form an enclosure filled with SF6 gas independent of two other poles. The SF6 gas density of each pole shall be monitored and regulated by individual temperature compensated gas density monitoring devices, which shall be mounted at a convenient and easily approachable location. The device shall have provision for low gas pressure alarm and breaker lockout arrangement. Also pressure gauge shall be mounted at a convenient height so that gas pressure can be visually observed. iv) The circuit-breaker shall be so designed that under various operating conditions, the temperature of each component shall be limited to values consistent with long life for the material used. The temperature shall not exceed that indicated in IEC-56/IS-13118 under specified ambient conditions. Also, the gap between open contacts shall be such that it can withstand rated maximum phase to ground voltage (Um) for at least eight hours at zero gauge pressure of SF6 gas which may occur due to gas leakage. The breaker shall be able to withstand all electric stresses imposed on it in open condition at lockout pressure continuously (i.e. 2.0 P.U. across the breaker contacts). v) The circuit-breaker shall have proper sealing so that leakage of gas outside is not more than 1% per annum under all conditions of operation. Further, it shall incorporate devices to absorb any moisture, which may exist/be released within breaker poles after assembly, gas charging and during operation. The devices shall be so located as to permit easy removal/replacement. vi) The operating rod connecting the operating mechanism to the arc chamber (SF6 media) shall have adequate seals. All gasketted surfaces shall be smooth, straight and reinforced, if necessary, to minimize distortion and make a tight seal. vii) The circuit-breaker units shall be complete with associated valves, piping, gauges, pressure switches, seals, lubricants and other accessories/materials to ensure proper assembly and functioning. viii) Suitable means shall be provided in the gas chamber of circuit breaker for pressure relief so as to avoid damages or distortion during occurrence of abnormal pressure increase or shock waves generated by internal electric fault arcs. The position of vents, diaphragms and pressure relief devices, if provided, shall be so arranged as to minimize danger to personnel in the event of gas or vapor escaping under pressure. ix) Each circuit-breaker shall be capable of withstanding a vacuum of minimum 8 mill bars without distortion or failure of any part. x) Breaker shall be furnished with first charge of SF6 gas plus additional 20% of total gas used which shall be supplied in non-returnable gas cylinders as spare for future use.

162

4.01.10

Main Contacts and Arc Quenching Chamber i) The main contacts shall have adequate area and contact pressure for carrying rated continuous and short time current without excessive heating liable to cause pitting and welding.

ii) The tips of the arcing and main contacts shall be heavily silver plated. iii) The contacts shall be adjustable to allow for wear, shall be easily replaceable and shall have minimum movable parts and adjustments. iv) The arc quenching device shall be of robust construction and shall not require any critical adjustment. The devices shall be easily accessible and removable for access to the breaker contacts. 4.01.11 Accessories and Attachments i) Necessary provision shall be made in the circuit-breaker for attaching an operational analyzer to it after its installation at site to record contact travel, speed and for making measurement of operating timings, pre-insertion timing of closing resistors, synchronization of contacts in one pole or all poles.

ii) The SF6 gas density monitor shall be dial type and properly temperature compensated. The density monitor shall meet the following requirements: a) It shall be possible to dismantle the density monitor for checking/replacement without draining the SF6 gas by using suitable interlocked non-return valve coupling. It shall damp pressure pulsation while filling the gas in service so that flickering of the pressure switch contacts does not take place.

b) 4.01.12 i)

Auxiliary Contacts Each breaker shall be provided with six (6) nos. N.O. and six (6) nos. N.C. electrically separate spare auxiliary contacts, in addition to those required for its own operation and indication. The auxiliary contacts shall be convertible type so that normally open contacts can be converted into normally close contact and vice-versa at site. The auxiliary contacts shall be rated 10A at 230 V A.C. and 2A at 24 V D.C. Control & Interlock All electrical and mechanical interlocks which are necessary for safe and satisfactory operation of the circuit breaker shall be furnished. Breaker operation shall be locked in case of low SF6 gas pressure and low air pressure at preset values. Alarms shall be provided for low gas pressure and low air pressure at values higher than lock-out pressure of SF6 gas and air. It is intended that before lock-out occurs, the breaker shall be in trip position. The close and trip circuits shall be designed to permit use of momentary contact switches and push buttons.
163

ii) iii) 4.01.13 i)

ii)

iii)

Each breaker pole shall be provided with two (2) independent tripping circuits, valves, pressure switches and coils each connected to a different set of protective relays. Each tripping circuit shall be fed through separate DC source. The breaker shall normally be operated by remote electrical control. Electrical tripping shall be performed by shunt trip coils. Provision shall be made for local electrical/local manual control. For this purpose, local/remote selector switch, close & trip control switch, auxiliary relays, indication lamps etc. shall be provided in the central control cabinet for the breaker. Remote located control switch/push buttons and indicating lamp shall be provided in the remote control panel which will be installed at electrical control room. The trip coils shall be suitable for trip circuit supervision during both open and close positions of the breaker. The trip circuit supervision relay would be provided in the remote control panel. Necessary terminals shall be provided in the control cubicles. Gas analyzer contacts, pressure switch contacts, etc. shall be suitable for direct use as permissive in closing, tripping, annunciation and control circuits. DC supplies for all auxiliary circuits shall be monitored and provision shall be made for remote annunciations.

iv)

v)

4.01.14 i) ii) iii) iv) v)

Insulator Insulator shall be wet-process porcelain, brown glazed and free from all blemishes. Metal parts and hardware shall be hot-dip galvanized. Insulator shall have adequate mechanical strength and rigidity to withstand the duty involved. When operated at maximum system voltage, there shall be no electrical discharge. Shielding rings, if necessary, shall be provided. Insulation shall be coordinated with basic impulse level of the system. The creepage distance shall correspond to heavily polluted atmosphere (25mm/kV). All routine tests shall be conducted on insulators as per IEC233/relevant IS in addition to the following tests: ai) b) c) d) e) Ultrasonic test. Pressure test. Bending load test in four directions at 50% specified bending load. Bending load test in four directions at 100% specified bending load as acceptance test of lot. Burst pressure test as a sample test.

vi)

The insulator, porcelain shall be in one integral place in green and fired stage. No jointed porcelain is acceptable.

164

4.01.15 i) ii)

Operating Mechanism Circuit Breaker shall be of spring / spring operating mechanism. The operating mechanism shall be suitable for high speed reclosing. It shall be anti-pumping and trip free (as per IEC definition) electrically and either mechanically or pneumatically under every method of closing (except during manual closing of a breaker for maintenance). A latch checking switch shall be provided on mechanically trip free mechanism to prevent enclosure before the breaker latches have reset. There shall be no objectionable rebound and the mechanism shall not require any critical adjustment. It shall be strong, rigid, positive and fast in operation. The operating mechanism shall be such that the failure of any auxiliary spring will not prevent tripping and will not cause trip or closing operation of the power operated closing devices. A mechanical indicator shall be provided to show open and close positions of breaker. It shall be located in a position where it will be visible to a man standing on the ground. An operation counter at 1000-1300 mm level shall also be provided. The counter readings shall be visible from the ground even with the mechanism housing closed. Closing coil and trip coil shall operate correctly at all values of voltage between 85% and 110% of the rated voltage. If additional elements are introduced in the trip coil circuit, their successful operation for similar applications on outdoor breakers shall be clearly brought out in the appropriate schedule. Operating mechanism shall normally be operated by remote electrical control. Electrical tripping shall be performed by trip coils. Provision shall be made for local electrical control Local/Remote selector switch and closing and trip push buttons/control switch shall be provided in the breaker control cabinet. In addition local manual trip button shall be provided. For the purpose of tripping, two electrically independent trip circuits along with separate shunt trip coils shall be provided. The auxiliary switch of the breaker shall be positively driven by the breaker operating rod. All three broken poles shall operate simultaneously. Pole discrepancy feature shall be provided to trip the broken out if all the poles do not close simultaneously.

iii) iv)

v)

vi)

vii)

viii) ix) x)

xi)

Spring Operated Mechanism Closing spring with limit switch for automatic charging and other necessary accessories to make the mechanism a complete operating unit shall also be provided.

165

As long as power is available to the motor, a continuous sequence of the closing and opening operations shall be possible. The motor shall have adequate thermal rating for this duty. After failure of power supply to the motor one close open operation shall be possible with the energy contained in the operating mechanism. Breaker operation shall be independent of the motor, which shall be used solely for compressing the closing spring. Facility for manual charging of the closing spring shall also be provided. The motor rating shall be such that it requires not more than 30 seconds for full charging of the closing spring. Closing action of circuit breaker shall compress the opening spring ready for tripping. When closing springs are discharged after closing a breaker, closing springs shall be automatically charged for the next operation and an indication of this shall be provided in the local and remote control cabinet. Provisions shall be made to prevent a closing operation of the breaker when the spring is in the partial charged condition. Mechanical interlocks shall be provided in the operating mechanism to prevent discharging of closing springs when the breaker is already in the closed position. The spring operating mechanism shall have adequate energy stored in the operating spring to close and latch the circuit breaker against the rated making current and also to provide the required energy for the tripping mechanism in case the tripping energy is derived from the operating mechanism. 4.01.16 i) ii) Sulphur Hexafluoride (SF6) Gas The SF6 gas shall comply with IEC 376, 376A and 376B and shall be suitable in all respects for use in the circuit breakers under the various operating conditions. SF6 gas shall be tested for quality, dew point, air, hydrolysable fluorides and water content as per IEC quoted above and test certificates shall be furnished covering all tests for each lot of SF6 gas. Further site test for moisture and air content to be done prior to commissioning of the breaker. The high pressure cylinders in which SF6 gas is shipped and stored at site shall comply with requirements of the following standards and regulations: IS-4379, IS-7311 The cylinders shall also meet Indian Boiler Regulations. 4.01.17 i) Control Cubicle A common control cubicle shall be furnished to house electrical, controls, monitoring devices and all other accessories except those which must be located on individual poles. The cubicle shall be IPW-55, of gasket weatherproof construction, fabricated from sheet steel minimum 2 mm thick.
166

iii)

ii)

iii) iv) v)

The cubicle shall have front access door with lock & keys and removable gland plate at the bottom. Thermostat controlled space heater, internal illumination lamp and 3-pin 5A socket with individual ON-OFF switches shall be provided in the cubicle. For local operation, following shall be provided : a) b) LOCAL/REMOTE selector switch TRIP/CLOSE push buttons

vi) 4.01.18 i) ii)

All electrical, pneumatic connections between the control cubicle and individual poles shall be furnished. Wiring Wiring shall be complete in all respects to ensure proper functioning of the control, protection, monitoring and interlocking schemes. Wiring shall be done with flexible 1100V grade, PVC insulated, switchboard wires with 2.5 mm stranded copper conductor. Wiring between individual poles and control cubicle shall be routed through G.I. conduits. Each wire shall be identified at both ends with permanent markers bearing wire numbers as per Contractor's wiring diagram. Wire termination shall be done with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals. All spare contacts of relays, push buttons, auxiliary switches etc. shall be wired upto terminal blocks in the control cubicle. Terminal Blocks Not more than two wires shall be connected to any terminals. Spare terminals equal in number to 20% active terminals shall be furnished. Terminal 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. Support Structure The equipment shall be supplied with all support structures that are integral part of the breaker. All support structure shall be hot dip galvanized after full chemical treatment as per IS: 4759 or equivalent.

iii) iv) v) 4.01.19 i) ii) 4.01.20

4.02.00 4.02.01 i) ii)

Disconnect Switch Design Criteria Disconnect switch shall be used in 33KV system, having characteristics as listed in Annexure A. Disconnect switch shall be furnished with fittings and accessories as listed in Annexure A.
167

iii) iv) v) vi) vii) viii) ix) x) 4.02.02 i) ii) iii)

Disconnecting switch shall be suitable for connection to twin AAAC conductor/Al.tube bus of required no. & size. The equipment will be installed outdoor in a hot, humid and tropical atmosphere. All equipment, accessories and wiring shall have tropical protection, involving special treatment of metal and insulation against fungus, insects and corrosion. The maximum temperature in any part of the equipment at specified rating shall not exceed the permissible limits as stipulated in the relevant standards. The equipment shall be capable of withstanding the dynamic and thermal stresses of listed short circuit current without any damage or deterioration. There shall be no radio interference when the equipment is operated at maximum service voltage. The safety clearances of all live parts of the equipment shall be as per relevant standards. Corona/grading ring as required shall be provided. Constructional Features The 3 pole disconnecting switch shall be gang operated, centre post rotating type so that all the poles make and break simultaneously. The disconnecting switch shall be designed for upright mounting on steel structure. Disconnecting switch and its earthing switches including their operating mechanism shall be so constructed that they cannot come out of their open or closed position by gravity, wind pressure, vibrations, reasonable shocks or accidental touching of the connecting rods of their operating mechanism. The mechanical linkages shall be such that then deflection is negligible. Facility of adjustment of the interpole operating rods and locking arrangement shall be provided. The disconnecting switch shall have padlocking arrangement in both `Open' and 'Closed' positions. All current carrying parts shall be of non-ferrous metal or alloy. All live parts shall be designed to avoid sharp points and edges. All metals parts shall be of such material and treated in such a way as to avoid rust, corrosion and deterioration due to atmospheric condition. Ferrous parts shall be hot-dip galvanized. Bolts, nuts, pins, etc. shall be provided with appropriate locking arrangement such as locknuts, spring washers, key etc.

iv)

v) vi) vii)

viii)

168

ix)

Bearing housing shall be weather-proof with provision for lubrication. The design, however, shall be such as not to require frequent lubrication. The requirement of lubrication shall be after 1000 operations or after 5 years whichever is earlier. All bearings in the current path shall be shorted by flexible copper conductor of adequate size. Main Contacts The main contacts shall be of silver-plated copper alloy and controlled by powerful springs designed for floating and pressure point contact. The thickness of the silver plate shall not be more than 25 micron. The contacts shall have sufficient area and pressure to prevent excessive heating liable to bring about pitting or welding. Contacts shall be adjustable to allow for wear, shall be easily replaceable and shall have minimum movable parts and adjustments. The blade shall be made of electrolytic copper tube of liberal section. Rotating feature of the blade at the end of travel for contact wiping shall be provided. The high-pressure type contacts of horizontal break isolators shall wipe the contact surfaces while opening and closing. The contacts shall be so designed that wiping action shall not cause scouring or abrasion on the contact surfaces. Arcing horns shall be provided to divert the arc from main contacts to the separating horns after the main contacts have opened. Arcing horns shall be renewable type. Arcing contacts shall close first and open last so that no damage due to arcing whatsoever shall be caused to the main contacts. Auxiliary Contacts Each disconnect switch shall be provided with minimum ten (10) normally closed and ten (10) normally open electrically separated spare contacts, in addition to the auxiliary contacts required for its operation and indication. The contacts shall be convertible type so that normally open contact may be converted to normally closed contact and vice-versa at site. The auxiliary contacts shall be rated 10A at 240V A.C. and 2A at 220V D.C. The auxiliary contacts shall be adjustable type to suit the following requirement: a) Signalling of 'Closed Position' shall not take place unless the main power contacts have reached a position so that rated normal and short time current can be carried safely. b) Signalling of 'Open Position' shall not take place unless the main power contacts are at a safe isolating distance.

x) 4.02.03 i)

ii) iii) iv)

v)

vi) 4.02.04 i)

ii) iii) iv)

169

4.02.05 i) ii) iii)

Interlocks All electrical and mechanical interlocks necessary for safe and satisfactory operation of the disconnect switch and its earthing with shall be furnished. The disconnect switch shall be suitable for sequential interlocking with associated equipment, for closing and opening. Interlocks are required to be provided: a) To prevent disconnect switch open on load. b) To prevent closing of earthing switch when disconnect switch is closed. c) To prevent closing of the line disconnect switch when earthing switch is closed.

4.02.06
i)

Insulators
Insulators shall be post type and composed of stacked units. Insulators of identical rating shall be interchangeable. Insulator shall be of wet-process porcelain, brown glazed and free from all blemishes. Metal parts and hardwares shall be hot-dip galvanised. Insulator shall have adequate mechanical strength and rigidity to withstand the duty involved. When operated at maximum system voltage there shall be no electrical discharge. Shielding rings, if necessary, shall be provided. Insulation shall be co-ordinate with basic impulse level of the system. The creepage distance shall be as indicated in the annexure. The insulators shall have the minimum cantilever strength of 6000 KNm. The insulators shall be so arranged that leakage current will pass tp earth and not between terminals of the same pole or between phases. Each rotating insulator shall be supported on double-roller or ball bearings.

ii) iii) iv) v) vi) vii) viii)

4.02.07

Blades All metal parts shall be of non-rusting and non-corroding metal. All castings except current carrying parts shall be made of malleable cast iron or cast steel. The live parts shall be designed to eliminate sharp joints. The isolators shall be so designed that the switch blade will not move to closed position if the operating shaft gets disconnected.

4.02.08

Operating Mechanism
A. The operating mechanism of the disconnect switch shall be motor operated type, with electrical control from remote as well as local position.

170

The mechanism shall also have provision for manual operation with detachable handle. The arrangement shall be such that one operator may be able to operate without undue efforts. Interlock shall be provided such that electrical power to the motor is cut off on insertion of manual operating handle. The mechanism of disconnect switch shall be so designed that its blade(s) are in positive continuous control throughout the cycle of operation. Visible indication of switch position and means to prevent false indication if the mechanism fails to complete the operation shall be provided. Starters, relays, limit switches shall be provided as required for operation, indication and interlocks. Electromagnetic brakes and/or adjustable mechanical stop shall be provided to limit over-travel. The motor operated mechanism shall be suitable for operation from 415 V, 3 phase, 50 Hz supply. The drive mechanism shall be such that during manual operation the motor drive shall be automatically de-coupled. Suitable reduction gearing shall be provided between the motor and the drive shaft of the disconnect switch. A quick electro-mechanical break shall be fitted on the higher speed shaft. Hydraulically operated mechanism shall be complete with operating unit with power cylinder, control valves, motor, etc. The oil pressure controlling the oil pump and pressure in the reservoir shall be continuously monitored.

C. D. E. F.

G.

H.

4.02.09

Mechanism Box
i) The mechanism box shall house the operating mechanism, electrical, controls, monitoring devices and all other accessories.

ii)

The box shall be IPW-55, of gasketedweatherproof construction, fabricated from sheet steel minimum 2 mm thick. They shall be dust, water and vermin proof.
The box shall have front access door with lock and key, and removable gland plate at bottom for cable entry. The box shall be suitable for mounting on disconnect switch support structure. The mounting height shall be such as to permit easy manual/electrical operation standing at grade level. Thermostat controlled space heater, internal illumination lamp and 3 pin 5A socket with individual ON/OFF switches shall be provided in the box.

iii) iv)

v)

vi)

For local operation following shall be provided : a) b) Local-remote selector switch. Open/Close/Stop Push Button.

4.02.10

Wiring
i) Wiring shall be complete in all respects to ensure proper functioning of the control, protection, monitoring and interlocking schemes.

171

ii)

Wiring shall be done with flexible 650V grade, PVC insulated switchboard wires with stranded copper conductor of 2.5 Sq mm. The operating coils and small wirings shall be tested as assembled for a power frequency voltage of 2 KV for one minute. Each wire shall be identified at both ends with permanent markers bearing wire numbers as per contractor's wiring diagram.

iii)

iv) v) 4.02.11

Wire terminations shall be done with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals. All spare contacts of push buttons, auxiliary switches etc. shall be wired upto the terminal blocks in the mechanism box.

Terminal Blocks
i) Terminal blocks shall be 650V grade, enclosed clamp type with engraved numbers suitable for termination of at least two numbers of 2.5 mm2 stranded copper conductor. Not more than two wires shall be connected to any terminal. Spare terminals equal in number of 20% active terminals shall be furnished. Terminal blocks shall be located to allow easy access. Wiring shall be so arranged that individual wires of an external cables can be connected to consecutive terminals.

ii) iii)

4.02.12

Earthing Switch
i) ii) Earthing switch shall be triple-pole, gang operated type, with provision for padlocking in both open and close positions The manual operating mechanism shall be such that it can be easily operated from standing height at grade level. The earthing mechanism shall only be locally operated The earth switches shall be power operated but shall be constructional interlocked. The various features of the operating mechanism and its mechanism box, wiring requirement etc are similar to those stipulated for the main disconnect switch. Mechanical and electrical safety interlocks shall be provided to prevent closing of earthing switch when the main disconnect switch is closed and vice-versa. Earthing switch shall be provided with minimum 4 NO + 4 NC contacts for indication and interlocking. All auxiliary switches & interlocking coils shall be wired up to terminal blocks in mechanism box through G.I. Conduits. The earthing blades shall be required to carry peak current and rated short time current as the main blades of the disconnect switch and shall withstand dynamic stresses. Each earth switch shall be provided with flexible copper braids for connection to the ground mat. These braids shall have same short time current carrying capacity as the earth blades.

iii)

iv) v)

vi)

vii)

172

4.02.13

Assembly
i) ii) The disconnect switch along with its base frame and operating mechanism shall be completely assembled and checked for correct alignment and operation at manufacturer's works prior to despatch. All parts and accessories shall have appropriate bench marks and part numbers for identifications at site.

4.02.14

Grounding
i) Each equipment shall be provided with two ground pads for connection to station ground.

ii)

The ground pad shall comprise buffed metal surface with two tapped holes, M 10 G.I. bolts and spring washers for connection to Cu flat of approved size. Each disconnect/earth switch operating rod shall be separately grounded at a point above the mechanism box. This is done by flexible copper braid of adequate section but in no case less than 70 mm.

iii)

4.02.15

Painting i) ii) Base frame, operating rod and all hardwares shall be hot-dip galvanised. Mechanism box will be finished with two coats of aluminium paints after surface treatment, involving chemical cleaning, phosphating and application of under coats. Sufficient quantity of touch-up paints shall be furnished for application at site.

iii) 4.03.00 4.03.01

Lightning Arresters Design Criteria i) The lighting arrester will be used in 33KV system having characteristics as listed in the Annexure A.

ii) The equipment shall be furnished complete with accessories as listed in the Annexure A. iii) The equipment will be installed outdoor in a hot, humid and tropical atmosphere with heavy pollution. iv) All equipment, accessories and wiring shall have tropical protection, involving special treatment of metal and insulation against fungus, insects and corrosion. v) The maximum temperature in any part of the equipment at specified rating shall not exceed the permissible limits as stipulated in the relevant standards.

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vi) The equipment shall be capable of withstanding the dynamic and thermal stresses of listed short circuit current without any damage or deterioration.

vii)

The safety clearances of all live parts of the equipment shall be as per relevant standards.

viii) Arresters shall be designed with sufficient cantilever strength to meet with stress due to wind pressure and short circuit forces arising from rated short time current. ix)
x) xi)

The lightning arrester shall be installed as close to the equipment as possible and also on the line entrance.
Lightning arrester shall be station class, heavy duty, metal oxide gapless type with ratings as detailed in the Annexure A. The arrester shall be suitable to protect the equipment having insulation level as indicated in the Annexure A.

xii) 4.03.02

The arrester shall have adequate thermal discharge capacity for severe switching surges, long duration surges and multiple strokes.

Constructional Features i) The arrester shall be single pole, hermetically sealed, with non-linear blocks of sintered metal oxide material so as to obtain a robust construction with excellent electrical, thermal and mechanical characteristics even after repeated operation. Insulator shall be wet process porcelain, brown glazed and free from imperfections. All metal parts and hardware shall be hot dip galvanised. Creepage distance shall correspond to that specified in the annexure. Grading ring, if required, shall be provided to maintain voltage gradient within permissible limit. The arrester shall be provided with pressure relief device to prevent shattering of porcelain in case excessive gas pressure builds up.

ii) iii)

iv) 4.03.03

Accessories a) Lightning arrester shall be furnished complete with insulating base, arrester disconnector, surge counter, leakage current monitor and anchoring hardware for mounting on steel structure A leakage current detector shall be furnished with the counter as an integral part. This is for monitoring the leakage to indicate any possible breakdown. Surge counter and leakage current meter shall be housed in an IP 55 enclosure and their reading shall be visible through inspection glass panel in the front. The surge counter shall be suitably enclosed for outdoor duty and be
174

b)

c)

d)

mounted at a convenient height for reading. Counter terminals shall be such as to permit connections with minimum possible bends. The mounting arrangement shall be such that it can be tilted 45 degree from horizontal plane for convenient of reading No auxiliary power supply or battery shall be required for operation of counter. e) f) 4.03.04 i) ii) A suitably sized by-pass shunt along with necessary terminals shall be furnished for bypassing the discharge counter if required. Grading ring/corona ring as applicable for the particular voltage class of arrester shall be provided.

Terminals All connection terminals shall be of corrosion resistant material and complete connection hardware. High voltage line terminal shall be provided with bimetallic terminal connector suitable for connection to the type and size of conductor indicated in Annexure A. All ground terminals shall have provision of connection to 50 x 6 mm Cu flat. 33 KV Control and Relay Panel
Electrical Control and Relay Boards as listed below, in accordance with this specification.

iii) 4.04.00
4.04.01

Board Description

Type

33 kV system electrical control Simplex & relay board, comprising two Type (2)* sets panels

Quantity (in Location Set) One (1) set Electrical for each Tr. Switchgear Room

The Control and Relay Board shall accommodate all switches, meters, annunciator, relays and auxiliary relays for control, metering, monitoring and protection of respective circuit.
Supply, mounting and wiring of all equipment, devices, accessories and setting of all relays to suit the requirements of protection, operation and interlocks.

Floor channel sills, vibration damping pads and kick plates for the panels complete with holding -down bolts and nuts. 33 KV Substations shall be provided with single main bus with bus section isolator. The main bus shall comprise of the following circuit: Two (2) nos. incoming bay from plant outdoor substation (132 KV/33 KV). Two (2) nos. outgoing bays to 10 MVA, 33/11 KV Power Distribution Transformers and three(3) nos. existing transformers. Further, there are two (2) no. bus section isolators as shown in enclosed single line diagram.
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Substation new 10MVA transformers feeders shall be controlled through associated circuit breakers and isolators from control room through hardware based control panels. Apart from that, control panel shall perform measurement, indication, monitoring and annunciation functions.
Annunciation window facia to annunciate system faults and unbalances shall be provided on the control board. Annunciations to be provided on these boards shall be decided by the Owner. Though an indicative list showing a minimum requirement only has been given elsewhere in this specification. Mimic representation of 33 KV system shall be provided on the panels.

4.04.02 i)

Construction The Control and Relay Boards shall be totally enclosed, floor mounted, free-standing, dead front assemblies conforming to IP-4X degree of protection. Design, material selection, and workmanship shall be such as to present a neat appearance outside and inside with no welds, rivets, screws or bolt heads apparent from the exterior surface of the Boards. The boards shall have a smooth and uniform mat finish, free from scratches, dents, and other imperfections. The panels shall be liberally sized so as to provide spacious layout of equipment and devices with sufficient working space in between. Each board may consist of a number of panels mounted side-by-side, in which case, these shall be bolted together to form a compact unit. Wherever, two panels meet, the joints shall be smooth, close-fitting and unobtrusive.

ii)

iii) iv)

v) The control boards shall be of folded sheet steel construction, assembled on channel/angle base plates with anti-vibration mountings. vi) The boards shall be fabricated of minimum 2 mm thick sheet steel, free from all surface defects. The boards shall have sufficient structural reinforcement to ensure a plane surface, to limit vibration, and to provide rigidity during shipment and installation.
vii) All doors and removable covers shall be provided with neoprene gaskets all around and latches sufficiently strong to hold them in alignment when closed. The door-operating handle shall have locking arrangement.

viii) All control panels shall have rear door with concealed type hinges and pad-locking arrangement. Doors shall be grounded by flexible copper braid. ix) The boards shall be complete with vibration damping pads, stainless steel kick plates, floor channel sills, anchor bolts and other necessary hardware for mounting. 4.04.03 i) ii) Equipment Mounting All relays, instruments, meters, switches etc. mounted on the front face of the panels shall be of flush or semi-flush type. No equipment shall be mounted on panel door.
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iii) iv) v) vi)

All equipment shall be so mounted that removal and replacement may be accomplished individually without interruption of services to others. All equipment inside the panels shall be so located that their terminals and adjustments are readily accessible for inspection or maintenance. In case cut-outs are provided on any panel for future mounting of equipment, the same shall be properly blanked off. The Centre line of switches, push buttons and indicating lamps shall not be less than 750mm from the bottom of the panel. The center line of relays, meters and recorders shall not be less than 450mm from bottom of panel. Name Plate Nameplates shall be provided on each panel and on each instrument or device mounted in the panel. The material of the nameplates shall be lamicoid or approved equal, 3 mm thick, with white letters on black background. The nameplates shall be held by self tapping screws. The size of nameplate shall be approx. 20 mm x 75 mm for equipment and 40 mm x 150 mm for panels. Nameplates for panels shall be provided both on the front and the rear. Control and meter selection switches shall have integral nameplates. Nameplates for all other devices shall be located below the respective devices. Instrument and devices mounted on the face of the control boards shall also be identified on the rear with the instrument or device number. The number may be painted on or adjacent to the instrument or device case Mimic Diagram Mimic diagram of electrical connections shall be furnished on the front face of electrical control panels. Mimic buses shall be at least 10 mm in width and 3 mm thick made of suitably treated metal strips or approved equivalent and colour coded to denote different voltages..
The mimic representation, colour and size of diagram shall be subject to approval of the Purchaser.

4.04.04 i) ii) iii)

iv) v) vi)

4.04.05 i) ii)

iii)

4.04.06 i)

Illumination, Space Heating and Receptacles Each panel shall be provided with interior lamp with door switch, space heater with thermostat and switch, and 16A, 5 pin receptacle with plug. Fifth pin of the socket shall be effectively grounded through the metallic structure.

ii) Compact Fluorescent Lamp, heater and receptacle circuits shall be suitable for
177

available AC supply and furnished with individual ON-OFF switch. iii) The Compact Fluorescent lamp shall be located at the ceiling and guarded with protective cage. Space heater shall be located near the floor so as not to pose any hazard to service personnel. 4.04.07 i) AC/DC Power Supply Necessary AC and DC supplies to each Control/relay Boards, marshaling Kiosks, Circuit Breakers, Isolators, Air-conditioned Kiosks, etc. as required for control and service, shall be arranged by the Contractor. Single feeders shall be arranged for AC supply but duplicate feeders shall be arranged for DC supply. These switches shall be mounted inside the panel. Alarm relays with reverse flag shall be provided to annunciate failure of main incoming AC and DC supplies and annunciation DC supply in each panel. Lamp indications shall be provided individually for Main DC Supply-1 Fail, Main DC Supply-2 Fail, and Panel Annunciation DC Supply Fail. A common AC electric bell shall be provided to give an audible alarm in case of failure of DC Supply-1/ DC Supply-2/ Annunciation DC Supply in any panel. A common push-button shall also be provided for cancellation of lamp indication and audible alarm.

ii) iii)

iv) Isolating switch fuse units/MCCB shall be provided for the incoming DC/AC power supplies. Power supply isolation switches shall be 4-pole, single throw, for AC (considering single feeder) and 2-pole, double throw with OFF, for DC v) Fuse and link/MCCB shall be provided for individual circuits for protection and also for isolation from bus bar without disturbing other circuits.

vi) The fuse requirements in each panel shall be grouped in easily accessible fuse blocks. The groupings shall be done in a neat and orderly fashion. 4.04.08 Wiring
The boards shall be fully wired at the factory to ensure proper functioning of control, protection, and metering schemes. When panels are arranged to be located side-by-side, all inter-panel wiring shall be carried out by longitudinal troughs extending the full length of the board.

i) ii)

All spare contacts of relays and switches shall be wired up to terminal blocks. All interconnections between the panels of the control board shall be furnished. Wiring shall be done with flexible, heat resistant, 1100V grade, PVC insulated, switch board wires with stranded copper conductor. The minimum size of the wires shall be 2.5 Sq. mm. for control and current circuits and 1.5 Sq. mm. for voltage circuits. Each wire shall be ferruled by plastic tube with indelible ink print at both end having terminal block no. & terminal no. as per approved wiring diagram. All wire terminations shall be made with insulated sleeve, solder less type tinned copper lugs. Wire shall not be tapped or spliced between terminals.
178

iii) iv)

v) Wiring shall be neatly bunched in groups by non-metallic cleats or bands. Each group shall be adequately supported along its run to prevent sagging or strain on the termination. 4.04.09 Terminal Block A. Terminals shall be box-clamp and clip-on type, suitable for terminating up to two wires of 2.5 sq. mm. cross section and provided with marking strips. Terminals for CT secondary leads shall have built-in disconnecting links with facility for shorting. Terminals for CT leads should have adequate cross section for terminating associated CT leads. Not more than two wires shall be connected to one terminal. If necessary, a number of terminals shall be jumpered together to provide wiring points. Each terminal shall be identified with designation as per approved schematic. At least 20% of the total number of active terminals shall be furnished as spare in each panel. The wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals. The terminal blocks shall be located to allow easy access and also to suit floor openings for cable entry. Terminal blocks shall generally be mounted vertically with adequate spacing (not less than 100 mm) between adjacent rows. The bottom of the terminal blocks shall be at least 200 mm above the incoming cable gland plate. Cable Entry a) The panel shall have provisions of cable entry from the bottom. Bottom plate shall be provided to make entry dust-tight.
b) The panels shall have provisions inside for fixing the multi-core cable glands. Cable glands shall be double compression type. Cable gland support plate shall be 4 mm thick and mounted not less than 200 mm above floor level.

B. C.

D. E. F. G. 4.04.10

4.04.11 i) ii) iii)

Grounding 50 x 6 mm tinned copper ground bus shall be provided in each panel extending along the entire length of the assembly. The ground bus shall have two-bolt drilling with GI bolts and nuts at each end for connection to 50x6mm Cu flat. The ground bus shall be bolted to the panel structures and effectively ground the entire assembly. The cases of relays, meters and other devices shall be grounded through the steel structure. Doors shall be connected by flexible copper braids for ground connection with fixed part of panel. Whenever a circuit is shown grounded, a single wire from the circuit shall be run
179

iv)

independently to the ground bus and connected to it. v) 4.04.12

i) ii) iii)

Potential and current transformer neutrals shall be grounded only at the terminal blocks where they enter the control boards from the transformers Painting
The steel surfaces shall be of tank chemically cleaned, rinsed, phosphate and dried. The relay panels shall be finished with electrostatic or powder painting process, white inside and RAL 7032 outside thickness of paint shall not be less than 20 micron. The boards shall have a smooth and uniform mat finish, free from scratches, dents and other imperfections sufficient quantity of touch-up paints shall be furnished for application at site.

iv) 4.04.13

The bidders are requested to furnish the details of process adopted by them for pre-treatment and painting of sheet metal for the control and relay panel. Operating Range
Unless otherwise specified, all instruments and relays shall be suitable for operation on 1A CT secondary circuits and/or 110V AC (phase-to-phase) or 63.5V AC (phase-toneutral) VT secondary circuits.

4.04.14

Relays Relays shall be furnished in rectangular /square dust tight, drawout or rugged plug in type, flash /semi flash mounting cases.

i)

The hardware design for protection and associated equipment shall use latest state of the art technology and shall generally be integrated numerical/digital, modular in nature. Where design is based on microprocessor technology adequate self-testing/monitoring/diagnostic facilities shall be provided. The design of the Transformer Protection and Switchyard Protections shall be based on numerical techniques. All the analogue signals will be converted into digital data, using analogue-to-digital conversion circuit. The data will be processed by a microprocessor, which will perform digital signal processing and executes various protection algorithms. The relay shall be designed to perform satisfactorily under highly noisy electrical environment. Sufficient degree of high frequency disturbance immunity and impulse voltage withstand capacity shall be built into electronic designs as stipulated in relevant standards. Relay characteristics shall be coordinated for proper functioning in conjunction with associated relays. The Contractor shall co-ordinate the characteristics of all relays to suit the system and equipment parameters. Relay ranges and settings shall be selected accordingly. The relays shall function satisfactorily being located in non-AC physical environment also. All protections shall be furnished compete with necessary auxiliary,
180

ii)

iii)

iv)

v)

vi)

supervisory, lock out etc, relays. Suitably separate sets of single phase auxiliary CT with multiple taps shall be provided with relay whenever required. vii) viii) ix) Visual and audible alarm annunciation shall be initiated in the event of operation of protective/supervisory relay. DC circuits shall be supervised by relays. Tripping shall be done through separate potential free contacts. High-speed lock out relays shall be used wherever requisite number of potential free contacts are not available. Switches Switches shall be dust protected, heavy duty, switchboard type complete with escutcheon plate. Contacts shall be silver surfaced and rated minimum 10A at operating voltage. The switch details and type of handle shall be as given below: Sl. No. a) Application Switch Type

4.04.15 i)

ii)

b)

c) d)

33 KV Breaker Control 120, 3-position (TRIP/NORMAL/ CLOSE), spring Switch return to normal with lost motion device, non-lockable, sequence device, large pistol grip handle 33 KV Isolator Discrepancy 150, 4-position (OPEN/NORMAL AFTER Switch OPEN/NORMAL AFTER CLOSE/CLOSE), spring return from close to normal after close and open to normal after open, discrepancy type with knob handle and built in lamp. This lamp shall FLICKER only on discrepancy between the position of the switch and any of the three poles of the isolators, but shall remain ON when the position of the switches corresponds to that of the isolators On-Off Switch/ Local- 90, 2-position (ON/OFF OR LOCAL/ REMOTE) Remote Selector Switch stayput type, non-lockable, spade handle Meter Selector Switches 4-position (OFF/R/Y/B for Ammeter selector switch and OFF/RY/YB/BR for Voltmeter selector switch), maintained contact, stayput type, knob handle. Ammeter selector switches shall have make- before-break contacts

NOTES: The above switches and any other type, if found necessary during detail engineering, shall be subject to approval of the purchaser.

4.04.16
i)

Push Button
Push buttons shall be, heavy duty, push to actuate type, with colored button and inscription plate marked with its function. The colour of ON and OFF push buttons shall be RED and GREEN respectively. All RESET push buttons shall be black.

ii)

Each push button shall have minimum 2 NO + 2 NC contacts, rated 10A at

181

operating voltage. iii) 4.04.17 i) Push button shall be shrouded type except for emergency trip button, which shall be mushroom type for easy identification. Lamps LED lamp shall be provided for status indication of circuits. The body shall be made of Poly Carbonate Unbreakable Lens. LED shall be protected by inbuilt fuse with surge suppressor or leakage voltage glow protection. LED circuit shall be PCB mounted. Intensity shall be greater than 200 mcd. 15% extra lamps and lenses shall be provided as part of initial supply. Semaphore Indicator Semaphore indicators shall be provided for remote indication of circuit breaker/isolator/earthing switch position. The indicator shall be suitable for semi-flush mounting with only the front disc projecting out and with terminal connection from the rear. Semaphore indicators shall be such that when the supervised object is closed, the pointer of the indicator shall take up a position in line with the mimic busbars and when the supervised object is open, the pointer shall take up a position at right angles to the mimic busbar. In case of supply failure, the pointer shall take up an intermediate position. Semaphore indicators of circuit breaker and isolator shall be of different sizes to enable easy identification Meters
All indicating instruments shall be switchboard type, back-connected, suitable for flush mounting, with 240 Deg. scale, antiglare glass, and accuracy class of maximum + 2% of _ the full scale. The dials shall be made of such material as to ensure freedom from warping, fading, and discoloring during the lifetime of the instruments.

ii) 4.04.18 i)

ii)

iii) 4.04.19
i)

ii) iii) iv)

All indicating instruments shall be enclosed in dust-tight cases suitable for tropical use. Meters shall be 96 mm x 96 mm (face dimensions) and shall have provision for zero-adjustment from front of the panel. Multifunction meter shall be 3-phase energy meter type with communication output. Meters shall be compensated for temperature errors and factory calibrated to read the primary quantities directly without using a multiplying factor. DC ammeters, wherever required, shall be provided with external shunt if the current exceeds 5A. The rated voltage drop for the shunts shall be 75 mV. The range of frequency meters shall be from 45 to 55 Hz, with 50 Hz. at the center of the scale. The range of power factor meters shall be from 0.5 lag to 0.5 lead, with unity
182

v) vi)

vii)

power factor being at the center of the scale. 4.04.20 Integrating Meters Integrating meters such as Watt-hour Meters, VARH Meters, Poly vector Meters, Maximum Demand Indicating (MDI) Meters etc. shall be static type, 2 element type, suitable for 3 phase, 3 wire connection, CT & VT operated. These meters shall preferably be furnished in drawout type cases. If furnished in non-draw out cases necessary test blocks with CT - shorting and CT/VT isolation facilities shall be furnished. 4.04.21 Transducer Transducers shall be of double channel output type. The output signal shall be 4-20 mA DC corresponding to the measurement range. The output coming out of the transducer shall be capable of driving loop resistance of at least 700 ohms at 24 V or proportionately with power supply. Transducer shall be two wire type. All equipment shall be suitable for satisfactory operation at the environment indicated elsewhere in this specification. Transducers shall be mounted on rack inside panel and shall provide easy access. 4.04.22 i. Annunciation System Each 33 KV control panel shall be provided with an annunciation window board. The annunciation boards shall be back-connected and suitable for semi-flush mounting. The annunciation system shall be microprocessor based programmable with optical isolation for input signals. The functional requirement shall be as given in Annexure A. Each annunciation group shall be independent, complete with its own power supply, audible alarms, acknowledge-reset-test buttons and other necessary accessories. The annunciation shall be non-integral type with hardware box mounted separately for easy access and maintenance. v. vi. vii. viii. ix. 4.04.23 Hooters with distinctly different tones shall be used for trip, non-trip, and ring back annunciations. The window size shall be such as to accommodate minimum three (3) lines of twelve (12) characters each. Each character shall be minimum 5mm. The annunciation system shall be suitable for operation from both NO and NC type initiating contacts. Minimum 20% annunciation channels and window facia shall be provided as spare on each panel, with a minimum of two (2). The annunciations to be provided on each control board shall be as per enclosed annexures and subject to approval of the Purchaser. Auxiliary Devices
183

ii.

iii.

iv.

The Contractor shall furnish, install, and wire-up all auxiliary devices such as interposing current or voltage transformers, timing/switching/lockout/auxiliary relays synchro-check relay as required for the proper functioning of the schemes offered. 5.00.00 5.01.00 5.01.01 TESTS Routine Test During manufacture and on completion, all equipment, clamps, connectors and accessories shall be subjected to the Routine Tests as laid down in latest revision of IEC/IS. Mechanical operation test (routine test) shall be conducted on disconnect switch (Main switch and earth switch). In addition to above tests specified by IEC, the speed curves for each breaker shall also be obtained with the help of a suitable operation analyzer to determine the breaker contact movement during opening, closing, auto-reclosing and trip-free operation under normal as well as limiting operating conditions (Control Voltage, pneumatic pressure etc.) Type Test Type tests on one set of each voltage class circuit breaker shall carried out as stipulated in relevant IEC/Indian Standards. Following additional type tests are to be conducted. i) ii) Out of phase closing test as per IEC-267 & IEC-56. Line charging breaking current test. The breaker shall be able to interrupt the line charging current with a test voltage of 1.4p.u. instead of 1.2 p.u. as per IEC-56. Seismic withstand test in unpressurised condition. Corona extinction voltage test for 400kV breaker only.

5.01.02 5.01.03

5.02.00 5.02.01

iii) iv) 5.02.02

Type tests on all equipment viz. disconnect switch & LA shall carried out as stipulated in relevant IEC/Indian Standards. Test certificates for type tests, as stipulated in Indian Standards, shall be furnished. Special Test Special tests listed under shall be carried out in presence of owners representative. i) Disconnect switch a) b) c) Test on insulators [as per IS: 2554; IEC: 168]. Test on terminal connectors [as per IS: 5561]. Test on galvanised components [as per IS: 2633].
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5.03.00 5.03.01

d) ii)

Stalled torque test on motor operating mechanism [at 110% of supply voltage].

Lightning arrestor a) b) c) d) e) Special thermal stability tests to be conducted on lightning arresters according to IEC, as an acceptance test. Temperature cycle test on the porcelain housing of the arrester to be conducted as per IS/IEC. The artificial pollution test shall be carried out as per applicable standards. The galvanisation test on metal parts shall be carried out as acceptance test. The functional (operational) acceptance tests shall be carried out on the surge counter.

5.04.00

Tests Witness Tests shall be performed in presence of owner /consultants representative if so desired by the owner. The Contractor shall give at least thirty (30) days' advance notice of the date when the tests are to be carried out.

5.05.00 5.05.01 5.05.02 5.05.03

Test Certificates Certified reports of all the tests carried out at the works shall be furnished in required no. of copies for approval of the owner/consultant. The equipment shall be despatched from works only after receipt of owner/consultants written approval of the test reports. Type test certificate on any equipment, if so desired by the owner/consultant, shall be furnished. Otherwise the equipment shall have to be type tested, free of charge, to prove the design.

6.00.00 6.01.00

SPECIAL TOOLS AND TACKLE A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied. The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended.

6.02.00

185

7.00.00 7.01.00

INSTALLATION REQUIREMENTS The Contractor shall perform erection, testing and commissioning of complete equipment including construction of foundation. Job includes safe storage at place of installation, unpacking, positioning in place, site assembly of loosely furnished accessories, connection & assembly of loose supply items, auxiliary circuits, including erection of MB, fixing of nuts and bolts etc., including all labour and materials, as per approved drawings, specifications of this tender and directions of Engineer-in-Charge/Manufacturer's supervisor. The contractor shall place all equipment on its foundation, assemble parts and erect the sheet steel chamber with danger plate fixed on the same. The storage and installation of switchgear, panels, battery etc shall be carried out in strict compliance with manufacturer's instruction.

7.02.00 7.03.00

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ANNEXURE-A RATINGS AND REQUIREMENTS A. 1.0 2.0 3.0

4.0

33 KV OUTDOOR CIRCUIT BREAKER Type Service Pole

i) Rated Voltage

: : :
:

VCB type Outdoor 3

33 KV r.m.s.

ii) Highest system voltage 5.0 6.0 7.0 8.0 8.1 8.2 8.3 9.0 9.1 9.2 9.3 9.4 10.0 Rated Frequency System Neutral Earthing Standard to be followed Insulation Level

: : : :

36 kV r.m.s 50Hz 3% Effectively Earthed IS:13118 / IEC-56

Impulse withstand Voltage (1.2/50 s): One minute power frequency withstand voltage Rated normal current Rated Breaking Capacity Rated Short circuit breaking current (symmetrical) Rated short circuit making current Rated peak withstand current Rated short time withstand current for 3 sec. i) Rated line charging interrupting current at 90 leading power factor : : : : : : :

170 KVP 70 KV r.m.s. 1250 A

25 KA 63 KA (Peak) 63 KA (Peak) 25 KA As per IS/IEC

ii) Rated Cable charging Breaking current 11.0 12.0 Rated small inductive current switching capability with over voltage less than 2.0 p.u. First pole to clear factor

: : :
187

50 Amps 0.5A to 10A 1.3

13.0 14.0 15.0 16.0

Rated Terminal Load Noise level Mounting Max. difference in the instants of closing/opening of contacts o o Within a pole Between poles

: : :

200 Kg. static 140 db On galvanized steel structure

: :

5 ms 10 ms 25 mm/KV 320 mm 320 mm Spring - spring operating mechanism 50 ms 0-.3-CO-3-CO 2 common to 3 pole

17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 24.1 24.2 24.3 24.4

Minimum creepage distance (mm/KV) : Phase to phase spacing Min. clearance between live parts & grounded objects Operating mechanism Total break time Operating Duty No. of Trip Coils Auxiliary Voltage Closing Tripping Spring Charge Motor Heater/Lamp/Socket : : : : : : : : : :

110 V DC (85% - 110%) 110 V DC (70% - 110%) 240V, 50Hz, 1 Ph, AC 240V 10%, 1 Ph, 2W, 50Hz

188

B. 01 02 03 04 05 06 07 08 a) b) 09 a) b) 10 a) b) c) d) 11 a) b) 12 13 a) b) 14 a) b) c) 15 16 a) b)

33KV DISCONNECT SWITCH Type Service Pole Rated voltage Rated frequency System Neutral Earthing Reference Standard Lightning Voltage Impulse Withstand : : 170 KV peak 170 KV peak : : : : : : : Centre break / Double end break, gang operated Outdoor Three 33/36 KV (Nominal/Max) 50 Hz 3% Ungrounded IEC 129 / IS 9921

Across isolating distance To earth & between poles One Minute Power Frequency Withstand Voltage Across isolating distance To earth & between poles Rated Current Continuous at site ambient Short time current Peak withstand current

: : : : :

70 KV r.m.s. 70 KV r.m.s. 800A 25 KA for 1 sec. 64 KA peak 64 KA peak

Rated short circuit making current : for Earth Switch Temperature Rise Design Ambient Temperature :

50C As per IS/IEC 31 mm / KV A.C. Motor Operated and Manual A.C. Motor Operated and Manual 415V 10%, 3ph, 50Hz 5% 110V DC (80% - 110%) 240V 10%, 1ph, 50Hz 5% Refer attached Layout drawing Refer attached Layout drawing Refer attached Layout drawing

Maximum temperature rise over : design ambient temperature : Minimum Creepage distance Operating Mechanism Main Blade Earth Switch Auxiliary Voltage Motor Control & interlock Heater/Lamp/Socket Phase to phase spacing (mm) Minimum clearances (mm) Phase to phase Phase to earth
189

: : : : : : : :

17 a) b) 18 19 20 C. 01 02 03 04 05 06 07 08 09 10 a)

Terminal Connector Type Suitable for Rated mechanical terminal load Mounting arrangement Seismic acceleration 33 kV SYSTEM ARRESTER Type Service Reference Standard System voltage Rated frequency No. of phases System Neutral Design Ambient Temperature LIGHTNING : : : : : : : : Station class, Metal-oxide, gapless Outdoor IS 3070 (Part 3) / IEC 60099-4 33/36 KV (Nominal/Max) 50 Hz 5% Three Ungrounded 50C 25 KA for 1 sec. : : : : : Bimetallic, Clamp type Twin AAAC conductor / Al. tube (Refer attached Layout dwg.) As per IS-9921 or calculated values, whichever is higher On galvanized steel structure Refer Site Data

Rated short time current of the : system Insulation level of equipment to be protected Surge Impulse Voltage i) ii) Transformer Circuit Breaker, Switch, CT, VT : Disconnect :

170 KV peak 170 KV peak

Duty cycle of the circuit breaker is 0 - 0.3sec - CO - 3min CO. 11 a) b) c) d) Surge Arrester Rating Rated voltage : 30 KV rms 10 KA peak 3 84 KV peak Nominal discharge current, 8/20 - : Sec : Long duration discharge class Maximum residual voltage at : lightning discharge current of 8/20 -sec wave at 10kA Maximum switching impulse : residual voltage at 1.0 kA Maximum protective level to full : wave impulse (1.2/50 -sec)

e) f)

70 KV peak 130 KV peak

190

g)

High current impulse impulse : withstand value (4/10 -sec impulse) Insulation Level of Arrester housing One minute power withstand voltage (wet) Lightning voltage impulse frequency : withstand : : : : : : : : :

100 KA

12 a) b) 13 14 15 16 17 a) b) 18 19

70 KV rms 170 KV peak 31 mm / KV 25 KA A On galvanized steel structure Bimetallic, clamp type Refer attached Layout dwg. Suitable for 75 x 10 mm G.S. flat Refer Site Data

Creepage distance Pressure relief current Pressure relief class Mounting Terminal connector Type Suitable for Ground terminal Seismic acceleration

191

ANNEXURE-B FITTINGS & ACCESSORIES A. 33 KV CIRCUIT BREAKER Each Circuit Breaker shall be furnished complete with fittings and accessories as listed below : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Complete SF6 gas system along with pipings, valves, pressure switches, pressure gauges, SF6 gas density monitor, etc. Various attachments & accessories for gas filling, operational analyzer, etc. Two ground pads per pole suitable for termination of 50 x 6 mm Cu flats. Base frame and anchor bolts and nuts. Operating mechanism, double tripping coils and closing coil, pole discrepancy feature and low pressure blocking device wherever required. Set of valves, pressure gauges and pressure switches as required. Auxiliary contacts and relays. LOCAL/REMOTE Selector switch, TRIP/CLOSE Push Buttons. Manual tripping devices with protective flap. Mechanical ON-OFF indicator. Operation counter. Weatherproof outdoor type control cubicle and pole boxes. Set of MCCB / MPCB for A.C. and switch fuse unit D.C. supply. Isolation valves for incoming air supply in case of pneumatically operated breakers. Space heater with thermostat and ON-OFF switch. Cubicle illumination lamp with ON-OFF switch. 3 Pin 5A Socket with ON-OFF Switch. Terminal blocks and internal wiring - lot as required. Set of pre-fabricated pipe with fittings, clamps and hardware for connection between control cubicle and pole boxes as required. Terminal connectors for horizontal/ vertical conductor/tube as required. Interconnecting wires, G.I. conduits and accessories for connection between control cubicle and pole boxes. Pole slipping relays The gas filling and internal pressure monitoring devices per pole for SF6 breakers.
192

20. 21.

22. 23. 24. 25.

Other standard accessories which are not specifically mentioned but usually supplied with breakers of similar type and rating for efficient and trouble-free operation. Bi-metallic terminal connectors with S.S. hardware. Ground pad for 50X6mm Cu. Supporting structure.

B. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. C. 1. 2. 3. 4. 5. 6. 7.

DISCONNECT SWITCH Clamp-type bimetallic connector Ground pads for 50x6mm Cu flat. Base frame with anchor bolts, nuts and washers. Operating mechanism with all accessories including operating rod of required length, for disconnect switch and for earth switch. Starters, relays and auxiliary switches. Local/Remote selector switch. Open/Stop/Close push buttons. Spare auxiliary switches 6 NO + 6 NC. Mechanical ON-OFF indicator. Weather-proof mechanism box with lock and key for disconnect switch and for earth switch, where indicated. Set of fuse switches for A.C. and D.C. supply. Space heater with thermostat and ON-OFF switch. Internal illumination lamp with ON-OFF switch. 3 pin 5A socket outlet with ON-OFF switch. Terminal blocks and wiring lot. Earthing switch, if specified, complete with safety interlocks and 4 NO + 4 NC auxiliary switches. Flexible copper braid for grounding of operating rod. LIGHTNING ARRESTER Each Lightning Arrester shall be furnished complete with the accessories as listed below : Insulating Base with anchoring bolts, nuts, etc. for fixing the equipment on to structure. Surge counter with integral leakage current monitor. By-pass shunt with connection provision. Ground terminals. Grading ring, if necessary. Other standard accessories which are not specifically mentioned but are usually provided with Lightning Arrester of such type and rating for efficient and trouble-free operation.

Each disconnect switch shall be furnished complete with fittings & accessories as listed below:

193

ANNEXURE- C ANNUNCIATOR TYPE

The annunciation system shall be manually reset type with ring back facility, suitable for operation on 110V DC ungrounded supply.

FUNCTION The sequence of operation shall be similar to ISA-2A with fast/slow blinking as detailed below: Field Visual Audible Condition Display Normal Off Abnormal Ring back Alarm Alarm

Silent Silent Fast blinking On

Silent

Acknowledge Steady On Silent Silent Return to normal Slow blinking Silent On Reset Off Silent Silent Normal Before Acknowledge Slow Blinking On On Acknowledge Steady On Silent On Reset Off Silent Silent Test Fast Blinking On On

194

ANNEXURE- D LIST OF PROTECTION

The following are the minimum principal protections, which shall be in control and relay panels. The protections shall be furnished with necessary accessories like timer, auxiliary relays, interposing CTs and VTs, Tripping Relays, Supervising Relays, Relay Testing, etc as required fulfilling the functional requirements of Control, Indication, Interlocking and Protection. This list is to be read in conjunction with typical Metering & Protection Single Line Diagram:

A.

RELAYS FOR OUTGOING TRANSFORMER FEEDERS 1. 2. 3. 4. 5. 6. 7. Transformer Differential protection with Harmonic restraint, biasing feature High Set instantaneous 3-phase overCurrent protection Non-directional IDMT 3-phase Overcurrent protection Transformer HV side E/F protection relay Restricted earth Fault protection Transformer neutral side Stand-by Earth Fault protection Auxiliary relays for Transformer Protection (viz. Buchholz, winding/Oil temperature, Oil level, Fire protection Relay) Lockout relay for associated circuit breaker Supervision relay for above Trip circuit pre & post supervision relays for Trip coil I & II 87 50 51 50N 64 50N/2 30

8. 9. 10.

86 95 95

Note : Any protection/relay other than those listed above, necessary for satisfactory and trouble free operation of the system are deemed included within the scope of this specification.

195

ANNEXURE- E INDICATIVE LIST OF ANNUNCIATION TO BE PROVIDED ON 33 KV Substation Transformer (10 MVA) Control & Relay Panel 1 2 3 4 5 6 7 8 9 10 11 12 33 KV Breaker trip circuit unhealthy 33 KV breaker trip Transformer 33 KV side IDMT O/C with High set instantaneous unit relay operated Transformer 33 KV side definite time E/F relay operated Transformer 11KV side restricted earth fault operated Transformer 11KV neutral side standby earth fault relay operated Protection DC fail Transformer Trouble Trip (Group alarm for Buchholz, Winding/Oil Temperature, Oil Level etc. Trip contacts) Buchholz alarm Winding temperature high-alarm Oil temperature high-alarm Oil level low alarm

196

SPECIFICATION NO. : 11P01-SPC-E-291-53.02 SUB-SECTION-IX 415V EMERGENCY DIESEL GENERATOR

197

SUB-SECTION-IX

415V EMERGENCY DIESEL GENERATOR CONTENTS CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 DESCRIPTION CODES & STANDARDS SCOPE OF WORK SPECIFIC REQUIREMENTS CONTROL AND INSTRUMENTATION TESTS SPECIAL TOOLS AND TACKELS ATTACHMENT ANNEXURE - A ANNEXURE - B RATINGS AND REQUIREMENT: DIESEL ENGINE RATINGS AND REQUIREMENT: GENERATOR 13 15 PAGE NO. 1 1 2 8 12 12

198

415V EMERGENCY DIESEL GENERATOR

1.00.00 1.01.00 CODES AND STANDARDS The design, manufacturing and testing of the equipment covered by this specification, shall unless specially mentioned otherwise, conform to the latest editions of the following standards and codes along with all addendum as applicable. i) ii) iii) iv) v) vi) vii) viii) ix) 2.00.00 2.01.00 ASME AND ANSI Power Test Code Heat Exchange Institute (USA) Standards AIEE Standards Instrument Society of American Standards Various Indian Standards for material and tests BS:2613 BS:822 Electrical Performance of Rotating Electrical Machinery Recommendations for Terminal Markings for Electrical Machinery and Apparatus.

BS Code of Practice CP:1014, protection of electrical equipment against climatic conditions. IS Specification for Rotating Electrical Machines. SCOPE OF WORK SCOPE OF SUPPLY Supply of one (1) no, 100,KVA, 415V silent LT DG for SPM project in MP. The equipment shall be offered in strict compliance with the annexure stating the type, rating and connections of the equipment.

2.01.02

DG shall be furnished complete with :a. Fittings and accessories

2.01.03 2.01.04 2.02.00

One set of special tools and tackles All relevant drawings, data and instruction manuals. Scope of Services The services of a senior engineer, experienced in the erection and commissioning of the equipment of similar type and rating on per diem basis. The work includes but not limited to :-

2.02.01

Complete checking of materials at site and advising the Owner/Purchaser any discrepancy thereof.

199

2.02.02 2.02.03 2.02.04 2.04.00 2.04.01 2.04.02 2.04.01

Advice on procedure of erection to be followed. Regular supervision and following up of erection work done by others. Testing, commissioning commercial operation. Delivery Schedule The delivery period shall be as per the TIME SCHEDULE D from the date of and putting the equipment into successful

issue of Notification of Award of contract or Purchase Order

Delivery period shall be inclusive of the time to be allowed for approval of drawings & test certificates and shall include transportation time to site. Delivery date shall be reckoned as the date of receipt of the complete equipment & materials at site. Mandatory spares, special tools and tackles shall be supplied with the first consignment. SPECIFIC REQUIREMENTS Diesel Engine The Diesel Generator set shall be capable of starting from cold condition on loss of normal A.C. supply and coming up to rated frequency and voltage within ten (10) seconds in the first attempt but not exceeding twenty-five (25) seconds in three attempt. The desired normal output at site referred to at the alternator terminals and with machines operating under ambient conditions shall be 100 KVA at 1500 RPM at 0.8 power factor at 415V 5%. Engine shall be derated in accordance with standard for the difference in site condition from standard conditions. The Diesel Generator set shall be running with high-speed diesel oil. All statutory approval / clearances from the statutory authority regarding the above shall be arranged by the Contractor. Engine Cooling System Radiator is offered by the contractor to cool the water received from the engine. The radiator shall be a heat exchanger in which the water will be cooled by the forced flow of atmospheric air around the pipes or tubes carrying the water. Fuel Oil System One (1) no. fuel oil day tank dedicated for operation of D.G. Set each along with accessories shall be provided. The tank shall be filled up from the oil tanker by hand operated pump. Further the day tank shall be complete with fuel level gauge, threaded pipe connections for toilet, engine suction, engine return, overflow, vent, drain all internal piping, wiring, finish paint, one fill connection. The tank shall have at least 15% expansion space above the maximum fuel level.
200

3.00.00 3.01.00
3.01.01

3.01.02

3.01.03 3.01.04

3.02.00
3.02.01

3.03.00
3.03.01

3.03.02

3.04.00

Combustion Air System The system shall be designed to maintain adequate airflow to the engine for good combustion without excessive pressure drop or noise.

3.05.00

Governing System The governor shall be mechanical type. The governor characteristics shall comply with the requirements of IS 10000 (Pt. VII). The basic performance requirements are

a) b)

Steady state speed regulation shall be capable of adjustment between 0% and 5% inclusive. Steady state incremental speed regulation shall be between 1% and 8% for power output greater than 10% and 1% to 10% for power outputs less than 10% with the steady state incremental speed regulation set at 2%. Steady state governing speed band shall not exceed 0.35% of rated speed. Momentary under speed shall not exceed 2% of the rated speed. Momentary over speed shall not exceed 8% of rated speed. Recovery time shall not exceed 3seconds. The speed changer shall be capable of adjusting the speed of the diesel generator speed from 100 to 102% inclusive at rated power output, from 90 to 106% inclusive at zero power output and from 100 to 0% inclusive, at power output reduced in direct proportion with speed from rated at its rated speed. Exhaust System The contractor shall furnish a complete diesel engine exhaust gas system and seamless stainless steel metal hose to assure expansion protection and vibration isolation. Exhaust gas outlet shall be raised sufficiently above (Not less than 3 meters) the adjoining building top level, which should also confirm to all statutory regulations applicable for this project. Duct work shall be provided from the Genset radiator exhaust to the opening to discharge hot radiator exhaust to the atmosphere. Duct shall be made of GI material 18 SWG thick, 180 gm/sq.m. mass of coating as per IS 227. Suffient bracing and supports shall be provided for rigidity of the duct. However the duct shall be easily removable of dismantled for maintenance work on the radiator of Genset. Necessary stiffener supports clamps shall be provided. All such components shall be galvanized.

c) d) e) f) g)

3.06.00 3.06.01

3.06.02

3.06.03

201

3.07.00

Rating plate generator engine In addition to the requirements IS the rating plate shall indicate the following : i) Maximum continuous rating in KW and corresponding temperature rise as applicable for cooling medium temperature. Bearing identification numbers (in case of ball/roller bearing and recommended lubricant)

ii)

3.08.00

ACOUSTIC ENCLOSURE

Outer Panels Shall be made out of 3 mm CRCA MS sheet bent as per the requirement. Anti-drumming coating: The inner side of the outer panels shall be provided with antidrumming coating for the absorption of noise and for reverberation control. Inter panels shall be made out of 0.8 mm G.I. sheet with 4 mm (holes) perforated sheets. This allows the noise to penetrate into mineral wool. Sound absorption insulation mineral wool material of high density cladded with perforated sheeting along with necessary rivets shall be provided for clamping purpose. Double door shall be provided to have access during DG machine removal and maintenance. This door is made of 2 mm MS sheet as outer panel with primer. The inner panel shall be provided with mineral wool with G.I. perforated sheets. A pad lock shall be provided for safety purpose. Louvers shall be provided as per design requirement for removing all the cooling system heat. A baffle shall be provided near radiator to not allow any hot air to circulate. Louvers of adequate size with sound absorbing material shall be provided to bring a lot of air through the action of radiation fan. In event of air-cooled engine special low speed, low noise fans shall be used. Noise level of canopy will be 75 dB(A) at a distance of 1 meters in free field condition. Necessary angle framework shall be provided to hold the container rigidly. As outer base frame is provided for stability. This shall be provided between the mineral wool layer and perforated sheet to avoid future leakage of wool due to vibration of the panels.

Inter Panels:

Mineral Wool:

Door:

Hot air louvers:

Cold Air Louvers:

Structure : RPT issue :

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3.09.00
3.09.01

Generator
The Generator shall be driven by the diesel engine, which shall match the generator in all respects. The generator shall also conform to IEC-34/IS-4722 or equivalent.

The D.G. Set i.e. diesel engine and alternator, shall be mounted on a steel skid base. 3.09.02 Rating There shall be one (1) nos. Diesel Generator sets and each generator shall be star connected synchronous generator and shall have a continuous rating of 100 KVA at 0.8 p.f. (Lag) 1500 rpm. at 415V, 50 Hz, 3 phase, 4 wire grounded system. 3.09.02.01 For detailed scope of work and equipment rating, Contractor shall follow the Schedule of Items enclosed with this tender document. 3.09.03. Terminal Voltage and Frequency The generator shall be capable of delivering rated output at 5% of rated voltage and 3% of rated frequency. 3.09.04 Short Circuit Condition The generator shall be capable of withstanding for three (3) seconds, without injury, a 3 short circuit at its terminal when operating at rated KVA, p.f. and a voltage at 5% over rated voltage, with fixed excitation. The value of negative sequence current shall be limited as per IS. The machine shall also be capable of withstanding, without injury any asymmetrical short circuit at its terminal for three (3) seconds duration or less or asymmetrical loading on the system, provided the per unit negative phase sequence component (I2) of the asymmetrical currents and duration of short circuit in seconds (t) are limited to values which give an integrated product I22 t equal to or less than the values shown below : For machines with indirectly cooled rotor windings I22 t 20. For machines with directly cooled rotor windings I22 t 7. Bidder shall indicate the method of cooling of rotor winding along with the offer. 3.09.05 Short Time Overload

3.09.05.01 The Generator shall be capable of withstanding on test, without injury for not less than fifteen (15) seconds a current of 50% in excess of its rated current after having attained the thermal equilibrium corresponding to rated load, the terminal voltage being maintained as near as the rated values possible.

3.09.05.02 Low Power Factor Operation and Transient Reactance Drop Limitation due to Large Motor Starting Load At the time of switching emergency loads of the plant there is necessity for
203

reaccelerating or restarting of certain number of important induction motor loads in addition to the lighting loads. This leads to large reactive power operation and the restart up of machines may result in low power factors say, 0.2 to 0.3 lagging. The generator and its regulation equipment must be capable to supply the load including starting current of the loads at the low power factor as mentioned above. 3.09.06 Short Circuit Ratio Short circuit ratio (S.C.R.) of the Generator at rated KVA and rated KV shall not be less than 0.45. 3.09.07 Over Speed The generator shall withstand without mechanical injury an over speed of 1.2 times the rated speed for a period of two (2) minutes. 3.09.08 Insulation and Temperature rise of Windings and Core The generator stator and rotor windings and all connections including main and neutral leads shall have Class-F insulation meeting the temperature rise limitations for Class-B set forth for air cooled machines in IS:4722. Ambient temperature shall be considered as 50C. 3.09.09 Generator Construction
All parts of the generator shall be capable of withstanding electrical, mechanical, thermal and other stresses experienced in normal operation and also on abnormal conditions such as short circuit and over speed. Enclosure of generator shall be of protection class IP54 and air cooled type.

3.09.10

Stator Terminals The line and neutral ends of phase winding of the generator shall be brought out on six (6) suitably located terminals. The neutral terminals shall be arranged for star connection.

3.09.11 3.09.12 3.09.13

Neutral Earthing The neutral of the stator winding of the alternator shall be grounded. Through Cuearth flat to be connected to isolated individual earth pit. Protection Protective devices required for safe operation of the Diesel Generator set. Actuation of any of the protective devices will cause the Diesel Generator tripped. All protective devices for generator shall be mounted on AMF panel. Following are the minimum protections to be provided in addition to other protections of the engine and as recommended by the bidder. o o o o Generator Over-current, Generator Earth fault, Generator Short-circuit protection
204

3.09.14

Current Transformers Cast resin type current transformers shall be provided for phase as well as neutral side of the generator at phase and neutral side terminal box. All secondary connection shall be brought out to AMF panel where Wye or Delta connection will be made. The C.T. ratio, accuracy class (for protective and metering C.Ts) shall be 5P20 for Protection C.T. and Class I for metering. VA burden and knee point voltage (for PS class CTs) shall be furnished by the contractor along with the necessary calculation for Owners approval. Instrument Security Factor (ISF) for metering CTs shall be less than or equal to 5 (ISF 5).

3.09.15

Space Heaters Suitably rated 240V, single phase, 50 Hz, space heaters located in lower part of alternator shall be provided to maintain internal temperature above the dew point to prevent moisture condensation on the insulation during shut-down.

3.10.00

Excitation System The generator shall be provided with a complete excitation system capable of supplying the excitation current of the generator under all conditions of output from no load to full load and capable of maintaining voltage of the generator constant at any value within+ 10% of the rated voltage. The type of insulation of _ the armature field winding of the exciter shall be Class-F and the temperature rise above 50 deg. C ambient shall not exceed the values specified in IS-4722 for different parts corresponding to Class-B.
Shaft driven A.C. brushless type exciter shall be provided.

3.11.00

Exciter-Voltage Regulators The exciter shall be of static type or semi conductor may be provided. Solid-state voltage regulator with all accessories and relays shall be provided for proper voltage regulation.

3.12.00

Voltage Regulator
An automatic, high speed, non-dead band type voltage regulator shall be furnished. The regulation system shall be provided with equipment for automatic and manual control. Necessary equipment shall be furnished for the following :

i) ii)

To prevent automatic rise of field voltage in case of failure of potential signal to AVR. To initiate transfer from automatic to manual control of excitation on fuse failure in the generator potential signal.

205

3.13.00

Terminal Box Suitable Alternator Terminal Box fabricated from minimum 14 SWG MS sheet duly painted shall be provided towards power output side as well as towards neutral side. Each termination box shall be equipped with copper busbar to be supported on epoxy resin support insulator having minimum 1.1 KV voltage grade, to accommodate CTs. Bus bar shall be suitable to withstand short circuit level of 50 KA for 1 sec. and rating shall be at least 25% higher than the rated capacity. Space heater with thermostat control for each box shall be provided. Double compression glands for power and control cables shall be provided for DG set scheme.

4.00.00 4.01.00

CONTROL AND INSTRUMENTATION Start-up and Control Auto-Main Failure (AMF) Panel shall be provided for each generator. There shall be one Auto-Manual-Off Selector switch for each generator. Each generator shall receive starting impulse from normal switchgear in case of power failure. In auto-mode, the generator shall start automatically on receipt of the starting impulse. Generator can be Switched Off, if necessary. In normal condition the above selector switches shall be kept to Auto position to facilitate auto starting of engine and connection of generator to their respective bus on build up of voltage and frequency. The necessary key shall be provided with each selector switch It is envisaged that in Auto position DG set shall be stopped manually after normal power is restored. The DG set shall have facility to stop from AMF panel under all operating conditions, irrespective of whether normal power supply is restored or not. All relays, current transformer (C.T.), meters, timers, indicating lamps, controls switches, etc. necessary to achieve the system shall be included in AMF Panel. The AMF panel shall also be equipped with control and interlock of starting, sequence starting, timers, protection relays and instruments etc. as required for safe and trouble-free operation of the Diesel Generator.

4.01.01.

The following items shall be included in the AMF Panels for each D.G. Set : 1) Power factor meter 2) AC voltmeter with selector switch (Off/Mains/Load/Alt) 3) AC ammeter with selector switch 4) Frequency meter 5) Kilowatt meter
206

6) Indicator, annunciator, raise lower switches, push buttons, etc. 7) Speedo meter 8) Running hour meter 9) Automatic voltage regulator 10) Power supply section (400V/230V transformer) 11) 1 no. signal lamp Load on set 12) 1 no. signal lamp (Load on mains) 13) 1 no. signal lamp (Let fails to start) 14) Battery charging equipment 15) Engine start/stop control relays, three attempt start facility & failure to start lockout 16) Auto-Manual-Test-Off Selector Switch 17) Push buttons such as start/stop/reset/test etc. 18) Selector switch for emergency control ON/OFF In AMF panel one power supply section shall be provided (along with 415V/230V, 1 phase, 50 Hz, adequately rated auxiliary transformer) for supplying auxiliary power to generator space heaters, AMF panel space heater, engine heaters prelubrication pumps, if any and battery charger. 4.01.02 Indicating Cum Starter panel of engine shall be consisting of following : 4.01.03 Cooling water temperature gauge Lube oil pressure gauge Lube oil temperature gauge Starting switch with key Battery charging ammeter

Readiness to Start A master relay shall be provided to monitor the pre-requisite conditions to be met before the set can be started and an indicating lamp on the AMF panel shall be provided to indicate when all the requirements are met. Some of them are Pre-requisite conditions for D.C. supply required for engine starting is satisfied. Pre-requisite conditions for jacket cooling water (if, any) for safety are satisfied. Pre-requisite conditions for lubricating oil pump/system, fuel oil systems, prelube systems, for safety are satisfied.
207

4.01.04

Manual Control of Speed and Voltage The manual control of the engine speed and generator voltage shall be provided through suitable Raise/Lower control switches on the AMF panel.

4.01.05

Control of Jacket Cooling Water Temperature In order to enable quick starting and loading of the diesel generator jacket water shall be kept warm by thermostat controlled electric heaters. Automatic control for maintaining the jacket water temperature within specified limits during running of the diesel engine shall be furnished.

4.02.00

Tripping Any one or more of the following defects shall cause the running diesel generator to be tripped and restart shall be prevented until the fault/faults are removed and manual resetting is done. A DG set which has failed to start even on successive attempts and finally blocked shall be possible to restart after the problem has been rectified and manual resetting is done. Engine and generator protection shall be made independent. Due to alternator problem, owners incoming breaker in the relevant board shall be tripped first and engine thereafter with a delay time for safeguard of engine parameters. necessary interlock for the same shall be provided Jacket water pressure low. Lube oil pressure inadequate. Over-speed. High jacket water temperature. Alternator stator temperature very high. Over load High lube oil temperature. Over voltage.

4.02.01

Necessary pressure switches, level switches, thermostats, flow switches, auxiliary relays, etc. required for the above alarm and annunciation system shall be furnished under the scope of this specification. The successful bidder shall take prior approval from the owner regarding make and technical particulars of such accessories to be used. Indication and Annunciation For alarm and indication, a hooter and individual indication lamps shall be provided. The alarm system shall have one set of accept, reset and test push button. On occurrence of fault, the hooter shall sound and an indication lamp shall flash. On pressing accept push button, hooter shall stop but the lamp shall continue to glow steady. On pressing reset push button, the lamp shall stop glowing but if the fault persists, the hooter shall not sound and the lamp shall glow steadily.
208

4.03.00 4.03.01

Necessary solid-state logic cards, push buttons, hooters, lamp boxes, etc. shall be furnished as required, to achieve the above function. However, separate window facia shall be provided for the following alarm, as a minimum. 4.03.02 4.03.03 4.04.00 4.04.01 Annunciator shall generally be actuated by closing of alarm contact (normally open contact). In some case, the reverse configuration may be required. The system operating voltage of the annunciation system shall be 12V D.C. Annunciation System Solid state alarm annunciators shall be audio-visual integral back lighted name-plate type with flasher and horn, with inbuilt power pack and sequence logic. The alarm system shall have one set of 'accept', 'reset' and 'test' push-key unit. Annunciator shall generally be actuated by closing of alarm contact (normally open contact). In some case, the reverse configuration may be required. Units shall be fully operable to all specifications through 9 Deg.C to 65 Deg.C and relative humidity of 95 percent. The system operating voltage of the annunciation system shall be 12V D.C. Specific Design Requirements i) The annunciation system shall be designed with adequate safeguard against malfunctioning due to random noise and transient pick-ups. An input filter for draining the high frequency noise, with a built-in adjustable time delay (variable from 0-1 second) shall be provided for elimination of transient pick-ups and noise. Annunciation circuitry shall be silicon solid state plug in module of state-of-art technology. All the components associated with the circuits shall be proven & guaranteed quality produced by reputed manufacturers. Printed circuit board shall be channelwise modular type and shall be of polarized construction. The boards shall be properly lacquered. Annunciation fascia lamps shall be mounted on the top of the panel front. The lamps shall be serviceable from panel front side. The annunciators shall be provided with two lamps per channel. The wattage rating of individual lamps shall be within 2.5 watts and the enclosure temperature rise with all the lamps glowing shall be guaranteed within 10 degrees centigrade without air conditioning. The lamps shall be off under normal conditions and shall flash or remain steady-on brightly under abnormal conditions. Expected life of the lamps with respect to cycles of operation shall be clearly mentioned in the offer.

4.04.02

4.04.03

4.04.04 4.04.05

ii) iii) iv) v) vi)

vii)

209

4.05.00

Contactors, Lamps, Meter, etc. All electrical components on the panel namely Push Puttons, Contactors, lamps, meters, control panels etc. shall meet the system requirements .

4.05.01

Moulded case circuit breaker (MCCB) i) The MCCBs shall conform to the latest applicable standards. ii) MCCBs in AC circuits shall be of triple pole construction arranged for simultaneous three pole manual closing and opening and for automatic instantaneous tripping on short circuit, operating mechanism shall be quick-make, quick break and trip free type. iii) The ON off and trip position of the MCCB shall be clearly indicated and visible to the operator when mounted as in serviced. iv) MCCBs shall be capable of withinstanding the thermal stresses caused by overload and mechanical stresses caused by the peak short circuit current of value associated with switchgear rating. The maximum tripping time under short circuit shall not exceed 20 millisecond. Iv MCCBs shall be provided with magnetic short circuit protection and bimetallic over load protection features.

5.00.00 5.01.00

TESTS Diesel Generator Set The following test shall be conducted on alternator & D.G. Set.

5.02.00

Factory Tests The factory tests shall incorporate the following. i) Routine tests ii) High voltage test iii) Short circuit current test v) Insulation resistance test Contractor shall furnish type tests certificate for engine and alternator. These tests shall be conducted as per the requirements of BS:2613 or IS:4722 and the original tests certificates shall be furnished.

6.00 00 5.01.00

SPECIAL TOOLS AND TACKELS The make/brand list of all the components shall be furnished by the bidder and are subjected to owner/consultants approval. 210

ANNEXURE-A
RATINGS AND REQUIREMENTS

FOR
COMPRESSION IGNITION DIESEL ENGINE

1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0

Type No. of units required Location Duty Engine Speed

: : : : :

Diesel Engine, Four Stroke Cycle, Silent One(1) Outdoor Continuous at full load 1500 RPM 100 KVA at 0.8 power factor (415 5%) V at 1500 r.p.m.

Nominal output of engine : at site referred to the alternator terminals and with machine operating under ambient conditions. Period during which the : engine will provide 10% greater output in every twelve (12) hours. De-rating of the engine :

7.0.0

One (1) hour

8.0.0

Shall be done in accordance with BS5514 Pt. I to VI for the difference in site condition from standard condition or as per engine manufacturer. 2.5%

9.0.0

The tolerance for : compression pressure, peak pressure and mean effective pressure Engine rating conditions to : be passed on ambient condition Over Speed Set Engine type Engine fuel Engine Cranking : : : :

10.0.0

As per site data

11.0.0 12.0.0 13.0.0 14.0.0

110% Engine Speed Turbocharged High Speed Diesel Oil a. DC Motor Starter (Inclusive of DC Battery System).

211

b. 15.0.0 16.0.0 17.0.0 Engine Starting Mode Engine Coupling generator Sound Level (in dB) with : : :

Provision of hand crank in arrangement. Auto and manual mode for cold and hot start applications. Direct coupling with gear box. Shall not exceed 75dB at 1 meter distance from the engine and its various component. Guarantees shall be given for the Diesel Generator Set. As per manufacturer standard.

18.0.0 19.0.0 20.0.0 20.1.0 21.0.0 21.1.0 21.2.0 21.3.0 21.4.0 21.5.0 21.6.0 21.7.0 21.8.0 21.9.0 21.10.0 21.10.1 21.10.2 21.10.3

Performance test required Primer and finish paint

: :

Diesel Engine shall have the following instruments and interlock apart from what is indicated elsewhere in this specification. Engine Speed Fuel oil day tank particulars Location Design Code Type Nominal Capacity Nos. required Fabrication Construction Steel standard Supplied by Testing and Inspection Radiography test required Hydrostatic test All tests to be witnessed : : : No As per code Yes by Owner : : : : : : : : : Outdoor IS : 804 Horizontal Cylindrical 8 hour running of DG Set One (1) At shop Welded IS-2062 Gr.A. Contractor : Local (L) Tachometer DG Panel (DGP) - Indicator

212

ANNEXURE-B
RATINGS AND REQUIREMENTS

FOR 415V LT DIESEL GENERATOR 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 Make Model Capacity Power Factor RPM Voltage with tolerance Frequency with tolerance Neutral Earthing Alternator body Earthing Details of AVR Excitation Control Details of Governor-speed Control : : : : : : : : : : : Refer to Clause 1.17.00 of Spec. 100KVA 0.8 p.f. lag 1500rpm 415V 5% 50Hz 3% Grounded through Cu-earth flat.

Transient capability of the alternator to start : highest capacity load when all other loads are running. (To indicate simultaneous maximum running load and maximum starting load)

213

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION-X POWER AND CONTROL CABLES

214

SUB-SECTION-X POWER AND CONTROL CABLES

CONTENTS

CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00

DESCRIPTION CODES AND STANDARDS SCOPE OF WORK DESIGN CRITERIA SPECIFIC REQUIREMENT TESTS INSTALLATION REQUIREMENTS

PAGE NO. 1 1 1 2 6 7

ATTACHMENTS

ANNEXURE-A
ANNEXURE-B ANNEXURE-C

H.V POWER CABLES (11 KV)

L.V POWER CABLES CONTROL CABLES

8
9 10

ANNEXURE-DSPECIFICATION OF ADSS FIBRES CABLE ANNEXURE-E CABLE SIZES

11 15

215

POWER AND CONTROL CABLES

1.00.00 1.01.00 CODES & STANDARDS All cable and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification. Cable and material conforming to any other standard which ensures equal or better quality, may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid. The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed. SCOPE OF WORK Scope of Supply
Power and Control Cables shall cover the requirement of entire Plant including the switchyard. The cables shall be furnished in accordance with this specification and annexure.

1.02.00

1.03.00

2.00.00 2.01.01
2.01.00

Other cables including special cables if any which are necessary as per proven engineering practice (i.e. no joints will be allowed, etc)for satisfactory & trouble free operation of the entire cable system of the main plant shall also be within the scope of supply. These shall include all such cables for electrical integral with mechanical equipment systems and subsystems. 2.02.00 Cable shall be furnished in accordance with this specification and the following annexures: a) b) c) 2.03.00 2.04.00 3.00.00 3.01.00 3.02.00 11 kV Power cables 1100V Power Cables Control Cables : : : Annexure - A Annexure B Annexure C

Approx. Length: -PowerCable length has to be taken as per route shown in the plot plan .There should be spare cables for future use. All relevant drawings, data and instruction manuals. DESIGN CRITERIA Cables will be generally laid on ladder type trays, perforated type cable trays or drawn through rigid steel conduits. For continuous operation at specified rating, maximum conductor temperature shall be limited to the permissible value as per relevant standard and/or this specification which one is more stringent.

216

3.03.00
3.04.00

The insulation and sheath materials shall be resistant to oil, acid and alkali and shall be tough enough to withstand mechanical stresses during handling. Armouring shall be single round wire of galvanized steel for multicore cables and aluminum for single core cable for power and control cables. For fire survival control cable, the armouring over inner sheath shall consist of single layer of wire / round galvanized steel wire as per IS 3975 amended upto date. For Fire survival power cable, Single core cables to be used in A.C. system, the armouring over inner sheath shall consist of single layer of round copper wire, for multi-core cables to be used in A.C. system and single/two core cables in D.C. System, the armouring over inner sheath shall consist of single layer of round galvanized steel wire. The outer sheath shall have flame retardant low smoke halogen evolution (FRLSH) characteristics or fire survival characteristics as applicable and shall meet the requirements of additional tests specified for the purpose. Core identification for multicore cable shall be provided by colour coding. HT cables shall be manufactured by triple extrusion dry cured (CCV) process using pressurized nitrogen. SPECIFIC REQUIREMENTS General Description All Cables shall be furnished in strict compliance with ratings and requirements and sizes as given in Annexures to this Specification.

3.05.00

3.06.00 3.07.00

4.00.00 4.01.00

4.02.00

Drum Length and Tolerance The cables shall be supplied in non-returnable packing steel drum for 11 KV power cables, wooden drums for 1100V power and control cables, each containing minimum 500 meters length of larger sizes of cable unless specifically asked for. For smaller sizes of cables, each drum shall contain 1000 meters length of cable. Allowable tolerance on individual drum length is +5%.

4.03.00

Non-Standard Length Owner/Purchaser may accept non-standard lengths upto 5% of the total ordered quantity. However the Contractor will be required to obtain Owner's/ Purchasers approval before packing the Cables on drums. Non-standard lengths shall not be less than 100 meters in any case.

4.04.00

Cable identification Cable identification shall be provided by embossing on every meter on the outer sheath the following: a) b) c) SPM Manufacturers name or trade mark Voltage grade
217

d) e) f) g) h) 4.05.00 4.05.01

Year of manufacture Type of insulation, e.g. XLPE/PVC/HR85 /IE2 etc. No. of core and size of cables. Type of improved fire performance, e.g. FR/FR-LSH/FS IS number

Packing Cables shall be supplied in non-returnable drums. The drums shall be of heavy construction. All wooden parts shall be manufactured from seasoned wood. All ferrous parts used shall be treated with suitable rust preventive finish or coating to avoid rusting during transit or storage. Wooden cable drum shall be treated by immersing in copper-nitrate solution.
Cable shall be wound and packed on drums in such a manner that it will be properly sealed and firmly secured to the drum. The ends of each length shall be sealed before shipment.

4.05.02

4.05.03

The cable drums should carry the following details in printed form: a) b) c) d) e) f) g) h) i) j) k) l) SPM Manufacturers name or trade make Type of cable & voltage grade Year of manufacture Type of insulation e.g. XLPE/HRPVC/IE2 No. of core and size of cables Cable code e.g. FRLS/FS Length of cable on drum No. of length on drum, if more than one Direction of rotation, by arrow Approx. gross mass. IS/IEC number and ISI mark

4.06.00

Joints and Terminations Materials of construction for a joint/termination shall perfectly match with the dielectric chemical and physical characteristics of the associated cables. The material and design concepts shall incorporate a high degree of operating
218

compatibility between the cable and joints. The protective outer covering (jacket) used on the joints/terminations shall have the same qualities as that of the cable outer sheath in terms of ambient/operating temperature withstand capability and resistance to hazardous environments and corrosive elements. Straight through joints and terminations for HT cables shall be heat shrinkable type. 4.06.00 4.06.01 Selection Criteria a) HT and LT power cables shall be selected on the basis of current Carrying capacity, short circuit rating and permissible voltage drop. b) While sizing power cables, following aspects shall be reckoned: i) Ground/Ambient Air temperature ii) Depth of Laying. iii) Power Cables touching each other. c) Cables, for circuit breaker controlled feeders, shall withstand the short circuit current for the fault clearing time. 0.2 Sec. d) For fuse protected circuits the conductor size shall depend upon full load current subject to voltage drop limited to 3% during running of all feeders and 15 % during starting for motor feeders with rigid coupling. For motors with fluid coupling the starting voltage drop can be considered as 20%. In addition, transformer regulation shall also be considered for loads fed from 415V PCC. e) For loads fed from local panels, the total running voltage drop in cable from 415V PCC to local panel and from local panel to individual motor shall be limited to 3% at full load motor current while the same during starting shall be limited to 15%. f) As per national electric code (NEC) current rating capacity of motor feeder/cables should be 125% of full load current.

g) For welding receptacle, 3% running drop shall only be considered. The minimum sizes of L.T cable to be chosen are as below: AL - 16 mm2 (3 core) & 6mm2 (2 core) Cu - 2.5 mm2 4.06.02 4.06.03 Apart from above, consideration shall also be given to limit the cable to some standard sizes instead of using too many types. The standard cable sizes, amp capacities, derating factors. as given in IS/IEC will be generally followed.

219

4.06.04

a)

For breaker protected circuits minimum size of the cable shall be as follows: 1100V Power : 2.50 Sq mm Cu

b)

For motor circuits the selection of size will be made ensuring that the cable shall withstand a short circuit fault directly following a second hot start.

4.06.05

For fuse protected circuit, the conductor size will depend on full load current subject to voltage drop not exceeding 3%. For practical purposes, the minimum size chosen is as below : a) b) Copper Copper : : 16 Sq. mm. 2.5 Sq. mm.

4.06.06 4.06.07

All control cables shall be 2.5 Sq. mm copper cable. Multicore control cables will generally have spare conductor (s) in accordance with the following chart: Conductors required 1 or 2 3 or 4 5 or 6 7 or 8 9 or 10 Above 10 Cables 1-3/C 1-5/C 1-7/C 1-9/C 1-12/C Two or more of above cables

4.06.08

Separate cables for each type of following services/functions as applicable shall be used for each feeder. Same multicore cable using different services shall not be acceptable.

a) b) c) d) e) f)

Power. Control, interlock and indication. Metering and measuring. Alarm and annunciation. C.T. Cables. V.T. Cables.

220

4.07.00

Cable Identification Cable identification shall be provided by embossing on the outer sheath the following: a) b) c) d) e) f) g) Manufacturer's name or trade mark Manufacturer's name or trade mark Voltage grade Year of manufacture Type of insulation, e.g. XLPE,HRPVC & IE2 etc. No. of core & size of cables Type of outer sheath e.g. FRLSH, FS etc.

4.08.00 5.00.00 5.01.00

Selected sizes of power and control cables are given in Annexure-E. TESTS Shop Tests The Cables shall be subject to shop tests in accordance relevant IS/IEC standards to prove the design and general qualities of the Cables as below: -

5.01.01 5.01.02 5.01.03 5.02.00

Routine tests on each drum of cables. Acceptance Tests on 1 drum out of every 10 drums chosen at random for acceptance of the lot for every size. Type test on each type and size of cable, inclusive of measurement of armor DC resistance of power cables on one drum out of every 10 drums of cable. Additional Tests Following additional acceptance tests shall also be performed on each type of cables having outer sheath with improved fire performance (Type FRLSH,FS):

5.02.01

Oxygen index test

The Oxygen index shall not be less than 29.

5.02.02

Temperature Index Test The measured value of temperature index shall be 21 at a temperature of 250C for FRLS cables and 350C for FS cables

5.02.03

Flame Retardance test on single cable and on bunched cables After the test, there should be no visible damages on the test specimen within 300mm from its upper end.

221

After burning has ceased, the cables should be wiped clean and the charred or affected portion should not have reached a height exceeding 2.5 meter above the bottom edge of the burner, measured at the front and rear of the cable assembly. 3 Hours fire rating test shall be carried out for FS cable as per IEC331

5.02.04

Halogen acid gas evolution test The level of HCL evolved shall not exceed 20 per cent by weight. HCL evolved shall not be exceed 2% for FS cable.

5.02.05

Smoke density test The cables shall meet the requirements of light transmission of minimum 40% after the test. Minimum transmission shall be 80% for FS cable.

5.02.06

Test for specific optical density of smoke

The cables shall meet the requirements of IS/IEC.

5.02.07

Test for rodent & termite repulsion property The test shall be carried out to note the presence of rodent and termite repelling chemical in PVC compound. Normal procedure is that a few chippings of the PVC compound are slowly ignited in a porcelain dish or crucible in a muffle furnace at about 600C. The resulting ignited ash is boiled with a little ammonium acetate solution (10%). A drop of aqueous sodium sulphide solution is placed on a thick filter paper and it is allowed to soak. The spot is touched with a drop of above extract. A black spot indicates the presence of anti-termite & rodent compound. Flammability test shall be carried on finished cables as per following standardsa) Swedish Chimney test SS:424-14-75 b) IEEE std.383 1974 latest c) IEC std. 332-1 and IEC 331

5.03.00

Test Witness Tests shall be performed in presence of Owner/Purchaser's representative. The Contractor shall give at least thirty (30) days' advance notice of the date when the tests are to be carried out.

5.04.00 5.04.01 5.04.02

Test Certificates Certified reports of all the tests carried out at the works shall be furnished for approval of the Owner/Purchaser. Test reports shall be completed with all details and shall also contain IS/IEC specified limit values, wherever applicable, to facilitate review.

222

5.04.03

The cables shall be dispatched from works only after receipt of Owner/ Purchaser's written approval of the test reports. INSTALLATION REQUIREMENTS Contractor shall follow the installation requirements as detailed in the enclosed sub-section XIV (B) : ERECTION CABLING, GROUNDING AND LIGHTNING PROTECTION SYSTEM

6.00.00 6.01.00

223

ANNEXURE-A RATINGS AND REQUIREMENTS (POWER AND CONTROL CABLE) 11 KV Power Cable
1.0 11000/11000V grade 900 C continuous rating under normal condition and 2500 C rating under short circuit condition heavy duty XLPE power cable suitable for use in 11000V non-effectively earthed system conforming to following requirement and in line with IS-7098, IS-8130, IS-5831 & IS-3975 ,manufactured by Triple Extrusion Dry Cure(CCV) process using pressurized Nitrogen.

1.1 1.2 1.3

1.4

Conductor Conductor Screen Insulation

Insulation Screen :

: : :

Stranded, high conductivity annealed plain copper generally conforming to IS: 613 - 1964 Extruded semi-conducting compound. Extruded cross linked polyethylene (XLPE) conforming to IS7098 (Part-2)
Extruded semi-conducting compound with

a layer of non-magnetic metallic tape. For single core armoured cables, the armouring shall constitute the metallic part of screening. The semi-conducting tape shall be easily strippable.

1.5 1.6

Core Identification Inner Sheath

: :

By colored strips applied on (For three core cables) cores or by numerals. Extruded HRPVC/FRLS compound conforming to type ST2 of IS: 5831 for three core cables. Single core cables shall have inner sheath. Filler material shall also be of type ST2 PVC.
Galvanized single round steel wire Armour for twin and multicore cables.

1.7

Armor

Non-magnetic hard drawn aluminum single round wire conforming to H4 of IS-8130 latest for single core cables. 1.8 1.9 Overall Sheath Drum : : Extruded FRLSH HRPVC compound conforming to type ST2 of IS: 5831. Steel Drum

224

ANNEXURE-B L.V. POWER CABLES 1.0 1100V grade, 90C rating heavy duty, Armoured power cable (A2XWY) conforming to following requirement and in line with IS: 7098, IS: 5831, IS: 8130 & IS: 3975. Conductor Insulation Core Identification (for three core cables) Inner sheath Armour Stranded, high conductivity annealed plain copper generally conforming to IS: 613 - 1964 Extruded XLPE conforming to IS: 7098 (Part-I) By colored strips applied on cores Pressure extruded PVC compound conforming to type ST2 of IS: 5831 for multi-core cables. Single core cables shall have no inner sheath. G.S. flat strip round wire armoured for twin and multicore cables. Non-magnetic hard drawn Al single round wire conforming to H4 grade of IS: 8130 for single core cables. Pressure extruded FRLS PVC compound conforming to type ST2 of IS: 5831 Conforming to IS: 10418

1.1 1.2 1.3 1.4 1.5

1.6 1.7

Overall sheath Drum

225

ANNEXURE-C

CONTROL CABLES
1.0 1100V grade, 70C rating, PVC control cable (YWY) conforming to following requirement and in line with IS: 1554, IS: 8130, IS: 5831 and IS: 3975.

2.1

Conductor

Stranded, non-compacted & circular, high conductivity annealed tinned copper, generally conforming to IS: 8130 & IS: 613. Extruded PVC compound conforming to type A of IS: 5831. Extruded PVC compound conforming to type ST1 of IS: 5831 for three core cables. Single core cables shall have no inner sheath. Galvanised single round steel wire armour for twin and multicore cables. Pressure extruded FRLS PVC compound conforming to type ST1 of IS:5831 Conforming to IS:10418

2.2 2.3

Insulation Inner sheath

2.4 2.5 2.6

Armour Overall sheath Drum

226

ANNEXURE-D

SPECIFICATION OF ADSS FIBRES CABLE

Manufacturing of Optical Fiber Cables shall be as per ITU-T Rec. G652. The specification of optical fibers is mentioned below :

Mode field diameter (m) Deviation in mode field diameter (m) Attenuation Coefficient (dB/Km) Attenuation variation (dB/Km) with a) b) Wavelength (25 nm) Temperature (%)

: : :

9.2 0.4 0.35 max.

: : : :

0.02 (1525-1575) 0.05 <1% 1260

Mode field non-circularity Cut-off wavelength (nm)

Chromatic dispersion (PS/nm2 Km) a) b) c) @1310 (1285-1330)nm @1310 (1270-1340)nm @1310 (1525-1575)nm : : : : : : : : : 3.5 6.0 20.0 1300 1324 0.092 1.47 Graded Matched 0.1

Zero dispersion Wavelength (nm) Zero dispersion slope (PS/nm2 Km) Refractive index Refractive index profile Cladding design Numerical aperture

227

ANNEXURE-D Bandwidth distance product (MHz Km) Bend performance Crush Resistance : : : N/A < 0.05 dB >4000 N

GEOMETRICAL CHARACTERISTICS Nominal MFD a) b) For depressed clad For matched clad : : : : : 8.1.-9.9 um 8.8-9.8 um 125 um + 0.7 um < 1% < 0.8 um

Nominal Cladding Dia. Cladding Non-circulatory Mode field concentricity error Diameter over primary coated with double UV cured acrylate (shall be measured on un-colouredfibre)

TRANSMISSION CHARACTERISTICS Attenuation a) At 1310 nm Between 1285 to 1330 nm b) At 1550 nm Note: 1. 2. Total Dispersion a) b) c) In 1285-1330 nm band In 1270-1340 nm band At 1550 nm : : < 3.5 ps/nm.KM : : : < 0.36 dB/Km < 0.38+0.02 dB/Km < 0.22 dB/Km

Sudden irregularity in attenuation shall be less than 0.05 dB. The spectral attenuation shall be measured on un-cabled fibre.

< 5.3 ps/nm.KM : < 18.0 ps/nm.KM.

228

Polarization mode dispersion at 1310 & 1550 nm a) b) Fiber Cabled Fiber : : < 0.1 ps/KM < 0.3 ps/KM

(Note: Measurement on un-cabled fiber may be used to generate cabled fiber statistics and correlation is established) c) d) Zero Dispersion Slope Zero dispersion wavelength range : : < 0.092 ps/(nm2.KM) 1302-1322 nm

Cut off wavelength of optical fibers a) 1320 nm max. : 1260 nm

(Note: The above cut off wavelength is w.r.t. 2M-sample length of fiber) Mechanical Characteristics a) b) Proof test for minimum strain level Strip ability force to remove primary coating of the fiber : : 1% 1.3 < F < 8.9 N

Note: The force required to remove 30 mm + 3 mm of the fiber coating shall not exceed 8.9 N and shall not be less than 1.3 N. c) Dynamic Tensile Strength
1) Unaged :

:
> 550 KPSl (3.80 Gpa)

2) d) e) f)

Aged

: : : :

> 440 KPSl (3.00 Gpa) > 20 > 20 < 0.10 dB.

Dynamic Fatigue Static Fatigue Change in attenuation measured at 1550 nm when fiber is coiled with 100 turns on 30 + 1.0 mm radius mandrel Fiber Curl Fiber micro bend (1 turn around 32 + 0.5 mm diameter mandrel)

g) h)

> 4 Meter radius of Curvature : < 0.5 dB at 1550 nm

229

Material Properties Fiber Materials a) b) The substances of which the fibers are made Protective material requirement i) The physical and chemical properties of the material used primary coating and for single jacket fiber The best way of removing protective: coating material Refractive Index of fiber Fiber Spool Length : : : It shall meet the requirement of Fibre coating stripping force To be indicated by the manufacturer To be indicated by the manufacturer Minimum 16 km shall be used for manufacturing of Optical Fiber Cable : to be indicated by the manufacturer

ii)

c) d)

230

ANNEXURE-E

CABLE SIZES
Sl. No. 1.0 1.1 1.2 1.3 1.4 1.5 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 H. T. CABLES 1 core 630 Sq.mm 1 core 500 Sq.mm 3 core 240 Sq.mm 3 core 300 Sq.mm 1 core 70 Sq.mm L. T. POWER CABLES 3 core 2.5 Sq.mm 2 core 16 Sq.mm 3 core 16 Sq.mm 4 core 16 Sq.mm 2 core 35 Sq.mm 3 core 35 Sq.mm 4 core 35 Sq.mm 3 core 95 Sq.mm 3.1/2 core 95 Sq.mm 3 core 185 Sq.mm 3.1/2 core 185 Sq.mm 3 core 240 Sq.mm 3.1/2 core 240 Sq.mm 3 core 300 Sq.mm 3.1/2 core 300 Sq.mm 1 core 630 Sq.mm CU CU CU CU CU CU CU Cu Cu Cu Cu Cu Cu Cu Cu Cu Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Armored (FRLSH) Cu Cu Cu Cu Cu Armored XLPE (FRLSH) Armored XLPE (FRLSH) Armored XLPE (FRLSH) Armored XLPE (FRLSH) Armored XLPE (FRLSH) Cable Size Conductor Insulation

231

Sl. No. 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4.0 3.1 3.2 3.3 3.4 3.5 3.6

Cable Size CONTROL CABLE 2 core 2.5 Sq.mm 3 core 2.5 Sq.mm 5 core 2.5 Sq.mm 7 core 2.5 Sq.mm 9 core 2.5 Sq.mm 12 core 2.5 Sq.mm 20 core 2.5 Sq.mm FS POWER CABLES 3 core 2.5 Sq.mm 2 core 16 Sq.mm 3 core 16 Sq.mm 4 core 16 Sq.mm 2 core 35 Sq.mm 3 core 35 Sq.mm 4 core 35 Sq.mm 3 core 95 Sq.mm 3.1/2 core 95 Sq.mm FS CONTROL CABLE 2 core 2.5 Sq.mm 3 core 2.5 Sq.mm 5 core 2.5 Sq.mm 7 core 2.5 Sq.mm 9 core 2.5 Sq.mm 12 core 2.5 Sq.mm

Conductor Cu. Cu. Cu. Cu. Cu. Cu. Cu.

Insulation HRPVC (FRLSH) HRPVC (FRLSH) HRPVC (FRLSH) HRPVC (FRLSH) HRPVC (FRLSH) HRPVC (FRLSH) HRPVC (FRLSH)

CU CU CU CU CU CU CU CU CU

EPR EPR EPR EPR EPR EPR EPR EPR EPR

Cu. Cu. Cu. Cu. Cu. Cu.

EPR EPR EPR EPR EPR EPR

232

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION-XI

ELECTRICAL INSTALLATION, TESTING & COMMISSIONING

233

SUB-SECTION-XI ELECTRICAL INSTALLATION, TESTING & COMMISSIONING CONTENTS

CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00

DESCRIPTION CODES AND STANDARDS SCOPE OF WORK SPECIFIC REQUIREMENTS SUPPLY SPECIFIC REQUIREMENTS SERVICES TESTS SPECIAL TOOLS & TACKLES DRAWINGS, DATA & MANUALS

PAGE NO. 1 1 3 4 10 11 11

ANNEXURES ANNEXURE-A SCHEDULE OF PRE-COMMISSIONING TESTS 12

234

ELECTRICAL INSTALLATION, TESTING & COMMISSIONING

1.00.00 CODES AND STANDARDS

1.01.01

All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) except where modified and/or supplemented by this specification. Equipment and materials conforming to any other standard which ensures equal or better quality may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid. The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Codes of Practice. In addition, other rules or regulations applicable to the work shall be followed. In case of any discrepancy, the more restrictive rule shall be binding.
SCOPE OF WORK

1.01.02

1.01.03

2.00.00

2.01.00 2.01.01

Scope of Supply The work involves timely procurement and transportation to site in properly packed condition of all hardware, materials and miscellaneous items as required to complete the erection of equipment, cabling and grounding work under this specification. These materials and miscellaneous items shall include but not limited to the followings: a) All necessary erection materials, hardware, consumables and sundry items to complete the installation for satisfactory and trouble free operations. Any materials and accessories which may not have been specifically mentioned but which is usual and/or necessary shall be supplied free of cost to the Owner.

b)

All materials and accessories to be supplied by the Bidder shall be brand new ones of reputed make. The contractor shall furnish data sheets and technical leaflets on each piece of materials. 2.02.00 Scope of Services The work includes but not limited to the followings: 2.02.01 Furnishing of all labour, skilled and unskilled, supervisory personnel, erection tools and tackles, testing equipment, implements, supplies, consumables & hardware, and transport for timely and efficient execution of the contract work. Complete assembly, erection and connection, testing and commissioning,
235

2.02.03

putting into successful and satisfactory commercial operations of all electrical equipment and accessories:: a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) t) 2.02.04 33 KV Outdoor circuit Breakers 33 KV Disconnecting switches 33 KV Lightning Arresters 33 KV steel Structures for 33 KV switchyard All civil and structural work for 33 KV switchyard 10 MVA, 33 KV/11 KV power transformers 11 KV switchgear Electrical Control and Relay Panels 11 KV Neutral Grounding Resistors 11 kV Power cable including cable termination 3000 KVA, 11 KV/433 V Distribution Transformers 415 V L.T. Distribution Boards LV Power and Control cable Battery and charger 415 V Emergency DG Set Grounding system Civil works, structural steel work Necessary miscellaneous hardware/software complete in all respect

The scope of work shall also include erection, testing and commissioning of following equipment/materials. a) All interconnecting Power & control cables covering all electrical equipment including installation, connection, testing and commissioning. All concrete foundation works for 33 KV switchyard. Supply of steel materials for different fabrication purposes.

b) c) 2.02.05

The items of work to be carried out on all equipment and materials shall include but not limited to the following: a) Proper storing arrangement at plant site with suitable enclosure for protection from weather and pilferage of items under their scope of supply and materials issued by the owner/suppliers of the material. Assemblies, erection and complete installation. Pre-commissioning check-up to ensure correctness of erection as per actual manufacturers instruction.

b) c)

236

d)

Final checking, testing and commissioning of all equipment in presence of SPM representatives including checking of interlocks and correctness of wiring as per scheme. (include DCPL also.) Satisfactory routine and emergency maintenance of the equipment/systems erected and commissioned by the contractor till the completion of the contract. Obtaining engineers approval and owners/DCPL written acceptance of satisfactory performance. Abiding to all rules and regulations in vogue at owners premises in reference particularly to the administration, security, safety etc.

e)

f) g)
3.00.00

SPECIFICREQUIREMENT - SUPPLY

3.01.00 3.01.01 3.01.02 3.01.03

Accessories and Materials Accessories and materials shall comply with description, rating, type and size as detailed in this specification, drawings and annexures. Accessories and materials furnished shall be complete and operative in all details. All accessories, fittings, supports, hangers, anchor bolts etc. which are necessary for safe and satisfactory installation and operation of the equipment shall be furnished. All parts shall be made accurately to standard gauges so as to facilitate replacement and repair. All corresponding parts of similar accessories shall be interchangeable. After the treatment of steel surface damaged during transit sufficient quantity of anti-corrosive paint shall be applied and subsequently finished with two coats of final paint of approved shade. Conduits and Accessories Conduits shall be of rigid steel, hot-dip galvanized, furnished in standard length of 3 meters, threaded at both ends. Conduits diameter upto and including 25mm size shall be of 16 SWG and conduits above 25 mm diameter shall be of 14 SWG. Minimum diameter of conduits shall be 19 mm. Each piece of conduit shall be straight, free from blister and other defects, internal surface shall be of smooth finish and covered with capped bushings at both ends. Flexible conduits shall be made with bright, cold rolled, annealed and electrogalvanized mild steel strips coated internally with epoxy and the sizes shall be 19, 32,51,63 & 76m.

3.01.04

3.01.05

3.02.00 3.02.01 3.02.02

3.02.03

3.02.04

237

3.03.00 3.03.01

Terminals Multiway terminal blocks of approved type, complete with screws, nuts, washers and marking strips shall be furnished for connection of incoming/outgoing wires. Each control cable terminal shall be suitable for connection of 2 nos. 2.5 sq.mm. stranded copper conductors without any damage to the conductor or looseness of conductors. Cable Termination & Jointing Kits The Bidder shall supply cable termination and jointing kits for H.T. Power Cables, L.T. Power and Control Cables along with all accessories. For the cable terminations and straight through joints for HT / LT power and control cables, supply of jointing kit including necessary boxes, if any, sealing compound, ferrules, tapes, lugs, glands etc., shall be of RAYCHEM or M-Seal make. Cable end terminations on HV electrical equipment shall be suitable for indoor & outdoor uses, as the case may be. Cable Glands Cable glands shall be tinned brass gland, double compression type complete with necessary armor clamp and tapered washer etc. Cable glands shall match with the sizes of different H.T./L.T./Control cables.

3.03.02

3.04.00 3.04.01 3.04.02

3.05.00

3.06.00

Cable Lugs Cable lugs shall be tinned brass lugs suitable for termination of different crosssections of H.T./L.T./Control cables. Lugs for power cables shall be compression type whereas lugs for Control shall be crimping type.

4.00.00

SPECIFICREQUIREMENTS - SERVICES

4.01.00 4.01.01

Responsibility of Erection The Contractor shall be fully and finally responsible for proper erection, safe and satisfactory operation of plant and equipment under his scope of work to the entire satisfaction of the Engineer. The work shall be executed in accordance with the directions, instructions, drawings and specifications of each electrical equipment under scope of erection. If in the opinion of the Contractor any work is insufficiently specified or require modification, the Contractor shall refer the same in writing to the Engineer and obtain his instruction/ approval before proceeding with the work. If the Contractor fails to refer such instances any excuse for the faulty erection, poor workmanship or delay in completion shall not be entertained. Equipment and material which are wrongly installed shall be removed and reinstalled to comply with the design requirement at the Contractor's expense, to the satisfaction of the Engineer.
238

4.01.02

4.01.03

4.01.04 4.01.05

4.02.00 4.02.01 4.02.02

Supervision The Engineer shall have the overall responsibility for coordination of Contractor's work and his direction shall be final. Such direction and supervision however shall not relieve the Contractor of his responsibility of correctness and quality of workmanship and of other obligation under the contract. Drawings Drawings and schedules enclosed with this sub-specifications are for general guidance of the Bidder to assess the type and volume of work involved. These drawings and schedules will be revised to suit the actual requirement in related systems. Additional drawings and schedules will also be furnished to Contractor if/when necessary. Final drawings and schedules will be furnished to the Contractor from time to time as detailed designs are developed. Pls check all the necessary drawing shall be provided by the contractor during & after the project like G.A,SLD,Layout,PID ,As built, Wiring diagram etc. Methods and Workmanship All work shall be installed in a first class, neat workmanlike manner by mechanics/ electricians skilled in the trade involved. The erection work shall be supervised by competent supervisors holding relevant supervisory license from the Government. All details on installation shall be electrically and mechanically correct. The installation shall be carried out in such a manner as to preserve access to other equipment installed. Protection of Work The Contractor shall effectively protect his work, equipment and materials under his custody from theft, damage or tampering. Finished work where required shall be suitably covered to keep it clean and free from defacement or injury. For protection of his work Contractor shall provide fencing and lighting arrangement, connect up space heaters and provide heating arrangement as necessary or directed by the Engineer. Contractor shall be held responsible for any loss or damage to equipment and material issued to him until the same is taken over by the Owner according to contract. Safety Measures All safety rules and codes as applicable to work shall be followed without exception.
239

4.03.00 4.03.01 4.03.02

Note :4.05.00 4.05.01 4.05.02 4.05.03 4.05.04 4.06.00 4.06.01 4.06.02 4.06.03

4.06.04

4.07.00 4.07.01

4.07.02

All safety appliance and protective devices including belts, hand gloves, aprons, helmets, shields, goggles etc. shall be provided by the Contractor for his personnel. The Contractor shall provide guards and prominently display caution notices if access to any equipment/area is considered unsafe and hazardous. Co-operation The Contractor shall at all times work in close coordination with the Owner's supervising personnel and afford them every facility to become familiar with erection and maintenance of the equipment. The Contractor shall arrange his schedule of work and the method of operation to minimize inconvenience to other Contractors working on the Project. In case of any difference between Contractors, the decision of the Engineer shall be final and binding on all parties concerned. Erection Programmes and Progress The Contractor shall submit at such times and in such forms as may be requested by the Engineer, schedule showing the programmes and the order in which the Contractor proposes to carry out the work with dates and estimated completion time for various parts of the work. Such schedules shall be approved by the Engineer prior to starting the erection. The Contractor shall adhere to this approved programmes for all practical purposes. If for any reason the work is held up, the Contractor shall bring it to the attention of the Engineer in writing without any delay. During the progress of work the Contractor shall submit monthly progress report and such other reports on erection work and organization as the Engineer may direct. Consumables and Hardware The Contractor shall furnish all erection materials, hardware and consumables required for the completed installation. The materials shall include but not limited to the following : a. b. Consumables : Hardware : Welding rods & gas, oil and grease, cleaning fluids, paints, electrical tape, soldering materials etc. Bolts, nuts, washers, screws, brackets, supports, clamps, hangers, saddles, cleats, sills, shims etc.

4.07.03 4.08.00 4.08.01

4.08.02 4.08.03 4.09.00 4.09.01

4.09.02

4.09.03

4.10.00 4.10.01 4.10.02

Supply of steel, cement, sand, stone etc. required for execution of the contract shall be the responsibility of contractor.

240

4.11.00 4.11.01

Erection Tools & Tackles The Contractor shall provide all tools, tackle, implements, mobile equipment such as crane, trailers, scaffoldings, ladders, welding machines, gas cutting, bending machine, hand cart, chain pulley blocks wire clues, hydraulic jack/ motorized jack, wooden slipper, drill machine, hand/hydraulic compression tools for cable termination, vacuum cleaners box spanner of various size etc. which are required for transportation, handling and erection of the plant and equipment. Testing Equipment All testing equipment, to be required for testing of all electrical equipment under scope of erection, testing and commissioning, shall be arranged by the Contractor. Taking Delivery The Contractor shall take delivery of materials of his own from his store yard / shed or railway siding. Materials delivered shall be brought to the erection site, stored or erected as necessary. Indents for materials shall be placed sufficiently in advance so as to enable the Owner to arrange for the delivery from store in time. The Contractor shall submit a detailed account of materials issued to him after completion of work and transport back the excess materials to Owner's stores. Installation - General Installation work shall be carried out in accordance with good engineering practices and also manufacturer's instructions/ recommendations where the same are available. Equipment shall be installed in a neat workmanlike manner so that it is level, plumb, square and properly aligned and oriented. The equipment will be furnished in a dis-assembled condition as received at site. The contractor shall assemble all these parts, mount and wire-up loose equipment, fittings and accessories and complete with all connections. Equipment will be generally supplied with necessary floor/support steel, holding down bolts, nuts, anchors etc. In case of non-supply of these items with the equipment, following procedure shall be followed : i) ii) Owner will arrange for floor/support steel as necessary and contractor shall fabricate and install them. Contractor shall furnish and install all bolts, nuts, screws and anchors as required to complete the installation.

4.12.00 4.12.01

4.13.00 4.13.01 4.13.02 4.13.03 4.13.04 4.14.00 4.14.01

4.14.02 4.14.03

4.14.04

241

4.14.05

Any internal wiring of the equipment which has been left incomplete because of shipping split or which requires minor modifications shall be carried out by the Contractor. All erection work shall be carried out in strict compliance with manufacturers instructions and shall include all necessary adjustments, checks & measurements. The contractor shall record results of all erection tests & measurements. The contractor shall submit copies of those tests results to the owner for his reference & record. Conduit and Accessories a. b. c. d. Conduit/pipes shall be used only in short lengths in certain areas where required and/or as directed by the Engineer. The Contractor shall furnish all conduits complete with accessories as required. Conduits shall be rigid type in general. However, flexible type conduit if required shall also be supplied by the Contractor. Except for inside an enclosure wherever the cable enters or leaves the conduit, the conduit end shall be sealed by suitable sealing compound, having fire withstand capability

4.14.08

4.14.09

4.15.00

4.16.00 4.16.01 4.16.02 4.16.03 4.16.04 4.17.00 4.17.01 4.17.02

Excavation and Backfilling The Contractor shall perform all excavation and backfilling as required for buried cable and ground connections. Excavation shall be performed upto the required depth. Such sheeting and shoring shall be done as may be necessary for protection of the work. The Contractor shall make use of his own arrangements for pumping out any water that may be accumulated in the excavation. All excavation shall be backfilled to the original level with good consolidation Painting All equipment shall be given touch-up paint as required after installation. All damaged galvanized surfaces shall be coated with cold galvanizing paint.

4.17.03

All equipment after erection shall be touched-up where required with coats of finish paint.

4.17.04

All primer & paint including touch-up paint shall be supplied by the Bidder.

242

4.18.00 4.18.01

Cleaning up of Work Site The Contractor shall, from time to time, remove all rubbish resulting from execution of his work. No materials shall be stored or placed on passage or drive ways. Upon completion of work, the Contractor shall remove all rubbish, tools, scaffoldings, temporary structures and surplus materials etc. to leave the premises clean and fit for use. Commissioning and Trial Run Following successful inspection and testing, the equipment shall be commissioned and put on trial run along with the main plant in a manner mutually agreed upon based on the commissioning schedule of main plant. The Contractor shall assist the Owner in commissioning and trial run with men and material as required and/or as directed by the SPM. Inspection & Testing On completion of erection works, the Contractor shall request the SPM for inspection and tests with minimum fourteen (14) days advance notice. The Engineer shall arrange for joint inspection of the installation for completeness and correctness of the work. Any defect pointed out during such inspection shall be promptly rectified by the Contractor. The installation shall be then tested and commissioned in presence of the SPM and put on trial run for stipulated contract period. All rectification, repair or adjustment work found necessary during inspection, testing, commissioning and trial run shall be carried out by the Contractor without any extra cost.

4.18.02

4.19.00 4.19.01

4.19.02 4.20.00 4.20.01 4.20.02

4.20.03 4.20.04

4.21.00 4.21.01 4.21.02 4.21.03 4.22.00

Taking over of Installation On successful testing, commissioning and trial run, the Contractor shall request SPMin writing for taking over the installation. The SPM, on receipt of the request, shall arrange to take over the installation either wholly or in part as the case may be after a final inspection. Till such taking over, the responsibility of the whole installation against theft or damage of any kind shall remain with the Contractor. Guarantee In the installation if any trouble arises due to the use of defective or faulty material and/or bad workmanship within a period of 12 months from the date of taking over, the Contractor shall guarantee to replace or repair the defective part or parts at site to the entire satisfaction of the Engineer free of charge.
243

5.00.00

TESTS

5.01.00 5.01.01

Site Tests Contractor shall thoroughly test and meggar all cables, wires and equipment to prove the same are free from ground and short circuit after erection and installation at site. If any ground or short circuit is found, the fault shall be rectified or the cable and/or equipment replaced. All equipment shall be demonstrated to operate in accordance with the requirements of this specification. All equipment shall be subjected to High Potential test. All protective relays shall be checked for correctness of operations. All current transformers shall be subjected to Primary Injection test. Generator Bus-duct Polarization Index (P.I. value) shall be measured. Test Witness All tests shall be performed in presence of Owner/Consultants representatives, if so desired by the Owner. The Contractor shall give at least thirty (30) days advance notice of shop tests and seven (7) days advance notice of site tests. Test Certificates a. Certified copies of all tests carried out at site shall be furnished in six (6) copies for approval of the Owner/Consultant.

5.01.02 5.01.03 5.01.04 5.01.05 5.01.06 5.01.07 5.02.00 5.02.01 5.02.02 5.03.00

6.00.00

SPECIAL TOOLS & TACKLES

A set of special tools & tackles supplied by different manufacturers of Equipment which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment may be made available to the Contractor at the discretion of Engineer.
7.00.00 DRAWINGS, DATA & MANUALS

7.01.00

Drawings, data and manuals shall be submitted in triplicate with the bid and in quantities and procedures as specified in the General Condition of Contract and/or elsewhere in this specification for approval and subsequent distribution after the issue of Notification of Award of contract or Purchase Order.

244

7.02.01 7.02.01 7.02.02 7.02.03 7.02.04 7.02.05 7.02.06 7.02.07 7.02.08 7.03.00 7.03.01 7.03.02 7.03.03 7.03.04 7.03.05

To be submitted with the Bid A network showing the proposed construction schedule specifically indicating the milestone event. List of tools and tackles available with Bidder for erection, testing and commissioning along with their capacity and rating. Make, type and catalogue number of different equipment and accessories along with technical leaflets, data sheets, curves etc. Typical general arrangement drawings showing constructional features, fixing arrangement of pre-fabricated cable trays. Bill of Materials for cable trays, conduits & accessories. List of past experience as per format. List of technical personnel with their qualification & experience. Type test certificates. To be submitted for Approval and Distribution Network showing construction schedule Dimensional drawings and data sheets for different equipment supplied under this specification. Technical leaflets and data sheet on each piece of equipment/ device . Complete relay setting calculation, co-ordination & charts for all equipment under scope of erection of this package. Complete pre-commissioning/commissioning check lists for all equipment under scope of erection of this package.

245

ANNEXURE-A SCHEDULE OF PRE-COMMISSIONING TESTS 1.0 Transformers a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) 2.0 Physical checking of various parts/equipments, Drying out by using Stream line filter, centrifuge and heater set. Insulation resistance of oil in both main and OLTC chamber. Insulation Resistance of windings Checking of Phase Sequence Test Continuity Test No load voltage ratio at all tap positions Checking of Vector Group Tap changer operation check (Mechanical and Electrical) including indication and alarm circuits. Magnetizing Current Check at 415V, 3 Phase, 50 Hz supply for all the three phases. Magnetic balance test Measurement of Winding resistance. Cooler control, indication and alarm circuits Breather (Check for Silica gel) Buchholz's relay operation Low oil level for Main tank/OLTC chamber Physical line connections as per phasing diagram Neutral connection to earth effectively. Calibration of different temperature indicators, relays and switches

Switchgear a) b) c) Physical checking of various parts/equipment I.R. Test on each pole with HV megger I.R. test on Control Circuit
246

d) e) f) g) h) i) 3.0

Measurements of control resistance (in micro- ohms) for all the three phase of circuit breaker. Measurement of resistance of the closing and tripping coils Checking the close trip operation at 70% and 100% of the rated auxiliary D C Voltage. Checking the auxiliary circuits Checking of interlock provided and tripping of breaker through relay Space heater operation check

Current Transformer a) b) c) d) e) f) Polarity Continuity I.R. value of windings Checking of all ratios on all cores by primary injection of current (ratio identification test) Connection to correct taps (if any) Checking CT magnetization characteristics

4.0

Potential Transformer a) b) c) d) Polarity I.R. value of winding Ratio test Connection to proper taps (if any)

5.0

Distribution Board a) b) c) d) Physical checking of various parts/connections I.R. test Checking of control circuit Checking of overload relay & other protective devices

247

6.0

Relay / Meters a) b) c) Calibration test Operation test Secondary injection test for in site checking

7.0

Battery & Battery Charger a) b) c) d) e) Physical checking of various parts/connections Electrolyte filling & topping up Charging & discharging of batteries. Checking cell voltage and specific gravity Functional check of battery charger

8.0

Cables a) b) c) d) Physical checking of laying & termination Checking continuity of connections I.R. Test High Voltage test

9.0

Grounding a) b) Physical checking of connections Continuity of grounding connection The tests specified above are not exhaustive. Any other pre-commissioning and field test not included in the above list but specified in the relevant standards, Electricity Rules, Code of practice and/or recommended by the manufacturer of the equipment shall also be deemed to be included under the scope of this specification.

NOTE :

248

SPECIFICATION NO. : 11P01-SPC-E-291-53.02 SECTION-XII ERECTION, CABLING, GROUNDING AND LIGHTNING PROTECTION SYSTEM

249

SECTION-XII ERECTION, CABLING, GROUNDING AND LIGHTNING PROTECTION SYSTEM CONTENTS CLAUSE NO. 1.00.00
2.00.00

DESCRIPTION CODES AND STANDARDS

SCOPE OF WORK

PAGE NO. 1
1

3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 8.00.00 9.00.00

SCOPE OF SUPPLY DESIGN CRITERIA SPECIFIC REQUIREMENTS SUPPLY METHODS AND WORKMANSHIP INSTALLATION TESTS DRAWINGS, DATA & MANUALS

1 4 8 14 15 23 24

ATTACHMENTS
ANNEXURE-A GENERAL PRACTICE FOR APPLICATION / INSTALLATION SCHEME FOR FIRE STOP MORTAR SEAL & FIRE RETARDANT CABLE COATING COMPOUND 29

250

ERECTION CABLING, GROUNDING AND LIGHTNING PROTECTION SYSTEM

1.00.00 1.01.01 CODES AND STANDARDS All cable and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification. The electrical installation shall meet the requirements of Indian Electricity Rules as amended up to date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed. SCOPE OF WORK The scope of work covers Erection, Testing and Commissioning of complete Electrical system including cabling, grounding & lightning protection system, Fire Stop mortar seal, fire retardant cable coating system. The scope shall broadly cover, but not be limited to: 1. 2. 3. 4. 5. 6. Paper Machine#5 Building. Boiler area,. 33 KV switch yard and 11KV switchgear building. All auxiliary buildings including electrical substation. Pipe cum cable rack. All electrical equipment as described in different sections.

1.01.02

2.00.00 2.01.00

The scope of work shall also include all civil and structural works necessary for successful installation and commercial operation of all electrical equipment to be erected under this specification.

3.00.00 3.01.00
3.01.01

SCOPE OF SUPPLY The scope of supply shall include but not be limited to the followings:
Timely procurement and transportation to site in properly packed condition of all materials and miscellaneous items required to complete the erection work under this specification.

These materials and miscellaneous items shall include but not be limited to the following: a)
b)

Galvanized steel pre-fabricated cable trays, coupler plates, nuts, bolts & washers, reducers, covers, wall brackets, hanger clamps, straight run, elbows, bends etc.
Galvanized steel rigid/flexible conduits and accessories, ferrules, lugs, glands, terminal blocks, galvanized sheet steel junction boxes, cable fixing clamps, nuts & bolts etc. as required. 251

c)
d)

Cable termination and jointing kits as necessary.

All necessary erection materials, consumables and sundry items including arc welding rods to complete the installation for satisfactory and trouble free operation.

e) f) g)

Stranded Copper cables and Copper flats required for grounding and lightning protection system shall be supplied in standard lengths. Fire Stop mortal seal, fire retardant cable coating system. Any item of works or erection materials which have not been specifically mentioned but are necessary to complete the work involved shall be deemed to be included in the scope of this specification and shall be furnished by the contractor without any extra charge to the Purchaser. Main Ground Mat Laying underground conductors and cad welding the conductors at each crossing and straight run (lap joint). The conductors at the periphery of the mat shall be 1 no. 240 mm (min) bare stranded copper cable and the internal cross conductors of the mat shall be 1 no. 240 mm(min) bare stranded copper cable. Suitable pigtails shall be provided and shown in the layout drawing for connection with existing plant ground grid.

3.01.02

a)

b)

Grounding Electrode Fabrication and driving into ground 20 mm (min) diameter 3000 mm long copper cladded steel rod and connecting them to the grounding mat by welding.

c)

Column Grounding i) Concrete Columns Erection of 1 no. 20 mm (min) dia. Copper cladded steel rod from grounding mat to all concrete columns including necessary fixing, welding of one end of the rod with ground mat and the other end with the column above ground by welding with a short Cu flat to edge angles. ii) Steel Columns
Erection and connection of 1 No. 20 mm (min) diameter copper cladded steel rod from grounding mat to all steel columns including necessary fixing welding with ground mat and the other end with the column above ground with a short Cu flat.

252

d)

Risers Erection and connection of all risers from underground mat to above ground levels where the ends will be left free for connecting to the equipment. Each riser will be 1 No. 240 mm (min) bare copper conductor and Minimum 600 mm above grade level/concrete floor level.

e)

All other ancillary works in connection with the items of work described above which are not specifically mentioned but are necessary to complete the work, shall be under the scope of this specification.

3.02.00 3.03.00

All materials and accessories to be supplied by the Bidder shall be brand new ones of reputed make. Necessary drawings, data sheets and Technical leaflets on each piece of material. Scope of Services The scope includes but is not limited to the followings :

3.04.00

3.04.01

Furnishing of all erection tools and tackles, testing equipment, implements, supplies, hardware and transport for timely and efficient execution of the erection work. The items of erection work shall be performed with respect to the following equipment/materials: a) b) c) Power Cables Control, instrument and special cables Entire cable tray and cable shaft arrangements inside building & other areas including outdoor cable trench & bridges and all associated civil and structural works including foundation and cable trenches. Supply and Erection of Grounding system. Supply and erection of lightning Protection system. Fire Stop mortal seal, fire retardant cable coating system .

3.04.02

d) e) f)

Note :- Cables directly laid or buried in ground is not accepted. 3.05.00 3.05.01 Erection Schedule The entire erection work shall be carried out in a phased manner. A schedule of the work showing the sequence of erection shall be submitted by the tenderer for this purpose.
253

3.05.02

The erection schedule, as approved by the Owner's Engineer shall be strictly followed by the contractor. If, for any reason beyond the control of the Contractor, the work is held-up then the Contractor shall bring it to the notice of the Owner's Engineer without any delay. DESIGN CRITERIA Grounding System Grounding shall follow the relevant standards/codes amended till date as below: a. b. c. d. e. f. Indian Electricity rules National Electrical Code Code of Practice of Earthing IS 3043 Protection of building and allied structures against lightning IS 2309 IS- 732, IS 226, IS 2629, IS 2633 & IS 4759 IEEE -80, IEEE-665

4.00.00 4.01.00 4.01.01

The station grounding system shall be an interconnected network of Copper conductor and Cu ground rods. The system shall be provided to protect plant personnel and equipment from the hazards, which can occur during power system faults and lightning strikes Design Basis The station grounding system shall be designed in compliance with the IEEE80/ IEEE- 665 considering fault current of 50kA for 1 sec. and shall be subject to approval of owner/consultant. Actual soil resistivity measurement shall be carried out at proposed site for new units during dry season. These datas along with above mentioned datas shall be considered and the bidder shall use the higher value of Soil resistivity i.e. between the measured value and the value used for existing units. However, the surface resistivity shall be considered as 1000-ohm meter. a) Major items of equipment, such as generator, switchgear, transformer, motor, relay panels and control panels etc shall have integral ground buses or connection points which shall be connected to the station ground grid. Electronic panels and equipment, where required, shall be grounded utilizing an insulated ground wire connected in accordance with the manufacturer's recommendations. Where practical, electronics ground loops shall be avoided. Where this is not practical, isolation transformers shall be furnished. All indoor and outdoor electrical equipment and associated non-current carrying system, metal works, support structures, buildings columns, fence, neutrals, masts, arrestors, etc shall be connected to the plant ground system. Instrumentation cable screens shall be single point bonded to the instrument earth network to minimize the effects of electrical interference. For Signal/case/intrinsically safe signal, grounding of control room instruments, separate earth pit not connected to main ground grid shall be used. Control cabinets shall be connected to this separate earth pit. A single copper flat as grounding conductor shall be routed parallel to all power conductors operating above 240 volts. All ground wires installed in conduits shall be non-insulated.
254

b)

c) d)

e) f)

g) h)

Embedded grounding grid of 50x6mm Cu flat at basement/grade slab as well as upper floor/suspended slabs shall be provided. In addition tinned Copper ground pads at different locations i.e. on wall/floor/ceiling inside the buildings/tunnels/trenches shall be provided. These pads will be in turn connected to below ground level earth mat through copper flat or riser. Each ground pad shall have provision for connection of at least four 50x6mm Cu flats. Treated earth pit shall be provided for system earthing at locations where generator and transformer neutrals are grounded. Two pits shall be provided for each neutral. Dedicated treated earth pit shall be provided for lightning protection system. Clean earthing for instrumentation shall be provided with dedicated earthing system and separate treated earth pits below the main control room . In order to meet the above objectives, ground grid mesh will be provided for the main plant mill complex. viz.33KV switchyard, boiler area, all auxiliary buildings. Interconnection between existing grid and new plant ground grid shall be done at least four points. All electrical equipment, non-current carrying metal parts, structures, building steel, lightning protection system, transformer neutrals will be connected to this station ground grid. The major aspects to be considered for grounding system design are given below:

i) j) k)

4.01.02

4.01.03

Ground Grid Conductor a) b) Minimum 240 mm stranded bare copper cable shall be used as Ground grid conductor for the plant. The minimum conductor section to be determined on the basis of ground fault current. This section is then increased by an allowance to account for the soil corrosion loss of 0.3 mm per year over the design life of 30 years.

4.01.04

Above Ground Connections a) b) Copper flats of50x6mm shall be used for all connections above earth. Inside building, ground conductors will be run for each floor supported on building steel and/or cable trays. These ground conductors in turn will be connected to the station ground grid through riser (at least two) coming up along building columns/cable shafts. Two separate and distinct ground connections will be provided for each electrical equipment in compliance with I.E. Rules. All connections above ground will be welded type except connection to equipment/structures which shall be bolted type.

c) d)

255

4.01.05

Equipment Ground Connection Equipment ground connections will be sized to carry the available ground fault current. Considerations shall also be given to mechanical ruggedness of the connections and to limit the number of sizes.

4.01.06 4.01.07

The minimum ground conductor sizes for various equipment and structures are given in enclosed drawings for grounding. Entire erection of grounding work shall be carried out in such a way as to be capable of withstanding the intended services of carrying full short circuit level currents to ground mat without any damage/deformation. Lightning Protection System Lighting protection system design shall be as per IS:2309

4.02.00

4.02.01

The main purposes of lightning protection system are to : a) b) Provide protection to structures from lightning strokes. Provide a low resistance-conducting path to lightning discharge.

4.02.02 4.02.03 4.02.04 4.02.05

Lightning protection shall be provided for Main Mill building & 33KV switch yard and other auxiliary buildings. Lightning protection will be provided where the overall rise factor exceeds 10-6 as per IS: 2309 or Building higher than 55 meters in height For metal structures which are electrically continuous down to the ground level, no lightning protection is required except adequate grounding connections. System Design a) b)
c)

Air termination network with down conductors and earthing electrodes will be provided on the basis of IS Code of Practice. Horizontal air termination shall be so laid out that no part of the roof will be more than 9 meters from the nearest conductor. The vertical air terminal rods shall be installed at the roof of buildings (including power house building), to protect these objects from lightning strokes. Shielding angle for one vertical air termination shall be 45 degrees. For more than one rod, shielding angle between the rods shall be taken as 60 Degrees. Down conductors will run along the outer surfaces of the building and shall have a test joint about 1500 mm above ground. An earth electrode will be provided at the connection point of the down conductor with the station ground.

d)

e) f)

256

g)

Copper cladded steel rods and flats will be generally used for air termination and connections. All connections will be welded type.

4.03.00 4.03.01 4.03.02 4.03.03

Cabling System Erection of cabling work shall be carried out in such a way as to provide a reliable and assured electric power supply system to all station auxiliaries. Cable routing will be done on unit basis as far as possible. Cables will generally be laid on cable trays, cable rack, overhead supported from building steel/structures or cable bridge/cable trestle. Cables shall be run in concrete trenches only in transformer yard, concrete trenches is not accepted for other areas/ buildings . Cables buried directly in ground is not acceptable. In indoor pumps, mechanical equipment areas overhead cable trays shall generally be used.

4.03.04

For underground crossing of railways, road etc. additional protection shall be provided in form of Hume pipe or concrete encased rigid steel conduits (duct bank). A.C. and D.C. circuit will not be run in same cable. Further, separately fused circuit will run in separate cables. Cables for redundant equipment system shall be run in separate trays, as far as possible. Erection of cabling work shall be executed keeping in view all necessities and requirements of fire fighting codes for paper plant having an adverse industrial environment. Vertical Cable Tray arrangement shall be adopted in dust ingested areas . Suitable embedded steel inserts shall be provided on wall/floor/ ceiling surfaces for welding of cable tray bracket in order to make the cable tray system withstand horizontal/vertical accelerations due to seismic forces for indoor trays and also wind load for outdoor trays in addition to normal tray cable loadings. All erection work to be carried out under this specification shall conform to the notes and details given in Drawing for cabling to this specification.

4.03.05 4.03.06 4.03.07

4.03.08

4.04.00

5.00.00 5.01.00 5.01.01

SPECIFIC REQUIREMENTS SUPPLY Equipment and Material Equipment and material shall comply with description, rating, type and size as detailed in this specification, drawings and annexures.

257

5.01.02 5.01.03

Equipment and materials furnished shall be complete and operative in all details. All accessories, fittings, supports, hangers, anchor bolts etc. which form part of the equipment or which are necessary for safe and satisfactory installation and operation of the equipment shall be furnished. All parts shall be made accurately to standard gauges so as to facilitate replacement and repair. All corresponding parts of similar equipment shall be interchangeable. Pre-fabricated Cable Trays Cable trays shall be pre-fabricated ladder type, perforated type cable trays sheet steel with hot dip galvanizing furnished in standard length of 2.5 metres. In areas, where acid/alkali ingration is likely to occur, glass reinforced plastic trays with fire retardant corrosion resistance properties shall be used. Cable trays shall be of standard width specified in Annexure-A. Cable trays shall be complete with all necessary hot dip galvanized sheet steel accessories such as coupler plates, ground continuity connections, nuts, bolts, washers, hangers, clamps etc. Also horizontal/vertical bends, horizontal/vertical Tee, Reducers, Horizontal cross-pieces, protective covers shall be supplied along with straight runs in order to take care of cable tray alignments in different routes. All fittings like horizontal/vertical elbow, horizontal crosspiece, reducer, horizontal tee etc. should be prefabricated. Cable trays, fittings & accessories as well as elbows, reducers, tees, crosses etc. shall be fabricated out of 14 gauge (2 mm thick) hot rolled mild steel sheets. Contractor shall supply 14 gauge (2 mm thick) perforated type hot rolled mild steel sheet covers for vertical cable shafts up to a height of 2.5 metres from floor level. The perforated covers used for the vertical raceways may be of one or more pieces along the width of the raceway, depending on the width of the raceway and shall be bolted to the structural framework of the raceway. The cable trays, fittings and accessories including all bolts, nuts, screws, washers etc. shall be hot dip galvanized after fabrication as per IS:2629. Galvanizing shall be uniform, clear, smooth and free from acid spots. Should the galvanizing of the samples be found defective, the entire batch of steel will have to be regularized at Contractor's cost. The amount of zinc deposited shall not be less than 610 gms per square meter of surface area and in addition the thickness of the zinc deposit at any spot whatsoever, shall not be less than 75 microns. The Owner reserves the right to measure the thickness of zinc deposit by Elco meter or any other instrument and reject any component, which shows thickness of zinc at any location to be less than 75 microns.

5.01.04

5.02.00 5.02.01

5.02.02 5.02.03

5.02.04 5.02.05

5.02.06

5.02.07

258

5.02.08

Each 2.5M long section of all types of cable trays & each fittings like elbow, tees, crosses etc. shall be provided with two nos. hot dip galvanized side coupler plates & associated bolts, nuts and washers on each side. The Contractor shall perform all tests necessary to ensure that the material and workmanship conform to the relevant standards and that such tests are adequate to demonstrate that the equipment will comply with the requirement of this specification. The tolerance on dimensions shall be in accordance with appropriate Indian Standards. The extent of the tests to be performed by the contractor shall include but not be limited to the following: Deflection Test A 2.5 meter straight section of each type of cable trays shall be simply supported at the two ends. A uniformly distributed load of 100 Kg per meter will be applied along the length of the tray. The maximum deflection at mid span shall not exceed 7 mm.

5.02.09

5.02.10 5.03.00 5.03.01 5.03.02

For other details refer CABLING NOTES AND DETAILS annexed to this specification. Conduits and Accessories Conduits shall be of rigid steel, hot-dip galvanized, furnished in standard length of 5 meters, threaded at both ends. Conduits diameter upto and including 25mm size shall be of 16 SWG and conduits above 25 mm diameter shall be of 14 SWG. Minimum diameter of conduits shall be 20 mm. Each piece of conduit shall be straight, free from blister and other defects, internal surface shall be of smooth finish and covered with capped bushings at both ends. The contractor shall provide and install all rigid steel conduits, mild steel pipes, flexible conduits rigid PVC pipes etc. complete with accessories such as tees, bends, adopters, locknuts, pull boxes, conduit plugs, caps etc as required for the cabling work. Steel conduits with interior coating of silicon epoxy ester for ease of wire/cable pulling shall be seamed by welding and flo-coat metal conduit/hot-dip galvanized. These shall be supplied in standard length of 5M with minimum wall thickness as specified in IS: 9537. In chemical handling areas, Battery Room etc., the exterior surface shall be further coated with chromate and polymer for better resistance to corrosion. HDPE conduits shall be used for these areas. Conduits, fittings & accessories shall have ISI mark. For sizes above 63 mm mild steel pipes with necessary fittings & accessories shall be provided and installed by the contractor. Pipes shall be manufactured by electric welding process. These pipes shall be of heavy duty class as per IS:1239 and shall have ISI mark. Pipes shall be supplied in lengths of approximately 5 meters. Pipes, fittings & accessories shall be hot dip galvanized both on inside and outside.
259

5.03.03

5.03.04

5.03.05

5.03.06

5.03.07

Flexible conduits shall comply with IS:3480. They shall be made with bright, cold rolled, annealed and electro-galvanized mild steel strips. Flexible conduits shall be used between embedded conduits/pipes and the motor terminals. Flexible conduits shall also be used between fixed conduit and any equipment terminal boxes where vibration is anticipated or equipment that require regular removal. Rigid PVC conduits conforming to IS:4985 shall generally be used for control & instrumentation cables in some areas where cable trays do not exist and where the runs are straight ones generally the PVC pipes with special Bell Mouthing shall be of 110 mm,160 mm & 200 mm outside diameter and shall be suitable for working pressure of 6 kg/sq. cm. The length of each pipe shall be 5 to 6 meters. Necessary fittings & accessories as may be required for the installation shall also be provided. Junction Boxes Glass Fiber Reinforced Junction Boxes 1. No. of Ways:12 / 24 / 36 / 48 with 20% spare terminals. 2. Design: Junction boxes shall be Glass Fiber Reinforced with saturated polyester informing to standards like DIN 16911 type 803 / 16913 type 834, 5 selfextinguishing in accordance with ASTM D 635 / UL 94 VO. Junction boxes for use in outdoor or damp locations shall be sturdy construction. Temperature resistance between 10 to 100oC. Impact resistance shall be greater than 7 Nm, (EN 50 014). Protective insulation shall be in line with VDE 0100, dielectric strength shall be greater than 10 KV / mm, halogen free toxicity, the enclosure and door cover shall be painted and electrostatically powder coated (preferably in RAL 7032). Earth connection (studs size shall be M 6) shall be provided on the cover as well as door. Doors: With integrated viewing window of 3 mm resistant Flexi glass or equivalent. The doors shall have industrial heavy duty hinges. The doors shall be easily but firmly lockable with quick release fastener. a. Protection Class: Protection Category shall be IP 66 to EN60 529. There shall be guaranteed perfect seal to meet Protection class IP 66 providing sealing arrangement like highly elastic foamed in special type seal like polyurethane / chloroprene. The sealing rubber shall not have aging effect and shall retain its sealing characteristics for more than 20 yrs. Bidder shall indicate this in data sheet. The rubber seal should be pasted at its place with pasting technology for like more than 20 yrs. ( double sealing arrangement is preferred).

5.03.08

5.04.00
5.04.01

260

b. Mounting clamps and accessories: Suitable for mounting on walls, columns and structure. Brackets, bolts, nuts, screws, glands and lugs required for erection shall be of brass. The accessories like mounting plants etc. of steel shall be powdered coated. The support rails for terminal box shall be zinc coated. c. General: i. ii. JBs shall have small canopy at the top. There shall be rainwater collection arrangement from top and side of the outer ages to ensure that any leakage in to the junction box shall be avoided and it shall fall outside. Cable entry shall be from bottom side only.

iii.

iv. Ensure gland plate sealing perfect. It shall be of the same quality and arrangement as that of door to cover arrangement. 5.04.02 Steel Junction Boxes: a. No. of Ways:12 / 24 / 36 / 48 with 20% spare terminals. b. Design: Junction boxes shall be designed in accordance with NEC, article 370, paragraph 18, 20 or equivalent standards. c. Enclosure: Junction boxes for use in outdoor or damp locations shall be sturdy steel construction. The enclosure and door cover shall be surface finished clean , degreased, phosphate, deep coated primed (preferably in RAL 7044 ) and electro statically powder coated (preferably in RAL 7032). Earth connection (studs size shall be M 6) shall be provided on the cover as well as door. The sheath steel thickness shall be minimum 2 mm. d. Doors: The doors shall be hinged and lockable. The doors shall have industrial heavy duty hinges. The doors shall be easily but firmly lockable with quick release fastener. e. Protection Class: Protection Category shall be IP 66 to EN60 529 / 10.91 complies with NEMA 4.. There shall be guaranteed perfect seal to meet Protection class IP 66 providing sealing arrangement like highly elastic foamed in special type seal like polyurethane. There shall be an arrangement like multifold protection channel for additional stability and prevention of ingress of dust and water when the enclosure is open. The sealing rubber shall not have aging effect and shall retain its sealing characteristics for more than 20 yrs. Bidder shall indicate this in data sheet.
261

The rubber seal should be pasted at its place with pasting technology for like more than 20 yrs (double sealing arrangement is preferred). f. Mounting clamps and accessories: Suitable for mounting on walls, columns and structure. Brackets, bolts, nuts, screws, glands and lugs required for erection shall be of brass. General: i. ii. JBs shall have small canopy at the top. There shall be rainwater collection arrangement from top and side of the outer ages to ensure that any leakage in to the junction box shall be avoided and it shall fall outside. Cable entry shall be from bottom side only. Ensure gland plate sealing perfect. It shall be of the same quality and arrangement as that of door to cover arrangement.

iii. iv. 5.05.00 5.05.01

Terminals Multi way terminal blocks of approved type, complete with screws, nuts; washers and marking strips shall be furnished for connection of incoming/outgoing wires. Each control cable terminal shall be suitable for connection of 2 nos. 2.5 sq.mm. stranded copper conductors without any damage to the conductor or looseness of conductors. Cable Termination & Jointing Kits
The Bidder shall supply cable termination and jointing kits in requisite quantity for H.T. Power Cables, L.T. Power, Control Cables, Instrumentation Cables etc. along with all accessories & consumables required for making termination and joints complete. All the materials and components of the termination/joints shall be suitable and compatible with the type of cables for which the terminals/joints are intended.

5.05.02

5.06.00
5.06.01

5.06.02

For HT cables, the end terminations & jointing kits shall be of heat shrinkable type of Raychem, REPL, CCI or of approved make. For LT cables, the jointing kits & termination kits shall be Raychem/REPL/CCI/ Mahindra (M-seal) or of approved make. Cable joint or end terminations on Electrical equipment shall be suitable for Indoor & Outdoor use, as the case may be. Glands and lugs required for termination of H.T., L.T. and instrumentation cables shall be supplied by the Contractor in required quantity. Cable Glands Cable glands shall be nickel plated gland, double compression type complete with necessary armour clamp and tapered washer etc. Cable glands shall match with the sizes of different HT/LT/Control cables.

5.06.03 5.07.00

262

5.08.00

Cable Lugs All cable lugs shall be Cd plated copper. Cable lugs shall be suitable for termination of different cross-sections of H.T./L.T./Control/Instrumentation cables and shall be of following types: i) Copper tubular terminal end for solder less crimping to copper conductors. Solder less crimping of terminals shall be done by using corrosion inhibiting compound. The cable lugs shall suit the type of terminals provided on the equipment. Lugs for control/instrumentation cables shall be PVC insulated/sleeved type. ii) Cable lugs for control cable termination shall be insulated. These lugs shall be flat type/ring type/U type to suit the terminals provided in the panels.

5.09.00 5.09.01 5.09.02

Consumables and Hardware The Contractor shall furnish all erection materials, hardware and consumables required to complete the installation. The materials shall include but not be limited to the following : Consumables Hardware : : Welding rods & gas, oil and grease, cleaning fluids, paints, electrical tape, soldering materials etc. Bolts, nuts, washers, screws, brackets, supports, clamps, hangers, saddles, cleats, sills, shims etc. 5.09.03 Supply of cement, sand, stone etc. required for the execution of the contract shall be the responsibility of the Contractor.

5.10.00 5.10.01

Testing Equipment The major testing equipment that are required to be provided by the Contractor are listed below : a) Insulation Tests i) ii) b) c) d) e) f) g) Power operated Meggar- 2.5 KV to 10 KV grade Hand operated Meggar- 1 KV grade

Hand driven earth Resistance Meggar, range 0-1/3/30 ohms. High potential testing set - roller mounted type. Tong testers of suitable ranges. Contact resistance measuring set for micro-ohms. Torque wrench of various sizes. Multi meters, test lamp, field telephone with buzzer set, different gauges etc.
263

5.10.02

The list of equipment is indicative only. Any other test equipments will be arranged by the Contractor.

required

6.00.00 6.01.00 6.02.00 6.03.00 6.04.00 7.00.00 7.01.01

METHODS AND WORKMANSHIP All work shall be installed in a first class, neat workmanlike manner by mechanics/electricians skilled in the trade involved. The erection work shall be supervised by competent supervisors holding relevant supervisory license from the Government. All details on installation shall be electrically and mechanically correct. The installation shall be carried out in such a manner as to preserve access to other equipment installed. INSTALLATION Installation work shall be carried out in accordance with good engineering practices and also as per manufacturer's instructions/ recommendations where the same are available. Equipment shall be installed in a neat workmanlike manner so that it is level, plumb, square and properly aligned and oriented. Cable installation work shall mean erection of cable trays/racks, supports, hangers, junction boxes, conduits, laying of cables either in ground or on trays inside trenches tunnels/overhead trays in conduits etc. dressing and clamping, jointing and termination inclusive of supply of necessary jointing/termination kits, lugs, glands, ferrules, tapes etc. and other accessories, grounding of cable armour. In case of direct laying in ground, all excavation work, necessary back-filling, supply of bricks and protective concrete slabs, removal of excess earth shall be part of the installation work. Grounding installation work shall mean erection, jointing/ brazing/welding, connection and painting, testing of ground conductors including supply of necessary steel/copper. Lightning protection system installation work shall mean erection, jointing, welding, connection and painting, testing of air termination network, down conductors, shielding masts, connection to ground grid, electrodes, risers, horizontal conductors etc. of lightning protection system. Cable Trays Pre-fabricated cable trays and accessories shall be assembled & erected at site. Adequate spaces will be provided to facilitate installation of cable system and to allow routine inspection and modification after installation. Cable trays either inside concrete trenches or inside buildings and racks inside cable shafts shall be aligned and leveled properly. All tray runs shall be installed parallel to the trench/building walls and floors except otherwise noted in the approved drawings.
264

7.01.02 7.01.03

7.01.04

7.01.05

7.02.00 7.02.01

7.02.02

7.02.03 7.02.04
7.02.05

As far as practicable, cable trays shall be supported from one side only in order to facilitate installation and maintenance of cables from the other side. The cable trays shall be supported in general at a span of exceeding 1.25 metres horizontally and 1.0 metre vertically.
Sufficient spacing not less than 300 mm shall be provided between trays and maintained to permit adequate access, for installing and maintaining the cables. In areas like Boiler, CHP etc. where excessive dust coal ingression is expected Vertical Tray Arrangement shall be provided. In areas, where acid/alkali ingression is likely to occur, Fire Retardant, Corrosion resistance trays of glass reinforced plastic shall be used.

7.02.06

Complete cable tray support structure after installation shall be inspected/tested for welding strength, straightness, accuracy, use of proper sizes and compliance to drawings. Complete cable tray and accessory installation work shall be inspected/tested for proper alignment, leveling, use of proper accessories, high quality workmanship etc. The Contractor shall remove the RCC/steel trench covers whenever required and shall again place the same in their positions after the erection work in the particular area is completed or when further work is not likely to be taken up for some time. Whenever any pipe/conduit/cable tray emerges out or enters into a building care should be taken to ensure that no water enters into the building.

7.02.07

7.02.08

7.02.09

7.02.10

Cable trays in areas subject to excessive coal dust, oil spillage, mechanical damage or accessible to personal contact shall be provided with raised sheet metal tray covers, installed on upper tray in horizontal run and front in vertical run. Cable trays/racks shall be so arranged that they do not obstruct or impair clearances of passage way. Cable tray/conduit system will be so designed as to accommodate maximum pulling tension and minimum bending radius of cable. Cable tray/conduit system will be constructed to prevent drainage of water into equipment or building. Cable tray/conduit system shall be electrically continuous and grounded. Different voltage grade cables will be laid in separate trays when trays are run in tier formation. Power cables will normally be on top trays and control/instrumentation cable on bottom trays.

7.02.11 7.02.12 7.02.13 7.02.14 7.02.15

265

7.03.00 7.03.01

Cable and Conduits The Contractor shall install, terminate and connect up all cable and conduits as per approved drawings and cable schedules. The drawings shall be strictly followed except where obvious interference occurs. In such cases, the routing shall be changed as directed and/or approved by the Engineer.
Approximate lengths of cable and conduit runs will be shown by the contractor in the cable schedule for guidance only. Before commencement of work the Contractor shall take actual measurements and prepare his own cable-cutting schedule to reduce wastage to a minimum.

7.03.02

7.03.03

7.03.04

The Contractor shall also maintain and submit when requested, a record of cable insulation value when drawn from store, after laying, before and after termination/jointing. Where direct heat radiation exists, heat isolating barriers, shall be adopted for cabling system. Cabling/wiring in offices, laboratories, control rooms etc. shall be taken through concealed G.I. or rigid PVC pipes as directed by the owner's Engineer. At certain places where hazardous fumes/gasses may cause fire to the cables, cable trenches after installation of cables shall be sand filled. Conduit and Accessories Conduit/pipes shall be used only in short lengths in certain areas where required and/or as directed by the Engineer. The Contractor shall furnish all conduits complete with accessories as required. Conduits shall be flexible type in general. However, rigid type steel conduit if required shall also be supplied by the Contractor.
Except for inside an enclosure wherever the cable enters or leaves the conduit, the conduit end shall be sealed by suitable sealing compound, having fire withstand capability.

7.03.05 7.03.06 7.03.07

7.04.00 7.04.01 7.04.02 7.04.03

7.04.04

7.04.05 7.04.06 7.04.07 7.04.08

The entire metallic conduit system, when embedded or exposed shall be electrically continuous and grounded. Where it is possible for water or other liquids to enter conduits, sloping of conduit runs and drainage of flow points shall be considered. Pull boxes will be installed between termination points where required to facilitate cable pulling, but at a maximum interval of 30 meters. Conduits shall be firmly fastened within 900 mm of each junction box/pull box/cabinet/fitting etc. Conduits shall be supported at least every 2000 mm.
266

7.05.00
7.05.01

Cables : Storage and Handling Cable drums shall be stored on hard and well-drained surface so that they may not sink. In no case shall the drum be stored on the flat, i.e., with flange horizontal. Rolling of drums shall be avoided as far as practicable, for short distance, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum.
In absence of any indication, the drums may be rolled in the same direction as it was rolled during taking up the cable.

7.05.02

7.05.03

7.05.04 7.05.05
7.05.06

For unreeling the cable, the drum shall be mounted on jacks or on cable wheel. The spindle shall be strong enough to carry the weight without bending. The drum shall be rolled on the spindle slowly so that the cable should come out over the drum and not below the drum.
While laying cable, cable rollers shall be used at an interval of 2000 mm. The cables shall be pushed over the roller by a gang of people positioned in between rollers over a suitable distance. Care shall be taken so that kinks and twists or any mechanical damage does not occur in cables. Only approved cable pulling grips or other devices shall be used. Cables shall not be dragged on ground or along structure while laying out from cable drums.

7.05.07

Cable shall not be pulled from the end without having intermediate pushing arrangement. Bending radius of the cable during installation shall not be less than what is specified by the manufacturer.
Empty cable drums shall be returned to the owner.

7.05.08

7.06.00
7.06.01

Cable Laying
Cable shall generally be installed in ladder type prefabricated trays uniformly loaded proportionate to the size of the tray except for some short run in rigid/flexible conduit for protection or crossings. Trays shall be away from steam, oil, coal pipelines and hot ducting.

7.06.02

Cables laid on trays and risers shall be neatly dressed and clamped as stated subsequent clauses at an interval of 750 mm. for horizontal and 500mm for vertical runs, in case of both power, control and instrumentation cables. All single core power cables for 3 Ph. AC circuits shall be laid in trefoil formation and suitably clamped with self-locking type fire resistant nylon trefoils clamps at an interval of 750 mm for horizontal run or 500mm for vertical run. All H.T. multicore power cables and L.T. multicore power cables with cross-sectional area including & above 95 sq.mm shall be clamped individually by glass reinforced nylon claw type clamps. L.T. power cables of cross sectional area less than 95 sq. mm. and all control and Instrumentation cables shall be clamped in bunches with 25x3 mm Aluminum strip. The number of cable in one bunch shall not exceed eight (8).
267

7.06.03

7.06.04

7.06.05

7.06.06 7.06.07

Prior to laying of cables inside the indoor and outdoor trenches, the contractor shall properly clean the trenches. When cables crosses road/railway track, adequate protection shall be provided in the form of hume /galvanized iron pipes laid at a minimum depth of 1 meter below ground.
After completion of installation and prior to connection, all power cables shall be subjected to a high potential test. Machine ferruling shall be adopted.

7.06.08

7.07.00
7.07.01

Cable Tags & Markers

Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedules. Cables and conduits shall be tagged at their entrance, bends, every 30.0M and exit from any equipment, junction box. When a cable/conduit passes through a wall, tags shall be fitted on both sides of the wall.

7.07.02

The tags shall be of aluminum with the number punched on it and securely attached to the cable by not less than two turns of 16 SWG G.I. wire. For single core cable the wire shall be of non-magnetic material. The location of cable joints, if any, shall be clearly indicated with cable marker with an additional inscription 'cable-joint'. The Contractor shall furnish and install all tags and markers stated above. For buried cable, the marker shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at every change of direction. Cable Termination and Connection The termination and connection of cables shall be done strictly in accordance with manufacturer's instruction, drawings and/or as directed by the Engineer. The work shall include all clamping, fitting, fixing, soldering, tapping, compound filling, cable jointing, crimping, shorting and grounding as required for the complete job. All equipment required for all such operations shall be of Contractor's procurement. Furnishing of all consumable materials such as soldering material, electrical tape, sealing material as well as cable jointing kits shall be included in the offer.
Cable joint kits for all cables shall be supplied by Contractor under this specification. Responsibility for proper termination shall lie on the contractor. Guarantee for termination shall also have to be given by Contractor.

7.07.03 7.07.04 7.07.05 7.08.00 7.08.01 7.08.02

7.08.03
7.08.04

7.08.05 7.08.06

The equipment will be generally provided with blank bottom plates for cable/conduit entry and cable end box for power cables. The Contractor shall perform all drilling, cutting on the blank plate and any minor modification work required to complete the job.

268

7.08.07

If the cable end box or terminal enclosure provided on the equipment is found unsuitable and requires major modification, the same shall be carried out by the contractor. Control/instrumentation cable cores entering control panel/ switchgear/MCC etc. shall be neatly bunched and served with PVC perforated tape to keep it in position at the terminal block. The Contractor shall put ferrules on all control cable cores in all junction boxes and at all terminations. The ferrules shall carry terminal numbers as per drawings. All ferrules shall be colored, plastic & interlocked type. Spare cores shall be similarly ferruled, crimped with lug and taped on the ends. Spare cores shall be ferruled with individual cable number. Machine ferruling shall be adopted. Termination and connection shall be carried out in such a manner as to avoid strain on the terminals. All cable entry Points shall be properly sealed and made vermin and dust proof. Unusual opening, if any, shall be effectively closed. Sealing work shall be carried out with approved sealing compound having fire withstand capability for at least three hours. Termi-point Connection
a)

7.08.08

7.08.09

7.08.10

7.08.11 7.08.12

7.09.00

The conductor (solid or stranded) is forced against the contact area of the 2.4 x 0.8 mm or 1.6 x 0.8 mm connection pin by means of a tin-coated bronze clip, which maintains a constant pressure. In the Maxitermi-point method, 2.4 x 0.8 mm pins is used without exception. The conductor is "shot" onto the pin together with the clip. The resulting friction causes both the wire and the contact area of the pin to be cleaned and any oxide layers to be penetrated. Apart from this the wire and the clip are deformed in such a way that a gas-tight connection with very good electrical and mechanical properties is established. A special manually or pneumatically driven gun is required. Up to 3 adjacent connections can be "shot" onto one pin. In most cases only one clip at the base of the pin is attached. The sections above usually remain vacant. Any part of a connection pin may be reused several times after removal of the existing clip connection. Contact areas below existing connections that have become vacant can be reused by pushing the connections above the vacant space downwards, so that the new connection can be "shot" on above the top connection. The single jumper wires need not be specially prepared as the end insulation is stripped within the tool. This connection method requires special insulation of the wires. The diameter of solid conductors is 0.8 mm the cross-section of stranded conductors 0.5 Sq.mm.
269

b)

c)

d)

e)

f) g)

The conductor is deformed greatly when attached and is to be shortened by 3 mm when disconnected and reused. Strips and special tools for termi-point connection shall be supplied by the Contractor.

7.10.00 7.10.01 7.10.02 7.11.00

7.11.01

Cable Joints Cable shall be installed without joints as far as practicable. If however jointing becomes necessary, it shall be made only by qualified cable jointer and strictly in accordance with manufacturer's recommendation. Grounding The Contractor shall carryout the interconnection among various peripheral earthing grids/mats, steel structures, lightning protection system as well as grounding of all electrical equipment, etc. The grounding work shall be carried out as per provisions of I.E. rules Indian standards and enclosed grounding and lightning protection notes and details. The grounding shall be done by conductors of sizes as laid down in grounding drawings and the same shall be connected to the risers of main ground mat. For fabricated cable trays, a separate ground conductor (50x6 mm Cu flat) shall run along the entire length of each route of cable tray being suitably clamped on the cable tray. Individual cable trays of each section shall be connected to above ground conductor through 50x6 mm Cu flat or copper jumper to maintain continuity of ground path. All ground conductor connections shall be made by electric arc welding/brazing unless otherwise specified. Ground connections shall be made from nearest available station ground grid risers. All ground conductors shall be painted green for easy identification. Equipment ground connections, after being checked and tested by the Engineer, shall be coated with anti-corrosive paint. Whether specifically shown or not, all conduits, trays, cable armour and cable end box, electrical equipment such as motors, switchboards, panels, cabinets, junction boxes, lockout switches, fittings, fixtures, etc. shall be effectively grounded. If there is no provision to ground the L.T. transformer neutral at transformer end, to make an effectively earthed 415V system the neutral bus of all 415V distribution boards shall be connected to ground grid at two different and distinct points. The underground mat will be made of 240 mm stranded bare copper cable laid underground in length and breadth of the area at a depth shown in drawing but not less than 1 metre below grade level. All crossings and straight run shall
270

7.11.02 7.11.03

7.11.04

7.11.05 7.11.06 7.11.07

7.11.08

7.11.09

be cad welded for good electrical continuity. Ground conductors, when crossing underground trenches, directly laid underground pipe and equipment foundation, if any, shall be at least 300 mm below the bottom elevation of such trenches/pipes as shown in the relevant drawing. The Contractor will plan and organize works to lay the grounding mat in the same sequence in which the building and equipment foundation is being done. 7.11.10 Ground Electrode Ground electrodes will be 40mm (min) dia and 3 metre long M.S. rod. These are to be fabricated and driven into the ground by the side of mat conductor. All connections to the conductors shall be done by are wilding process. 7.11.11 Risers Risers are required for connecting the equipment and structures with the ground mat. These will be 1 No. 40 mm (min) dia M.S. rod. laid from ground mat to above ground level properly clamped or supported along the outer edge of the concrete foundation. Connection to the ground mat shall be done by arc welding and the other end is to be kept free at least 300 mm above grade level/concrete floor level unless otherwise shown. 7.11.12 Column Grounding All columns are required to be grounded by 1 no. 40mm(min) dia M.S. rod from ground mat. Laying, supporting along with foundation, connecting at ground mat are within the scope of this specification. At least 300 mm length of the above rods shall be left free above the grade level/concrete floor level for connection with columns. 7.12.00 7.12.01 Painting The Contractor shall paint steel fabrications at site with two (2) coats of red oxide primer and two (2) coats of battleship grey (shade no. 632 of IS:5) synthetic enamel paint. Galvanizing The galvanizing shall be uniform, clean, smooth, continuous and free from acid spots. Should the galvanizing of the samples be found defective, the entire batch of steel has to be re-galvanized, at Contractor's cost. The amount of zinc deposit shall not be less than 610 grams per square meter of surface area and in addition, the thickness of the zinc deposit at any spot whatsoever shall not be less than 75 microns. The Owner reserves the right to measure the thickness of zinc deposit by Elko meter or any other instrument and reject any component which shows thickness of zinc at any location less than 75 microns. Excavation and Back Filling The Contractor shall perform all excavation and backfilling as required for buried cable and ground connections.
271

7.13.00
7.13.01

7.14.00 7.14.01

7.14.02

Excavation shall be performed up to the required depth. Such sheeting and shoring shall be done as may be necessary for protection of the work. The Contractor shall make use of his own arrangements for pumping out any water that may be accumulated in the excavation. All excavation shall be backfilled to the original level with good consolidation. Steel Fabrication All racks, trays, supports, hangers & brackets wherever necessary shall be fabricated by the Contractor. Steel for fabrication shall be straightened and cleaned of rust and grease. All fabrication shall be free of sharp edge and burns so as not to cause any damage to personnel or cables. Cleaning up of Work Site The Contractor shall, from time to time, remove all rubbish resulting from execution of his work. No materials shall be stored or placed on passage or drive ways. Upon completion of work, the Contractor shall remove all rubbish, tools, scaffoldings, temporary structures and surplus materials etc. to leave the premises clean and fit for use. TESTS Shop Tests All equipment shall be completely assembled, wired, adjusted and routine tested as per relevant Indian Standards at manufacturer's works. Tests on panels/junction boxes shall include: a) b) c) Wiring continuity tests. High voltage and insulation tests. Operational tests.

7.14.03 7.14.04 7.15.00 7.15.01 7.15.02

7.16.00
7.16.01

7.16.02

8.00.00 8.01.00
8.01.01

8.01.02

8.02.00 8.02.01 8.02.02

Site Tests Contractor shall thoroughly test and Meggar all cables, wires and equipment to prove the same are free from ground and short circuit. If any ground or short circuit is found, the fault shall be rectified or the cable and/or equipment replaced.

272

8.02.03

All power cables after installation and prior to connections shall be subjected to High Potential tests. Also the insulation resistance values shall be measured both before and after Hipot test for comparison. The leakage current shall also be measured during the Hipot test at site.

Cable cores shall be tested for : a) b) c) d) e) f) 8.02.04 8.03.00 8.03.01 Physical damage Continuity Correctness of connections as per relevant wiring diagram Insulation resistance to earth Insulation resistance between conductors Proper earth connections of cable glands, cable boxes, cable armour, screens etc.

All equipment shall be demonstrated to operate in accordance with the requirements of this specification. Test Certificates Type test certificate on any equipment, if so desired by the Owner, shall be furnished. Otherwise the equipment shall have to be type tested, free of charge, to prove the design. DRAWINGS, DATA & MANUALS To be submitted with the Bid. Make, type and catalogue number of different electrical items and accessories along with technical leaflets, data sheets etc. Typical General arrangement drawings showing constructional features, fixing arrangement of pre-fabricated cable trays. Bill of Materials for cable trays and accessories, conduits & accessories. Layout of Grounding system and lightning protection system showing connection and other details along with backup design calculations and detailed write up. Bill of materials for grounding and lightning protection system. Drawing showing details of equipment grounding. To be submitted after Award of Contract
273

9.00.00 9.01.00
9.01.01

9.01.02 9.01.03 9.01.04

9.01.05 9.01.06 9.02.00

9.02.01 9.02.02 9.02.03

9.02.04

Make, type and catalogue number of cable termination kits, joints and accessories. Detail dimensional drawings showing constructional features, grounding, fixing arrangement etc. Bill of Materials for Pre-fabricated cable tray and accessories, Conduits & accessories. Dimensional G.A. drawings and data sheets for different equipment and items supplied under this specification. Layout drawing of Grounding system and Lightning protection system showing connection details along with backup design calculation and detailed write up. Bill of material for grounding system and lightning protection system. Drawing showing details of equipment grounding system.

9.02.05 9.02.06 9.02.07

274

ANNEXURE-A NOTES AND DETAILS FOR CABLING SYSTEM 1.00.00

1.01.00

GENERAL
These notes and details shall be read and construed in conjunction with Specification and the drawings meant for cable tray details and supporting arrangements in Trench, Racks etc., enclosed elsewhere. In case of conflict between these notes and drawings, the latter shall prevail.

1.02.00

The Cabling System installation work shall conform to the requirements of the latest revisions of the following standards/codes a) b) Indian Electricity Rules, 1956, with up to date amendment. I.S. Code of Practice.

2.00.00 2.01.01

CABLE ROUTING/LAYING Cables shall generally be laid on ladder type cable trays either in trenches or overhead supported from building steel/structures except in some cases cables may have to be laid underground and for short runs in conduits for protection or crossing.
For underground crossing of railways, roads etc. hume pipes shall be used and shall be laid at a depth of minimum 1000 mm such that cables shall not be damaged.

2.01.02

2.01.03

Different voltage grade cables shall be laid in separate trays when trays are arranged in tiers. Power cables shall be on top trays and Control/Instrumentation cables on bottom trays, and it is recommended that trays for cables of different voltage levels be stacked in descending order with higher voltage level above. Cables for redundant equipment/system shall be run in separate trays in separate route. Cables from two different services viz. supply from station board and supply from unit board shall be fully segregated to prevent simultaneous damage due to fire in one of the services. Low level signal cables and other special Instrumentation and Control cables shall run in separate trays. In general, a minimum of 1500 mm clearance shall be maintained between these cables and noise generating equipment (large motors, generators, transformers etc.). The floor of the cable spreader rooms will have to be made water proof so that water does not percolate to lower levels in the event of fire fighting operations. Adequate arrangement for efficient drainage of water shall be provided. The cable raceways should also be suitably curved to avoid water entry through this place.

2.01.04 2.01.05

2.01.06

2.01.07

275

2.02.00 2.02.01

Cable Trays/Supports Cable trays and covers shall be pre-fabricated type, constructed from minimum 14 SWG sheet steel for trays and 16 SWG for covers and hot-dip galvanized after fabrication. Cable tray supports shall be cantilever type for each installation. All supports and hardware shall be hot-dip galvanized. Standard cable tray width shall be 600 mm. However, trays with 450, and 300, 150 mm width may be used in some places considering the requirement and space restrictions. For instrumentation and control purpose, some perforated type cable trays of width 150 and/or 100mm may be used particularly in Boiler Platform area, and 600, 450, 300 mm perforated trays may be used depending on site requirement. Cable trays shall be ladder type with 250 mm rung spacing, 100 mm depth and rung width not less than 50 mm. All weld for cable tray supports shall have a minimum throat thickness of 6 mm. Cable trays in areas subjected to excessive coal dust, or mechanical damage will have hot-dip galvanized sheet metal tray cover installed on front tray in vertical run and inverted `V' type on upper tray in horizontal run. Where covers are used on trays containing power cables, consideration should be given to ventilation requirements. In area where acid/alkali ingression is like to occur, cable trays of glass fibre reinforced plastic with fire retardant & corrosive resistance properties shall be used.

2.02.02
2.02.03

2.02.04 2.02.05 2.02.06

2.03.00 2.03.01 2.03.02

Conduits Conduits shall be rigid steel coated type; minimum size of conduit shall be limited to 19mm. Steel conduits shall be seamed by welding and flo-coat metal conduit/hot-dip galvanized. These shall be supplied in standard length of 5M with minimum wall thickness as specified in IS: 9537 Part-II. In Chemical Handling Area, Battery Room, WTP, etc. HDPE conduits shall be used for better resistance to corrosion Conduit runs shall be supported at an interval of 750 mm for vertical run and 1000 mm for horizontal run. Conduits shall be sized so that conduit fill (ratio of total cable area to conduit area) shall not exceed the following: One Cable Two Cable Three Cables & Up : : : 53% 31% 40%

2.03.03 2.03.04

2.03.05

Conduit runs shall be provided with necessary bends as required.

276

2.04.00 2.04.01

Installation The Contractor shall install, terminate and connect up all cables and conduits with supporting arrangements as per drawings, cable schedules and interconnection chart/drawings. The HV power cables of 11 KVKV shall be laid in trays or racks as follows: a) b) c) In single layer only. 3 core cables to be laid giving one diameter gap of the largest diameter adjacent cable. Single core cables to be laid in trefoil formation with spacing equal to diameter of the trefoils.

2.04.02

2.04.03
2.04.04

1100V grade power cables shall be laid in single layer in trays.

1100V grade multicore power cables above and including 95 sq. mm shall be laid in single layer giving one diameter gap of largest cable & single core cables shall be laid in trefoil formation with gap of 2D between trefoils.

2.04.05 2.04.06

Control and Instrumentation cables can be laid up to a maximum of three layers in each tray. The trays shall be run with a vertical spacing of 300 mm for overhead cable trays as well as inside cable trenches. A minimum of 225 mm clearance shall be provided between the top of tray and beams, cold piping, 500 mm clearance for hot piping/object to facilitate installation of cables in tray. Adequate pull boxes shall be provided in conduit run to facilitate cable pulling in long runs and also to ensure that there will be no more than 270 Deg. bends between pull points. Cable tray/conduit system shall be installed to accommodate cable manufacturer's recommended maximum pulling tension and minimum bending radius. All openings in the floor and wall for cable access shall be sealed after installation of the cable system with non-inflammable materials, as follows : i) ii) iii) Fire stop/Penetration seal shall be installed in the cable spreaders and cable raceways. Similarly in the trenches fire stop/penetration seals shall be provided at suitable interval to avoid spread of fire. For all H.T., L.T., Relay and Control panels, Control desk, instrumentation panels, battery charger, D.C. Dist. boards and other miscellaneous panels, fire-stops should be provided below base plate.

2.04.07

2.04.08

2.04.09

277

2.04.10

All floor/wall openings for cable entry to the electrical equipment and accessories shall be sealed with non-inflammable materials, after completion of cable installation. Thickness of such materials shall be equal to the thickness of floor/wall unless specified otherwise. The portion of galvanized steel, which, if required, undergoes any welding at site shall be coated with two (2) coats of cold galvanizing anti-corrosive paint after welding. The cables shall be coated with fire protection coating as specified elsewhere. Identification The complete cabling system shall be properly identified. Methods for identification of cabling system shall be furnished to the successful tenderer and the Contractor shall strictly adhere to the said methods. Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedule. Location of cables laid directly underground shall be clearly indicated with cable marker made of galvanized iron plate, projected above ground level. 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, at each bend and at every thirty (30) meters in cable tray/trench runs. Cable tags shall also be provided inside the switchgear, MCC, control & relay panels etc. wherever required for cable identification, such as where a number of cables enter together through a gland plate.

2.04.11

2.04.12 2.05.00 2.05.01

2.05.02 2.05.03
2.05.04

278

ANNEXURE-B GENERAL PRACTICE FOR APPLICATION / INSTALLATION SCHEME FOR FIRE STOP MORTAR SEAL & FIRE RETARDANT CABLE COATING COMPOUND. A) Fire Barriers using Fire Stop Mortar Seal shall be installed at following locations. The thickness of Fire Barrier shall be Minimum 225 mm to achieve 3 hr fire rating. Control Room / Cable Vaults and in plant area. 1) Panel bases in control room shall be sealed (wherever any other type of fire sealing system is not already installed and wherever it is structurally and maintenance wise feasible to install.) 2) All wall openings and floor openings in control room / cable vaults shall be sealed. 3) All cable entry openings from trenches or overhead cable trays racks shall be sealed. Trenches 1) Barriers shall be installed inside the trenches at every intersection or Tee joints and bends at every 2 meters from center line of cable rack inside the trench. 2) Barriers shall be installed at every 15 meters in straight runs of trenches.

B) Fire Protective Coating shall be applied at following locations. The average thickness of the coating shall be 2 mm. Control Room / Cable Vaults and in plant area. 1) All vertical cables coming out below the panels shall be coated to a full length of vertical drop from bottom of panel plus 1.5 to 2.5 mtrs. Horizontal run after the bend. 2) All vertical cable runs anywhere in the area are to be coated full. 3) All horizontal cable runs to be coated for a length of 1.5 mtrs at an interval of every 2 to 3 mtrs. At bends / intersections and Tee joints, coating should be done 2 mtrs from center line of cable tray on each side. Trenches 1) All vertical cables coming down into the trenches from the equipment are to be coated full. 2) At the intersection / joints / bends in the trenches all cables to be coated 2 mtrs from center line of the cable tray rack. 3) All horizontal cable runs to be coated for a length of 3 mtrs in the center of every 15 mtrs i. e. at the center of two fire stop mortar seal barriers and in the same proportion if the distance is less than 15 mtrs and more than 6 mtrs. NOTE : The above instructions are general and the application shall be carried out as per suitability to individual site condition to achieve maximum fire protection.

279

ANNEXURE-B TECHNICAL SPECIFICATION FOR FIRE STOP MORTAR SEAL Fire Seal shall be dry cement with other chemical ingredients capable of controlled swelling, non-shrinking, homogeneous and smoke/gas-tight fire seal for cable and pipe penetration. Composition Colour Bulk Density Toxicity Combustibility P(H) value : : : : : : It shall consists of inorganic binders, filters and lightweight aggregates with special additives and agent Preferably Grey colour Approx. 550 gm./litre (Minimum) It shall be Non-toxic It shall be Non-combustible 10.0 (at working consistency) + 5 deg.C to 50 deg.C in dry conditions. Minimum Two years, in original unopened packing stored in a dry place. Shall be packed in Gunny bags containing not more than 50 Kg.Fire Seal Compound. Approx. 0.6 gm. per CC. Approx. 6-7 N per Sq.mm. 1 kg Dry Fire Seal shall yield approx. 1.5 litre mixture of wet mortar Fire Seal shall provide 3 Hrs. Fire Resistance. Approx. 3% by volume at 20 Deg.C Recommended for both wall openings and floor cut-outs The FIRE SEAL should have approval of the Institution like CBRI for its fire retardant properties The application should have been done successfully preferably in Power Stations

Storage temperature : Shelf life Packaging : :

Density of cured : Material Compressive Strength : Yield : Fire Resistance Expansion : :

Recommended Uses : Approval Experience : :

280

ANNEXURE-B FIRE RETARDANT COATING COMPOUND Fire Retardant coating compound shall be a ready to mix and easily brushable one. Composition : Fire Retardant coating compound shall be water based, solvent free coating comprising of thermoplastic resins, certain flame retardant chemicals and other inorganic incombustible fibers, filters and pigments. Fire Retardant should not contain asbestos fibers. Preferably Off White colour 1.25 to 1.35 gm per cc. 70 to75% by weight 6-8 It shall be odourless It shall be Non-combustible one Max 50 Deg.C, must be protected from freezing Shall be 2 years, in original unopened packing & min. 18 months in unpacked condition, at room temperature. Recommended Coating Thickness, min 2.0 mm Shall be packed in Plastic drums containing not more than 50 Kg. Fire Retardant Compound Shall be only by water 1.5 to 1.6 8 hrs. touch dry. Rough Fire Retardant Coating shall provide minimum 30 minutes fire : The FIRE RETARDANT COATING COMPOUND should have approval of the Institution like CBRI for its fire retardant properties The application should have been done successfully preferably in Power Stations

Colour Density Solid contents PH value Odour Toxicity Storage temp. Shelf Life Coating Thickness Packing Thinning Specific Gravity Drying Time Surface Gravity Fire Resistance resistance Approval

: : : : : : : : : : : : : : : :

Experience

281

ANNEXURE-B

FIRE RETARDANT COATING COMPOUND SPECIAL FEATURES Water Resistance : A Fire Retardant coated cables shall not show any effect when dipped in water at 40 Deg.C for 10 days A Fire Retardant coated cable shall not show any effect when dipped in salt water for 16 days. A Fire Retardant coated cable shall not show any effect on application of 2% Conc. Sulphuric Acid A Fire Retardant coated cable shall not show any effect on application of 10% soap solution for half an hour and 2% solution of Sodium Bicarbonate for an additional half an hour. On application of Fire Retardant coating, there shall be no effect on the current capacity of the cable. 15 to 80 Deg.C Cycle Fire Retardant Coated HRPVC Cable may be bent 20 Times radius without cracking or peeling off. Shall have no effect. Shall be highly Resistance to immersion in mineral oil For 48 hours at room temp. There shall be no physical and chemical changes observed. Dry film of Fire Retardant shall be ant rodent Shall be Highly Resistant to moisture and humidity.

Salt Water Resistance : Acid Resistance Alkali Resistance : :

Current Carrying Capacity of Cables Resistance to Heat Flexibility Hydrocarbon Solubility

: : : :

Mineral Oil Resistance:

Ant rodent

Effect of Atmospheric : Conditions

282

SPECIFICATION NO. : 11P01-SPC-E-291-53.02 SUB-SECTION - XIII CIVIL WORKS

283

SUB-SECTION - XIII CIVIL WORKS CONTENTS

CLAUSE NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
10.0 11.0

DESCRIPTION SCOPE OF WORK SITE PREPARATION ANTI-WEED TREATMENT & STONE SPREADING TRANSFORMER FOUNDATION CABLES & PIPE TRENCHES FOUNDATION / R.C.C. CONSTRUCTION CHAIN LINK FENCING, GATE

PAGE NO. 1 2 4 5 7 7 11

BUILDINGS / STRUCTURES - GENERAL REQUIREMENTS 13 STORM WATER DRAINAGE FOR SWITCHGEAR BUILDINGS 18
MISCELLANEOUS GENERAL REQUIREMENTS INTERFACING 18 20

12.0 13.0

WATER SUPPLY STATUTORY RULES

20 20

284

CIVIL WORKS
1.0 SCOPE OF WORK The specification covers the following: 1.1 Design, engineering, and construction of all civil works at 33KV existing Switchyard& 11 KV switchgear building and outdoor area cable trenches from 33KV MRSS to PM5 substation. All civil works shall also satisfy the general technical requirements specified in other Sections of this Specification and as detailed below. They shall be designed to the required service condition / loads as specified elsewhere in this Specification or implied as per National and International Standards. All civil works shall be carried out as per applicable Indian Laws, Standards and Codes. All materials shall be of best quality conforming to relevant Indian Standards and Codes. 1.3 The Contractor shall furnish all design, drawings, labour, tools, equipment, materials, temporary works, constructional plant and machinery, fuel supply, transportation and all other incidental items not shown or specified but as may be required for complete performance of the Works in accordance with approved drawings, specifications and direction of Purchaser. The work shall be carried out according to the design/drawings to be developed by the Contractor and approved by the purchaser based on Tender Drawings supplied to the Contractor by the Purchaser. For all buildings, structures, foundations etc. necessary layout and details shall be developed by the Contractor keeping in view the functional requirement of the substation facilities and providing enough space and access for operation, use and maintenance based on the input provided by the Purchaser. Certain minimum requirements are indicated in this specification for guidance purposes only. However, the Contractor shall quote according to the complete requirements covered under the scope of work. The Contractor shall consider following major civil work in his scope :a) All civil Foundation for 33/11 KV & 11/0.415 KV transformers including common oil pit. b) All Civil work for cable trenches, drains, gravel filling fencing etc inside the 33KV switchyard. c) All civl work for 11KV NGRs d) Modification of existing 11 KV Switchgear building inside 33 KV switchyard. e) All civil work for cable trench from 33KV MRSS upto PM5 substation. f) All minor chipping, leveling, alignment, minor modification required to complete this package.

1.2

1.4

1.5

285

2.0 2.1

SITE PREPARATION Scope The design and execution of the work for site preparation, such as clearing of the site, the supply and compaction of fill material, excavation and compaction of backfill for foundation, road construction, drainage, trenches and final topping by stone (broken hard stone).

2.2 2.2.1

General The Purchaser shall make fairly leveled land available to the Contractor. The layout and levels of all structure etc shall be made by the Contractor at his own cost from the general grids of the plot and benchmarks set by the Contractor and approved by the Purchaser. the Contractor shall give all help in instruments, materials and personnel to the Purchaser for checking the detailed layout and shall be solely responsible for the correctness of the layout and levels. The Contractor shall develop the site area to meet the requirement of the intended purpose. The site preparation shall conform to the requirements of relevant sections of this specification or as per stipulations of standard specifications.
If fill material is required, the fill material shall be suitable for the above requirement. The fill shall be such a material and the site so designed as to prevent the erosion by wind and water of material from its final compacted position or the in-situ position of undisturbed soil.

2.2.2

2.2.3

2.2.4
2.2.5

Material unsuitable for founding of foundations shall be removed and replaced by suitable fill material and to be approved by the Purchaser.
Backfill material around foundations or other works shall be suitable for the purpose for which it is used and compacted to the density described under Compaction. Excavated material not suitable or not required for backfill, shall be disposed off in area's as directed by purchaser upto a maximum lead of 2 km

2.3

Site Grading The land has been developed by separate agency and done by cutting and filling so that net difference between cutting & filling shall remain minimum. The filling at places varies from 1 to 2 meter. The top of tentative formation level are mentioned in the tender drawing as a guide line to the Contractor. The Contractor shall finally fix the top of grades to suit actual site condition matching all functional requirements and be approved by the Owner prior to execution.

2.4 2.4.1.
2.4.2.

Excavation and Backfill Excavation and backfill for foundations shall be in accordance with the relevant code. Whenever water table is met during the excavation, it shall be dewatered and water table shall be maintained below the bottom of the excavation level during excavation, concreting and backfilling.
286

2.4.3.

When embankments are to be constructed on slopes of 15% or greater, benches or steps with horizontal and vertical faces shall be cut in the original slope prior to placement of embankment material. Vertical face shall measure not more than 1 m in height. Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be constructed by compacting the material in successive uniform horizontal layers not exceeding 15 cm in thickness. (of loose material before compaction). Each layer shall be compacted as required by means of mechanical tampers approved by the Purchaser. Rocks larger than 10 cm in any direction shall not be placed in embankment adjacent to structures. Earth embankments of roadways and site areas adjacent to buildings shall be placed in successive uniform horizontal layers not exceeding 20 cm in thickness in loose stage measurement and compacted to the full width specified. The upper surface of the embankment shall be shaped so as to provide complete drainage of surface water at all times. Compaction The density to which fill materials shall be compacted shall be as per, relevant IS and as per direction of Purchaser. All compacted sand filling shall be confined as far as practicable. Backfilled earth shall be compacted to minimum 95% of the Standard Proctor's density at OMC. The sub grade for the roads and embankment filling shall be compacted to minimum 95% of the Standard Proctor's density at OMC. Cohesion less material sub grade shall be compacted to 70% relative density (minimum). At all times unfinished construction shall have adequate drainage. Upon completion of the road's surface course. adjacent shoulders shall be given a final shaping, true alignment and grade. Each layer of earth embankment when compacted shall be as close to optimum moisture content as practicable. Embankment material which does not contain sufficient moisture to obtain proper compaction shall be wetted. If the material contains any excess moisture, then it shall be allowed to dry before rolling. The rolling shall begin at the edges overlapping half the width of the roller each time and progress to the center of the road or towards the building as applicable. Rolling will also be required on rock fills. No compaction shall be carried out in rainy weather Requirement for Fill Material Under Foundation The thickness of fill material under the foundations shall be such that the maximum pressure from the footing, transferred through the fill material and distributed onto the original undisturbed soil will not exceed the allowable soil bearing pressure of the original undisturbed soil. For expansive soils the fill materials and other protections etc. to be used under the foundation is to be got approved by the Purchaser.

2.4.4.

2.4.5.

2.5 2.5.1.

2.5.2.

2.5.3

2.6

287

3.0 3.1

ANTIWEED TREATMENT & STONE SPREADING Scope The Contractor shall furnish all labour, equipment and materials required for complete performance of the work in accordance with the drawings specification and direction of the Purchaser. Stone spreading shall be done in the areas of the switchyard wherever equipments and or structures are to be provided under present scope of work.

3.2 3.2.1 3.2.2

General Requirement The material required for site surfacing shall be free from all types of organic materials and shall be of standard quality, and as approved by the Purchaser. The material to be used for stone filling/site surfacing shall be uncrushed/crushed/broken stone of 20 mm nominal size (ungraded single size) conforming to Table 2 of IS:383 - 1970. Hardness, Flakiness shall be as required for wearing courses are given below : Sieve Analysis limits (Gradation) (IS: 383 - Table - 2) Sieve Size 40mm 20mm 10mm 4.75 mm % passing by weight 100 85 100 0 20 0-5

'One Test' shall be conducted for every 500 cu.m. Hardness Abrasion value (IS:2386 Part-IV) - not more than 40% Impact value (IS:2386 Part-IV) - not more than 30% and frequency shall be one test per 500 cum with a minimum of one test per source. Flakiness Index One test shall be conducted per 500 cum of aggregate as per TS:2386 Part I and maximum value is 25% 3.2.3 After all the structures/equipments are erected and anti-weed treatment is complete, the surface of the switchyard area shall be maintained, rolled/compacted to the lines and grades as decided by SPM/DCPL. Deweeding including removal of roots shall be done before compaction is commenced. Engineer-in-Charge shall decide final formation level so as to ensure that the site appears uniform devoid of undulations.
288

-...

3.2.4

A base layer of uncrushed/crushed/broken stone of 20 mm nominal size (ungraded single size) shall be spread, and rolled/compacted by using half ton roller with 4 to 5 passes and water sprinkling to form a minimum 50 mm layer on the finished ground level of the specified switchyard area excluding roads, drains, cable trench and tower and equipment foundations as indicated in the drawing. Over the base layer of site surfacing material, a final surface course of minimum 50 mm thickness of 20 mm nominal size (single size ungraded) broken stone as specified above shall be spread and compacted by light roller using half tone steel roller (width 30" and 24" dia meter) with water sprinkling as directed by the Engineer-in-Charge. The water shall be sprinkled in such a way that bulking does not take place. In areas that are considered by the Engineer-in-Charge to be too congested with foundations and structures for proper rolling of the site surfacing material by normal rolling equipments, the material shall be compacted by hand, if necessary. Due care shall be exercised so as not to damage any foundation structures or equipment during rolling compaction. Before taking up stone filling, anti-weed treatment shall be applied in the switchyard area wherever gravel filling is to be done, and the area shall be thoroughly de-weeded including removal of roots. The recommendation of local agriculture or horticulture department shall be sought wherever feasible while choosing the type of chemical to be used. Nevertheless the effectiveness of the chemical shall be demonstrated by the contractor in a test area of 10M x 10M (approx.) and monitored over a period of two to three weeks by the Engineer-in-Charge. The final approval shall be given. by Engineer-in-Charge and final approval given based in the results. The anti-weed chemical shall be procured from reputed manufacturers. The dosage and application of chemical shall be strictly followed as per manufacturer's recommendation. The contractor shall execute the work in such a manner so that the area should remain free from weeds for a period of 1 year from the date of completion of work in all respects. TRANSFORMER FOUNDATION The Contractor shall provide a RCC foundation with rails at top to enable installation and the replacement of any failed unit. The transformer/reactor track system shall be suitable to permit the movement of any failed unit fully assembled (including OLTC), and oil, without the de-energisation of any other equipment in the station. This system shall enable the removal of any failed unit from its foundation to the nearest road. If trench / drain crossings are required then suitable R.C.C. culverts shall be provided in accordance with I.R.C. Code / relevant IS. The rail shall be of commercial quality flat bottom. A pylon support system shall be provided, if required, for supporting the fire fighting system by the Contractor.

3.2.5

3.2.6

3.2.7

3.2.8.

4.0

289

4.1 4.1.1

Description of Oil Recovery System Pit below Transformer The oil recovery system shall be provided for transformer / reactor (containing insulating oil or any inflammable or polluting liquid) in order to avoid spread of fire by the oil, and for environmental protection. Each transformer/reactor including oil conservator tank and cooler banks etc. shall be placed in a self sufficient pit surrounded by retaining walls (Pit walls). The clear distance of the retaining wall from the transformer/reactor shall be 20% of the transformer/reactor height or 0.8 m whichever is more. The oil collection pit thus formed shall have a void volume equal to 1/3rd volume of total oil in the transformer/reactor. The MS grating placed at the formation level shall be covered with 100 mm thick layer of broken / crushed / noncrushed stone 40 mm nominal size which acts as an extinguisher for flaming oil. Each oil collection pit shall be drained towards a sump pit within the collection pit whose role is to drain water and oil due to leakage within the collection pit so that collection pit remains dry & clean. The pit shall be connected by 150 mm diameter GI pipe at 1:96 slope to common oil pit.

4.1.2

Common Oil Pit in Transformer Yard A common RCC oil pit shall be constructed for all the transformers/reactors for drain away of transformer pit. The effective volume of the oil pit shall be calculated based on the following Quantity of oil in the largest transformer Quantity of water for sprinkler system based on 10.2 liter/min/sq meter of transformer surface area and 10 minutes operation of spray system Rainwater collection 7% of total transformers oil quantity of associated

The pit shall be provided with one permanently installed sump pump to remove regular rain water collection to nearest surface drain. The sump pump shall be started manually, however shall stop automatically if level falls to certain level. 4.2 Materials The retaining walls which make up the oil collection pit shall be made of fire resistant material such as reinforced cement concrete, fire brick etc. and shall be impervious to oil. The minimum height of the retaining walls shall be 1.5 cm above the finished level of the ground to avoid outside water pouring inside. The bottom of the pit shall have an uniform slope towards the sump pit

290

5.0 5.1. 5.2.

CABLE & PIPE TRENCHES The cable trenches and pre-cast removable RCC cover (with lifting arrangement) shall be constructed using RCC of M25 grade. The cable trench walls shall be designed for the following loads.: Dead load of 155 kg/m length of cable support + 75 Kg on one tier at the end. Triangular earth pressure + uniform surcharge pressure of 2T/m2.

5.3. 5.4. 5.5.

Cable trench covers shall be designed for self weight of top slab + UDL of 2000 Kg/m2 + concentrated load of 200 kg at center of span on each panel. Cable trench crossing the road/rails shall be designed for class AA. loading of IRC/relevant IS Code and should. be checked transformer/reactor loading. Trenches shall be drained. Necessary sumps be constructed and sump pumps if necessary shall be supplied. Cable trenches shall not be used as storm water drains The top of trenches shall be kept at least 100 mm above the finished ground level. The top of cable trench shall be such that the surface rain water do not enter the trench. All metal parts inside the trench shall be connected to the earthing system Cables from trench to equipments shall run in hard conduit pipes. Trench wall shall not foul with the foundation. Suitable clear gap shall be provided. The trench bed shall have a slope of 1/500 along the run & 1/250 perpendicular to the run. All the construction joints of cable trenches i.e. between base slab to base slab and the junction of vertical wall to base slab as well as from vertical wall to wall and all the expansion. joints shall be provided with approved quality PVC water stops of approx. 230 x 5 mm size for those sections where the ground water table is expected to rise above the junction of base slab and vertical wall of cable trenches. Cable trenches shall be blocked at the ends if required with brick masonry in cement sand mortar 1:6 and plaster with 12mm thick 1:6 cement and mortar FOUNDATION / RCC CONSTRUCTION General Work covered under this Clause of the Specification comprises the design and construction of foundations and other RCC constructions for switchyard structures, equipment supports, trenches. drains, jacking pad. pulling block. control cubicles, bus supports, Autotransformer/Reactors, marshaling kiosks, auxiliary equipments& systems buildings, tanks or for any other equipment. or
291

5.6.

5.7. 5.8. 5.9. 5.10. 5.11.

5.12. 6.0 6.1 6.1.1.

service and any other foundation required to complete the work. This clause is as well applicable to the other RCC constructions.
6.1.2. Concrete shall conform to the requirements mentioned in IS: 456 and all the tests shall be conducted as per relevant Indian Standard Codes as mentioned in Standard field quality plan appended with the specification. A minimum grade of M25 concrete shall be used for all structural/load bearing members as per latest IS:456 (latest revision). If the site is sloppy, the foundation height will be adjusted to maintain the exact level of the top of structures to compensate such slopes.

6.1.3.

6.1.4. 6.1.5.

The switchyard foundation's plinths and building plinths shall be minimum 300mm and 500 mm above finished ground level respectively. Minimum 75mm thick lean concrete (1:4:8) shall be provided below all underground structures, foundations, trenches etc. to provide a base for construction.
Concrete made with Portland slag cement shall be carefully cured and special importance shall be given during the placing of concrete and removal of shuttering.

6.1.6.

6.1.7.

The design and detailing of foundations shall be done based on the approved soil data and sub-soil conditions as well as for all possible critical loads and the combinations thereof. The Spread footings foundation or pile foundation as may be required based on soil/sub-soil conditions and superimposed loads shall be provided. If pile foundations are adopted, the same shall be cast-in-situ driven/bored or pre-cast or under-reamed type as per relevant parts of IS Code 2911. Only RCC piles shall be provided. Suitability of the adopted pile foundations shall be justified by way of full design calculations. Detailed design calculations shall be submitted by the bidder showing complete details of piles/pile groups proposed to be used. Necessary initial load test shall also be carried out by the bidder at their cost to establish the piles design capacity. Only after the design capacity of piles have been established, the Contractor shall take up the job of piling. Routine tests for the piles shall also be conducted. All the work (design & testing) shall be planned in such a way that these shall not cause any delay in project completion. Design
All foundation shall be of reinforced cement concrete. The design and construction of RCC structures shall be carried out as per IS :456 and minimum grade of concrete shall be .M-25.

6.1.8

6.2
6.2.1.

6.2.2 6.2.3.

Limit state method of design shall be adopted unless specified otherwise. in the specification.. For detailing of reinforcement IS:2502 and SP:34 shall be followed. Cold twisted deformed bars conforming to IS:1786 shall be used as reinforcement. However, in specific areas mild steel (Grade I) conforming to IS:432 can also be used. Two layers of reinforcement (on inner and outer face) shall be provided for wall & slab sections having thickness of 150 mm and above. Clear cover to reinforcement towards the earth face shall be minimum 40 mm
292

6.2.4.

RCC water retaining structures like storage tanks, etc. shall be designed as uncracked section in accordance with IS:3370 (Part I to IV) by working stress method. However, water channels shall be designed as cracked section with limited steel stresses as per IS:3370 (Part I to IV) by working stress method. The procedure used for the design of the foundations shall be the most critical loading combination of the steel structure and or equipment and/or superstructure and other conditions which produces the maximum stresses in the foundation or the foundation component and as per the relevant IS Codes of foundation design. Detailed design calculations shall be submitted by the bidder showing complete details of piles/pile groups proposed to be used. Design shall consider any sub-soil water pressure that may be encountered following relevant standard strictly. Necessary protection to the foundation work. if required shall be provided to take care of any special requirements for aggressive alkaline soil. black cotton soil or any other type of soil which is detrimentallham1ful to the concrete foundations. RCC columns shall be provided with rigid connection at the base. All sub-structures shall be checked for sliding and overturning stability during both construction and operating conditions for various combinations of loads. Factors of safety for these cases shall be taken as mentioned in relevant IS Codes 01' as stipulated elsewhere in the Specifications, For checking against overturning. weight of soil vertically above footing shall be taken and inverted frustum of pyramid of earth on the foundation should not be considered. Earth pressure for all underground structures shall be calculated using coefficient of earth pressure at rest. co-efficient of active or passive earth pressure (whichever is applicable). However, for the design of substructures of any underground enclosures, earth pressure at rest shall be considered. In addition to earth pressure and ground water pressure etc., a surcharge load of 2T/Sq.m shall also be considered for the design of all underground structures including channels, sumps, tanks, trenches, and substructure of any underground hollow enclosure tec., for the vehicular traffic in the vicinity of the structure. Following conditions shall be considered for the design of water tank in pumps house, channels, sumps, trenches and other underground structures : a) Full water pressure from inside and no earth pressure & ground water pressure & surcharge pressure from outside (application only to structures, which are liable to be filled up with water or any other liquid). Full earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside. Design shall also be checked against buoyancy due to the ground water during construction and maintenance stages. Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the superimposed loadings.
293

6.2.5.

6.2.6. 6.2.7.

6.2.8. 6.2.9.

6.2.10.

6.2.11.

6.2.12.

b) c)

6.2.13.

Base slab of any underground enclosure shall also be designed for empty condition during construction and maintenance stages with maximum ground water table (GWT). Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the super-imposed loadings. Base slab of any underground enclosure like water storage tank shall. also be designed for the condition of different combination of pump sumps being empty during maintenance stages with maximum GWT. Intermediate dividing piers of such enclosures shall be designed considering water in one pump sump only and the other pumps sump being empty for maintenance. The foundations shall be proportioned so that the estimated total and differential movements of the foundations are not greater than the movements that the structure or equipment is designed to accommodate. The foundations of transformer/reactor and circuit breaker shall be of block type foundation. Minimum reinforcement shall be governed by IS:2974 and IS:456. The tower and equipment foundations shall be checked for normal condition and also for short circuit condition against sliding, overturning and pullout.. Admixtures & Additives Only approved admixtures shall be used in the concrete for the Works. When more than one admixture is to be used, each admixture shall be batched in its own batch and added to the mixing water separately before discharging into the mixer. Admixtures shall be delivered in suitably labeled containers to enable identification. Admixtures in concrete shall conform to IS: 9103. The water proofing cement additives shall conform to IS: 2645. Concrete Admixtures/ Additives shall be approved by Purchaser. The contractor may propose and the Purchaser may improve the use of a water-reducing set-retarding admixture in some of the concrete. The use of such an admixture will not be approved to overcome problems associated with inadequate concrete plant capacity or improperly planned placing operations and shall only be approved as an aid to overcoming unusual circumstances and placing conditions. The water-reducing set-retarding admixture shall be an approved brand ofLigno-sulphonate type admixture. The waterproofing cement additives shall be used as required/advised by the Purchaser. MISCELLANEOUS GENERAL REQUIREMENT Dense concrete with controlled water cement ratio as per IS-code shall be used for all underground concrete structures such as pump-house, tanks, water retaining structures, cable and pipe trenches etc. for achieving watertightness.
294

6.2.14.

6.2.15.

6.2.16.

6.2.17. 6.3 6.3.1.

6.3.2.

6.3.3.

6.3.4. 6.3.5. 7.0 7.1

7.2

All joints including construction and expansion joints for the water retaining structures shall be made water tight by using PVC ribbed water stops with central bulb. However, kicker type (externally placed) PVC water stops shall be used for the base slab and in other areas where it is required to facilitate concreting. The minimum thickness of PVC water stops shall be 5 mm and minimum width shall be 230 mm. All steel sections and fabricated structures which are required to be transported on sea shall be provided with anti corrosive paint to take care of sea worthiness. All mild steel parts used in the water retaining structures shall be hot-double dip galvanized. The minimum coating of the zinc shall be 750 gm/sq. m. for galvanized structures and shall comply with IS:2629 and IS:2633. Galvanizing shall be checked and tested in accordance with IS:2633. The galvanizing shall be followed by the application of an etching primer and dipping in black bitumen in accordance with BS:3416.
A screed concrete layer not less than 100 mm thick and of grade not weaker than M10 conforming to IS:456-1978 shall be provided below all water retaining structures. A sliding layer of bitumen paper or craft paper shall be provided over the screed layer to destroy the bond between the screed and the base slab concrete of the water retaining structures.

7.3

7.4

7.5

7.6

Bricks having minimum 75 kglcm2 compressive strength can only be used for masonry work. Contractor shall ascertain himself at site regarding the availability of bricks of minimum 75 i\:g/cm2 compressive strength before submitting his offer. Doors and windows on external walls of the buildings (other than areas provided, with insulated metal claddings) shall be provided with RCC sunshade over the openings with 300 mm projection on either side of the openings. Projection of sunshade. from. the wall. shall be. minimum 450mm over window openings and 750 mm over door openings. ..
All stairs shall have maximum riser height of 150 mm and a minimum tread width of 300 mm. Minimum width of stairs shall be 1500 mm. Service ladder shall be provided for access to all roofs. RCC fire escape staircase shall be provided in control buildings.

7.7

7.8

7.9

Angles 50x50x6 mm (minimum) with lugs shall be provided for edge protection all round cut outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe trenches supporting covers, edges of manholes supporting covers, supporting edges of manhole pre-cast cover and any other place where breakage of comers of concrete is expected.

7.10

Anti termite chemical treatment shall be given to column pits, wall trenches, foundations of buildings, filling below the floors etc. as per IS:6313 and other relevant Indian Standards. Hand-railing minimum 900mm high shall be provided around all floor/roof openings, projections/balconies, walk ways, platforms, steel stairs etc. All handrails and ladder pipes shall be 32 mm nominal bore MS pipes (medium
295

7.11

class) and shall be galvanized (medium-class as per IS:277). All rungs for ladder shall also be galvanized as per IS:277 medium class. For RCC stairs, hand railing with 20 mm square MS bars, balustrades with suitable MS flats & aluminum handrails shall be provided. 7.12 The details given in tender drawings shall be considered along with details available in this section of the specification while deciding various components of the building. Items/components of buildings not explicitly covered in the specification but required for completion of the project shall be deemed to De included in the scope. INTERFACING The proper coordination & execution of all interfacing civil works activities like fixing of conduits in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of supports/embedment, provision of cutouts etc. shall be the sole responsibility of the Contractor. He shall plan all such activities in advance and execute in such a manner that interfacing activities do not become bottlenecks and dismantling, breakage etc. is reduced to minimum. 9.0 WATER SUPPLY
i) Water shall be made available by purchaser at any feasible point near scope boundary at single point to the contractor. Contractor shall state the total water requirement both in terms of quantity and head to the Purchaser.

7.13

8.0

ii)

The Contractor shall carry out all the plumbing/erection works required for supply of water in control room building beyond the single point as at (i). A scheme shall be prepared by the Contractor indicating the layout and details of water supply which shall be got approved by the Purchaser before actual start of' work including all other incidental items not shown or specified but as may be required for complete performance of the works. Bore wells and pumps for water supply is not in the scope of contractor.

iii)

iv) 10.0 10.1

STATUTORY RULES Contractor shall comply with all the applicable statutory rules pertaining to factories act (as applicable far the State). Fire Safety Rules of Tariff Advisery Committee. Water Act for pollution control etc. Provisions for fire proof doors, no. of staircases, fire separation wall. plastering on structural members (in fire prone areas) etc. shall be made according to the recommendations of Tariff Advisory Committee. Statutory clearance and norms of State Pollution Control Board shall be followed as per Water Act for effluent quality from plant.

10.2

10.3

296

~ 10.4 Foundation system adopted by Bidder shall ensure that relative settlement and other criteria shall be as per provision in IS: 1904 and other Indian Standards. All water retaining structures designed as uncracked section shall also be tested for water tightness at full water level in accordance with clause no. 10 of IS :33 70 (Part-I). Construction joints shall be as per IS: 456. All underground concrete structures like basements, pumps houses, water retaining structures etc. shall have plasticizer cum water proofing cement additive conforming to 18:9103. In addition, limit on permeability as given in 18:2645 shall also be met with. The concrete surface of these structures in contact with earth shall also be provided with two coat of bituminous painting for water/damp proofing. In case of water leakage in the above structures, Injection Method shall be applied for repairing the leakage. '

10.5

10.6 10.7

'

..

297

(Section VIII)

QUALITY CONTROL REQUIREMENTS

1.00.00 1.01.00 QUALITY ASSURANCE PROGRAMME
To ensure that the equipment and services under the scope of Contract whether manufactured or performed within the Contractor's works or at his Sub-contractor's premises or at the Purchaser's Site or at any other place or work are in accordance with the specifications, the Contractor shall adopt suitable quality assurance programme to control such activities at all points, as necessary. Such programmes shall be detailed by the Contractor and shall require acceptance and approval by the Purchaser/Authorized representative before the award of Contract. A quality assurance programme of the Contractor shall generally cover the following: a) His organization structure for the management and implementation of the proposed quality assurance programme. b) Qualification data for key personnel. c) Use of suitably qualified and experienced personnel in required number for each type of work. d) The procedure for quality assurance in design & engineering. e) The methods, procedures and programme for presenting, collating and assessing information from the various sources, and its incorporation in designed submissions. f) Documentation control system. g) The procedure for purchase of materials, parts, components and selection of Sub-contractor's services including vendor analysis, source inspection, incoming raw-material inspection, verification of materials purchased etc. h) The method of protection, storage, stock control and issue of materials at site. i) System for shop manufacturing and site erection control including process controls and fabrication and assembly controls. j) Inspection, sampling, testing, and acceptance procedures for plant and materials delivered to site. k) Control of non-conforming items and system for corrective actions. l) Inspection and test procedure both for manufacture and all site related works. m) Control of calibration and testing of measuring and testing equipment. n) System for quality audit and self-monitoring of QA Systems. o) System for indication and appraisal of inspection status. p) q) r) s) System for authorising release of manufactured products to the Purchaser. System for handling, storage and delivery to site. Final inspection and certification of completed sections of work. Site security procedures.
298

1.02.00

t)

1.03.00

1.04.00

The recording and processing of variations to the Works and their incorporation on record drawings. u) System for maintenance of records. v) Furnishing of quality plans for design & engineering, manufacturing and field activities detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of work. The Quality Assurance arrangements shall include the preparation of and adherence to documented quality plans. After approval by the Engineer the Quality Assurance arrangements shall form an integral part of the Contract. No changes shall be made without the prior written approval of the Engineer. The Bidder shall list his proposed sub-contractors and shall provide the following information in respect of each sub-contractor: a) The items which the Bidder proposes to sub-contract. b) The basis on which the Bidder has assessed, or proposes to assess, the quality assurance arrangements of the sub-contractors. c) How sub-contractors' quality plans/procedures will be approved, monitored and audited on site during the Contract period. d) The results of any recent evaluations and audits of the sub-contractor which have been performed by the Bidder or other organizations external to the sub-contractor. The Bidder shall also state the level of detail of the Quality Plan proposed for each sub-contracted item. The information supplied in response to the above in the Bid shall be deemed a part of the Bidder's proposed Quality Assurance arrangements. The Contractor shall provide documentation in such a manner that the Engineer is thereby enabled to satisfy himself as to the effectiveness with which the Contractor is implementing those provisions of the agreed and accepted Quality Assurance arrangements which relate to the monitoring by the Contractor to sub-tier Quality Assurance arrangements. Audits of sub-tier Quality Assurance arrangements shall be recorded in such a manner that the relevant documentation constitutes, inter alia, objective evidence of the extent of the audits and of the effectiveness with which they have been conducted. All such documentation relating to any one audit shall be made available to the Engineer, on request, as a single self-contained document or as one discrete self-contained package of documents.

1.05.00

1.06.00

1.07.00 1.07.01

General Requirements - Quality Assurance All materials, components, equipment and systems covered under this specification shall be designed, procured, manufactured, erected, commissioned and tested at all the stages, as per a comprehensive Quality Assurance Programme. Inspections, and tests at works including shop performance tests and test at site for all equipment and systems shall be as per respective codes and standards and also as required in the specification.

299

1.07.02

1.07.03

1.08.00

1.08.01

1.08.02

1.09.00

1.10.00

1.11.00

Bidder shall furnish a detailed and exhaustive list of all inspections and tests that he or his sub-contractors shall carry out at works and at site for all equipment and systems covered under this specification. The list shall have to be approved by the Purchaser/Consultant before Award of Contract. The Quality Plan for design and engineering shall cover the procedure for independent verification, validation and assessment of designs in terms of fitness for purpose, constructability, safety, compliance with standards, maintenance requirements, cost effectiveness etc. The detailed Quality Plans for manufacturing and field activities( where applicable) shall be drawn up by the Bidder separately and shall be submitted to Purchaser for approval. Schedule of finalization of such Quality Plans shall be finalized before award of Contract. Manufacturing Quality Plan will detail out for all the components and equipment, various tests/inspections to be carried out as per the requirements of this specification and standards mentioned therein and quality practices and procedures followed by Contractor's Quality Control organization, the relevant reference documents and standards, acceptance norms, inspection documents raised etc., during all stages of materials procurement, manufacture, assembly and final testing/performance testing. Field Quality Plans will detail out for all the equipment, the quality practices and procedures etc. to be followed by the Contractor's site Quality Control organization, during various stages of site activities from receipt of materials/equipment at site. The Bidder shall also furnish copies of the reference documents/plant standards/acceptance norms/tests and inspection procedure etc., as referred in Quality Plans along with Quality Plans. These Quality Plans and reference documents/standards etc. shall be subject to Purchaser's approval without which manufacture shall not proceed. These approved documents shall form a part of the Contract. In these approved Quality Plans, Purchaser/Authorized representative shall identify Customer Hold Points (CHP). A Customer Hold Point signifies a stage in any item of work which requires documented proof of approval based on tests/checks which shall be carried out in presence of the Purchasers Engineer or his authorized representative and beyond which the work shall not proceed without consent of Purchaser/Authorized representative in writing. All deviations to this specification, approved quality plans and applicable standards must be documented and referred to Purchaser/Authorized representative for approval. The Contractor shall submit to the Engineer complete field welding schedule for all field welding activities for approval. The field welding schedule shall be submitted along with all supporting procedures like welding procedures, heat treatment procedures, NDT procedures etc. No material shall be dispatched from the manufacturer's works before the same is accepted subsequent to pre-dispatch final inspection including verification of records of all previous tests/inspections by Purchaser's Engineer/Authorized representative, and duly authorized for dispatch.

300

1.11.01

1.11.02

1.12.00

1.13.00

1.14.00

1.15.00

1.16.00

Quality assurance/Inspection group of Purchaser or its representative would issue a Material Dispatch Clearance Certificate (MDCC) after the inspection clearance which will enable the Contractor to dispatch the equipment and claim the payment. Further the Contractor will also be required to ensure at all stages of shipment that packing of all shipments dispatched are suitable for ocean freight to Mumbai, the port of entry, inland transportation and preservation at site up to erection. All materials used or supplied shall be accompanied by valid and approved materials certificates and tests and inspection report. These certificates and reports shall indicate the sheet numbers or other such acceptable identification numbers of the material. The material certified shall also have the identification details stamped on it. Castings and forgings used for construction shall be of tested quality. Details of results of chemical analysis, heat treatment record, mechanical property test results shall be furnished. All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with requirements of ASME Section-IX/BS-4870 or other International equivalent standard acceptable to the Purchaser. All brazers, welders etc. employed on any part of the contract at Contractor's/Sub-Contractor's works or at site shall be qualified as per ASME Section-IX or BS-4871 or equivalent international standard approved by the Purchaser. Such qualification tests shall be conducted in presence of Purchaser/ Authorized representative. All non-destructive examinations (NDT) shall be carried out in accordance with approved international standard. The NDT operator shall be qualified as per SNT-TC-IA (of American Society of non- destructive examination). Results of NDT shall be properly recorded and submitted for approval. All the sub-vendors proposed by the Contractor for procurement of equipment, material and services and their quality assurance plans shall be subject to Purchaser's approval. The list of all major sub-contractors would be submitted along with the Bid the list would be submitted within six (6) months of the award of the Contract . Quality Plans of the successful vendors shall be discussed finalized and approved by the Purchaser/Authorized representative and form part of the Purchase Order between the Contractor and the Vendor. All the purchase specifications for the major bought-out items, list of which shall be drawn up by the Contractor and finalized with the Purchaser shall be furnished to the Purchaser for comments and subsequent approval before orders are placed. Purchaser reserves the right to carry out quality audit and quality surveillance of the systems and procedures of the Contractor's or their sub vendor's quality management and control activities. The Contractor shall provide all necessary assistance to enable the Purchaser carry out such audit and surveillance. Quality audit/approval of the results of tests and inspection shall not prejudice the right of the Purchaser to reject an equipment not giving the desired
301

1.16.01

1.16.02

1.17.00

1.18.00

1.19.00 1.20.00 1.21.00 1.21.01

performance after erection and shall not in any way limit the liabilities and responsibilities of the Contractor in earning satisfactory performance of equipment as per specification. Quality requirements for main equipment shall equally apply for spares and replacement items. Repair/rectification procedures to be adopted to make any job acceptable shall be subject to the approval of the Engineer. Quality Assurance Document The Contractor shall be required to submit two (2) copies and two (2) sets of electronic files of the following Quality Assurance documents within three (3) weeks after dispatch of the equipment: a) Material mill test reports on components as specified by the specification. b) The inspection plan with verification, inspection plan check points, verification sketches, if used and methods used to verify that the inspection and testing points in the inspection plan were performed satisfactorily. c) Non-destructive examination results/reports including radiography interpretation reports. d) Factory tests results for testing required as per applicable codes and standards referred in the specification. e) Welder identification list listing welder's and welding operator's qualification procedure and welding identification symbols. f) Sketches and drawings used for indicating the method of traceability of the radiographs to the location on the equipment. g) Stress relief time temperature charts. h) Inspection and test reports duly signed by QA personnel of the Purchaser and Contractor for the agreed customer hold points. During the course of inspection, the following will also be recorded: i) When some important repair work is involved to make the job acceptable. ii) The repair work remains part of the accepted product quality. iii) Letter of conformity certifying that the requirement is in compliance with finalized specification requirements. Inspection, Testing and Inspection Certificates The Engineer, his duly authorized representative and/or an outside inspection agency acting on behalf of the Purchaser shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its manufacture or erection and if part of the works is being manufactured or assembled on other premises or works, the Contractor shall obtain for the Engineer and for his duly authorized representative permission to inspect as if the works were manufactured or assembled on the Contractor's own premises or works. The Contractor shall give the Engineer/Inspector fifteen (15) days written notice of any material being ready for testing. Such tests shall be to the Contractor's account except for the expenses of the Inspector. The Engineer/Inspector, unless the witnessing of the tests is virtually waived, will attend such tests
302

1.22.00 1.22.01

1.22.02

1.22.03

1.22.04

1.22.05

1.22.06

1.23.00

within fifteen (15) days of the date on which the equipment is notified as being ready for test/inspection failing which the Contractor may proceed with test which shall be deemed to have been made in the Inspector's presence and he shall forthwith forward to the Inspector duly certified copies of test reports in six (6) copies. The Engineer or Inspector shall within fifteen (15) days from the date of Inspection as defined herein give notice in writing to the Contractor, or any objection to any drawings and all or any equipment and workmanship which is in his opinion are not in accordance with the Contract. The Contractor shall give due consideration to such objections and shall either make modifications that may be necessary to meet the said objections or shall confirm in writing to the Engineer/Inspector giving reasons therein, that no modifications are necessary to comply with the contract. When the factory tests have been completed at the Contractor's or sub-contractor's works, the Engineer/Inspector shall issue a certificate to this effect fifteen (15) days after completion of tests but if the tests are not witnessed by the Engineer/ Inspectors, the certificate shall be issued within fifteen (15) days of the receipt of the Contractor's test certificate by the Engineer/Inspector. Failure of the Engineer/Inspector to issue such a certificate shall not prevent the Contractor from proceeding with the works. The completion of these tests, or the issue of the certificates shall not bind the Purchaser to accept the equipment should it, on further tests after erection be found not to comply with the Contract. In all cases where the contract provides for tests whether at the premises or works of the Contractor or any sub-contractor, the Contractor, except where otherwise specified shall provide free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Engineer/Inspector or his authorized representatives to carry out effectively such tests on the equipment in accordance with the Contractor and shall give facilities to the Engineer/Inspector or to his authorized representative to accomplish testing. To facilitate advance planning of inspection in addition to giving inspection notice as per Clause 9.22.02, the Contractor shall furnish quarterly inspection programme indicating schedule dates of inspection at customer hold points and final inspection stages. Updated quarterly inspection plans will be made for each three consecutive months and shall be furnished before beginning of each calendar month. Archiving In addition to the requisite number of hard copies as specified, four (4) copies of all quality assurance documents, final inspection and test certificates etc. shall be made available to the Purchaser in Compact Disks before handing over of the plant. The testing and inspection shall be carried out as per IS:3177 with latest amendments and those should also meet the requirements of the factories act. Final load testing shall be carried out at the Purchasers premises by the Vendor. However, necessary tests loads and slips shall be supplied by the Purchaser.
303

1.24.00

(Section IX)

QUALIFICATION / ELIGIBILITY CRITERIA

1. Bidder firm should have manufactured, supplied, installed and commissioned at least one (1) No. similar electrical substations of rating 33/11 kV or above with minimum 10 MVA installed capacity during last five (5) years ending March 31st, 2011. 2. Bidder must have an annual capacity to manufacture and supply of at least one (1) No. similar installations as above. 3. The average annual turn-over of the Bidder firm during the last three (3) financial years, ending March 31st, 2011 should be at least Rs.3.8 Crores. 4. The Bidder firm should not have suffered any financial loss for more than one (1) financial year during the last three (3) financial years ending March 31st, 2011. 5. The net worth of the Bidder firm should not have eroded by more than 30% during the last three (3) financial years ending March 31st, 2011. 6. Either the Indian agent on behalf of the principal/OEM or principal/OEM itself can bid both cannot bid simultaneously for the same item/product in the same tender. 7. If an agent submits bid on behalf of the principal/OEM, the same agent shall not submit a bid on behalf of another principal/OEM for the same item/product. Note: 1. All experience, past performance and capacity/capability related data should be certified by the authorized signatory of the Bidder firm. The credentials regarding experience and past performance to the extent required as per the above eligibility criteria as would be submitted by the Bidder should be verified from the parties for whom work has been done. 2. All financial standing data should be certified by certified accountants e.g. Chartered Accountants (CA) in India and Certified Public Accountant/ Chartered Accountant of other countries. MOST IMPORTANT NOTE: BIDDER TO FURNISH STIPULATED DOCUMENTS IN SUPPORT OF FULFILLMENT OF QUALIFYING CRITERIA. NON-SUBMISSION OR INCOMPLETE SUBMISSION OF DOCUMENTS MAY LEAD TO REJECTION OF OFFER.

304

(Section X)

TENDER FORM
Date. To . . . (Complete address of SPM) Ref: Your Tender document No. dated We, the undersigned have examined the above mentioned tender enquiry document, including amendment No.--------, dated--------- (if any), the receipt of which is here by confirmed. We now offer to supply and deliver. (description of goods and services) inconformity with your above referred document for the sum of (total tender amount in figures and words), as shown in the price schedule(s), attached herewith and made part of this tender. If our tender is accepted, we undertake to supply the goods and perform the services as mentioned above, in accordance with the delivery schedule specified in the List of Requirements. We further confirm that, if our tender is accepted, we shall provide you with a performance security of required amount in an acceptable form in terms of GCC clause 6, read with modification, if any, in Section V Special Conditions of Contract, for due performance of the contract. We agree to keep our tender valid for acceptance for a period up to 165,as required in the GIT clause 19, read with modification, if any in Section-III Special Instructions to Tenderers or for subsequently extended period, if any, agreed to by us. We also accordingly confirm to abide by this tender upto the aforesaid period and this tender may be accepted any time before the expiry of the aforesaid period. We further confirm that, until a formal contract is executed, this tender read with your written acceptance thereof within the aforesaid period shall constitute a binding contract between us. We further understand that you are not bound to accept the lowest or any tender you may receive against your above-referred tender enquiry Dated this day of .. For and on behalf of (With seal) Signature Name In the capacity of (DULY AUTHORISED TO SIGN THE BID)

305

(Section XI)

PRICE SCHEDULE
Name of Bidder Offer No. & Date Plant/ Item : : :

SPMs Enquiry Ref. :

PART A
S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DESCRIPTION Material as per SUB SEC-II OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-III OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-IV OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-V OF TECHINCAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-VI OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-VII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-VIII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-IX OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-X OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-XI OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Material as per SUB SEC-XII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document Packing & Forwarding charges Freight charges Taxes as applicable(if any)
TOTAL PRICE of 1 to 14 (IN FIGURES) F.O.R. SPM-HOSHANGABAD TOTAL PRICE of 1 to 14 (IN WORDS) F.O.R. SPM-HOSHANGABAD

UNIT LOT LOT LOT LOT LOT LOT LOT LOT LOT LOT LOT

QTY 1 1 1 1 1 1 1 1 1 1 1

PRICE (In Rs)

306

PART B
S.No. 1 2 DESCRIPTION CIVIL WORK as per SUB SEC-XIII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document. Taxes as applicable (if any)
TOTAL PRICE of 1 to 2 (IN FIGURES) F.O.R. SPM-HOSHANGABAD TOTAL PRICE of 1 to 2 (IN WORDS) F.O.R. SPM-HOSHANGABAD

UNIT LOT

QTY 1

PRICE (IN RS)

PART C
S.No 1 2 DESCRPTION SERVICES (Installation & Commissioning) Complete Erection, Testing, Start Up, & Commissioning fulfilment of guaranteed performance obligation including training of Purchasers operation and maintenance staff. Taxes as applicable (if any)
TOTAL PRICE of 1 to 2 (IN FIGURES) F.O.R. SPM-HOSHANGABAD TOTAL PRICE of 1 to 2 (IN WORDS) F.O.R. SPM-HOSHANGABAD

UNIT LOT

QTY 1

PRICE (IN Rs.)

GRAND TOTAL PART(A+B+C) In Words in Rs. :GRAND TOTAL PART(A+B+C) In Figures in Rs.:Note:The method of evaluation of L1 criteria for awarding the Contract shall be on consolidated offer by the bidder and will be decided taking into consideration of total offered price including Part (A+B+C) as above.

Bidders Signature

__________________

307

(Section XII) QUESTIONAIRE

The tenderer should furnish specific answers to all the questions/issues mentioned below .In case a question/ issue does not apply to a tenderer, the same should be answered with the remark not applicable. Wherever necessary and applicable, the tenderer shall enclose certified copy as documentary proof/ evidence to substantiate the corresponding statement. In case a tenderer furnishes a wrong or evasive answer against any of the under mentioned question/ issues, its tender will be liable to be ignored. 1. Brief description of Work and services offered: 2. Offer is valid for acceptance up to . 3. Your permanent Income Tax A/C No. as allotted by the Income Tax Authority of Government of India : Please attach certified copy of your latest /current Income Tax clearance certificate issued by the above authority. 4. Status : a) Are you currently registered with the Directorate General of Supplies & Disposals (DGS&D), New Delhi, and/or the National Small Industries Corporation (NSIC), New Delhi, and/or the present SPMICL and/or the Directorate of Industries of the concerned State Government for the goods quoted? If so, indicate the date up to which you are registered and whether there is any monetary limit imposed on your registration. b) Are you currently registered under the Indian Companies Act, 1956 or and other similar Act? Please attach certified copy(s) of your registration status etc. in case your answer(s) to above queries is in affirmative. 5. Please indicate name & full address of your Banker(s) : 6. Please state whether business dealings with you currently stand suspended/ banned by any Ministry/ Dept. of Government of India or by any State Govt. . (Signature with date) . . (Full name, designation & address of the person duly authorized sign on behalf of the tenderer) For and on behalf of (Name, address and stampof the tendering firm)

308

(Section XIII)

BANK GUARANTEE FORM FOR EMD

Not applicable

309

(Section XIV)

MANUFACTURERS AUTHORIZATION FORM

To (Name and address of SPM) Dear Sirs, Ref. Your Tender document No. dated We, . Who are proven and reputable manufacturers of (name and description of goods offered in the tender) having factories at . hereby authorize Messrs. (name and address of the agent) to submit a tender, process the same further and enter in to a contract with you against your requirement as contained in the above referred tender enquiry documents for the above goods manufactured by us. We further confirm that no supplier or firm or individual other than Messrs. ........(name and address of the above agent) is authorized to submit a tender, process the same further and enter into a contract with you against your requirement as contained in the above referred tender enquiry documents for the above goods manufactured by us. We also hereby extend our full warranty, as applicable as per clause of the General Conditions of Contract read with modification, if any, in the Special Conditions of Contract for the goods and services offered for supply by the above firm against this tender document. Yours faithfully, . (Signature with date, name and designation) For and on behalf of Messrs. . (name and address of the manufacturers) Note : This letter of authorization should be on the letter head of the manufacturing firm and should be signed by a person competent and having the power of attorney to legally bind the manufacturer.

310

(Section XV)

BANK GUARANTEE FORM FOR PERFORMANCE SECURITY

__________________[insert :Banks Name, and Address of Issuing Branch or Office] Beneficiary __________________________[insert: Name and Address of SPM] Date: _________ PERFORMANCE GUARANTEE No.: ___________________

WHEREAS.. (name and address of the supplier) (hereinafter called the supplier) has undertaken, in pursuance of contract no. dated . to supply (description of goods and services) (herein after called the contract). AND WHERE AS it has been stipulated by you in the said contract that the supplier shall furnish you with a bank guarantee by a scheduled commercial bank recognized by you for the sum specified therein as security for compliance with its obligations in accordance with the contract; AND WHERE AS we have agreed to give the supplier such a bank guarantee; NOW THEREFORE we here by affirm that we are guarantors and responsible to you, on behalf of the supplier, upto a total of .(amount of the guarantee in words and figures),and we undertake to pay you, upon your first written demand declaring the supplier to be in default under the contract and without cavil or argument, any sum or sums within the limits of (amount of guarantee) as aforesaid, without you needing to prove or to show grounds or reasons for your demand or the sum specified therein. We here by waive the necessity of your demanding the said debt from the supplier before presenting us with the demand. We further agree that no change or addition to or other modification of the term soft he contract to be performed thereunder or of any of the contract documents which may be made between you and the supplier shall in anyway release us from any liability under this guarantee and we here by waive notice of any such change, addition or modification. We undertake to pay SPM up to the above amount upon receipt of its first written demand, without SPM having to substantiate its demand. This guarantee will remain in force for a period of forty five days after the currency of this contract and any demand in respect thereof should reach the Bank not later than the above date. . (Signature of the authorized officer of the Bank) . . Name and designation of the officer . Seal, name & address of the Bank and address of the Branch . Name and designation of the officer . .. Seal, name & address of the Bank and address of the Branch

311

(Section XVI)

CONTRACT FORM
(Address of SPMs office issuing the contract)
Contract No. dated. This is In continuation to this office Notification of Award No.., dated . 1. Name & address of the Supplier: .. 2. SPMs Tender document No dated. Amendment No.., dated (If any), issued by SPM and subsequent

3. Suppliers Tender Nodated..and subsequent communication(s) Nodated .. (If any), exchanged between the supplier and SPM in connection with this tender. 4. In addition of this Contract Form, the following documents etc, which are included in the documents mentioned under paragraphs 2 and 3 above, shall also be deemed to form and be read and construed as part of this contract: i) ii) iii) iv) v) vi) vii) viii) ix) General Conditions of Contract; Special Conditions of Contract; List of Requirements; Technical Specifications; Quality Control Requirements; Tender Form furnished by the supplier; Price Schedule(s) furnished by the supplier in its tender; Manufacturers Authorization Form (if applicable for this tender); SPMs Notification of Award

Note : The words and expressions used in this contract shall have the same meanings as are respectively assigned to them in the conditions of contract referred to above. Further, the definitions and abbreviations incorporated under SectionV-General Conditions of Contract of SPMs Tender document shall also apply to this contract. 5. Some terms, conditions, stipulations etc. out of the above-referred documents are reproduced below for ready reference: i) Brief particulars of the goods and services which shall be supplied/provided by the supplier are as under: Schedule No. Brief description of goods/ services Accounting unit Quantity to be supplied Unit Price (in Rs.) Total price

Any other additional services (if applicable) and cost thereof: .. Total value (in figure) (ii) (iii) (iv) ___________(In words) ____________________________

Delivery schedule Details of Performance Security Quality Control

312

(a) Mode(s), stage(s) and place(s) of conducting inspections and tests. (b)Designation and address of SPMs inspecting officer (v) (vi) (vii) (viii) (ix) Destination and dispatch instructions Consignee, including port consignee, if any Warranty clause Payment terms Paying authority

. (Signature, name and address of SPMs authorized official) For and on behalf of Received and accepted this contract (Signature, name and address of the suppliers executive duly authorized to sign on behalf of the supplier) For and on behalf of . (Name and address of the supplier) . . (Seal of the supplier) Date: Place:

313

(Section XVII)

LETTER OFAUTHORITY FOR ATTENDING A BID OPENING

(Refer to clause 24.2 of GIT)
The General Manager Security Paper Mill Hoshangabad M.P 461 005 Subject : Authorization for attending bid opening on ___(date) in the ___________________________________________ __________________. Tender of

Following persons are hereby authorized to attend the bid opening for the tender mentioned above on behalf of ___________________________ (Bidder)in order of preference given below. Order of Preference I. II. Alternate Representative Signatures of bidder or Officer authorized to sign the bid Documents on behalf of the bidder. Name Specimen Signatures

Note: 1. Maximum of two representatives will be permitted to attend bid opening. In cases where it is restricted to one, first preference will be allowed. Alternate representative will be permitted when regular representatives are not able to attend. 2. Permission for entry to the hall where bids are opened may be refused in case authorization as prescribed above is not produced.

314

(Section XVIII)

SHIPPING ARRANGEMENTS FOR LINER CARGOES

Not applicable

315

(Section XIX)

PROFORMA OF BILLS FOR PAYMENTS

(Refer Clause 22.6 of GCC)
Name and Address of the Firm..................................................................................... Bill No............................................................... Dated................................................. Purchase order No.........................Dated................................................ Name and address of the consignee ........................................................................... Sl.No. Authority for purchase Description of Stores Number or quantity Rate Rs. P. Price per Rs. P. Amount Rs. P.

Total 1. 2. 3. 4. 5. 6. 7. 8. C.S.T./Sales Tax Amount Freight (If applicable) Excise Duty(if applicable) Packing and Forwarding charges (if applicable) Others (Please specify) PVC Amount (with calculation sheet enclosed) (-) deduction/Discount Net amount payable (Rupees in Words)

Dispatch detail: RR No. /other proof of dispatch..........................Dated.......................... (enclosed) Inspection Certificate No..................................... Dated........................... (enclosed) Modvat Certificate No ................................................................................. (enclosed) Excise DutyGatepass......................................................................... (enclosed) Received`............................. (Rupees in Words)......................................................... I hereby certify that the payment being claimed is strictly in term so the contract and all the obligations on the part of the supplier or claiming that payment has been fulfilled as required under the contract.

316

(Section XX)

SL.NO.
1.
2. 3. 4. 5. 6. 7. 8.

DRAWING NO.
11P01-DWG-E-100, Rev-e 11P01-DWG-M-111-050.01, Rev 2 11P01-DWG-E-111-050.01, Rev 0 A- SPM PM5 BUILDING, Rev.0 1327-001377 Sht.1 of 2 1327-001377 Sht.2 of 2 1002-0000110350, Rev.1.0 (4 Sheets) 11P01-DWG-E-40-ND-400 (14 Sheets) 11P01-DWG-E-53-2341 (28 Sheets) Part List TPE1/TPE2/TPE3 (3 Sheets)

TITLE / DESCRIPTION
Key Single line diagram Plot Plan 33KV Switchyard Layout Single Line Diagram Earthing Layout Basement Level PM5 Earthing Layout Machine Level PM5 Typical Grounding Details for PM5 Building General Arrangement of cable tray, Trench & support details Grounding notes and details List of Groundings

9. 10.

317

LEGEND

DRAWN : REVIEWED : APPROVED :

CHECKED :

SCALE DATE JOB NO.

DATE:- 28.02.12

Main Power supply

M

xxx A

MVSG
customer

xxx A

xxx A

xxx A

Field Installation
customer

Transformer Box
customer

T1
2 MVA 2 MVA

T2
2 MVA

T3

Field Installation
customer

PCC customer
only Voith consumers are shown

3000 A

3000 A

3000 A

M M

2500 A

xx A

1500 A

250 A

500 A

xx A 250A

300 A

1500 A

XXXX A

Customer utilities
16 kW needed for lightening sheeter & winder

D Field Installation
customer cable by Voith cable by Voith

MCC Stockprep/WEP Chemical plant

Voith

MCC 2

2500 A

1500 A

winder C1

Sheeter C2

MCC 4
300 A

MCC 3

250 A

1500 A

MCC PM area

Power distribution for wire workshop

MMD
DC_Bus

variable speed drives

~
N F = E

~
=
xx A xx A xx A

~
F F C ~ C ~

~
F C ~

~
800 kvar 800 kvar

I N U

I N U

B Field Installation
Voith

Motors
Voith

48 A 48 A 48 A 48 A 48 A 48 A 48 A 48 A 48 A 48 A

48 A

48 A

48 A

48 A

A
Summe RDC 146 kW Summe inst. Power 243 kW

A
Single Line Diagramm
VPAH-passas
File: Single Line

Voith Paper Automation

Hoshangabad PM5
Drawing no. REV.

rev 0
Scale 1:1

ASheet

0
1/1

Hoshangabad_SLD_rev00b.vsd 1

H
M

H
2000 A

T1
40 MVA 1730 A

T2
40 MVA 1730 A

T3
40 MVA 1730 A

SS1

SS2
56

SS3
56
3 3 3
M

56
3 3 3
M

G
M

3 3 3

+342AR01

nn

17

18

T1
40 MVA 1730 A

2000 A

A
Single Line Diagramm
VPAH-prvs

A
Voith Paper Automation

my Project
Drawing no. REV.

XXX
Scale 1:1

ASheet

0
1/1

Hoshangabad_SLD_rev00b.vsd 1

File: Single Line

H Transformer Box
Outside Building Inside Building Outside Building

H Cable Room
Inside Building Cable Room

Machine Hall

Machine level

Door Transformer Box

Transformer Box Electrical Room

3,49 3,13

1,00

Grounding Plate/ Earthing fixpoint

Grounding Plate/ Earthing fixpoint

0,50

1,07

E-Room level

E
Basement level

Cable Room
0,17

Grounding Plate/ Earthing fixpoint

Basement level

Machine level

Sideview

Sideview

Sideview

Machine level

Electrical Room Grounding Bar Grounding Plate/ Earthing fixpoint Grounding Plate/ Earthing fixpoint
0,20 0,50 Transformer level

1,00

Wall

Grounding Bar Grounding Plate/ Earthing fixpoint

E-Room level

Grounding Bar

Cable Room
0,17 Machine level Basement level

Basement level

View from outside building

Frontview from inside building

Frontview

Voith Paper Automation Grounding Plates Hoshangabad PM5

M 1:100 2010-10-26
Drawing no. REV.

A
1.0
1/4

TPE1
1 2 3

TPE2
4 5

TPE3
6

VPAH-passas
2011_08_12 Hoshangabad PM5 grounding Typicals.vsd

1002-0000110350

2011.03.10 12:01

H to Grounding Bar in Cable Room

Sideview

Section A
5

wall column

for example Dehn PartNo.: 472207

F

Grounding Plate/ Earthing fixpoint

E
10
16mm

1a 9
120mm

7 Grounding Plate/ Earthing fixpoint 1a

120mm 800

200

1b

Transformer

5
500

for example Dehn PartNo.: 478019

Transformer level

14
350 160

7
2-5MVA 1070

13
---------

315-800kVA 670
---------

C to door and door frame

16mm

10 9
120mm 120mm

rail

rail

Basement level

Typical transformer box_TPE1

VPAH-passas
2011_08_12 Hoshangabad PM5 grounding Typicals.vsd

Voith Paper Automation Hoshangabad PM5

M 1:100 2010-10-26
Drawing no. REV.

A
1.0
2/4

1002-0000110350

2011.03.10 12:01

Section A Frontview
5

cabinets G column G

E-Room
F column
PE

for example Dehn PartNo.: 472237

max. 10m

F E-Room level

Grounding Plate/ Earthing fixpoint

E
1a

9
120mm

E
9
grounding bar to transformer boxes 120mm

grounding bar to transformer boxes

10

16mm

10

16mm 1b

to other erthing devices 16mm to pipes 16mm 16mm 16mm

10
to Ventilation duct

for example Dehn PartNo.: 478019

10 7 14
-

14

Cable-Room / MV Switch Gear A

Machine level

800

13 5
120mm

550

170

250

250

1a Grounding Plate/ Earthing fixpoint

350

Typical cable room_TPE2

VPAH-passas
2011_08_12 Hoshangabad PM5 grounding Typicals.vsd

Voith Paper Automation Hoshangabad PM5

M 1:100 2010-10-26
Drawing no. REV.

A
1.0
3/4

1002-0000110350

2011.03.10 12:01

Frontview
machine level

Section A
5

G column

Terminal box (example)

F
PE

for example Dehn PartNo.: 472237 Grounding Plate/ Earthing fixpoint

11
16mm

E
Tank, Reservoir 16mm steel construction 16mm 70mm
steal construction Motors

E
11
70mm Motors (only with Siemens FU)

M 3~

1a

10

Machine level D

steel construction to pipes cabletray connection 16mm 16mm 16mm 750 500

1b

15

7 14
10mm 70mm

for example Dehn PartNo.: 478019

10

1000

11

15

10mm 70mm

C
120mm

5 9 1a
250 250

Grounding Plate/ Earthing fixpoint

B
Tank, Reservoir

B M 3~
Earthing conductor steal construction Motors

Motors (only with Siemens FU)

Basement level
Typical machine hall_TPE3
VPAH-passas
2011_08_12 Hoshangabad PM5 grounding Typicals.vsd

Voith Paper Automation Hoshangabad PM5

M 1:100 2010-10-26
Drawing no. REV.

A
1.0
4/4

1002-0000110350

2011.03.10 12:01