OPTCL Technical Specification

ORISSA POWER TRANSMISSION
CORPORATION LIMITED
CONSTRUCTION OF SUB-STATION ALONG

WITH TRANSMISSION LINE & ASSOCIATED
SYSTEMS
(COMMON DOCUMENT FOR ALL PACKAGES)
TECHNICAL SPECIFICATION
VOLUME-II
BID DOCUMENT NO: NESCL/OPTCL/CS-OS-616-01 TO 07
NTPC ELECTRIC SUPPLY COMPANY LIMITED
CONTENTS OF THE BIDDING DOCUMENTS

CHAPTER No
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DESCRIPTION
PAGES
GENERAL CLAUSES
GENERAL TECHNICAL CLAUSES FOR
DESIGN
SYSTEM DATA
GENERAL METEROLOGICAL DATA
DESIGN CLAUSES FOR SUB STATION
CIVIL WORKS
SWITCHYARD STRUCTURE
DRAWING,TEST CERTIFICATE,O&M
MANUALS
ELECTRICAL EQUIPMENT
INSTALLATION & COMMISSIONING
GENERAL EQUIPMENT & SUBSTATION
ACCESSORIES
CIRCUIT BREAKER
CURRENT TRANSFORMER
ISOLATORS
STATION TRANSFORMER
SURGE ARRESTER
IVT,CVT
BATTERY & BATTERY CHARGER
PLCC
DISTRIBUTION BOARD
CONDUCTOR,EARTH
WIRE,INSULATORS,HARDWARES,
CLAMPS & CONNECTORS
CONTROL & RELAY PANEL
AIR CONDITIONER
CONTROL &POWER & COAXIAL CABLES
SUB STATION LIGHTING
TESTING INSTRUMENTS
&MAINTENANCE KITS
TRANSMISSION LINES
STANDARD DRAWINGS
PIPE ELECTRODE
ROD ELECTRODE
EARTHING OF SURGE ARRESTER
EARTHING OF CVT
EARTHING OF CT
EARTHING OF ISOLATOR
EARTHING OF TANDEM ISOLATOR
AUXILIARY EARTHMAT
EARTHING OF CABLE TRENCH
NESCL/OPTCL/CS-OS-616
1-13
1-34
1-2
1-2
1-8
1-55
1-9
1-16
1-12
1-25
1-55
1-37
1-16
1-18
1-21
1-29
1-30
1-35
1-25
1-78
1-67
1-3
1-30
1-10
1-10
1-91
CONTENTS OF THE BID- Page 1 of 2
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EARTHING OF LIGHTNING MAST

EARTHING OF POST INSULATOR
EARTHING OF TOWER WITH PEAK
EARTHING OF WAVE TRAP
EARTHING OF TRANSFORMER
EARTHING OF RAIL TRACK
EARTHING OF LT TRANSFORMER
EARTHING OF GATE
CONTENTS OF THE BID- Page 2 of 2
ORISSA POWER TRANSMISSION CORPORATION LIMITED
FOR
GENERAL
GENERAL CLAUSES
E1-GENERAL CLAUSE-Page 1 of 13
TABLE OF CONTENTS
1. GENRAL CONDITIONS
2. GENERAL PARTICULARS OF SYSTEM
3. DRAWINGS ATTACHED WITH TENDER DOCUMENT
4. GUARANTEES TECHNICAL PARTICULARS
5. COMPLIANCE WITH SPECIFICATION
6. TEST AND MAINTENANCE EQUIPMENT
7.
SPARES
8.
TRAINING
9.
ERECTION AT SITE AND ACCOMMODATION
10.
SITE CONSTRUCTION SUPPLIES
11.
SUPERVISION AND CHECKING OF WORK ON SITE
12.
RESPONSIBILITY FOR THE RUNNING OF PLANT BY CONTRACTOR
13.
COMPLIANCE WITH REGULATIONS
14.
MAINTENANCE AND CLEARING OF SITE
10
15.
INSURANCE
10
16.
PROTECTION OF MONUMENTS AND REFERENCE POINTS
11
17.
WORK AND SAFETY REGULATIONS
11
18.
FOREIGN PERSONNEL
13
1. GENERAL CONDITIONS
1.1 Responsibility of the Contractor
The Contractor shall also be responsible for the complete design and engineering, overall co-ordination
with internal and external agencies, project management, training of Employers manpower, loading,
unloading, storage at site, inventory management at site during construction, dismantling, re-erection of
installations as per Engg Incharge (Divisional Engr.)s advice, handling, moving to final destination,
obtaining statutory authoritys clearance for successful erection, and testing and commissioning of the
substation.
1.2 Specific exclusions:
The following items of work are specifically excluded from the Contractors scope of work unless
otherwise specifically brought out..
I.
Substation site selection
II.
Land acquisition
1.3 Interfacial point for line termination at substation

The line Contractor shall terminate the transmission line along with insulator hardware and other
essential fittings at the substation gantry. The substation Contractor shall provide necessary anchoring
plates in co-ordination with the transmission line contractor. The substation Contractor shall be
responsible for providing the necessary electrical interconnection from the line conductor to the
substation.
1.4 Limit of contract
The scope of work shall also include all work incidental for successful operation and commissioning
and handing over of works whether specifically mentioned or not. In general works are to be carried out
by the Contractor in accordance with stipulations in Conditions of Contract.
1.5 Quantity variation
The Employer reserves the right to order and delete such works which may be necessary for him within
the quantity variation option laid down in the conditions of the contract. This shall include but not be
limited to: the manufacture, supply, testing, delivery to site, erection and commissioning as may be
required in accordance with the Conditions of Contract at the prices stated in the Schedules.
The Employer shall be at liberty to order from the Contractor such quantities of the apparatus at any
time before the expiration of the maintenance period of the scope of work, provided that such quantities
do not exceed the limitation of the Contract Value as defined in the Conditions of Contract. Each
separate order for Work at the Option of the Employer shall constitute a section for the purpose of
payment and taking over.
The Employer shall also be at liberty to delete from the Contractor such quantities of the apparatus at
any time before commencement of supply of works under the detailed scope of work.
1.6 Supply of non specified equipment/service during execution of contract.
The Employer may require the Contractor to supply and install a number of items such as testing and
measuring instruments, vehicles, repairing of existing equipment, removal and refurbishment of
plant/equipment from one place to another etc. which in the opinion of the Engg Incharge (Divisional
Engr.) are to the interest of the project execution. These items and services shall not be limited to
proprietory goods provided for the project.
Such supplies and services shall be reimbursed against supply and service invoices for the materials
or services actually supplied from the manufacturer or supplier of these items. The bidder shall quote
on cost for these items for the earmarked funds in appropriate schedules which shall be considered in
bid prices. How ever these costs shall be payable to the Contractor on pro rata basis for the actual
amount spent for procurement and availing of the services.
For such items of supply the Contractor shall follow the fair principle of contracting procedure to the
satisfaction of Engg Incharge (Divisional Engr.).
2. GENERAL PARTICULARS OF SYSTEM
System description
The following are the general particulars governing the design and working of the complete system of
which the Contract Works will eventually form a part:
Electrical energy is generated at a number of thermal and hydro power plants generally located in the
North, Central and Southern areas of Orissa State. The system is three phase, 50 Hz and power is
transmitted at 400kV, 220kV and 132kV to the distribution system, via grid substations, which operate
at 33kV, 11kV and 400V. The 400kV and 220kV networks tie into the national 400kV and 220kV grid
systems operated by the Power Grid Corporation of India. The proposed works will increase the
interconnection of, and will thus reinforce the 400kV and 220kV networks within Orissa State. The
detailed technical parameters of the system are given in the schedules.
Substation description:
OPTCL has adopted the philosophy of installing open terminal air insulated substations. The busbars
may be of either rigid type or flexible strain type depending upon the choice of the designer considering
the overall suitability and economy of the substation to be installed.
Layout arrangement
The Contractor shall study the details of layout arrangements already indicated in the schedules details
for the existing substations. The bay width and height of the conductors for these substations shall be
achieved by the Contractor in case of extension substations. However the Contractor shall finalise the
layout arrangements in case of new substations in line with this Specification with the approval of the
Engg Incharge (Divisional Engr.) which shall be meeting at least the basic minimum electrical
clearances as specified in the schedules.
Location and site description
Details of the sub-substation locations, their approach , geography and topography has been provided to
the extent possible. The Bidder shall make necessary visit to the substation sites and fully appraise
himself before bidding. Deviations on account of inadequate data for substation works shall not be
acceptable and the Bid shall not be considered for evaluation in such cases.
Meteorological data
Appropriate meteorological data is given in the schedules.
Soil data
Detailed soil investigations in respect of various substations have not been made. However the general
characteristics of the soil are given in the schedules. The Contractor shall investigate the properties of
the substations and measure the soil resistivity as part of the scope of work.
Completeness and accuracy of information
The Contractor shall note that the information provided above and in the relevant schedules may not be
complete or fully accurate at the time of bidding. For his own interest the Contractor is advised to make
site visits and fully satisfy himself regarding site conditions in all respects, and shall be fully
responsible for the complete design and engineering of the substations.
3. DRAWINGS ATTACHED WITH TENDER DOCUMENT

The various drawings and schedules provided are a part of the specification and for information
purposes only. These are not necessarily binding on the part of the Contractor. Bids shall be prepared
by the Bidder based on information provided in the drawings and schedules and that gathered by the
Bidder himself.
4. GUARANTEES TECHNICAL PARTICULARS
The Contract Works shall comply with the guaranteed technical particulars specified or quoted in the
bid. All plant and apparatus supplied under this Contract shall be to the approval of the Engg Incharge
(Divisional Engr.).
All plant and equipment supplied under this contract must have been type tested, have been in
manufacture and satisfactory service at identical ratings for at least two years. The bidder shall furnish
in his bid the necessary supporting data in specified formats for consideration during bid evaluation. If
during evaluation non compliance is identified the successful Contractor shall be bound to supply the
equipment from manufacturers complying with the stipulated requirements / OPTCL approval renders.
The Contractor shall be responsible for any discrepancies, errors or omissions in the particulars and
guarantees.
The Bidder for his own interest, shall establish the technical responsiveness of his bid, shall provide all
data in appropriate technical data sheets, general/ technical information, literature, and pamphlets etc.
along with the bid.
5. COMPLIANCE WITH SPECIFICATION
All apparatus should comply with this Specification. Any departures from the requirements of this
Specification shall be stated in the relevant Bid Proposal Schedules and will be considered during Bid
evaluation. Unless brought out clearly in the technical schedules, it will be presumed that the equipment
is deemed to comply with the technical specification.
In the event of there being any inconsistency between the provisions of the conditions of contract and
the provisions of this Specification in respect of commercial requirements, the provisions of the
conditions of contract shall take precedence for commercial matters and the provisions of this
Specification shall take precedence in respect of technical matters.
In case of inconsistency between technical specification & bid proposal sheet, quantities of various
items as specified in the bid proposal sheet shall be considered for quoting however the work shall be
executed as specified in the technical specification. Only brief description is given in the BPS & the
work shall be executed in line with the requirement given in the TS.
The manufacturer and places of manufacture, testing and inspection of the various portions of the
Contract Works shall be stated in the relevant Bid Proposal Schedules.
6. TEST AND MAINTENANCE EQUIPMENT
The Contractor shall supply the type and quantity of test and maintenance equipment specified in the
Schedules as part of the contract works.
7. SPARES
7.1 General
The Contractor shall provide the mandatory spares detailed in the Schedules and shall, where
considered necessary, provide a list of recommended spare parts (optional spares) together with their
individual prices. The Employer may order all or any of the spare parts listed at the time of contract
award and the spare parts so required by the Employer, shall be supplied as part of the Works under this
specification. Additional spares may be ordered at any time during the contract at the rates stated in the
Price Schedule.
7.2 Mandatory spares
The Employer has indicated the requirement of mandatory spares as a percentage of the population of
main equipment together with proposed storage locations. The quantities shall be determined by the
Contractor and indicated in the relevant Bid Price Schedules. These quantities shall be considered for
evaluation of the bids.
7.3 Optional spares
The Contractor may recommend a list of optional spare parts together with the quantity and usage rates
for their equipment in the relevant Bid Proposal Schedule. The Engg Incharge (Divisional Engr.) shall
assess their requirement and place orders.
The spares shall include consumable items sufficient for a plant operational period of five years after
commissioning, as well as essential replacement parts to cover the event of a break-down which would
affect the availability or safety of the plant. Spares shall be available during the life of the equipment
and the Contractor shall give 12 months notice of his, or any sub-contractors, intention to cease
manufacture of any component used in the equipment.
The Contractor shall ensure that sufficient spare parts and consumable items are available for his own
use during commissioning of the plant. Spares ordered by the Employer shall not be used by the
Contractor without the written consent of the Engg Incharge (Divisional Engr.) and any spares so used
by the Contractor during the commissioning of the plant shall be replaced by the Contractor at the
Contractors expense.
Any spare apparatus, parts and tools shall be subject to the same specification, tests and conditions as
similar material supplied under the Scope of Works of the Contract. They shall be strictly
interchangeable and suitable for use in place of the corresponding parts supplied with the plant and
must be suitably marked and numbered for identification and prepared for storage by greasing or
painting to prevent deterioration.
All spare apparatus or materials containing electrical insulation shall be packed and delivered in cases
suitable for storing such parts or material over a period of years without deterioration. Such cases shall
have affixed to both the underside and topside of the lid a list detailing its contents. The case will
remain the property of the Employer.
8
TRAINING
The Contractor will be required to provide suitable training for selected staff both on site and at the
Contractor's place of work. Details of the training considered appropriate shall be stated clearly, at the
bidding stage, based on the number of trainees specified. The cost of training including all course fees
shall be included.
The areas in which it is considered training should be provided, and duration of the training courses, are
given in this section. Alternative arrangements, where considered appropriate, should be suggested.
Four categories of training are considered appropriate namely :
I.
Hardware maintenance.
II.
Operator familiarisation.
III.
Software management.
IV.
Installation and commissioning techniques.
8.1 Hardware maintenance

Courses for hardware maintenance shall identify techniques for preventative physical maintenance and
for identification, isolation and replacement of faulty components. This course shall take place before
equipment is delivered to site.
An essential part of the hardware maintenance course shall include highlighting the philosophy of
computer based preventive maintenance and identification of the various diagnostic/interrogation
facilities available. The Contractor shall supply adequate documented instructions to enable a detailed
interrogation and analysis process to be carried out using the diagnostic software facilities. All items of
hardware to be supplied shall be covered by the course.
8.2 Operator familiarisation
This course is intended to familiarise the operators with the system and its use in operating and
controlling the PLCC network. The course shall ensure that the control room staff are completely
familiar with all operational aspects of the equipment. The means of obtaining special data, report logs
and all other facilities which would enable the operators to be fully conversant with the system, shall
also be incorporated.
It is envisaged that it will be necessary for the Contractor to run operator familiarisation courses each of
approximately one week in duration at site for the training of the Employer's staff.
8.3 Software management
This course shall comprise two main areas and shall take place at the Contractor's works before
equipment is delivered to site .
I). A FORMAL COURSE ON THE SOFTWARE FOR EPAX ETC. DETAILING THE
VARIOUS MODULES USED AND THEIR INTERACTION.
II). A PRACTICAL COURSE ON EDITING THE DATABASE (TO INCORPORATE
EXTENSIONS TO THE POWER NETWORKS, INCLUSION OF ADDITIONAL
ANALOGUE/DIGITAL SIGNALS FROM EXISTING EQUIPMENT, ETC.) AND
GENERATING NEW LOGS, ALPHANUMERIC DISPLAYS, ETC.
It is envisaged that the software management courses shall extend for a period of approximately six
weeks.
II.A) Installation and commissioning techniques
The Employer's staff will be present during the installation and commissioning period and it is essential
that they be fully involved in any on-site corrections or modifications to hardware and software
equipment.
It is envisaged that it will be necessary for the Contractor to run installation and commissioning
techniques courses each of approximately one week in duration at site for the training of the Employer's
staff.
II.B) Proposals for training and manning
For each course recommended the following information shall be provided:
I.
Course name and identification.
II.
Short description of the curriculum.
III.
Level of competency required for each course.
IV.
Date and duration.
V.
Maximum number of staff that can attend.
VI.
Location.
VII.
Other important information.
The times at which the various training courses will take place shall be stated, and fully documented
notes shall be available to the Employer not later than two months before the commencement of the
course.
All training course notes and documentation shall be in the English language.
An estimate of the total number of the Employer's staff required to run, operate and service the works
covered by this Specification shall be given if this is different to the numbers specified.
The prices of the training courses shall be detailed in full such that additions or deletions to personnel
or courses can be calculated by the Employer without necessarily having to contact the Contractor. This
is particularly important for the 'Software management' courses where prices for formal course days and
practical course days shall be individually detailed.
9
ERECTION AT SITE AND ACCOMMODATION
The Contractor shall provide, at his own cost and expense, all labour, plant and material necessary for
unloading and erection at the Site and shall be entirely responsible for its efficient and correct
operation.
The Contractor shall be responsible for arranging and providing all living accommodation services and
amenities required by his employees. He shall also provide suitable office accommodation at each
substation site for the sole use by the Engg Incharge (Divisional Engr.) for new substations only.
10 SITE CONSTRUCTION SUPPLIES
The Contractor shall provide at his own cost and expense, any site supplies of electrical energy which
he may require for supplying power for heavy erection plant, welding plant or other tools and lighting
and testing purposes.
All wiring for such tackle and for lighting from the point of supply shall be provided by the Contractor
and all such installations shall comply with all appropriate statutory regulations to which the Employer
is subject.
Wiring shall be of the best quality double insulated flexible cable, suitably fixed, protected and
maintained. All necessary precautions shall be taken to ensure the safety of every person employed or
working on the Site and this shall include routine inspection of all temporary installations and portable
equipment.
The Engg Incharge (Divisional Engr.) or his authorised representative may require the disconnection or
alteration of any parts which he may consider dangerous.
As soon as any part or the whole of the Contractors installation is no longer required for the carrying
out of the works, the Contractor shall disconnect and remove the same to the satisfaction of the Engg
Incharge (Divisional Engr.) or his authorised representative.
The contractor shall be responsible for arranging construction water at his own cost.
How ever in case water is available at any substation site, Contractor may request Engg Incharge
(Divisional Engr.) for availing water at one point, which shall be charged to the contractor at prevailing
rates for supply of water by Govt. Dept. / Municipal Authorities.
In no case the work shall suffer on account of the Employer not making available the supply of water
and electricity for construction purposes.
11 SUPERVISION AND CHECKING OF WORK ON SITE
All work on site included in the Contract scope of works shall be supervised by a sufficient number of
qualified representatives of the Contractor.
Before putting any plant or apparatus into operation the Contractor shall satisfy himself as to the
correctness of all connections between the plant and apparatus supplied under this and other contracts.
The Contractor shall advise the Engg Incharge (Divisional Engr.) in writing, giving the period of notice
as specified in the General Conditions of Contract, when the plant or apparatus is ready for inspection
or energisation.
12 RESPONSIBILITY FOR THE RUNNING OF PLANT BY CONTRACTOR
Until each Section of the Contract Works has been taken over or deemed to have been taken over under
the Conditions of Contract, the Contractor shall be entirely responsible for the Contract Works, whether
under construction, during tests, or in use for the Employers service.
The Contractor shall instruct the Employers operating staff in the recommended method of operation
of the plant supplied. Such instruction shall commence prior to the commissioning of the plant and shall
be followed by practical instruction for a period of up to one month after the plant is taken over by the
Employer. During this one month period the Contractor shall provide an engineer, on each site that is
taken over, to assist with operation of the plant and to provide on-site training of the Employers
operating staff. The training schedule and programme for each substation shall be submitted to the
Engg Incharge (Divisional Engr.) for approval, three months prior to the substations planned
completion date.
If the Employer shall so require, the Contractor shall provide the services of a skilled engineer
acquainted with the running of the plant for any period required by the Employer between commencing
of use of any portion of the plant (whether taken over or not) and the expiry of the period of
maintenance, the wages for such services being paid by the Employer to the Contractor, except in
respect of the carrying out of any work already covered by the Contractors obligations under this
Contract.
When the Contractor ceases to be obliged to maintain a supervising engineer on the Site under the
foregoing provisions of this clause, the Contractor shall, until the expiration of the period of
maintenance, make such arrangements as to ensure the attendance on site within 24 hours of being
called upon by the Engg Incharge (Divisional Engr.), of a competent supervising engineer for the
purpose of carrying out any work of maintenance or repair for which the Contractor shall be liable.
During such part or parts of the said period as the Engg Incharge (Divisional Engr.) shall deem it
necessary the said representative shall be continuously available on the Site.
Any work which may be necessary for the Contractor to carry out in pursuance of his obligations under
the Conditions of Contract shall be carried out with the minimum of interference to the normal
operation of the substation. Work on the Site shall be carried out at such time and during such hours as
the Engg Incharge (Divisional Engr.) may require.
13 COMPLIANCE WITH REGULATIONS
All apparatus and material supplied, and all work carried out shall comply in all respects with such of
the requirements of all Regulations and Acts in force in the country of the Employer as are applicable to
the Contract Works and with any other applicable regulations to which the Employer is subject.
The Contractor shall fully inform himself of the requirements of the local Laws, Regulations and rules
in-force in the State of Orissa, especially with respect to local employment laws, licensing
requirements, electrical safety rules and regulations, building regulations and planning procedures.
The Contractor shall be responsible for applying for all necessary licenses; including Electrical
Contractors License, Workmans Permits and Certificates of Competency for Supervisors, and local
government approvals required for the contract works and for the payment of all necessary fees
associated with such licenses and approvals.
Correspondence with the Electrical Inspector shall be conducted through the Engg Incharge (Divisional
Engr.), but the Contractor shall provide all necessary information, regarding the contract works, as may
be required by the Electrical Inspector.
Additionally the Contractor shall also follow the minimum regulations on safety, employees welfare,
industry etc. as stipulated under the relevant Clause of this section.
14 MAINTENANCE AND CLEARING OF SITE
The placing of materials and plant near the erection site prior to their being erected and installed shall
be done in a neat, tidy and safe manner. The Contractor shall at his own expense keep the site area
allocated to him and also the erection area of the Contract Works reasonably clean and shall remove all
waste material as it accumulates and as directed by the Engg Incharge (Divisional Engr.) from time to
time.
15 INSURANCE
15.1
General
In addition to the conditions covered under the Clause titled insurance in the Special Conditions of
Contract, the following provisions will also apply to the portion of works to be done beyond the
Suppliers own or his sub-Contractors manufacturing Works.
15.2
Workmen's Compensation Insurance
This insurance shall protect the Contractor against all claims applicable under the Workmens
Compensation Act, 1948 (Government of India). This policy shall also cover the Contractor against the
claims for injury, disability, disease or death of his or his sub-contractor's employees, which for any
reason are not covered under the Workmans Compensation Act, 1948. The liabilities shall not be less
than;
I.
Workmens Compensation As per statutory provisions
II.
Employee's liability
As per statutory provisions
* According to the Govt. rules.

15.3
Comprehensive automobile insurance
This insurance shall be in a such a form to protect the Contractor against all claims for injuries,
disability, disease and death to members of public including the Employer's men and damage to the
property of others arising from the use of motor vehicles during on or off the Site operations,
irrespective of the ownership of such vehicles. The minimum liability covered shall be as herein
indicated:
I.
Fatal Injury
Rs. 100,000/- each person
II.
Property
Rs. 200,000/- each occurrence
III.
Damage
Rs. 100,000/- each occurrence
* As per latest prevailing Govt. rules.

15.4
Comprehensive General Liability Insurance
This insurance shall protect the Contractor against all claims arising from injuries, disabilities, disease
or death of members or public or damage to property of others, due to any act or omission on the part of
the Contractor, its agents, its employees, its representatives and sub-contractors or from riots, strikes
and civil commotion.
The hazards to be covered will pertain to all works and areas where the Contractor, its sub-contractors,
agents and employees have to perform work pursuant to the Contracts.
The above are only an illustrative list of insurance covers normally required and it will be the
responsibility of the Contractor to maintain all necessary insurance coverage to the extent both in time
and amount to take care of all its liabilities either direct or indirect, in pursuance of the Contract.
16 PROTECTION OF MONUMENTS AND REFERENCE POINTS

The Contractor shall ensure that any finds such as relics, antiques, coins, fossils, etc. which he may
come across during the course of performance of his works either during excavation or elsewhere, are
properly protected and handed over to the Employer. Similarly, the Contractor shall ensure that the
bench marks, reference points, etc. which are marked either with the help of Employer or by the
Employer shall not be disturbed in any way during the performance of his works. If any work is to be
performed which disturbs such reference points, the same shall be done only after these are transferred
to other suitable locations under the direction of the Employer. The Contractor shall provide all
necessary materials and assistance for such relocation of reference points etc.
17 WORK AND SAFETY REGULATIONS
The Contractor shall ensure safety of all the workmen, plant and equipment belonging to him or to
others, working at the Site. The Contractor shall also provide for all safety notices and safety equipment
required by the relevant legislation and deemed necessary by the Engg Incharge (Divisional Engr.).
The Contractor will notify, well in advance to the Engg Incharge (Divisional Engr.), his intention to
bring to the Site any container filled with liquid or gaseous fuel, explosive or petroleum substance or
such chemicals which may involve hazards. The Engg Incharge (Divisional Engr.) shall have the right
to prescribe the conditions under which such a container is to be stored, handled and used during the
performance of the works and the Contractor shall strictly adhere to and comply with such instructions.
The Engg Incharge (Divisional Engr.) shall also have the right, at his sole discretion, to inspect any
such container or such construction plant and equipment for which materials in the container is required
to be used and if in his opinion, its use are not safe, he may forbid their use.
No claim due to such prohibition or towards additional safety provisions called for by him shall be
entertained by the Employer.
Further, any such decision of the Engg Incharge (Divisional Engr.) shall not, in any way, absolve the
Contractor of his responsibilities and in case use of such a container or entry thereof into the Site areas
is forbidden by the Engg Incharge (Divisional Engr.), the Contractor shall use alternative methods with
the approval of the Engg Incharge (Divisional Engr.) without any cost implication to the Employer or
extension of work schedule.
Where it is necessary to provide and/or store petroleum products or petroleum mixtures and explosives,
the Contractor shall be responsible for carrying out such provision and/or storage in accordance with
the rules and regulations laid down in Petroleum Act 1934, Explosives Act 1948 and amendments
thereof, and Petroleum and Carbide of Calcium Manual published by the Chief Inspector of Explosives
of India. All such storage shall have prior approval of the Engg Incharge (Divisional Engr.). In case,
any approval is necessary from the Chief Inspector (Explosives) or any statutory authorities, the
Contractor shall be responsible for obtaining the same.
All equipment used in construction and erection by Contractor shall meet Indian or International
Standards and where such standards do not exist, the Contractor shall ensure these to be absolutely safe.
All equipment shall be strictly operated and maintained by the Contractor in accordance with
manufacturers operation manual and safety instructions and as per any existing Guidelines/Rules in this
regard.
Periodical examinations and all tests for all lifting and hoisting equipment and tackle shall be carried
out in accordance with the relevant provisions of Factories Act 1948, Indian Electricity (Supply) Act
and associated Laws/Rules in force, from time to time. A register of such examinations and tests shall
be properly maintained by the Contractor and will be promptly produced as and when desired by Engg
Incharge (Divisional Engr.).
The Contractor shall provide suitable safety equipment of prescribed standard to all employees and
workmen according to the need, as may be directed by the Engg Incharge (Divisional Engr.) who will
also have the right to examine such safety equipment to determine its suitability, reliability,
acceptability and adaptability.
Where explosives are to be used, the same shall be used under the direct control and supervision of an
expert, experienced and qualified competent person, strictly in accordance with the Code of
Practices/Rules framed under Indian Explosives Act pertaining to handling, storage and use of
explosive.
Contractors employing more than 250 workmen whether temporary, casual, probationer, regular or
permanent or on contract, shall employ at least one full time officer exclusively as Safety Officer to
supervise safety aspects of the equipment and workmen. Such an officer will co-ordinate with the
Project Safety officer of the Employer.
The name and address of the Safety Officer of the Contractor will be promptly informed in writing to
the Engg Incharge (Divisional Engr.) with a copy to the Safety Officer-in-charge before he starts work
or immediately after any change of the incumbent is made during currency of the Contract.
In case any accident occurs during the construction, erection or other associated activities undertaken
by the Contractor, thereby causing any minor or major or fatal injury to his employees due to any
reason whatsoever, it shall be the responsibility of the Contractor to promptly inform the same to the
Engg Incharge (Divisional Engr.) and also to all the authorities envisaged under the applicable laws.
The Engg Incharge (Divisional Engr.) shall have the right at his sole discretion to stop the work, if in
his opinion the work is being carried out in such a way as may cause accidents or endanger the safety of
the persons and/or equipment. In such cases, the Contractor shall be informed in writing about the
nature of hazards and possible injury/accident and he shall remove shortcomings immediately. The
Contractor, after stopping the specific work, can if felt necessary appeal against the order of stoppage of
work to the Engg Incharge (Divisional Engr.) within three days of such stoppage of work and the
decision of the Engg Incharge (Divisional Engr.) in this respect shall be conclusive.
The Contractor shall not be entitled for any damages or compensation for stoppage of work due to
safety reasons and the period of such stoppage of work will not be taken as an extension of time for
completion of work, nor will it be the grounds for waiver of any part of suppliers liability for timely
completion of the works.
The Contractor shall follow and comply with all Safety Rules, relevant provisions of applicable laws
pertaining to the safety of workmen, employees, plant and equipment as may be prescribed from time to
time without any demur, protest or contest or reservation. In case of any conflict between statutory
requirement and Safety Rules referred above, the most stringent clause shall be applicable.
If the Contractor fails in providing safe working environment as per Safety Rules or continues the
works even after being instructed to stop work by the Engg Incharge (Divisional Engr.), the Contractor
shall promptly pay to the Employer on demand, compensation at the rate of Rs. 5,000/- per day or part
thereof till the instructions are complied with and so certified by the Employer. However, in case of
accident taking place causing injury to any individual, the provision contained in subsequent paragraph
as here below shall also apply in addition to the compensation mentioned in this paragraph.
If the Contractor does not take all safety precautions and comply with Safety Rules as prescribed by the
Engg Incharge (Divisional Engr.) or as prescribed under the applicable law, to safeguard equipment,
plant and personnel the Contractor shall be responsible for payment of compensation to the Employer
as per the schedule given below.
If the Contractor does not prevent hazardous conditions which may cause injury to his own employees,
employees of other Contractors, or the Employer or any other person at Site or adjacent thereto, the
Contractor shall be responsible for payment of compensation to the Employer as per the following
Schedule:
Fatal injury or accident causing death.
Rs. 100,000/- per Applicable for injury or death to

person
any person whomsoever.
Major injuries or accident causing 25% or Rs. 20,000/- per Applicable for injury or death to
more permanent disability.
person
any person whomsoever.
* As per prevailing Govt. rules.

Permanent disability shall have the same meaning as indicated in Workmen's Compensation Act. The
compensation mentioned above shall be in addition to the compensation payable to the
workmen/employees under the relevant provisions of the Workmen's Compensation Act and rules
framed thereunder or any other applicable law as applicable from time to time. In case the Employer is
made to pay such compensation, the Contractor will reimburse the Employer such amount(s) in addition
to the compensation indicated above.
18 FOREIGN PERSONNEL
If necessary for the execution of the works, the Contractor shall bring foreign supervisors for the
execution of the Contract at his own cost. The Contractor shall submit to the Employer data on all
personnel he proposes to bring into India for the performance of the works under the Contract, at least
Sixty (60) days prior to their arrival in India. Such data shall include the name of each person, his
present address, his assignment and responsibility in connection with the works, and a short resume of
his qualifications and experience etc. in relation to the work to be performed by him.
Any person unsuitable and unacceptable to the Employer, shall not be brought to India. Any person
brought to India, and found unsuitable or unacceptable to the Employer shall be immediately removed
from Site and repatriated. If found necessary, he may be replaced by other personnel acceptable to the
Employer.
No person brought to India by the Contractor for the works shall be repatriated without the consent of
the Employer in writing, based on a written request from the Supplier for such repatriation giving
reasons for such an action to the Employer. The Employer may give permission for such repatriation
provided the Employer is satisfied that the progress of work will not suffer due to such repatriation.
The cost of passports, visas and all other travel expenses to and from India, shall be to the Contractor's
account. The Employer will not provide any residential accommodation and/or furniture for any of the
Contractors personnel including foreign personnel. Contractor shall make his own arrangements for
such facilities.
The Contractor and his expatriate personnel shall respect all Indian Acts, Laws, Rules and Regulations
and shall not in any way, interfere with Indian political and religious affairs and shall conform to any
other rules and regulations which the Government of India, and the Employer may establish on them.
The Contractors expatriate personnel shall work and live in close co-operation and co-ordination with
their co-workers and the community and shall not engage themselves in any other employment either
part-time or full-time nor shall they take part in any local politics.
The Employer shall assist the Contractor, to the extent possible, in obtaining necessary certificates and
other information needed by the Government agencies.
OFFICE OF THE SR. GENERAL MANAGER,

CENTRAL PROCUREMENT CELL,
JANAPATH, BHUBANESWAR 751022.
FOR
GENERAL TECHNICAL CLAUSES
FOR DESIGN
E2-GENERAL TECHNICAL CLAUSE- Page 1 of 34
GENERAL TECHNICAL CLAUSES

TABLE OF CONTENTS
1. GENERAL
2. DESIGN AND STANDARDISATION
3. QUALITY ASSURANCE
3.1. General
3.2. Quality assurance programme
3.3. Quality plans
3.4. Inspection and testing
3.5. Non-conforming product
3.6. Monitoring of quality arrangements
3.7. Sub-contractors
3.8. Method statement
4. HEALTH, SAFETY AND ENVIRONMENT (HSE) PLAN
4.1. General
4.2. Content of HSE Plan
4.3. General structure of HSE Plan
4.4. Section 6 of HSE Plan
4.5. Standards, Procedures and Guidelines
10
4.6. Supervision strategy
10
5. PROGRESS REPORTING
10
6. STANDARDS
11
7. LANGUAGE AND SYSTEM OF UNITS
11
8. CORRESPONDENCE, DRAWINGS, APPROVAL PROCEDURE AND SAMPLES11

8.1. Correspondence
11
8.2. Drawings and samples
11
8.3. Approval procedure
12
8.4. Final as-built drawings
13
8.5. Operation and Maintenance Manuals
14
9. MASS AND SIZE OF PARTS AND QUANTITIES OF OIL
14
10. GENERAL REQUIREMENTS
14
10.1. Bolts and nuts
14
10.2. Galvanising.
15
10.3. Cleaning, painting and tropicalisation
16
10.4. Provision for exposure to hot and humid climate
18
10.5. Labels and plates
18
10.6. Padlocks
19
10.7. Earthing
20
10.8. Lubrication
20
11. PRODUCTION PROCESS REQUIREMENTS
20
11.1. Castings
20
11.2. Forgings
21
11.3. Fabricated components
21
11.4. Welding and welders qualifications
21
12. WIRING, CABLING AND CABLE INSTALLATION
24
12.1. Cubicle wiring
24
12.2. LV power cabling
25
12.3. Multi-core cables and conduit wiring
25
12.4. Laying and installing of cables
26
12.5. Termination of cables and wires
27
13. DEGREES OF PROTECTION
28
14. SUPPLY VOLTAGE
28
15. MAINTENANCE TELEPHONE POSITIONS
28
16. ERECTION CONDITIONS
29
16.1. General
29
16.2. Regulation of local authorities and statutes
29
16.3. Inspection, testing and inspection certificates
29
16.4. Contractor's field operation
29
16.5. Facilities to be provided by the contractor
29
16.6. First-Aid and general hygiene
30
16.7. Security
30
16.8. Materials handling and storage
30
17. CONSTRUCTION MANAGEMENT
31
17.1. General
31
17.2. Field office records
31
17.3. Protection of property and Contractor's liability
31
18. CODE REQUIREMENTS
31
19. EMPLOYER'S SUPERVISION
31
20. TESTING AND INSPECTION
32
21. FIRE PRECAUTIONS
32
22. PACKING, SHIPPING AND TRANSPORT
33
23. ERECTION MARKS
34
24. SPANNERS AND SPECIAL TOOLS
34
25. RUNWAY BEAMS, EYE BOLTS AND LIFTING TACKLE
34
1.
GENERAL
The following provisions shall supplement all the detailed technical specifications and requirements
brought out in accompanying Technical Specifications. The Contractors proposal shall be based upon
the use of equipment and materials complying fully with the requirements specified herein. It is
recognised that the Contractor may have standardised on the use of certain components, materials,
processes or procedures different to those specified herein. Alternate proposals offering similar
equipment based on the manufacturers standard practice will also be considered, provided such
proposals meet the specified design standard and performance requirement and are acceptable to the
Engg. Incharge (Divisional Engr.).
2.
DESIGN AND STANDARDISATION
The Works covered by the specification shall be designed, manufactured, built, tested and
commissioned in accordance with the Act, Rules, Laws and Regulations of India. The Equipment(s)
shall also conform to the requirements detailed in the referred standards, which shall form an integral
part of the Specification, in addition to meeting the specific requirements called for elsewhere in the
Specification.
The Contract works shall be designed to facilitate inspection, cleaning and repairs, and for operation
where continuity of supply is the first consideration. Apparatus shall be designed to ensure satisfactory
operation in all atmospheric conditions prevailing at the Site(s) and during such sudden variation of
load and voltage as may be met with under working conditions on the system, including those due to
faulty synchronising and short circuit.
The design shall incorporate all reasonable precautions and provisions for the safety of those concerned
in the operation and maintenance of the Contract Works and of associated works supplied under other
contracts.
Where the Specification does not contain characteristics with reference to workmanship, equipment,
materials and components of the covered equipment, it is understood that the same must be new, of
highest grade of the best quality of their kind, conforming to best engineering practice and suitable for
the purpose for which they are intended.
In case where the equipment, materials or components are indicated in the specification as 'similar' to
any special standard, the Engg. Incharge (Divisional Engr.)shall decide upon the question of similarity.
When required by the Specification; or when required by Engg. Incharge (Divisional Engr.)the
Contractor shall submit, for approval, all the information concerning materials or components to be
used in manufacture. Machinery, equipment, materials and components supplied, installed or used
without such approval shall run the risk of subsequent rejection, it being understood that the cost as well
as the time delay associated with the rejection shall be borne by the Contractor.
The design of the Works shall be such that installation, future expansions, replacements and general
maintenance may be undertaken with a minimum of time and expense. Each component shall be
designed to be consistent with its duty and suitable factors of safety, subject to mutual agreements and
shall be used throughout the design. All joints and fastenings shall be so devised, constructed and
documented that the component parts shall be accurately positioned and restrained to fulfil their
required function.
All outdoor apparatus and fittings shall be designed so that water cannot collect at any point. Grease
lubricators shall be fitted with nipples and where necessary for accessibility, the nipples shall be placed
at the end of extension piping.
All water and oil pipe flanges shall be to IS 6392/BS 4504 or other equivalent standard, as regards both
dimensions and drilling, unless otherwise approved.
Cast iron shall not be used for chambers of oil filled apparatus or for any part of the equipment which is
in tension or subject to impact stresses.
Kiosks, cubicles and similar enclosed compartments shall be adequately ventilated to restrict
condensation. All contactor or relay coils and other parts shall be suitably protected against corrosion.
All apparatus shall be designed to obviate the risk of accidental short circuit due to animals, birds,
insects, mites, rodents or micro-organisms.
Corresponding parts shall be interchangeable. Where required by the Engg. Incharge (Divisional
Engr.)the Contractor shall demonstrate this quality.
3.
QUALITY ASSURANCE
3.1.
General
To ensure that the supply and services under the scope of this Contract, whether manufactured or
performed within the Contractors works or at his Sub-Contractors premises or at Site or at any other
place of work are in accordance with the Specification, with the Regulations and with relevant Indian or
otherwise Authorised Standards the Contractor shall adopt suitable Quality Assurance Programmes and
Procedures to ensure that all activities are being controlled as necessary.
The quality assurance arrangements shall conform to the relevant requirements of ISO 9001 or
ISO 9002 as appropriate.
The systems and procedures which the Contractor will use to ensure that the Works comply with the
Contract requirements shall be defined in the Contractors Quality Plan for the Works.
The Contractor shall operate systems which implement the following:
Hold Point
A stage in the material procurement or workmanship process beyond which work shall
not proceed without the documented approval of designated individuals or organisations.
The Engg. Incharge (Divisional Engr.) written approval is required to authorise work to progress
beyond the Hold Points indicated in approved Quality Plans.
Notification Point
A stage in material procurement or workmanship process for which advance
notice of the activity is required to facilitate witness.
If the Engg. Incharge (Divisional Engr.)does not attend after receiving documented notification in
accordance with the agreed procedures and with the correct period of notice then work may proceed.
3.2.
Quality assurance programme
Unless the Contractors Quality Assurance System has been audited and approved by the Engg.
Incharge (Divisional Engr.), a Quality Assurance Program for the Works shall be submitted to the Engg.
Incharge (Divisional Engr.)for approval a minimum of one month prior to commencement of the works,
or such other period as shall be agreed with the Engg. Incharge (Divisional Engr.). The Quality
Assurance Program shall give a description of the Quality System for the Works and shall, unless
advised otherwise, include details of the following:
The structure of the Contractors organisation
The duties and responsibilities assigned to staff ensuring quality of work
The system for purchasing, taking delivery and verification of materials
The system for ensuring quality of workmanship
The system for the control of documentation
The system for the retention of records
The arrangements for the Contractors internal auditing
A list of the administration and work procedures required to achieve and verify the Contracts
Quality requirements. These procedures shall be made readily available to the Engg. Incharge
(Divisional Engr.)for inspection on request.
3.3.
Quality plans
The Contractor shall draw up for each section of the work Quality Plans which shall be submitted to the
Engg. Incharge (Divisional Engr.)for approval at least two weeks prior to commencement of the
particular section. Each Quality Plan shall set out the activities in a logical sequence and, unless advised
otherwise, shall include the following:
An outline of the proposed work and program sequence
The structure of the Contractors organisation for the Contract
The duties and responsibilities assigned to staff ensuring quality of work for Contract
Hold and Notification points
Submission of engineering documents required by the Specification
The inspection of materials and components on receipt
Reference to the Contractors work procedures appropriate to each activity
Inspection during fabrication/construction
Final inspection and test
3.4.
Inspection and testing
The prime responsibility for inspection and testing rests with the Contractor. The inspection or its
waiver by the Engg. Incharge (Divisional Engr.)does not relieve the Contractor of any obligations or
responsibilities to carry out the work in accordance with the Contract.
The inspection and testing shall be documented such that it is possible to verify that it was performed.
Records of inspection shall include as a minimum the contract identity, operation/inspection, technique
used, acceptance standard, acceptability, identity of inspector/tester and date of inspection/test.
3.5.
Non-conforming product
The Contractor shall retain responsibility for the disposition of non-conforming items.
3.6.
Monitoring of quality arrangements
During the course of the Contract the Engg. Incharge (Divisional Engr.) may monitor the
implementation of the Quality Assurance arrangements. Monitoring will be by surveillance of the
activities at work locations and/or by formal audits of the adherence of the Contractor to the systems
and procedures which constitute his Quality Assurance arrangements. Corrective actions shall be agreed
and implemented in respect of any deficiencies
The Contractor shall provide any facilities, including access, which may be required by the Engg.
Incharge (Divisional Engr.)for monitoring activities.
The Engg. Incharge (Divisional Engr.)may participate on an agreed basis in the Contractors monitoring
of a sub-contractors Quality Assurance arrangements.
3.7.
Sub-contractors
The Contractor shall ensure that the Quality Assurance requirements of this Specification are followed
by any sub-contractor appointed by him under the Contract.
The Contractor shall assess the sub-contractors Quality Assurance arrangements prior to his
appointment to ensure its compliance with the appropriate ISO 9000 standard and the Specification.
Auditing of the sub-contractors Quality Assurance arrangements shall be carried out by the Contractor
and recorded in such a manner that demonstrates to the Engg. Incharge (Divisional Engr.)the extent of
the audits and their effectiveness.
3.8.
Method statement
Prior to commencing work, the Contractor shall submit a method statement setting out full details of his
method of working. This is a Hold Point.
Details of the Contractors method of working shall also be submitted at the time of Bidding.
4.
HEALTH, SAFETY AND ENVIRONMENT (HSE) PLAN
4.1.
General
Within one month of award of contract the Contractor shall produce a HSE Plan for the contract and
submit for the approval of the Engg. Incharge (Divisional Engr.). The HSE Plan is described in the
following sections.
The primary objective of the HSE Plan is for the contractor to demonstrate that he has the capability to
carry out the contract work in a cost effective manner, giving due consideration to the Health, Safety
and Environmental management of both his own employees, those of the Employer and anyone who
may be affected by his activities.
4.2.
Content of HSE Plan
The general structure of the HSE Plan is outlined in 1.9.8.3. The HSE Plan will comprise two parts i.e.:
Part : I : Sections 1 to 5, covering general HSE management and controls.
The following would be attached as appendices, where appropriate:
Organisation chart showing the proposed Contractors HSE organisational structure
The CVs, duties and responsibilities of the following personnel:

(i) Contract Manager
(ii) Contractors Site Representatives
(iii) Safety Officer
(iv) Site Safety Officers
Part : II : Section 6, providing a summary of hazards and controls.
4.3.
General structure of HSE Plan
The HSE Plan shall conform to the following general structure:

1.
Contractors Policy Statement
2.
Health
2.1
First Aid
2.2
Primary health care
2.3
Occupational health
3.
Safety
3.1
Objectives and targets
3.2
Organisation and responsibilities
3.3
HSE meetings
3.4
Motivation and communication
3.5
HSE training
3.6
Audits and inspections
3.7
Emergency response
3.8
Safety function
3.9
Accident investigating and reporting
3.10 Standards
3.11 Personal protective equipment
4.
Environment
4.1
Waste management
4.2
Chemicals management
4.3
Environmental impact
5.
Critical areas
5.1
Subcontractors
6.
Summary of hazards and controls
4.4.
Section 6 of HSE Plan
In addition to general hazards and their controls, the following hazards have been identified as specific
to this contract and therefore the contractor should demonstrate that he is capable of providing the
necessary controls for the work:
Working within a Permit to Work system
Working adjacent to live high voltage equipment
Working adjacent to, and in the vicinity of, live high voltage overhead lines
Working at elevation
Lifting operations
Use of explosives
Use of heavy machinery including cranage, pile rigs and concrete mixers
Excavation works
Work in confined spaces
Working with insulating oil
Working with compressed gas
Rotating machinery
The Contractor should demonstrate his understanding of these hazards by either proposing specific
controls for each of them or by giving supporting documentation which demonstrates that such controls
already exist.
4.5.
Standards, Procedures and Guidelines
The HSE Plan shall identify the Standards, Procedures and Guidelines that will be applicable to the
project. These will include the Indian Electricity Rules and The OPTCL Operations Safety Manual 1997 (Draft), and will be subject to the approval of the Engg. Incharge (Divisional Engr.).
4.6.
Supervision strategy
The Contractor will provide supervisors with a minimum of five years experience of this type of work
such that they are able to supervise the quality and standards of the work without intervention by the
Employer. The role of the Employer will be to monitor and audit the quality of the work to ensure that it
is of adequate standard and that it is being safely and successfully managed.
5.
PROGRESS REPORTING
The Contractor shall submit for approval, within four weeks of the issue of letter of award, an outline of
the design, engineering, material procurement, production, site mobilisation, man and machine
deployment, delivery, erection, testing, commissioning, and handing over programme. Within a further
period of 4 weeks the Contractor shall provide a detailed programme of all these activities in a form to
be agreed by the Engg. Incharge (Divisional Engr.). The Contractor shall submit monthly progress
reports to the Engg. Incharge (Divisional Engr.) office not later than the fifth day of the following
month. The reports shall show clearly and accurately the position of all activities associated with
design, material procurement, manufacture, works tests, shipping, site erection, testing and
commissioning with regard to the agreed contract programme.
In addition to the routine monthly progress report the Contractor shall also submit to the Engg. Incharge
(Divisional Engr.), by the 25th day of every month, a man hour schedule for the following month,
detailing the man hours scheduled for that month, skill-wise and area-wise.
The preferred format for presentation of programmes is MS Project version 4.0 or any latest. The
programmes and monthly updates shall be submitted on CD.
The design aspect of the progress report shall include a comprehensive statement on drawing and
calculations submitted for approval.
The position on material procurement shall give the date and details of orders placed and indicate the
delivery date quoted by the manufacturer. If any delivery date has an adverse affect on the contract
programme the Contractor shall state the remedial action taken to ensure that delays do not occur.
The position on manufacture shall indicate the arrival of material, the progress of manufacture and date
at which the equipment will be ready for transport. Any events that may adversely affect completion in
the manufacturers works shall also be reported.
All works tests executed shall be listed and the test-results shall be remarked upon. Any test failures
shall be highlighted and the Contractor shall detail the necessary steps taken in order to avoid any
adverse affect on the contract completion dates.
The despatch of each order shall be monitored on the progress report giving the date by which the
equipment will be available for transport, the estimated time of arrival on site and the dates actually
achieved.
The site works shall be segregated into civil, mechanical and electrical works for reporting purposes and
each section of the site works shall be monitored giving the percentage completion and the estimated
completion date in accordance with the contract programme. The number of men working on site, both
labour and supervisory staff, shall be reported together with any incidents or events that may affect the
progress of site works.
Any delays which may affect any milestone or final completion dates shall be detailed by the Contractor
who shall state the action taken to effect contract completion in accordance with the contract
programme.
The contractor shall provide two copies of the progress report to the Engg. Incharge (Divisional Engr.)
office.
6.
STANDARDS
Except where otherwise specified or implied, the Contract Works shall comply with the latest edition of
the relevant Indian Standards, International Electrotechnical Commission (IEC) standards and any other
standards mentioned in this Specification. The Contractor may submit for approval, equipment or
materials conforming to technically equivalent National Standards. In such cases copies of the relevant
Standards or part thereof, in the English language shall be submitted with the Tender. In case of conflict
the order of precedence shall be (1) IEC, (2) IS and (3) other alternative standard.
Reference to a particular standard or recommendation in this Specification does not relieve the
Contractor of the necessity of providing the Contract Works complying with other relevant standards or
recommendations.
The list of standards provided in the schedules of this Specification is not to be considered exhaustive
and the Contractor shall ensure that equipment supplied under this contract meets the requirements of
the relevant standard whether or not it is mentioned therein.
7.
LANGUAGE AND SYSTEM OF UNITS
The English language shall be used in all written communications between the Employer, the Engg.
Incharge (Divisional Engr.) and the Contractor with respect to the services to be rendered and with
respect to all documents and drawings procured or prepared by the Contractor pertaining to the work,
unless otherwise agreed by the Employer.
It is required that danger plates, equipment designation labels or plates, instruction notices on plant and
general substation notices be written in English, Hindi and Oriya. Control switch and lamp labels,
indicator lamp and annunciator inscriptions shall be in English only.
The Contractor must furnish a schedule giving the English, Hindi and Oriya version of all labels,
notices, etc., for approval.
The design features of all equipment shall be based on the SI system of units.
8.
CORRESPONDENCE, DRAWINGS, APPROVAL PROCEDURE AND SAMPLES
8.1.
Correspondence
All correspondence shall be addressed to the Sr. G.M, TP, OPTCL / Sr. G.M, C.P.C, OPTCL
8.2.
Drawings and samples
A list of the drawings to be submitted by the Contractor with his Bid and a list of drawings and samples
to be submitted after the Commencement Date, are to be given in the Schedules. The Contractor shall
also provide free of charge any additional drawings and/or copies of any drawing required by the Engg.
Incharge (Divisional Engr.). All design drawings and calculations shall be submitted for approval not
later than 180 days after commencement of the contract.
Within 30 days of contract commencement the Contractor shall submit, for approval by the Engg.
Incharge (Divisional Engr.), a schedule of the drawings to be produced detailing which are to be
submitted for Approval and which are to be submitted For Information Only. The schedule shall
also provide a programme of drawing submission, for approval by the Engg. Incharge (Divisional
Engr.), that ensures that all drawings and calculations are submitted within the period specified above.
Details of the loads and fixing arrangements of the circuit breakers and transformers, supplied under a
separate contract, shall be provided by the Engg. Incharge (Divisional Engr.)in order to enable the
Contractor to design the foundations for these items of plant.
All drawings submitted by the Contractor including those submitted at the time of bid shall be in
sufficient detail to indicate the type, size, arrangement, material description, Bill of Materials, weight of
each component, break-up for packing and shipment, the external connections, fixing arrangement, and
the dimensions, required for installation and interconnections with other equipment and materials,
clearances and spaces required for installation and interconnections between various portions of
equipment and any other information specifically requested in the specification.
The Contractor shall submit samples of materials for approval as required from time to time by the
All dimensions marked on drawings shall be considered correct although measurement by scale may
differ from general arrangement drawings. Detailed drawings shall be worked to where they differ from
general arrangement drawings.
All detail drawings submitted for approval shall be to scale not less than 1 : 20. All important
dimensions shall be given and the material of which each part is to be constructed shall be indicated on
the drawings.
All documents, drawings and samples shall be submitted in accordance with the provisions of this
Specification and shall become the property of the Employer.
All drawings and calculations, submitted to the Engg. Incharge (Divisional Engr.), shall be on
international standard size paper, either A0, A1, A2, A3 or A4. All such drawings and calculations shall
be provided with a contract title block and shall be assigned a unique project drawing number; the
contact title block and project numbering system shall be agreed with the Engg. Incharge (Divisional
Engr.).
All drawings for approval shall have the OPTCL-LOGO and the name of the Employer.
Technical drawings must be shown, in such a form that the information necessary to construct an
installation or part of an installation must be understandable by the technicians/skilled workmen
responsible for construction and supervision. The drawings must therefore conform to following
standards.
For presentation of design drawings and circuit documents IEC Publication 617 or equivalent standards
for graphical symbols are to be followed.
Script sizes and thickness of scripts and lines be selected so that if reduced by two stages the
alphanumeric characters and lines are still perfectly legible so as to microfilm them .
8.3.
Approval procedure
The Contractor shall submit all drawings and samples for approval in sufficient time
modifications to be made if such are deemed necessary, and the drawings and samples
submitted without delaying the initial deliveries or completion of the Contract Works. The
schedule shall be adhered for submission, approval, re-submission and final distribution
documents.
to permit
to be refollowing
drawings/
Initial submission:
All drawings, designs and documents requiring

approval of Engg. Incharge (Divisional Engr.)- not
later than 100 days from award of contract.
Approval/comments of 1st submission:
Within 30 days of receipt.
Re-submission where required:
Within 21 days of receipt including postal time both

ways.
Approval/comments of re-submission:
Within 15 days of receipt.
Submission of distribution copies:
Within 15 days of approval.
Three copies of all drawings shall be submitted for approval and three copies for any subsequent
revision. The Engg. Incharge (Divisional Engr.)reserves the right to request any additional information
that may be considered necessary in order to fully review the drawings. Drawings for approval shall be
submitted as paper prints and shall bear the approved contract references. Submittals should where
possible be staggered to facilitate maintenance of the above schedule.
If the Engg. Incharge (Divisional Engr.)is satisfied with the drawing, one copy will be returned to the
Contractor marked with Approved stamp. If the Engg. Incharge (Divisional Engr.)is not totally
satisfied with the drawing, then Approved subject to comment status will be given to it and a
comment sheet will be sent to the Contractor. If the drawing does not comply with the requirements of
the specification then it will be given Not Approved status and a comment sheet will be sent to the
Contractor. In both the latter cases the Contractor will have to modify the drawing, update the revision
column and resubmit for final approval.
Following approval copies of final drawings will be required as given below.
Reproducible on Tracing Films or Papers
3 copies
Hard Copies on paper (Blue print or Xerox)
20 copies
Computer CD ROM
1 copy
Any drawing or document submitted for information only should be indicated as such by the
Contractor. Drawings submitted for information only will not be returned to the Contractor unless the
Engg. Incharge (Divisional Engr.)considers that such drawings do need to be approved, in which case
they will be returned suitably stamped with comments.
Drawings, samples and models submitted by the Contractor and approved by the Engg. Incharge
(Divisional Engr.)shall not be departed from without the instruction in writing of the Engg. Incharge
(Divisional Engr.).
The Contractor shall be responsible for any discrepancies or errors in or omissions from the drawings,
whether such drawings have been approved or not by the Engg. Incharge (Divisional Engr.). Approval
given by the Engg. Incharge (Divisional Engr.)to any drawing or sample shall neither relieve the
Contractor from his liability to complete the Contract Works in accordance with this Specification and
the conditions of contract nor exonerate him from any of his guarantees.
If the Contractor needs approval of any drawing within a period of less than four weeks in order to
avoid delay in the completion of the Contract Works, he shall advise the Engg. Incharge (Divisional
Engr.)when submitting the drawings and provide an explanation of the documents late submission. The
Engg. Incharge (Divisional Engr.)will endeavour to comply with the Contractors time scale, but this
cannot be guaranteed.
8.4.
Final as-built drawings
After completion of work on site all drawings shall be revised where necessary to show the equipment
as installed and three copies submitted duly signed by site-in-charge. Following approval, two
reproducible transparencies and twenty prints shall then be provided as required by the Engg. Incharge
(Divisional Engr.), and shall be of sufficient detail to enable all parts to be identified. The contractor
shall also submit, where possible, digitally stored copies of all as-built drawings on disc or CD-ROM in
a format compatible with the Employers drawing system.
8.5.
Operation and Maintenance Manuals
Six months prior to the contractual completion date for each substation site the Contractor shall forward
to the Engg. Incharge (Divisional Engr.), two copies of the Operation and Maintenance Manual unique
to the substation site being handed over.
After approval by the Engg. Incharge (Divisional Engr.), the Contractor shall deliver ten (10) copies of
the complete manual .
The Taking Over Certificate will not be issued until the required number of approved copies of the
manuals have been provided by the Contractor.
The manuals shall be as complete and as specific as possible and shall incorporate documentation that is
specific to the materials and equipment used on the contract. Because the nature of the work varies from
site to site the manuals will have to be tailored to the specific needs of each site.
All precautions and warnings relative to the safety of life and equipment shall be included in the
manuals.
The manuals should also show exploded views wherever required.
9.
MASS AND SIZE OF PARTS AND QUANTITIES OF OIL
The mass and dimensions of any item of equipment shall not exceed the figures stated in the Schedules.
Each item shall be labelled to indicate its mass, quantity of oil (if any) and any special handling
instructions.
10.
GENERAL REQUIREMENTS
10.1.
Bolts and nuts
All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate
national standards for metric threads, or the technical equivalent.
Except for small wiring, current carrying terminal bolts or studs, for mechanical reasons, shall not be
less than 6 mm in diameter.
All nuts and pins shall be adequately locked.
Wherever possible bolts shall be fitted in such a manner that in the event of failure of locking resulting
in the nuts working loose and falling off, the bolt will remain in position.
All bolts, nuts and washers placed in outdoor positions shall be treated to prevent corrosion, by hot dip
galvanising or electro galvanising to service condition 4. Appropriate precautions shall be taken to
prevent electrolytic action between dissimilar metals.
Where bolts are used on external horizontal surfaces where water can collect, methods of preventing the
ingress of moisture to the threads shall be provided.
Each bolt or stud shall project at least one thread but not more than three threads through its nut, except
when otherwise approved for terminal board studs or relay stems. If bolts and nuts are placed so that
they are inaccessible by means of ordinary spanners, special spanners shall be provided.
The length of the screwed portion of the bolts shall be such that no screw thread may form part of a
shear plane between members.
Taper washers shall be provided where necessary.
Protective washers of suitable material shall be provided front and back on the securing screws.
10.2.
Galvanising.
10.2.1. General
All machining, drilling, welding, engraving, scribing or other manufacturing activities which would
damage the final surface treatment shall be completed before the specified surface treatment is carried
out.
10.2.2. Galvanising
All metal surfaces shall be subjected to treatment for anti-corrosion protection. All ferrous surfaces for
external use shall be hot dip galvanised. High tensile steel nuts, bolts and spring washers shall be electro
galvanised to service condition 4. All steel conductors including those used for earthing and grounding
(above ground level) shall also be galvanised according to IS 2629.
All galvanising shall be applied by the hot dip process and shall comply with IS 2629, IS 2633, IS 4759,
IS 1367 or IS 6745.
All welds shall be de-scaled, all machining carried out and all parts shall be adequately cleaned prior to
galvanising. The preparation for galvanising and the galvanising itself shall not adversely affect the
mechanical properties of the coated material.
The threads of all galvanised bolts and screwed rods shall be cleared of spelter by spinning or brushing.
A die shall not be used for cleaning the threads unless specially approved by the Engg. Incharge
(Divisional Engr.). All nuts shall be galvanised with the exception of the threads which shall be oiled.
Surfaces which are in contact with oil shall not be galvanised or cadmium plated.
Partial immersion of the work will not be permitted and the galvanising tank must therefore be
sufficiently large to permit galvanising to be carried out by one immersion.
Galvanising of wires shall be applied by the hot dip process and shall meet the requirements of IS 2141.
The minimum weight of the zinc coating shall be 610 gm/sq.m and minimum thickness of coating shall
be 86 microns for all items thicker than 5 mm. For items of less than 5 mm thickness requirement of
coating thickness shall be as per BS 729. For surface which shall be embedded in concrete, the zinc
coating shall be a minimum of 800 gm/sq.m.
The galvanised surfaces shall consist of a continuous and uniform thick coating of zinc, firmly adhering
to the surface of steel. The finished surface shall be clean and smooth and shall be free from defects
such as discoloured patches, bare spots, unevenness of coating, spelter which is loosely attached to the
steel globules, spiky deposits, blistered surface, flaking or peeling off, etc. The presence of any of these
defects noticed on visual or microscopic inspection shall render the material liable to rejection.
After galvanising no drilling or welding shall be performed on the galvanised parts of the equipment
excepting that nuts may be threaded after galvanising. Sodium dichromate treatment shall be provided
to avoid formation of white rust after hot dip galvanisation.
The galvanised steel shall be subjected to six one minute dips in copper sulphate solution as per IS
2633.
Sharp edges with radii less than 2.5 mm shall be able to withstand four immersions of the Standard
Preece test. All other coatings shall withstand six immersions. The following galvanising tests should
essentially be performed as per relevant Indian Standards.
Coating thickness
Uniformity of zinc
Adhesion test
Mass of zinc coating
Galvanised material must be transported properly to ensure that galvanised surfaces are not damaged
during transit. Application of zinc rich paint at site shall not be allowed.
10.3.
Cleaning, painting and tropicalisation
10.3.1. General
All paints shall be applied in strict accordance with the paint manufacturers instructions.
All painting shall be carried out on dry and clean surfaces and under suitable atmospheric and other
conditions in accordance with the paint manufacturers recommendations.
An alternative method of coating equipment such as with epoxy resin-based coating powders will be
permitted, subject to the approval of the Engg. Incharge (Divisional Engr.), and such powders shall
comply with the requirements of IEC 455. The Contractor shall provide full details of the coating
process to the Engg. Incharge (Divisional Engr.)for approval.
It is the responsibility of the Contractor to ensure that the quality of paints used shall withstand the
tropical heat and extremes of weather conditions specified in the schedules. The paint shall not peel off,
wrinkle, be removed by wind, storm and handling on site and the surface finish shall neither rust nor
fade during the service life of the equipment.
The colours of paints for external and internal surfaces shall be in accordance with the approved colour
schemes .
10.3.2. Works painting processes
All steelworks, plant supporting steelworks and metalwork, except galvanised surfaces or where
otherwise specified, shall be shot blasted to BS 7079 or the equivalent ISO standard. All sheet steel
work shall be degreased, pickled, phosphated in accordance with the IS 6005 Code of Practice for
phosphating iron and sheet steel. All surfaces shall then be painted with one coat of epoxy zinc rich
primer, two pack type, to a film thickness of 50 microns. This primer shall be applied preferably by
airless spray and within twenty minutes but not exceeding one hour of shot blasting.
All rough surfaces of coatings shall be filled with an approved two pack filler and rubbed down to a
smooth surface.
The interior surfaces of all steel tanks and oil filled chambers shall be shot blasted in accordance with
BS 7079 or the equivalent ISO, and painted within a period of preferably twenty minutes, but not
exceeding one hour with an oil resisting coating of a type and make to the approval of the Engg.
The interior surfaces of mechanism chambers, boxes and kiosks, after preparation, cleaning and priming
as required above, shall be painted with one coat zinc chromate primer, one coat phenolic based
undercoating, followed by one coat phenolic based finishing paint to a light or white colour. For
equipment for outdoor use this shall be followed by a final coat of anti-condensation paint of a type and
make to the approval of the Engg. Incharge (Divisional Engr.), to a light or white colour. A minimum
overall paint film thickness of 150 microns shall be maintained throughout.
All steelworks and metalwork, except where otherwise specified, after preparation and priming as
required above shall be painted with one coat metallic zinc primer and two coats of micaceous iron
oxide paint followed by two coats of either phenolic based or enamel hard gloss finished coloured paint
to the approval to an overall minimum paint film thickness of 150 microns.
Galvanised surfaces shall not be painted in the works.
All nuts, bolts, washers etc., which may be fitted after fabrication of the plant shall be painted as
described above after fabrication.
The painted metal works shall be subjected to paint qualification test as per draft ANSI/IEEE-Std 37.21
-1985 clause 5.2.5.
10.3.3. Site painting
After erection at site, the interior surfaces of mechanism chambers and kiosks shall be thoroughly
examined, and any deteriorated or mechanically damaged surfaces of such shall be made good to the
full Specification described above.
After installation/erection at site all surfaces of steelworks and metalwork shall be thoroughly washed
down. Any deteriorated or otherwise faulty paint-work removed down to bare metal and made good to
the full Specification described above, then painted one further coat of phenolic based undercoating and
one coat phenolic based hard gloss finishing paint to provide an overall minimum paint film thickness
of 200 microns.
Any nuts, bolts, washers, etc., which have been removed during site erection, or which may be required
to be removed for maintenance purposes shall be restored to their original condition.
All paint work shall be left clean and perfect on completion of the works.
10.3.4. Colour Schemes
The Contractor shall propose a colour scheme for the sub-station for the approval of Engg. Incharge
(Divisional Engr.). The decision of Engg. Incharge (Divisional Engr.)shall be final. The scheme shall
include:
Finishing colour of indoor equipment
Finishing colour of outdoor equipment
Finish colour of all cubicles
Finishing colour of various auxiliary system equipment including piping.
Finishing colour of various building items.
All steel structures, plates etc. shall be painted with non-corrosive paint on a suitable primer. It may be
noted that normally all Employers electrical equipment in Employers switchyard are painted with
shade 631 of IS:5 and Employer will prefer to follow the same for this project also. All indoor cubicles
shall be of same colour scheme and for other miscellaneous items colour scheme will be subject to the
approval of the Engg. Incharge (Divisional Engr.).
Sl. No.
Equipment
Application Environment
Indoor
Outdoor
Colour
Code
Colour
Code
IS:5
IS:5
400kV/220kV/132kV Class
Equipment
1
2
3
4
5
Transformers
Marshalling boxes, CTs, PTs,
CVTs, surge counter casings,
junction boxes etc.
Control and relay panels, PLCC
cabinets etc.
Porcelain parts i.e. insulators
All structures/ metallic parts
exposed to atmosphere
Light Admiralty
grey.
697
Light grey
Light Admiralty
grey.
631
697
Smoke grey
692
Dark brown
Hot dip galvanised
412
Dark brown
412
Smoke grey
Smoke grey
692
692
Light grey
631
Smoke grey
Smoke grey
Smoke grey
Matt Paint
Smoke grey
Smoke grey
Smoke grey
Smoke grey
Smoke grey
Smoke grey
692
692
692
Light grey
Light grey
Light grey
Light grey
631
631
631
631
33kV Class equipment

6
7
8
9
10
11
12
13
14
15
16
17
18
Switchgear cubicles
Control and relay panels
LT switchgear
LT switchgear exterior
ACDB/ MCC
DCDB
LT bus duct in side enclosure
LT bus duct outside enclosure
Motors
Diesel generator engine
Diesel generator
LT transformers
Battery charger
Mimic diagram
692
692
692
692
692
692
400kV
220kV
132kV
33kV
11kV
19
20
21
22
23
24
25
26
415V
Miscellaneous
Control modules and console inserts
Lighting package equipment outside
Lighting package equipment inside
Water pipes
Air pipes
Transformer oil pipes
Fire Installations
Insulating oil/ gas treatment plant
Table 10.3.4.
10.4.
Dark violet
Golden yellow
Sky blue
Signal red
Canary yellow
Middle brown
Smoke grey
Light grey
Glossy white
sea green
Sky blue
Light brown
Fire red
Gulf red
796
356
101
537
309
411
692
631
Light grey
Light grey
Glossy white
sea green
Sky blue
Light brown
Fire red
Gulf red
631
631
217
101
410
536
473
217
101
410
536
473
Recommended colour schemes
Provision for exposure to hot and humid climate
Outdoor equipment supplied under the Specification shall be suitable for service and storage under
tropical conditions of high temperature, high humidity, heavy rainfall and environment favourable to
the growth of fungi and mildew. The indoor equipments located in non air-conditioned areas shall also
be of same type.
10.4.1. Anti-condensation Provisions:
Space heaters where provided shall be suitable for continuous operation at 240V supply voltage. On-off
switch and fuse shall be provided.
One or more adequately rated permanently or thermostatically connected heaters shall be supplied to
prevent condensation in any compartment. The heaters shall be installed in the lower portion of the
compartment and electrical connections shall be made from below the heaters to minimise deterioration
of supply wire insulation. The heaters shall be suitable to maintain the compartment temperature at
approximately 10C, above the outside air temperature to prevent condensation. This shall be
demonstrated by tests.
10.4.2. Fungistatic treatment
Besides the space heaters, special moisture and fungus resistant varnish shall be applied to parts which
may be subjected or predisposed to the formation of fungi due to the presence or deposit of nutrient
substances. The varnish shall not be applied to any surface or part where the treatment will interfere
with the operation or performance of the equipment. Such surfaces or parts shall be protected against
the application of the varnish.
10.4.3. Ventilating specifications
In order to ensure adequate ventilation, compartments shall have ventilation openings provided with
fine wire mesh of brass or galvanised steel to prevent the entry of insects and to reduce to a minimum
the entry of dirt and dust. Outdoor compartment openings shall be provided with shutter type blinds.
10.5.
Labels and plates
All apparatus shall be clearly labelled indicating, where necessary, its purpose and service positions.
Each phase of alternating current and each pole of direct current equipment and connections shall be
coloured in an approved manner to distinguish phase or polarity.
The material of all labels and the dimensions, legend, and method of printing shall be to approval. The
surface of indoor labels shall have a matt or satin finish to avoid dazzle from reflected light.
Colours shall be permanent and free from fading. Labels mounted on black surfaces shall have white
lettering. Danger plates shall have red lettering on a white background.
All labels and plates for outdoor use shall be of non corroding material. Where the use of enamelled
iron plates is approved, the whole surface including the back and edges, shall be properly covered and
resistant to corrosion. Protective washers of suitable material shall be provided front and back on the
securing screws.
Labels shall be engraved in Hindi, English and Oriya. Name plates shall be white with black engraved
lettering and shall carry all the applicable information specified in the applicable items of the Standards.
Any other relevant information which may be required for groups of smaller items for which this is not
possible e.g. switch bays etc. a common name plate in Oriya with the title and special instructions on it
shall be provided.
No scratching, corrections or changes will be allowed on name plates.
All equipment mounted on front and rear sides as well as equipment mounted inside the panels shall be
provided with individual name plates with equipment designation engraved.
On the top of each panel on front as well as rear sides large name plates with bold size lettering shall be
provided for circuit/ feeder/ cubicle box designation.
All front mounted equipment shall be also provided, at the rear, with individual name plates engraved
with tag numbers corresponding to the one shown in the panel internal wiring to facilitate tracing of the
wiring. The name plates shall be mounted directly by the side of the respective equipment wiring.
Name plates of cubicles and panels may be made of non rusting metal or 3 ply lamicoid. These name
plates may be black with white engraved lettering.
The name plate inscription and size of name plates and letters shall be submitted to the Engg. Incharge
(Divisional Engr.)/Engineer for approval.
The nameplates of the apparatus shall include, at least, the information listed below, together with any
other relevant information specified in the applicable standards :
Concise descriptive title of the equipment
Rating and circuit diagrams
Manufacturer's name, trade-mark, model type, serial number
Instruction book number
Year of manufacture
Total weight (for capacitor racks indicate weight, for capacitors indicate quantity of liquid)
Special instructions, if any, about storage, transportation, handling etc.
Each measuring instrument and meter shall be prominently marked with the quantity measured e.g. kV,
A, MW etc. All relays and other devices shall be clearly marked with manufacturers name,
manufacturers type, serial number and electrical rating data.
Danger plates and plates for phase colours shall be provided as per requirement. The Contractor shall
devise a system to designate equipment and sub-systems. The nameplates/labels displaying these
designations shall be installed at appropriate locations. Whenever motion or flow of fluids is involved,
plates showing direction of motion or flow shall also be provided.
10.6.
Padlocks
For each item of plant the Contractor shall provide a padlockable handle and a non-ferrous padlock with
different key changes in order to prevent access to control cabinets, cubicles and relay panels. The
Contractor shall provide two keys for each lock and a master key for each substation.
Cabinets for the accommodation of padlocks and keys, whilst not in use, shall be provided and shall be
suitably labelled so that keys will be readily identifiable.
10.7.
Earthing
Metal parts of all equipment other than those forming part of an electrical circuit shall be connected
directly to the main earth system via two separate conductors of adequate capacity at two different
points.
All main members of structural steelworks shall be earthed by galvanised iron flat connections bonded
by welding or bolting to the steelworks.
Connections to apparatus and structures shall be made clear of ground level, preferably to a vertical face
and protected as appropriate against electrolytic corrosion. They shall be made between clean surfaces
and of sufficient size and pressure to carry the rated short circuit current without damage.
Earth bars installed directly into the ground should normally be laid bare and the trench back-filled with
a fine top soil. Where the soil is of a hostile nature, special precautions must be taken to protect the
earth bar, the method used being subject to the agreement of the Engg. Incharge (Divisional Engr.).
Joints in earth bars shall be welded and then coated with a suitable anti-corrosion protection treatment.
Facilities shall be provided on the earth bar run between equipment and the base of structures,
comprising a looped strip, so as to permit the attachment of portable earth connections for maintenance
purposes.
The cross sectional area of the earth bar and connections shall be such that the current density is not
greater than 100 A/mm2 for a 3 second fault duration.
10.8.
Lubrication
Bearings which require lubrication either with oil or grease shall be fitted with nipples.
11.
PRODUCTION PROCESS REQUIREMENTS
11.1.
Castings
11.1.1. General
All castings shall be true to pattern, free from defects and of uniform quality and condition. The
surfaces of castings which do not undergo machining, shall be free from foundry irregularities. The
castings shall be subject to NDT, chemical, mechanical and metallographic tests. Details of the same
shall be furnished to Engg. Incharge (Divisional Engr.)for review/approval. Magnetic particle
inspection (MPI) test, wherever applicable, shall be carried out in longitudinal and transverse direction
to detect radial and axial cracks.
11.1.2. Iron castings
Iron casting material shall be in accordance with ASTM A 126 Class B. A copy of the ladle analysis
shall be sent to the Engg. Incharge (Divisional Engr.). Each casting shall have a test bar from which
tension test specimens may be taken. Test specimen shall be in accordance with ASTM A 370 and
tested in accordance with ASTM E8. The Contractor shall submit his procedures for testing and
acceptance for iron castings for approval by the Engg. Incharge (Divisional Engr.).
11.1.3. Steel castings
Steel castings shall be manufactured in accordance with ASTM A 27 and shall be subjected to
appropriate tests and inspection as detailed herein.
Copies of mandatory documentation, such as ladle analyses and mechanical test results, shall be sent to
the Engg. Incharge (Divisional Engr.). (Non-ferrous casting material and castings shall be manufactured
in accordance with the appropriate ASTM standards for the material concerned).
11.2.
Forgings
When requested by the Engg. Incharge (Divisional Engr.), forgings will be subjected to inspection in
the regions of fillets and changes of section by suitable method. Magnetic particle, dye-penetration,
radiographic or ultrasonic, or any combination of these methods may be used to suit material type and
forging design.
The testing is to be carried out after the rough machining operation and is to be conducted according to
the appropriate ASTM standards.
MPI test on forging shall be carried out to detect both radial and axial cracks. Ferrous forgings shall be
demagnetised after such tests.
Any indentations which prove to penetrate deeper than 2.5% of the finished thickness of the forging
shall be reported to the Engg. Incharge (Divisional Engr.)giving location, length, width and depth. Any
indentations which will not machine out during final machining shall be gouged out and repaired using
an approved repair procedure.
Repair of rotating elements by welding will only be accepted subject to detailed examination of the
proposal by the Engg. Incharge (Divisional Engr.)prior to the repair being carried out.
The forging shall be tested for mechanical and metallographic tests as per ASTM. The details shall be
mutually discussed/agreed upon.
11.3.
Fabricated components
All components machined or fabricated from plate, sheet or bar stock shall meet the material
requirements of ASTM or material specification approved by the Engg. Incharge (Divisional Engr.).
Structural steel, rolled shapes, bars, etc. shall comply with the latest ASTM for A36.
Plate steel shall be of a designation and quality suitable for the function it is intended to perform.
Insofar as it is compatible with its function, it shall comply with ASTM A283 structural quality.
All, or a representative number of such components, shall be subjected to one or more of the following
tests: visual, dye penetration, magnetic particle (transverse and longitudinal), ultrasonic or radiographic.
These tests shall be in accordance with the recommended practices of the ASTM. The terms of
reference for acceptance shall be the applicable ASTM Specifications.
11.4.
Welding and welders qualifications
11.4.1. General
All welding shall be carried out by qualified welders only.
All welding shall be in accordance with the corresponding standards of the American Welding Society
or the American Society of Mechanical Engineers.
Other standards to determine the quality of welding process and qualifications of welders may be
considered, provided that sufficient information is first submitted for the approval of the Engg. Incharge
(Divisional Engr.).
Prior to the start of fabrication, the Contractor shall submit to the Engg. Incharge (Divisional Engr.)for
approval, a description of each of the welding procedures which he proposes to adopt, together with
certified copies of reports of the results from tests made in accordance with these procedures.
The Contractor shall be responsible for the quality of the work performed by his welding organisation.
All welding operators, to be assigned work, including repair of casting, shall pass the required tests for
qualification of welding procedures and operators. The Engg. Incharge (Divisional Engr.)reserves the
right to witness the qualification tests for welding procedures and operators and the mechanical tests at
the samples.
The Contractor shall bear all his own expenses in connection with the qualification tests. If the work of
any operator at any time appears questionable, such operator will be required to pass appropriate prequalification tests as specified by the Inspector and at the expense of the Contractor.
11.4.2. Welding
All welding shall be performed in accordance with the appropriate standards. The design and
construction of welded joints subject to hydraulic pressure shall conform to the applicable requirement
of ASME Boiler and Pressure Vessel Code shall be qualified in accordance with Section IX of this
Code. The design and construction of welded joints not subjected to hydraulic pressure shall, as a
minimum, conform to the requirements of AWS Specification for Welded Highway and Railway
Bridge D2.0. Except for minor parts and items specifically exempted from stress relieving, all shopwelded joints shall be stress relieved in accordance with the requirements of the ASME Boiler and
Pressure Vessel Code Section VIII.
In addition to satisfying the procedural and quality requirements set forth in the applicable code and/or
these Specifications, all welding shall meet the following requirements for workmanship and visual
quality:
Butt welds shall be slightly convex, of uniform height and shall have full penetration.
Fillet welds shall be of the specified size, with full throat and legs of equal length.
Repairing, chipping and grinding of welds shall be done in a manner which will not gouge,
groove or reduce the thickness of the base metal.
The edges of the member to be joined shall expose sound metal, free from laminations, surface
defects caused by shearing or flame-cutting operations or other injurious defects.
Welded joints subject to critical working stress shall be tested by approved methods of non-destructive
testing, such as radiographic and ultrasonic examination, magnetic particle and liquid penetration
inspection. All expenses in connection with these tests shall be borne by the Contractor. The extent of
testing shall be as stipulated by the ASME Boiler and Pressure Vessel Code, Section VIII, but without
prejudice to the rights of the Inspector or the Engg. Incharge (Divisional Engr.)to ask for additional
tests,
The arc-welding process to be used and the welding qualifications of the welders employed on the work
shall be used in accordance with AWS requirements and Section VIII and IX of the ASME (American
Society of Mechanical Engineers) Code, latest edition, as they may apply. All welding rods shall
conform to the requirements of the latest issue of Section It, part C of the ASME Code.
Gas shielded welding (TIG or MIG) used as appropriate for aluminium, stainless steel or other material
shall be carried out in accordance with the best commercial practice and the following standard
specifications:
Specifications for copper and copper-alloy welding rods (AWS A5.7, ASTM B259)
Specification for corrosion-resisting chromium and chromium-nickel steel welding rods and bare
electrodes (AWS A5.9, ASTM A371)
Specifications for aluminium and aluminium alloy rods and bare electrodes (AWS A5.10, ASTM
B285).
Specifications for nickel and nickel-base alloy bare welding filler metal (AWS A5.14, ASTM
B304).
Gas welding will not normally be used in the equipment. When a particular equipment manufacture
requires the use of gas welding, the proposed process and the welders qualification shall be in
accordance with AWS B3.0.
Welding of galvanised components will not be allowed in the equipment.
Strict measures of quality control shall be exercised throughout the Equipment/ Works. The Engg.
Incharge (Divisional Engr.)may call for an adequate NDT test of the work of any operator, who in his
opinion is not maintaining the standard of workmanship. Should this NDT test prove defective, all work
done by that operator, since his last test shall be tested at the Contractors expense. If three or more of
these tests prove defective, the operator shall be removed from the project.
A procedure for the repair of defects shall be submitted to the Engg. Incharge (Divisional Engr.)for his
approval prior to any repairs being made.
11.4.3. Welding of pipes
Before welding, the ends shall be cleaned by wire brushing, filing or machine grinding. Each weld-run
shall be cleaned of slag before the next run is deposited.
Welding at any joint shall be completed uninterrupted. If this cannot be followed for some reason, the
weld shall be insulated for slow and uniform cooling.
Welding shall be done by manual oxy-acetylene or manual shielded metal are process. Automatic or
semi-automatic welding processes may be done only with the specific approval of Engg. Incharge
(Divisional Engr.).
As far as possible welding shall be carried out in flat position. If not possible, welding shall be done in a
position as close to flat position as possible.
Downward technique is not allowed while welding pipes in horizontal position, unless permitted by the
Combination of welding processes or usage of electrodes of different classes or makes in a particular
joint shall be allowed only after the welding procedure has been duly qualified and approved by the
No backing ring shall be used for circumferential butt welds.
Welding carried out in ambient temperature of 5C or below shall be heat treated.
A spacer wire of proper diameter may be used for weld root opening but must be removed after tack
welding and before applying root run.
Tack welding for the alignment of pipe joints shall be done only by qualified welders. Since tack welds
form part of final welding, they shall be executed carefully and shall be free from defects. Defective
welds shall be removed prior to the welding of joints.
Electrodes size for tack welding shall be selected depending upon the root opening.
Tack welds should be equally spaced.
Root run shall be made with respective electrodes/filler wires. The size of the electrodes shall not be
greater than 3.25 mm (10 SWG) and should preferably be 2.3 mm (12 SWG). Welding shall be done
with direct current values recommended by the electrode manufacturers.
Upward technique shall be adopted for welding pipes in horizontally fixed position. For pipes with wall
thickness less than 3 mm, oxyacetylene welding is recommended.
The root run of butt joints shall be such as to achieve full penetration with the complete fusion of root
edges. The weld projection shall not exceed 3 mm inside the pipe.
On completion of each run craters, weld irregularities, slag etc. shall be removed by grinding or
chipping.
During the process of welding, all movements, shocks, vibration or stresses shall be carefully avoided in
order to prevent weld cracks.
Fillet welds shall be made by shielded metal arc process regardless of thickness and class of piping.
Electrode size shall not exceed 10 SWG. (3.25 mm). At least two runs shall be made on socket weld
joints.
12.
WIRING, CABLING AND CABLE INSTALLATION
12.1.
Cubicle wiring
Panels shall be complete with interconnecting wiring between all electrical devices in the panels.
External connections shall be achieved through terminal blocks. Where panels are required to be located
adjacent to each other all inter panel wiring and connections between the panels shall be carried out
internally. The Contractor shall furnish a detailed drawing of such inter panel wiring. The Contractor
shall ensure the completeness and correctness of the internal wiring and the proper functioning of the
connected equipment.
All wiring shall be carried out with 1.1 kV grade, PVC insulated, single core, stranded copper wires.
The PVC shall have oxygen index not less than 29 and Temperature index not less than 250C. The
wires shall have annealed copper conductors of adequate size comprise not less than three strands
The minimum cross sectional area of the stranded copper conductor used for internal wiring shall be as
follows :
All circuits excepting CT circuits and energy metering circuit of VT
2.5 sq.mm
All CT circuits and metering circuit of VT
2.5 sq. mm
All internal wiring shall be supported, neatly arranged, readily accessible and connected to equipment
terminals and terminal blocks. Wiring gutters and troughs shall be used for this purpose.
Cubicle connections shall be insulated with PVC to IEC 227. Wires shall not be jointed or teed between
terminal points.
Bus wires shall be fully insulated and run separately from one another. Auxiliary bus wiring for AC and
DC supplies, voltage transformer circuits, annunciation circuits and other common services shall be
provided near the top of the panels running throughout the entire length of the panel suite. Longitudinal
troughs extending throughout the full length of panel shall be preferred for inter panel wiring.
All inter connecting wires between adjacent panels shall be brought to a separate set of terminal blocks
located near the slots of holes meant for the passage of the inter connecting wires. Interconnection of
adjacent panels on site shall be straightforward and simple. The buswires for this purposes shall be
bunched properly inside each panel.
Wire termination shall be made with solderless crimping type and tinned copper lugs which firmly grip
the conductor. Insulated sleeves shall be provided at all the wire terminations. Engraved core
identification plastic ferrules marked to correspond with panel wiring diagram shall be fitted at both
ends of each wire. Ferrules shall fit tightly on the wire and shall not fall off when the wire is
disconnected from terminal blocks. Numbers 6 and 9 shall not be included for ferrules purposes unless
the ferrules have numbers underscored to enable differentiation. (i.e. 6 and 9 ).
Fuses and links shall be provided to enable all circuits in a cubicle, except a lighting circuit, to be
isolated from the bus wires.
The DC trip and AC voltage supplies and wiring to main protective gear shall be segregated from those
for back-up protection and also from protective apparatus for special purposes. Each such group shall be
fed through separate fuses from the bus wires. There shall not be more than one set of supplies to the
apparatus comprising each group. All wires associated with the tripping circuits shall be provided with
red ferrules marked Trip.
It shall be possible to work on small wiring for maintenance or test purposes without making a
switchboard dead.
The insulation material shall be suitably coloured in order to distinguish between the relevant phases of
the circuit.
When connections rated at 380 volt and above are taken through junction boxes they shall be adequately
screened and DANGER notices shall be affixed to the outsides of junction boxes or marshalling
kiosk.
Where connections to other equipment and supervisory equipment are required the connections shall be
grouped together.
12.2.
LV power cabling
LVAC cable terminals shall be provided with adequately sized, hot pressed, cast or crimp type lugs.
Where sweating sockets are provided they shall be without additional clamping or pinch bolts. Where
crimp type lugs are provided they shall be applied with the correct tool and the crimping tool shall be
checked regularly for correct calibration. Bi-metallic joints between the terminals and lugs shall be
provided where necessary.
Terminals shall be marked with the phase colour in a clear and permanent manner.
A removable gland plate shall be provided by the Contractor. The Contractor shall be responsible for
drilling the cable gland plate.
Armoured cables shall be provided with suitable glands for terminating the cable armour and shall be
provided with an earthing ring and lug to facilitate connection of the gland to the earth bar.
12.3.
Multi-core cables and conduit wiring
External multi-core cabling between items of main and ancillary equipment shall form part of the
Contract Works and shall consist of un-armoured multi-core cable with stranded copper conductors
PVC insulated and PVC over sheathed complying with the requirements of IEC 227 and 228 as
applicable.
Multi-core cable for instrumentation and control purposes shall be supplied with 2.5 mm2 stranded
copper cores. Multi-core cables for CT and VT circuits shall be supplied with two by 2.5 mm2 stranded
copper cores and the cores shall be identified by the phase colour.
Where conduit is used the runs shall be laid with suitable falls and the lowest parts of the run shall be
external to the equipment. All conduit runs shall be adequately drained and ventilated. Conduits shall
not be run at or below ground level.
Multi-core cable tails shall be so bound that each wire may be traced to its cable without difficulty. All
multi-core cables shall be provided with 20 % spare cores and the spare cores shall be numbered and
terminated at a terminal block in the cubicle. Where cables are terminated in a junction box and the
connections to a relay or control cubicle are continued in conduit, the spare cores shall be taken through
the conduit and terminated in the cubicle. The dc trip and ac voltage circuits shall be segregated from
each other as shall the circuits to main protective gear be segregated from those for back-up protection.
The screens of screened pairs of multi-core cables shall be earthed at one end of the cable only. The
position of the earthing connections shall be shown clearly on the diagram.
All wires on panels and all multi-core cable cores shall be crimped with the correct size of crimp and
crimping tool and will have ferrules which bear the same number at both ends. At those points of
interconnection between the wiring carried out by separate contractors where a change of number
cannot be avoided double ferrules shall be provided on each wire. The change of numbering shall be
shown on the appropriate diagram of the equipment. The same ferrule number shall not be used on
wires in different circuits on the same panels.
The Contractor shall provide a two (2) metre loop of spare cable at both ends of all multi-core cable
runs and shall leave sufficient lengths of tails at each end of the multi-core cables to connect up to the
terminal boards. The Contractor shall also strip, insulate, ring through and tag the tails and shall also
seal the cable boxes. The Contractor shall be responsible for re-checking the individual cores and for
the final connecting up and fitting of numbered ferrules within all equipment provided on this contract.
The drilling of gland plates, supply and fitting of compression glands and connecting up of power
cables included in the Contract scope of work shall be carried out under this contract.
12.4.
Laying and installing of cables
12.4.1. General
For cable laying the following shall apply:
Switchyard area
In concrete cable troughs (cable trench having cable racks with cable `
trays)
Control Room
On cable racks consisting of slotted type and ladder type cable trays
Buildings
Conduits
Directly buried cables shall be used wherever necessary with the approval of Engg. Incharge
(Divisional Engr.).
12.4.2. Laying of cable
Cables shall be laid in concrete troughs provided under this contract or drawn into pipes or ducts or on
cable racks or directly buried as may be required by the Engg. Incharge (Divisional Engr.). Concrete
troughs shall be designed so that the cables are supported on cable support systems and the supports
shall be arranged so as to allow the segregation of power, control (including CT and VT circuits) and
communications cables onto different layers of cable supports. All cable supports shall be earthed in
accordance with IS 3043. The minimum vertical separation between layers of cable tray shall be not
less than 300 mm.
The cable support system shall be designed and constructed to carry the required cables without undue
crowding of the supports and without overloading the supports. The maximum number of layers of
cable that shall be permitted on a single cable support shall be three. The width of the cable supports
shall be selected to ensure that the supports are not crowded, the cable supports are not overloaded and
that sufficient space is provided in the cable trough to allow for personnel access during and after cable
installation. The width of cable supports should not exceed 750 mm.
Cables shall be laid direct in the ground only at the discretion of the Engg. Incharge (Divisional Engr.).
All cables laid direct in the ground outside buildings shall be laid in a trench and protected by
reinforced concrete slabs or cable tiles.
For auxiliary cables the top of the slab or tile shall be at a depth not less than 300 mm below the surface
of the ground and there shall be a layer of fine well packed riddled earth 75 mm thick in between the
cable and the bottom of the trench and between the top of the cable and the underside of the slab.
The Contractor shall be responsible for the proper laying of all cables in the ground. Where cables in
the same trench are laid over each other, they shall be separated by not less than 75 mm of riddled earth.
The riddled earth used for this purpose shall have been passed through a screen having a 12 mm square
mesh.
Where cables pass under roadways they shall be laid in pipes at a depth not less than 800 mm below the
surface.
The Contractor shall be responsible for the excavation of trenches which shall include all pumping and
baling required and the provision of all necessary labour, plant, tools, water, additional soil, fuel or
motor power for such purposes.
Cables in trenches will be inspected by the Engg. Incharge (Divisional Engr.)before the trenches are
backfilled.
The running of communications and power cables along the same route shall be avoided as far as
possible. Where this is not possible they shall be segregated, the one group from the other. Power and
communication cables shall be laid in separate tiers. For other than directly buried cables the order of
laying of various cables shall be as follows:
Power cables on top tiers.

Control/ instrumentation and other service cables in bottom tiers.
12.4.3. Cable tags and markers
Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedule.
The tag shall be of aluminium with the number punched on it and securely attached to the cable conduit
by not less than two turns of 20 SWG GI wire conforming to IS 280. Cable tags shall be of rectangular
shape for power cables and of circular shape for control cables.
Location of cables laid directly in the ground shall be clearly indicated with cable marker made of
galvanised iron plate.
Location of buried cable joints shall be indicated with a cable marker having an additional inscription
"Cable joint".
Cable markers shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at
every change in direction. They shall be located on both sides of road and drain crossings.
Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on
both sides of a wall or floor crossing, on each duct, conduit entry and at every twenty meters (20 m) in
cable tray/trench runs. Cable tags shall be provided inside switchgear, motor control centres, control
and relay panels etc.. and wherever required for cable identification when a number of cables enter
together through a gland plate.
The price of cable tags and markers shall be included in the installation rates for cables/conduits quoted
by the Bidder.
12.4.4. Cable supports and cable tray mounting arrangements in control room
The control room will normally be provided with embedded steel inserts on concrete floors/walls for the
purpose of cabling in the control room. The supports shall be secured by welding to these inserts or
available building steel structures. However, in cases where no such embedded steel inserts are
available, the same shall have to secured to the supports on walls or floors by suitable anchoring .
12.4.5. Cable support structure in switchyard cable trenches
The contractor shall fabricate and install cable support structures in cable trenches. These supports shall
be provided at 750 mm spacing along the run of cable trenches.
Cable supports and cable racks shall be fabricated from standard structural steel members, channels,
angles and flats of required size. The fabrication. welding and erection of these structures shall conform
to the relevant clauses of this Specification, in addition to the specification given herein.
12.5.
Termination of cables and wires
Where cables leave the apparatus in an upward direction the cable boxes shall be provided with a
barrier joint to prevent leakage of cable oil or compound into the apparatus. Where cable cores are
liable to contact with oil or oil vapour the insulation shall be unaffected by oil.
PVC sheathed cables shall be terminated by compression glands complying with BS 6121 (or
equivalent).
Auxiliary PVC insulated cables shall be terminated with compression type glands, clamps or armour
clamps complete with all the necessary fittings.
Colours shall be marked on the cable box, cable tail ends and single core cables at all connecting points
and/or any positions the Engg. Incharge (Divisional Engr.)may determine. Cable boxes shall be
provided with suitable labels indicating the purpose of the supply where such supply is not obvious or
where the Engg. Incharge (Divisional Engr.)may determine.
All cables shall be identified and shall have phase colours marked at their termination.
All incoming and outgoing connections shall be terminated at a terminal block. Direct termination into
auxiliary switches will not be accepted.
13.
DEGREES OF PROTECTION
Degrees of protection shall be provided in accordance with IEC 144 and IEC 529 and be as follows:
For outdoor applications, IP 55.
For indoor applications where purpose built accommodation is provided, e.g. switch and control
and relay rooms in auxiliary plant buildings, IP 41.
Where dust can adversely affect equipment within the enclosure, this equipment should be
separately housed with a degree of protection of IP 51.
For indoor applications where the equipment is housed in the same building as that enclosing
water and steam operated equipment, the degrees of protection stated in the previous paragraph
shall be up-rated to IP 44 and IP 54 respectively.
Where more severe environments exist, e.g. steam and oil vapour or other deleterious chemical
environments, special measures will be necessary and the degree of protection required will be specified
separately.
The Contractor shall submit a schedule for providing the degree protection to various control boxes,
junction boxes etc. for the Engg. Incharge (Divisional Engr.)s approval.
14.
SUPPLY VOLTAGE
All incoming supplies of greater than 125 V to earth shall have their termination shrouded by a suitable
insulating material.
The auxiliary supply voltages on site shall be as follows:
15.
Nominal
Voltage V
Variation
Frequency
Hz or DC
Phase
Wires
Neutral
Connection
430
10%
505%
Solidly earthed
240
10%
505%
Solidly earthed
220
187V - 242V
DC
DC
Isolated 2 wires
50
45V - 55V
DC
DC
+ve earthed
MAINTENANCE TELEPHONE POSITIONS
Telephone jack plug points shall be provided at each circuit breaker, at each power transformer
marshalling kiosk and on each control and relay panel. At each substation these plug points are to be
connected in parallel to form a site telephone circuit for use during maintenance and testing operations.
16.
ERECTION CONDITIONS
16.1.
General
The following shall supplement the conditions already contained in the other parts of these
specifications and documents and shall govern that portion of the work on this Contract to be performed
at Site.
16.2.
Regulation of local authorities and statutes
The Contractor shall comply with all the rules and regulations of local authorities during the
performance of his field activities. He shall also comply with the Minimum Wages Act, 1948 and the
payment of Wages Act (both of the Government of India and Govt of Orissa ) and the rules made
thereunder in respect of any employee or workman employed or engaged by him or his Sub-Contractor.
All registration and statutory inspection fees, if any, in respect of his work pursuant to this Contract
shall be to the account of the Contractor. However, any registration, statutory inspection fees lawfully
payable under the provisions of the statutory laws and its amendments from time to time during erection
in respect of the substation ultimately to be owned by the Employer, shall be to the account of the
Employer. Should any such inspection or registration need to be re-arranged due to the fault of the
Contractor or his Sub-Contractor, the additional fees to such inspection and/or registration shall be
borne by the Contractor.
The Contractor shall ensure that he obtains, from the Government of Orissa, an Electrical Contractors
Licence and a supervisory certificate of the appropriate grade to allow him to execute the electrical
works included in the Contract. The Contractor shall ensure that all workmen possess Workman
Permits, issued by the Government of Orissa, for engagement in the Contract Works.
16.3.
Inspection, testing and inspection certificates
The provisions of the General Conditions of Contract shall also be applicable to the erection portion of
the Works. The Engg. Incharge (Divisional Engr.)shall have the right to re-inspect any equipment
though previously inspected approved by him at the Contractor's works, before and after the same are
erected at Site.
16.4.
Contractor's field operation
16.4.1. General
The Contractor shall inform the Engg. Incharge (Divisional Engr.)in advance of field activity plans and
schedules for carrying-out each part of the works. Any review of such plans or schedules or methods of
work by the Engg. Incharge (Divisional Engr.)shall not relieve the Contractor of any of his
responsibilities towards the field activities. Such reviews shall not be considered as an assumption of
any risk or liability by the Employer or any of his representatives, and no claim of the Contractor will
be entertained because of the failure or inefficiency of any such plan or schedule or method of work
reviewed. The Contractor shall be solely responsible for the safety, adequacy and efficiency of plant
and equipment and his erection methods.
16.4.2. Progress Report
Progress reports shall be provided by the Contractor to the Engg. Incharge (Divisional Engr.)in
accordance with the relevant parts of this specification. Appropriate photographs shall accompany the
monthly progress reports.
16.5.
Facilities to be provided by the contractor
16.5.1. Unloading
Contractor shall make his own arrangement for unloading the equipment at site.
16.5.2. Tools, tackle and scaffoldings

The Contractor shall provide all the construction equipment tools, tackle and scaffoldings required for
offloading, storage, pre-assembly, erection, testing and commissioning of the equipment covered under
the Contract. He shall submit a list of all such materials to the Engg. Incharge (Divisional Engr.)before
the commencement of pre-assembly at Site. These tools and tackles shall not be removed from the Site
without the written permission of the Engg. Incharge (Divisional Engr.).
16.6.
First-Aid and general hygiene
The Contractor shall provide necessary first-aid facilities for all his employees, representatives and
workmen working at the site. At all times at least ten percent of all Contractors personnel assigned to
the worksite shall be shall be trained in administering first-aid.
The labour colony, offices and residential areas of the Contractors employees and workmen shall be
kept clean and neat to the entire satisfaction of the Engg. Incharge (Divisional Engr.). Proper sanitary
arrangements shall be provided by the Contractor in work-areas, offices and residential areas of the
Contractor.
Waste oil shall be disposed of in a manner acceptable to the Engg. Incharge (Divisional Engr.). Under
no circumstances shall waste oil be dumped into uncontrolled drains.
16.7.
Security
The Contractor shall have total responsibility for all equipment and material in his custody, stored,
loose, semi-assembled and/or erected by him at Site. The Contractor shall make suitable security
arrangements including employment of security personnel to ensure the protection of all materials,
equipment and works from theft, fire, pilferage and any other damages and loss.
16.8.
Materials handling and storage
All the equipment furnished under the Contract and arriving at Site shall be promptly received,
unloaded and transported and stored in the stores by the Contractor.
Contractor shall be responsible for examining the complete shipment and notifying the Engg. Incharge
(Divisional Engr.)immediately of any damage, shortage, discrepancy etc. for the purpose of Engg.
Incharge (Divisional Engr.)'s information only. The Contractor shall submit to the Engg. Incharge
(Divisional Engr.)every week a report detailing all the receipts during the weeks. However, the
Contractor shall be solely responsible for any shortages or damages during transit, handling, storage and
erection of the equipment at Site. Any demurrage, wharfage and other such charges claimed by the
transporters, railways etc. shall be to the account of the Contractor.
The Contractor shall maintain an accurate and exhaustive record detailing all equipment received by
him for the purpose of erection and keep such record open for the inspection of the Engg. Incharge
(Divisional Engr.).
All equipment shall be handled carefully to prevent any damage or loss. All equipment stored shall be
properly protected to prevent damage. Equipment from the store shall be moved to the actual location at
an appropriate time so as to avoid damage of such equipment at Site.
All the materials stored in the open or dusty location shall be covered with suitable weather-proof and
flameproof covering material.
The Contractor shall be responsible for making suitable indoor facilities for the storage of all equipment
which requires to be kept indoors.
17.
CONSTRUCTION MANAGEMENT
17.1.
General
Time is the essence of the Contract and the Contractor shall be responsible for performance of his
Works in accordance with the specified construction schedule. If at any time the Contractor is falling
behind the schedule, he shall take necessary action to make good for such delays by increasing his work
force or by working overtime to accelerate the progress of the work and to comply with schedule and
shall communicate such actions in writing to the Engg. Incharge (Divisional Engr.), providing evidence
that his action will compensate for the delay. The Contractor shall not be allowed any extra
compensation for such action.
17.2.
Field office records
The Contractor shall maintain at his Site office up-to-date copies of all drawings, specifications and
other supplementary data complete with all the latest revisions thereto. The Contractor shall also
maintain in addition the continuous record of all changes to the above contract documents, drawings,
specifications, supplementary data, etc. effected at the field. On completion of his total assignment
under the Contract, such drawings and engineering data shall be submitted to the Engg. Incharge
(Divisional Engr.)in the required number of copies.
17.3.
Protection of property and Contractor's liability
The Contractor will ensure provision of necessary safety equipment such as barriers, sign-boards,
warning light and alarms, personal protective equipment etc. to provide adequate protection to persons
and property. The Contractor shall be responsible for giving reasonable notice to the Engg. Incharge
(Divisional Engr.)and the owners of public or private property and utilities when such property and
utilities are likely to be damaged or injured during the performance of his works, and shall make all
necessary arrangements with such owners, related to removal and/or replacement or protection of such
property and utilities.
18.
CODE REQUIREMENTS
The erection requirements and procedures to be followed during the installation of the equipment shall
be in accordance with the relevant Indian/International Standards/Regulations, ASME codes, accepted
good engineering practice, drawings and other applicable Indian codes and laws and regulations..
19.
EMPLOYER'S SUPERVISION
To eliminate delays and avoid disputes and litigation, it is agreed between the Parties to the Contracts
that all matters and questions shall be referred to the Employer and without prejudice the Contractor
shall proceed to comply with the Employer's decision.
The work shall be performed under the direction and supervision of the Engg. Incharge (Divisional
Engr.). The scope of the duties of the Engg. Incharge (Divisional Engr.), pursuant to the contract, will
include but not be limited to the following:
Interpretation of all the terms and conditions of these documents and specifications.
Review and interpretation of all the Contractors drawing, engineering data etc.
Witness or authorise his representative to witness tests and trials either at the manufacturer's
works or at site, or at any place where work is performed under the Contract.
Inspect, accept or reject any equipment, material and work under Contract.
Issue certificate of acceptance and/or progressive payment and final payment certificates.
Review and suggest modification and improvements in completion schedules from time to time.
Supervise the Quality Assurance program implementation at all stages of the Works.
20.
TESTING AND INSPECTION
The Contractor shall carry out the tests stated in accordance with the conditions of this Specification,
without extra charge for such additional tests as in the opinion of the Engg. Incharge (Divisional
Engr.)are necessary to determine that the Contract Works comply with this Specification. The tests shall
be carried out generally in accordance with the relevant IECs or IS or equivalent standards. The
specific details of testing and inspection are given in the appropriate section of this Specification.
The Contractor shall submit Type Test Reports for all equipment being supplied by him for the Engg.
Incharge (Divisional Engr.)s approval. The Engg. Incharge (Divisional Engr.)may also give instruction
to carry out Type Tests, routine tests or acceptance tests. Type Test Charges shall be paid as per the
rates indicated in the Price Schedules.
All materials used shall be subjected to such routine tests as are customary in the manufacture of the
types of plant included in the Contract Works. These materials shall withstand satisfactorily all such
tests.
All tests shall be carried out to the satisfaction of the Engg. Incharge (Divisional Engr.), in his presence,
at such reasonable times as he may require, unless agreed otherwise. Not less than three weeks notice of
all tests shall be given to the Engg. Incharge (Divisional Engr.)in order that he may be represented if he
so desires. As many tests as possible shall be arranged together. Six copies of the Contractors test
reports and test sheets shall be supplied to the Engg. Incharge (Divisional Engr.)for approval.
Measuring apparatus shall be approved by the Engg. Incharge (Divisional Engr.)and if required shall be
calibrated at the expense of the Contractor at an approved laboratory.
The Contractor shall be responsible for the proper testing of the work completed or plant or materials
supplied by a sub-contractor to the same extent as if the work, plant or materials were completed or
supplied by the Contractor himself.
All apparatus, instruments and connections required for the above tests shall be provided by the
Contractor, but the Engg. Incharge (Divisional Engr.)may permit the use for the tests on site, any
instruments and apparatus which may be provided permanently on site as part of the contract works
conditional upon the Contractor accepting liability for any damage which may be sustained by such
equipment during the test.
The contractor shall supply suitable test pieces of all materials as required by the Engg. Incharge
(Divisional Engr.). If required by the Engg. Incharge (Divisional Engr.), test specimens shall be
prepared for check testing and forwarded at the expense of the Contractor to an independent testing
authority selected by the Engg. Incharge (Divisional Engr.).
Any costs incurred by the Employer in connection with inspection and re-testing as a result of a failure
of the subject under test, or damage during transport, or erection on site before take-over by the
Employer, shall be to the account of the Contractor.
No inspection or lack of inspection or passing by the Engg. Incharge (Divisional Engr.)of work, plant or
materials, whether carried out or supplied by the Contractor or sub-contractor, shall relieve the
Contractor from his liability to complete the Contract Works in accordance with the Contract or
exonerate him from any of his guarantees.
21.
FIRE PRECAUTIONS
All apparatus, connections and cabling shall be designed and arranged to minimise the risk of fire and
any damage which might be caused in the event of fire. When cabling is carried out as part of this
Contract the Contractor shall be responsible for sealing all holes in floors, walls, roofs etc. through
which the cabling may pass.
The work procedures that are to be used during the erection shall be those which minimise fire hazards
to the maximum extent practicable. Combustible materials, combustible waste and rubbish shall be
collected and removed from the site at least once each day. Fuels, oils and volatile or flammable
materials shall be stored away from the construction site and equipment and material stores in
appropriate safe containers.
All Contractors supervisory personnel and at least ten percent all of workers shall be trained for firefighting and shall be assigned specific fire protection duties. At least ten percent of all personnel
assigned to site at any one time shall be trained for fire fighting.
The contractor shall provide sufficient fire protection equipment of the types and sizes for the warehouses, office temporary structures, labour colony area etc.. Access to such fire protection equipment
shall be easy and kept open at all time.
22.
PACKING, SHIPPING AND TRANSPORT
The Contractor shall be responsible for the packing, loading and transport of the plant and equipment
from the place of manufacture, whether this is at his own works or those of any Contractor, to Site, and
for off-loading at site.
All apparatus and equipment shall be carefully packed for transport by air, sea, rail and road as
necessary and in such a manner that it is protected against tropical climate conditions and transport in
rough terrain and cross country road conditions. The method of packing shall provide complete
protection to all apparatus and equipment during transport and storage at site in heavy rain. The method
of packing shall provide adequate protection to main items of plant and those parts contained within and
attached without, for transportation.
Precautions shall be taken to protect parts containing electrical insulation against the ingress of
moisture.
All bright parts liable to rust shall receive a coat of anti-rusting composition and shall be suitably
protected. The machined face of all flanges shall be protected by means of a blank disc bolted to each
face.
Where appropriate all parts shall be boxed in substantial crates or containers to facilitate handling in a
safe and secure manner. Each crate or container shall be marked clearly on the outside of the case to
show TOP and BOTTOM positions with appropriate signs, and where the mass is bearing and the
correct position for slings. Each crate or container shall also be marked with the notation of the part or
parts contained therein, contract number and port of destination. It shall be the Contractors
responsibility to dispose of all such packing.
Any damage due to defective or insufficient packing shall be made good by the Contractor at his own
expense and within reasonable time when called upon by the Engg. Incharge (Divisional Engr.)to do so.
Four (4) copies of complete packing lists showing the number, size, marks, mass and contents of each
package shall be delivered to the Engg. Incharge (Divisional Engr.)immediately the material is
despatched.
The Contractor shall inform himself fully as to all relevant transport facilities and requirements and
loading gauges and ensure that the equipment as packed for transport shall conform to these limitations.
The Contractor shall also be responsible for verifying the access facilities specified.
The Contractor shall be responsible for all costs of repair or replacement of the equipment, including
those incurred by the Employer, arising from damage during transport, off-loading or erection on site,
until take-over by the Employer.
The Contractor shall be responsible for the transportation of all loads associated with the contract works
and shall take all reasonable steps to prevent any highways or bridges from being damaged by his traffic
and shall select routes, choose and use vehicles and restrict and distribute loads so that the risk of
damage shall be avoided. The Contractor shall immediately report to the Engg. Incharge (Divisional
Engr.)any claims made against the Contractor arising out of alleged damage to a highway or bridge.
23.
ERECTION MARKS
Before leaving the Contractors Works all apparatus and fittings shall be painted or stamped in two
places with a distinguishing number and/or letter corresponding to the distinguishing number and/or
letter on an approved drawing and material list. All markings shall be legible; weatherproof tags, where
used, shall be durable, securely attached and duplicated
The erection marks on galvanised material shall be stamped before galvanising and shall be clearly
legible after galvanising.
24.
SPANNERS AND SPECIAL TOOLS
A complete set of spanners shall be supplied for each station to fit every nut and bolt head on the
apparatus supplied under this Contract, together with all special tools required for the adjustment and
maintenance of the equipment. These tools shall be mounted in a lockable cabinet at each substation,
also to be provided under this Contract. Eye bolts which have to be removed after use shall be
accommodated in the cabinets.
Spanners and other maintenance equipment provided under the Contract shall not be used for the
purpose of erection of the contract Works.
Any special devices, slings or tackle necessary for the complete overhaul of the plant shall be handed
over to the Engg. Incharge (Divisional Engr.)in working order on completion of the Contract.
On delivering any or all of these tools to the Engg. Incharge (Divisional Engr.), a signature shall be
obtained from the Engg. Incharge (Divisional Engr.)s representative. Any tools not signed for shall be
deemed not to have been delivered.
25.
RUNWAY BEAMS, EYE BOLTS AND LIFTING TACKLE
Runway beams shall comply with the requirements of BS 2853, or its equivalent, and shall be tested
after erection in accordance with this standard and this Specification. The Contractor shall be
responsible for the provision of the appropriate test certificates which must be in accordance with
Appendix C of BS 2853.
All slings, eye bolts and other lifting tackle provided shall be proof tested to twice the safe working load
and suitably marked with embossed labels to show clearly the safe working loads.
FOR
SYSTEM DATA
E3-SYSTEM DATA- Page 1 of 2
SYSTEM DATA
Sl.No.
Description of Technical Parameter
Unit
1
2
3
Nominal system voltage

Maximum system voltage
Power frequency with stand voltage
kVrms
kVrms
kVrms
Switching surge withstand voltage (for

250/2500s
1. Line to earth
2. Across isolating gap
Lightning impulse withstand voltage
kVp
1.
2.
6
Line to earth
Across isolating gap
7
8
7
8
One minute power frequency withstand

value
Dry
Wet
System frequency
Variation in frequency
Corona extinction voltage
Radio interference voltage
9
10
11
12
12
System neutral rating

Continuous current rating
Symmetrical short circuit current
Duration of short circuit fault current
Dynamic short circuit current rating
13
Air clearances
Phase to ground
Phase to phase
System to system within a phase
Conductor spacing for AIS layouts
Phase to ground
Phase to phase
Design ambient temperatures
Pollution level as per IEC-815 and 71
Creepage distance
Maximum fault clearing time
Safety clearances
1. Section clearance
2. Ground clearances( between
ground and bottom most part of
energised object)
3. Horizontal clearance between the
fence and energised object
4. Horizontal clearance between the
road centre line and energised part
of the nearby equipment
Bay width
Height of bus equipment interconnection
from ground
Height of strung busbar
14
15
16
17
18
19
20
21
22
System
400kV
420kV
630kV
520kV
220kV
245kV
460kV
132kV
145kV
275kV
Not
1050kVp
Not
900kVp+345kVrms applicable applicable
kVp
(for 1.2
/50s)
kVrms
kVrms
Hz
%
1425kVp
1425kVp+
240kVrms
1050kVp
1200kVp
630
610
460
530
320kV
500V at
266KV
kA
Second
kAp
meters
meters
meters
meters
meters
meters
meters
oC
mm
ms
2000A
40
1
100
650kVp
750kVp
275
315
50
2.5
156kV
105kV
500V at
1000V at
167KV
93KV
Solidly earthed
2000A
1250A
40
31.5
1
1
100
79
33kV
36.kV
70kV
Not applicable
170kVp
195kVp
70
80
800A
25
3
62.5kA
3.5
4.2
-
2.1
2.4
-
1.3
1.3
480
530
6.5
7.0
4.5
4.5
3
3
1.5
1.5
10500
100
50
III
6125
3625
not exceeding 100ms
900
not exceeding 150ms
metres
metres
6.5
8
5
5.5
4
5
4
4
metres
As per I.E.
Rules
As per I.E.
Rules
As per
I.E. Rules
As per
I.E. Rules
As per I.E.
Rules
As per I.E.
Rules
As per I.E. Rules
metres
metres
27
8
18
5.5
11-13.1
5
5.5
4
metres
>15
10.5
8.5
5.5
metres
As per I.E. Rules
E3-SYSTEM DATA- Page 2 of 2

FOR
GENERAL METEROLOGICAL
DATA
E4-METEROLOGICAL- Page 1 of 2
METEROLOGICAL DATA
Description
Data
Annual mean of maximum monthly average

temperature.
50
Annual mean of minimum monthly temperature

in oC
Average rain fall in mm

Average thunder storms days per year
1500
77days
Design ambient temperature in oC
50
Maximum wind velocity in meter/sec.
50
Maximum relative humidity in %
100
Average relative humidity in %
85
Seismic co-efficient
0.06g Hori
0.01g Vert
E4-METEROLOGICAL- Page 2 of 2
FOR
DESIGN CLAUSES FOR SUBSTATIONS
E5-DESIGN CLAUSES FOR SUBSTATION- Page 1 of 8
DESIGN CLAUSES FOR SUBSTATIONS

TABLE OF CONTENTS
1. GENERAL
2. DESIGN PARAMETERS - OPEN TERMINAL
3. BUSBAR CONSTRUCTION.
4. PROVISION OF EARTH SWITCHES
5. INTERLOCKING
6. DESIGN PHILOSOPHY FOR PROTECTION, CONTROL AND METERING

SYSTEM
7. EARTHING SYSTEM
1. GENERAL
The substation shall adopt switching scheme as shown on the attached single line diagrams. The
Contractor shall propose the most economical substation layout that meets the desired degree of
operational flexibility, reliability, service continuity and expandability. The contractor shall submit
design considerations establishing the above and proposals for the Engg Incharge (Divisional Engr.)
approval. The attached drawings are intended to show the basic requirements to be satisfied, i.e.
switching arrangement, number of busbars, site location, available area, line termination etc. It is the
responsibility of the Contractor to prepare a detailed layout showing the manner in which the various
items of equipment offered can be accommodated to best advantage within the available area.
The arrangement shown on the attached drawings may be modified as necessary to accommodate the
various items, e.g. different types of disconnector, provided the basic principles are maintained.
The Bidder is at liberty to offer substation arrangements based on significantly different principles
where it is considered that these offer economies or technical advantages. It is emphasised, however,
that the Bidder's main offer should comply with the principles shown in the attached drawings, other
arrangements being submitted solely as alternatives to the main offer.
2. DESIGN PARAMETERS - OPEN TERMINAL
The substation design should be such as to minimise the number of levels of conductors and to ensure
that the consequences of a failure of one set of high level conductors are limited to the loss of that
circuit and a single busbar section. This principle shall also be applied with regard to earth wire
conductors. All materials and equipment for use in the substation shall be suitably rated to meet the site
conditions specified in the schedules.
All gantry type structures supporting conductors shall include facilities for ready access to all insulator
sets. There shall be permanently attached climbing devices with guard-rails and access to high level
beams shall not be possible without proper authorisation. Safety screens shall be provided between
adjacent circuits to maintain the specified safety clearances and to prevent accidental access to live
circuits.
Vehicle access to permit the transport of major switchgear equipment shall be provided. This shall be
achieved without the need to de-energise circuits. Access for vehicles which require the deenergisation of circuits shall be kept to a minimum and avoided wherever possible.
Each substation shall be adequately protected against direct lightning strikes, either by the use of spikes
or earth wires located on the substation structures, the use of spikes is preferred. The height, location,
and number of spikes or earth wires shall be such as to protect all equipment installed within the
substation to a failure rate of shielding from direct lightning strikes of not greater than 0.1 per cent per
annum.
Where the connection to the substation is by overhead line, overhead line conductors will be terminated
either at the substation gantry structures or to anchor blocks adjacent to the overhead line terminal
towers. The overhead line conductors complete with tension insulators, line tee off clamps, and
compression fittings (bi-metallic where necessary) shall be supplied and erected under a separate
contract. The Contractor shall provide facilities on the gantry structure for the fixing of the tension
insulators and arrange branching of conductors in to the sub-station from the transmission line
conductors.
The overhead line earth wire will be extended into the substation and the substation gantry structure
shall be arranged to receive this.
Where line traps are to be located within the substation, these should preferably be mounted integrally
with the coupling capacitor. Should this be impracticable, then the use of post type insulators is
preferred to suspension mounting.
Where disconnectors are of the pantograph type, the contact arrangements shall cater for conditions of
maximum wind loading coincident with either the maximum or minimum ambient temperature and
shall conform to the requirements of IEC 129. The Contractor shall also establish, through calculations,
the length of arm of each pantograph isolator so that the contact is proper and robust. The Contractor
shall also provide the required size and number of sag compensating springs where necessary.
Sub-station equipment, structures, roads, concrete cable troughs, drains etc.. shall be laid out in a neat
and organised manner to meet the employers requirement, facilitate movement of vehicles and ensure
safety of personnel and equipment.
Each substation shall be provided with safety grounding mat as per clause relevant clauses of this
section. While designing the ampacity of the buried conductor suitable corrosion allowance shall be
considered for thirty five (35) years. The conductors shall be buried at a depth of 600mm from finished
formation level. The conductors shall be welded suitably for maintaining a high degree of mechanical
rigidity and electrical connectivity.
The substation earth mat shall be designed to provide a ground potential rise within safe limits of
tolerable touch and step potential. The margins of limits shall confirm the international practices. The
design of earthmat shall be in accordance with IEEE-80/1986 and shall be submitted for Engg Incharge
(Divisional Engr.) approval.
3. BUSBAR CONSTRUCTION.
Busbars shall be made of aluminium tubes (for 220 KV only) or ACSR conductor. The busbar capacity
shall be designed for maximum ambient temperature conditions and symmetrical short circuit condition
of 40kA rms. The continuous current rating shall be so designed that no portion of the busbar is unduly
loaded, or over heated. For EHV sub-stations, the busbar and busbar fittings shall be made corona free
by the provision of corona rings or corona bells. There shall not be any harmful RIV from the
constructed busbars .
Tubular busbars shall be mounted on support insulators of adequate strength, mounted on support
structures above the ground in upright position, or hang from the structures depending upon the chosen
lay out.
Strain busbars shall be made bundled wherever necessary to carry the rated maximum continuous
current. The bundle size shall be determined by the Contractor to make such that it is corona free, and
fitted with spacers to limit the snatch forces such that no dangerous tensions are passed on to the
structures.
Interconnections to equipment shall be made from aluminium tubes or suitable flexible ACSR
conductors, through clamps and connectors only. Jumpers shall be made from flexible ACSR
conductors only.
There shall be no conductor joints in a span of strung strain busbars. Tubular busbars shall have a
maximum of one welded joint and shall be designed for thermal stresses and linear expansion, due to
temperature, so as to relieve the support structure and busbar fittings from stress.
The Contractor shall submit design calculations in support of the various dimensions of the busbar for
Engg Incharge (Divisional Engr.) approval.
The busbar deflection in respect of tubular busbars shall not exceed 50% of diameter. The stranded
conductor sag shall not exceed 1/80th of conductor span.
4. PROVISION OF EARTH SWITCHES

The earth switches shall be provided liberally in compliance to Indian Electricity Rules and as per latest
recommendations of CBIP Manual on EHV substations.
However the Employers practice is to provide earth switches with disconnector on busbar side and
feeder side of the circuit bay for all voltage class substations. For 400kV class substations earth
switches shall also be provided with disconnectors on circuit breaker side. In case the Electrical
Inspectorate requires provision of any further earth switches the same shall also be provided by the
Contractor.
Additional cost payable on account of providing such earth switches shall be mutually agreed between
the Contractor and the Employer on the basis of rates quoted by him for spare parts.
Each substation shall be provided with sufficient number of portable earth switches so as to carry out
maintenance works for at least two circuit bays.
5. INTERLOCKING
5.1 General
The applicable recommended interlocking facilities of IEC 517 shall be provided. Padlocking to the
requirements of this specification shall be provided for operational and maintenance security.
Earth switches on line circuits shall be capable of interrupting the current induced in the line at the
voltage specified in the schedules. This current may arise by induction from a fully loaded line in
parallel with the earthed line. If earth switches without the rated breaking capacity are provided, the
interlocking arrangements shall ensure the interruption of this induced current by the circuit breaker
before the earth switch is opened. Interlocking facilities shall be provided to release the circuit breaker
for maintenance whilst maintaining the earthing of the incoming line.
5.2 Philosophy
All disconnecting and earthing devices within the substation shall be interlocked in a manner that
ensures that they always operate safely. The system employed shall satisfy two distinct categories:
Operational interlocking: Interlocking associated with normal system operation and switching
and intended to ensure that a predetermined switching sequence is satisfied. Such interlocking
shall be achieved by electrical means in a manner that permits the equipment to perform any safe
operation.
Maintenance Interlocking: Interlocking associated with a series of switching operations to
render the equipment or sections of the substation safe for access and maintenance by personnel.
Such interlocking shall be achieved by mechanical interference type interlocks.
5.3 Principles
The design of the interlocking scheme shall be based upon the following principles:
a) Disconnectors are capable of switching the capacitive currents of associated connections.
b) Circuit breakers shall not be used as a point of safety isolation, this is the function of a
disconnector.
c) Disconnectors have neither load making nor breaking capacity.
d) Disconnectors are not capable of making or breaking transformer magnetising current.
e) Disconnectors are capable of the duty imposed when operated under parallel switching
conditions.
f) It shall not be possible to close or open any earth switch unless the point of application is
disconnected from all possible sources of supply, and the power operating devices of such
disconnectors are selected to the local control position.
g) It shall not be possible to operate any disconnector unless its associated circuit breaker is open.
h) It shall not be possible to operate any disconnector if an associated earth switch is already closed.
i) Disconnectors concerned with supplies from a remote point cannot be fully interlocked and shall
carry a warning notice to this effect. Similar notices shall be applied to earth switches.
6. DESIGN PHILOSOPHY FOR PROTECTION, CONTROL AND METERING SYSTEM
6.1 Protection Philosophy.
The control and protection system shall be closely inter related in the sub-station.
The protection system shall be designed for the fault clearing time, so that it prevents or limits damage
to primary equipment of the transmission system, and stability of the power system shall be protected.
The main protective system shall be capable of tripping (excluding circuit breaker operating time )
within 10 - 50ms. However, in any case the fault clearing time from the instant of inception of fault to
completion of the circuit breaker operation shall not exceed 100ms for 400kV and 220kV systems,
120ms for 132kV system and 150ms for 33kV system. Operating time of breakers to be provided by the
Employer are 40ms for 400kV, 50ms for 220kV, 50 ms for 132kV and 60 to 85ms for 33kV.
The protection system shall generally be a dedicated system organised at bay level for lines,
transformers etc., and at sub-station level for bus bar and breaker failure protection .
In the highest range of protection functions the protection unit and function shall be segregated as much
as possible. The protection shall not be compromised in any way by the requirements of the other
functions. The protection shall be permanently on line and shall be capable of tolerating faults in both
the hardware and software at bay level and sub-station level. The system shall be so designed that in the
event of loss of communication between the bay level and sub-station level, the continuity of
protection function shall be ensured.
The protection sub-system (relays ) should communicate with control and monitoring system to
provide information regarding operation, faulted phase, settings etc.. Information should also be
available at station computer level and for transmission to LDC via SCADA.
The protection system may also include new designs of protective relays incorporated with features
such as auto reclosing, fault recording , fault locating and synchronising check.
The recommended protection arrangement for different bays shall be in accordance with the protection
single line diagrams attached to this Specification.
Busbar protection systems shall be designed to initiate immediate tripping of all circuit breakers
connected to the faulted section of the busbar. In the event of non operation of a circuit breaker of a bay
all the circuit beakers connected to the associated busbar shall trip under breaker failure protection.
6.2 Control Philosophy.
The control function of the sub-station shall be the following:
Control Operation ( switching on or off or position change)
Control Monitoring ( alarms, annunciation, indication etc.)
The system shall efficiently perform the operation of circuit breakers, isolators, tap changers etc.. It
shall also perform the interlocking at bay level as well as substation level. The control system shall be
suitable for operating manually, electrically (remote) and via SCADA system from a remote control
centre.
Control shall be achieved at bay level, substation level and remote control centre level through
conventional MMI or computer based automated system, as specified in this Specification.
The system shall be designed, along with the communication system so that there shall be high
availability of bay protection associated with automatic functions such as auto reclosing. The systems
shall function autonomously and independently of adjacent bays, substation functions and units etc.
7. EARTHING SYSTEM
Electrical measurements of the subsoil at various depths up to 20 metres shall be made at the site of
each substation in order to determine the layered effects of the ground from which the effective ground
resistivity and hence the expected resistance of the proposed earth grid system may be predicted.
Wagners 4 - Electrode method as per IEEE-Std 81 may be followed for measurement of earth
resistivity.
The earthing system shall comprise a mesh grid formed by hot dip galvanised iron flat bar (GI flat) of
75 X 10 mm buried directly in the ground and arranged so as to utilise fully the available site area. A
continuous conductor shall be laid outside the periphery of the substation site at a distance of two
metres from the switchyard fence and at a depth of at least 0.7 metres (the earth mat top shall be at 700
mm below the finished ground level) below the surface. A mesh system shall be formed by
interconnection at various points to the perimeter conductor. The distance between two buried earth
flats shall be maximum 5 meters both way. The mesh system shall be designed such that the grid
potential rise limits the touch voltage to a value not greater than the maximum tolerable touch potential;
the fault clearance time to be used in the earthing calculations shall be taken as one second.
The earthing system shall be designed to meet the requirements of this specification and shall be in
accordance with IEEE 80 and IS 3043. The Contractor shall present calculations to show the earthing
system meets these requirements and can be shown to be safe in terms of touch, step and transferred
potentials. The calculations shall be carried out considering a layer of crushed metals of thickness
100mm and without the same; and if applicable recommend suitable site surfacing . The resistance of
the earth mat shall not exceed 0.5.
In the event of the substation resistance obtained with the foregoing installation being of a magnitude
unacceptable to the Engg Incharge (Divisional Engr.), then where practicable, the ground area enclosed
by the earth system should be increased by installing directly in the ground a GI flat conductor in the
form of a ring around the site at a significant distance from the boundary fence. Alternatively, earth
conductors can be directly buried radially outside the substation perimeter fence. The use of earth
plates as current carrying electrodes is not acceptable.
The earthing system shall be designed so as to include all overhead line terminal towers, which shall be
earthed by extending the system so as to envelope all towers within the earth system. Each tower shall
be bonded directly to the earth system from at least two locations. Structures and masts for lighting and
security surveillance equipment shall also be within the perimeter of the earth grid. No fixed low
voltage equipment, with the exception of a warning or alarm button and intruder alarms which shall be
of the double insulation type, shall be erected outside the perimeter of the earth grid.
Where a metal substation fence is provided, this shall be bonded electrically to the earthing grid on each
side at spacing not exceeding 0.25r (where r is the equivalent circular plate radius), at points adjacent to
each corner and immediately below any overhead line entering or leaving the Site. The location of the
mesh conductors shall be such as to enable all items of equipment to be connected to the earth system
via the shortest possible route.
Gate posts forming part of the substation fence shall be bonded together with below ground connections
and the gates themselves shall be electrically bonded to the posts at two points through flexible braids.
The current density of the earth conductor shall be not greater than 100 A/mm2. Single connections
between equipment and the earth system shall carry the total short circuit current, but the cross sectional
area of branch connections may be reduced to take account of current distribution in two or more
conductors. A distribution of 60 per cent shall be assumed for this purpose, i.e. the cross sectional area
of branch connections may be reduced to 60 per cent of the corresponding single conductor.
The earth conductor may be sized as per IEEE 80 and sufficient allowance for corrosion may be taken
in to account.
The grid voltage rise under fault conditions shall not exceed 15 kV. If the calculated grid voltage rise
exceeds 430 V, the local Telephone Authority shall be advised, by the Contractor, of the grid voltage
rise and the distance of the 650V contour from the substation grid periphery.
The alternative approach of independently earthing the fence and placing it outside the earth grid area
shall only be adopted if the above mentioned procedures prove insufficient or impracticable. The
Contractor shall provide calculations to show that this approach produces safe touch voltages at the
fence and shall ensure that the fence is isolated from all other buried metalwork.
Metal parts of all equipment, other than those forming part of an electrical circuit, shall be connected
directly to the main earth system at two points.For the same the size of the G.I flats shall also be
75X10mm.This is the raiser of the earth to the structures of column,beam and all equipment structures.
The arrangement of the mesh earth system shall be such as to minimise the length of these connections.
A separate set of earth electrodes (at least two), GI pipe, perforated, 40mm dia. 3000mm long in a
treated earth pit, shall be provided for the earthing for high frequency coupling equipment (CVT etc),
surge arresters, each neutral of the transformers and reactors at a position immediately adjacent to the
equipment being earthed in addition to the normal earth connection.
All main members of structural steelworks shall be earthed by GI flat(size 75X10mm) earthing
connections being bonded to the steelworks. The Contractor shall be responsible for earthing of the
transformers and circuit breakers installed on the substation site as per recommended.
Connections to apparatus and structures shall be made clear of ground level, preferably to a vertical
face and protected against corrosion.
Earth bars installed directly into the ground should normally be laid bare and the trench back-filled with
a fine top soil. Where the soil is of a hostile nature, precautions must be taken to protect the earth bar.
All exposed joints shall be at a minimum height of 150 mm above floor or ground level.
A facility shall be provided on the earth bar run between the equipment and the base of the structure,
comprising a looped copper strip(test link), so as to permit the attachment of portable earth connections
for maintenance purposes.
After installation of the earth system the Contractor shall measure the resistance of the substation. The
method used shall preferably be the "fall of potential" method, requiring the availability of a local low
voltage supply, but other methods using an earth resistance meter will be acceptable in the event of a
local supply being unavailable.
The fencing of the switchyard also to be earthed by using G.I flats of size 75X10mm to each post and a
continuous earth strip of size 50X6mm shall run all through the fence. The periphery of the switch yard
shall be provided with non treated earth pit at a distance of 5 mtrs all along the periphery. The size of
the non treated pit conductor shall be 40 mm dia MS rod of length 3000mm. The said earth MS Rod to
be placed in earth pit as per standard practice and the pit shall be filled with Bentonite powder mixed
with lomy soil at a ratio 1:10. There shall be provision of watering into the earth pits. A pipe of
adequate size should run all along the periphery and outlets shall be provided to each pit. The pipe shall
be connected to the overhead tank provided on the control room building and proper water control
valve should be provided. Contractor shall prepare a detail earthing provision considering as per
specification and shall obtain approval from OPTCL and the top of the MS rod shall be welded to the
buried earth mats.

FOR
CIVIL WORKS
E6-CIVIL WORKS- Page 1 of 55
CIVIL WORKS
TABLE OF CONTENTS
1. GENERAL
2. SITE CLEARANCE
3. STANDARDS
4. SOIL INVESTIGATION
5. MATERIALS AND WORKMANSHIP
10
6. EXCAVATION AND BACKFILL
12
7. SITE SURFACING
14
8. SITE DRAINAGE
15
9. SEWAGE SYSTEM
17
10. ROADS AND CULVERTS
18
11. AUTO TRANSFORMER / REACTOR FOUNDATION, RAIL TRACK / ROAD

CUM RAIL TRACK
19
12. FIRE PROTECTION WALLS
21
13. CABLE AND PIPE TRENCHES
23
14. FOUNDATION DESIGN
26
15. FOUNDATIONS AND R CC CONSTRUCTION
29
16. FENCING
39
17. BUILDING
41
18. MISCELLANEOUS GENERAL REQUIREMENTS
47
19. INTERFACING
48
20. WATER SUPPLY
48
21. STATUTORY RULES
49
22. SECURITY WATCH TOWERS
49
23. SECURITY SHED
49
24. STORE SHED,PLATFORM,RAMP & WINCH
49
25. ANTIWEED TREATMENT
50
26. GARDEN & PLANTATION
51
27. RAIN WATER HARVESTING
52
1. GENERAL
1.1 Scope of work
The scope of Civil works includes the following items.
The scope shall generally cover switchyard structures, including gantries and equipment support
structures and their foundations, cable trenches alongwith covers, cable trench crossings of road
and rails, sump pits, marshalling box/control cubicle foundations, switchyard levelling, site
clearance, soil investigation, roads, drains, fencing, gravelfilling, transformer / reactor
foundations, firewalls, control room building, other auxiliary buildings. Any other items, not
specifically mentioned here but required for the commissioning of switchyard/substation shall be
deemed to be included in the scope of this Specification. The scope shall further cover design,
engineering, erection, testing and commissioning of all civil works at each substation. All civil
works shall also satisfy the General Technical Clauses specified in other sections of this
specification and as detailed below.
Excavation, dewatering, carriage of excavated earth, plain cement concrete (PCC), casting of
reinforced cement concrete (RCC) foundations, super-structures for switchyard structures,
equipment supports, their control cubicles, bus post supports, lighting poles and panels, brick and
stone masonry, cable trenches, pipe trenches with necessary precast RCC removable covers, with
lifting facility and sump pits, cable supports and their embedment in cable trenches and cable
trench crossings road or rail track with backfilling complete as per drawings approved by the
OPTCL, shall be carried out by the contractor. The cable trenches inside the control room shall
be provided with MS chequered plate with angle stiffeners at the bottom for mechanical strength
and painting there of as per the standard practice.
The Contractor shall furnish all designs, (unless otherwise specified) drawings, labour, tools,
equipment, materials, temporary works, constructional plant and machinery, fuel supply,
transportation and all other incidental items not shown or specified but as may be required for
complete performance of the Works in accordance with approved drawings, specifications and as
per direction of the Engg Incharge (Divisional Engr.).
The work shall be carried out according to the design/drawings to be developed by the
Contractor, and approved by the Engg Incharge (Divisional Engr.) or supplied to the bidder by
the Engg Incharge (Divisional Engr.). For all buildings, structures, foundations etc. necessary
layout, levels and details shall be developed by the Contractor keeping in view the functional
requirement of the plant and facilities and providing enough space and access for operation, use
and maintenance based on the input provided by the Engg Incharge (Divisional Engr.). Certain
minimum requirements are indicated in this specification for guidance purposes only. However,
the Bidder shall quote according to the complete requirements.
2. SITE CLEARANCE
2.1 Clearing and Grubbing
The work shall consist of numbering of trees, removing and disposing of all materials such as
trees, bushes, woods, shrubs, grass, stumps, rubbish, rank vegetation, roots, foreign materials,
etc., which in the opinion of the Engg Incharge (Divisional Engr.) are unsuitable for incorporation
in the works, from within the limits and such other areas as may be specified on the drawings or
directed by the Engg Incharge (Divisional Engr.). Clearing and grubbing shall be performed in
advance of earthwork operations and in accordance with the requirements of these Specifications.
During clearing and grubbing, the contractor shall take all adequate precautions against soil
erosion, water pollution etc., and where required undertake additional works to that effect.
2.1.1 Provision of plantation and developing a garden inside the sub-station.

At least, 100 nos. of fruit & 100 nos. flowers bearing plants as per the advice of OPTCL to be
planted along the road side and in and around the control room and DG room building after
making surface treatment. Also, provision of developing a garden in front of the control room
building, the land to be developed shall be of size 30mtrs X 20 mtrs. Garden grass with variety of
flowering plants and show plants with crotons are to be provided after making proper surface
treatment. Provision of water taps facilities at different locations for watering the plants.
2.2 Setting out and making profiles
After the site has been cleared as per Clause 2.1 above, the limits of excavation shall be set out
true to lines, curves, slopes, grades and sections as shown on the drawings or as directed by the
Engg Incharge (Divisional Engr.). The Contractor shall provide all labour, survey instruments and
materials such as strings, pegs, nails, bamboos, stones, lime, mortar, concrete, etc., required in
connection with the setting out of works and the establishment of bench marks. A grid system of
co-ordinates shall be established by the Contractor at the site.
Masonry or concrete pillars shall be erected suitably at minimum of four places in the area to
serve as bench marks for the execution of the work. Each bench mark shall be protected from
damage or disturbance. These bench marks shall be connected with G.T.S. of any other
permanent bench mark approved by the Engg Incharge (Divisional Engr.). Necessary profiles
with pegs, bamboos and strings or Burjis shall be made to show the correct formation levels
before the work is started and the same shall be approved by the Engg Incharge (Divisional
Engr.).
2.3 Programme
The Contractor shall construct the works in compliance with the outline programme appended to
the Bidding Document, and shall submit for the approval of the Engg Incharge (Divisional Engr.)
a detailed programme in accordance with the requirements of this Specification.
2.4 Inclement weather
As per relevant Code, during hot weather, precautions shall be taken to avoid premature stiffening
of the fresh mix and to reduce water absorption and evaporation losses. During hot weather (
atmospheric temperature above 40 degree C ) or cold weather ( atmospheric temperature at or
below 5deg.C ) concreting shall be done as per the procedure set out in IS 7861.
3. STANDARDS
All Civil works shall be carried out as per applicable Indian Laws, latest revision of International
Standards and Codes. All materials shall be of best quality confirming to relevant Indian
Standards and Codes.
Civil works shall be designed to the required service conditions and /or loads as specified
elsewhere in this Specification or implied as per National and International Standards.
A list of code of practice and standards used for civil works in general is enclosed for reference.
In case of any conflict between I.S. Code and the Procedures specified herein, the later shall
prevail.
4. SOIL INVESTIGATION
4.1 General
The Contractor shall perform a detailed soil investigation to arrive at sufficiently accurate general
as well as specific information about the soil profile/strata and the necessary soil parameters of
the site in order that the foundations of the various structures can be designed and constructed
safely and rationally. Foundation systems adopted by the contractor shall ensure that relative
settlement shall be as per provision in IS 1904 and any latest IS and other Indian Standards.
This Specification covers all the work required for detailed soil investigation and preparation of a
detailed report. The work shall include mobilisation of necessary equipment, provision of
necessary engineering supervision and technical personnel, skilled and unskilled labour etc., as
required to carry out field investigation and tests, laboratory tests, analysis and interpretation of
data and results, preparation of detailed soil report including specific recommendations for the
type of foundations and the safe bearing capacity for different sizes of foundations at different
founding strata for the various structures of the substation. The Contractor shall make his own
arrangements for locating the coordinates and various test positions in field and also for
determining the reduced level of these locations with respect to the bench mark .All the test are to
be carried out before the OPTCL officials or before any agency engaged by OPTCL. Prior
intimation in this effect has to be given to OPTCL.
A report to the effect will be submitted by the Contractor for the Engg Incharge (Divisional
Engr.) specific approval giving details regarding his assumed data for Civil structures design.
Any variation in soil data shall not constitute a valid reason for any additional cost and shall not
affect the terms and condition of the Contract. Nothing extra what so ever shall be paid to the
Contractor on account of any variation in subsoil properties /or conditions. Tests must be
conducted under all the critical locations i.e. Control room building, autotransformer, lightning
mast, 400 kV/220 kV/132 kV column location etc. However, some of the soil parameters given
below for substations have to be determined and submitted to Engg Incharge (Divisional Engr.).
Dry density
Bulk density
Angle of internal friction/cohesion
Specific gravity
Natural moisture content.
4.2 Bore holes
Drilling of a specified number of bore holes of 150 mm dia. in accordance with the provisions of
IS 1892 at approved locations to specified depths or to refusal which ever occurs earlier. (By
refusal it shall mean that a standard penetration blow count (N) of 100 is recorded for 30 cm
penetration). However, at least 3 boreholes shall be drilled to the required depth (15 mts.
approximately).
Performing Standard Penetration Tests at approximately 2.0 m intervals in the bore hole starting
from 0.5 m below ground onwards and at every change of stratum. The disturbed samples from
the standard penetrometer shall also be collected for necessary tests.
Collecting undisturbed samples of 100/75 mm diameter 450 mm long from the bore holes at
intervals of 2.5 m and every change of stratum starting from 1.0 m below ground level onwards.
The depth of Water Table shall be recorded in each bore hole.

All samples, both disturbed and undisturbed, shall be identified properly with the bore hole
number and depth from which they have been taken. The sample shall be sealed at both ends of
the sampling tubes with wax immediately after the sampling and shall be packed properly and
transported to the Contractor`s laboratory without any damage or loss.
The logging of the bore holes shall be compiled immediately after the boring is completed and a
copy of the borelog shall be handed over to the Engg Incharge (Divisional Engr.).
4.3 Dynamic cone penetration test
Two Dynamic cone penetration tests under the locations of auto transformers shall be carried out
with the circulation of bentonic slurry at specified location and a continuous record of penetration
resistance (NG) upto 15 metre from natural ground level or refusal, shall be maintained by the
Contractor.
Dynamic cone penetration tests are conducted to correlate engineering properties such as
stratification density, bearing capacity, settlement, etc., of soils which are primarily cohesive in
nature. The tests shall be conducted by driving a standard size cone attached loosely or screwed
to a string of drill rods. The specification for the equipment and accessories required for
performing this test, test procedure, field observations and reporting of results shall confirm to IS
4968 part 11 latest revision. The driving system shall comprise of 65 kg weight having a free fall
of 75 cm. The cone size shall be 65 mm diameter, and provided with vents for continuous flow
of bentonite slurry through the cone and rods in order to avoid friction between the rods and soil.
The location for tests shall be as directed by the Engg Incharge (Divisional Engr.). On completion
of the test, the results shall be presented as a continuous record as the number of blows required
for every 300 mm penetration of the cone into the soil.
4.4 Trial pits
Trial pits shall be made at two locations as approved by the Engg Incharge (Divisional Engr.).
The trial pits shall two metres squar in size extending to (four) metres depth or as specified by the
Engg Incharge (Divisional Engr.). Undisturbed samples shall be taken from the trial pits as per
the direction of the Engg Incharge (Divisional Engr.).
4.5 Field California Bearing Ratio test
This test shall be carried out to obtain the properties of soil required for the construction of roads.
The equipment and accessories required for carrying out the test, test procedure, recording of
observations and presentation of results shall confirm to IS 2770 part XXXI. The test locations of
CBR test shall be on the road locations as per GA drawing. These tests shall be performed on
remoulded and undisturbed, soaked and un soaked samples.
4.6 Electrical resistivity test.
This test shall be conducted to determine the electrical resistivity of soil required for designing
safety grounding system for the entire station area. The specifications for the equipment and other
accessories required for performing electrical resistivity test, the test procedure, and reporting of
field observations shall confirm to IS 3043. The test shall be conducted using Wagners four
electrode method as specified in IS 1892, Appendix-B2. Unless otherwise specified at each test
location, the test shall be conducted along two perpendicular lines parallel to the coordinate axis.
4.7 Plate load test

Plate load test shall be conducted to determine the bearing capacity and load/ settlement
characteristics of soil at shallow depths by loading a plane and level steel plate kept at the desired
depth and measuring the settlement under different loads, until a desired settlement takes place or
failure occurs. The specification for the equipment and accessories required for conducting the
test, the test procedure, field observations and reporting of results shall conform to IS 1888. The
location and depth of the test shall be given by the Contractor and approved by the Engg Incharge
(Divisional Engr.). Undisturbed tube samples shall be collected at 1.0 m and 2.5 m depths from
the natural ground level for carrying out laboratory tests.
The size of the pit shall not be less than five times the plate size and shall be taken upto the
specified depth. All provisions regarding excavation and visual examination of pit shall apply
here.
If the ground water table is at a depth higher than the specified test depth, the ground water table
shall be lowered and maintained at the test depth for the entire duration of the test. Dewatering
shall be at Contractor`s cost.
Unless othewise specified the reaction method of loading shall be adopted. Settlement shall be
recorded from dial guages placed at four diametrically opposite ends of the test plate. The test
plate shall be 600 x 600 mm size and atleast 25mm thick. The bottom of the pit shall be levelled
before placing the plate in position for conducting the test.
A seating load of 70 gm/sq.cm shall be applied and after the dial gauge readings are stablised, the
load shall be released and the intital readings of the dial gauges recorded after they indicate
constant reading. The load shall be increased in stages. These stages shall be 20, 40, 70, 100,
150, 200, 250, 300, 400. 500, 600 and 800 KN per sq.m. or as directed by the Engg Incharge
(Divisional Engr.). Under each loading stage, record of time versus settlement shall be kept as
specified in IS 1888.
The load shall be maintained for a minimum duration of one hour or till the settlement rate
reduces to 0.02 mm/m. whichever is latter. No extrapolation of settlement rate from periods less
than one hour shall be permitted.
Loading shall be carried out in stages as specified above till one of the following conditions
occurs:
Failure of the soil under the plate i.e. the settlement of the plate at constant load becomes
progressive and reaches a value of 40 mm or more.
Total settlement of the plate is more than 4Omm.
Load intensity of 800 kN/sq.m is reached without failure of the soil.
Backfilling of the pit shall be carried out as per the directions of the Engg Incharge (Divisional
Engr.). Unless otherwise specified the excavated soil shall be used for this purpose. The quoted
rates shall include backfilling.
Dial gauge readings for settlement shall generally be taken at 1, 2, 4, 6, 9, 16, 25, 60, 90 and 120
minutes from the commencement of each stage of loading. Thereafter the readings shall be taken
at hourly intervals upto a further four hours and at two hours intervals thereafter for another six
hours.
4.8 Water sample

Representative samples of ground water shall be taken when ground water is first encountered
before the addition of water to aid drilling of boreholes. The samples shall be of sufficient
quantity for chemical analysis to be carried out and shall be stored in air-tight containers.
4.9 Laboratory Test
The laboratory tests shall be carried out progressively during the field work after a sufficient
number of samples have reached the laboratory, in order that the test results of the initial bore
holes can be made use of in planning the later stages of the field investigation and quantum of
laboratory tests.
All samples brought from field, whether disturbed or undisturbed shall be extracted/prepared and
examined by competent technical personnel, and the tests shall be carried out as per the
procedures laid out in the latest edition of the relevant IS Codes and Standards.
The following laboratory tests shall be carried out:
Visual and engineering classification.
Liquid limit, plastic limit and and shrinkage limit.
Natural moisture content, bulk density, dry density and specific gravity.
Grain size distribution.
Unconfined compression test.
Unconsolidated undrained test.
Swell pressure and free swell index determination.
California bearing ratio.
Consolidated undrained test.
Consolidated drained test.
Chemical tests on soil and water to determine the carbonates, sulphates, nitrates, chlorides,
Ph value, and organic matter and any other chemicals harmful to the concrete foundation.
4.10 Test results and reports
The Contractor shall submit the detailed report in four (4) copies wherein information regarding
the geological detail of the site, summarised observations and test data, bore logs, and
conclusions and recommendations on the type of foundations with supporting calculations for the
recommendations. Initially the report shall be submitted by the Contractor in draft form and after
the draft report is approved, the final report in eight (8) copies shall be submitted.
The report shall include, but not be limited to the following :
A plan showing the locations of an exploration work i.e. bore holes, dynamic cone
penetration tests, trial pits, plate load test, etc.
Bore logs: Bore logs of each bore holes clearly identifying the stratification and type of soil
stratum with depth upto the refusal. The values of Standard Penetration Test (SPT) at the
depths where the tests were conducted on the samples collected shall be clearly shown
against that particular stratum.
Test results of field and laboratory shall be summarised strata wise as well in combined
tabular form. All relavant graphs, charts tables, diagrams and photographs, if any, shall be
submitted along with report.
Recommendation The report should contain specific recommendations for the type of
foundation for the various structures envisaged at site. The Contractor shall acquaint
himself about the type of structures and their functions from the Engg Incharge (Divisional
Engr.). The observations and recommendations shall include but not be limited to the
following :
Geological formation of the area, past observations or historical data, if available, for
the area and for the structures in the nearby area, fluctuations of water table, etc..
Recommended type of foundations for various structures. If piles are recommended the
type, size and capacity of pile shall be given.
Allowable bearing pressure on the soil at various depths for different sizes of the
foundations based on shear strength and settlement characteristics of soil with
supporting calculations for the recommendations.
Recommendations regarding slope of excavations and dewatering schemes, if required.
Comments on the chemical nature of soil and ground water with due regard to
protective measures.
If expansive soil is met with, recommendation on removal or retainment of the same
under the structure/road etc. shall be given. In the latter case detailed specification of
any special treatment required including specification for materials to be used,
construction method and equipment to be deployed etc. shall be furnished.
Recommendations for additional investigation beyond the scope of the present work, if
Contractor considers such investigation necessary.
5. MATERIALS AND WORKMANSHIP
5.1 General
All materials used in the works shall be new and of the best quality of their respective kinds.
They shall comply with the requirements of the latest edition of any relevant Indian Standard or
Code of Practice where such exist, and current at the date of tendering.
All workmanship shall be of the highest standard, and shall be executed by competent men skilled
in their respective trades.
5.2 Samples
In addition to the special provisions made in this specification for sampling and testing of
materials by particular methods, samples of any materials and workmanship proposed to be used
in the Works may be called for at any time during the Contract by the Engg Incharge (Divisional
Engr.) and shall be furnished by the Contractor without delay and at the expense of the
Contractor. Samples when approved, shall be regarded as the acceptable standard, and any
material or workmanship subsequently not complying with that standard shall be rejected and
replaced by those of acceptable standard at the expense of the Contractor. Sample storage boxes
shall be provided by the Contractor free of cost if requested by the Engg Incharge (Divisional
Engr.).
5.3 Tests
Whenever considered desirable by the Engg Incharge (Divisional Engr.), Inspectors may be sent
to manufacturers or subcontractors premises to test materials or supervise their manufacture.
Where specified or requested the Contractor shall obtain from the manufacturer and send to the
Engg Incharge (Divisional Engr.) certificates of test, proof sheets, mill sheets, etc., showing that
materials have been tested in accordance with this Specification or the relevant Indian Standard.
Notwithstanding any tests which may be directed to be carried out at a manufacturers and/or
subcontractors works, the Engg Incharge (Divisional Engr.) may carry out any tests or further
tests he considers necessary or desirable after delivery of materials to the Site.
The Contractor shall provide all labour, equipment and facilities necessary for carrying out the
tests both in works and on site.
The cost of routine tests required by IS and this Specification shall be borne by the Contractor.
The cost of other tests shall be borne in accordance with the Conditions of Contract.
5.4 Names of suppliers and copies of orders
If so required, and before ordering material of any description, the Contractor shall submit for
approval the names of makers or suppliers proposed. Copies of orders shall also be submitted if
so required. The Engg Incharge (Divisional Engr.) may at any time withdraw his previously
given approval to obtaining materials from any maker or supplier should such maker or supplier
fail to supply materials of the specified quality or quantity in the requisite time.
5.5 Rejection of materials and workmanship
The Engg Incharge (Divisional Engr.) shall at any time have power to reject materials and
workmanship not complying with this Specification or with the approved Drawings. Materials so
rejected shall be immediately removed from site and replaced by materials of an approved
standard at the expense of the Contractor. Rejected workmanship shall be broken out and
replaced by work of an acceptable standard including the supply of new materials by the
Contractor, at the expense of the Contractor, and without delay.
5.6 Explosives and Blasting
All rules under the Explosive Act or other local rules in force shall be fully observed. All blasting
works shall be done in accordance with the stipulation contained in IS 4081. Written approval
shall be obtained from the Engg Incharge (Divisional Engr.) before explosives are used for
excavating foundations in rock and the Engg Incharge (Divisional Engr.) may impose conditions
for their use. The Contractor shall be responsible for complying with local regulations
concerning the use of explosives and for the safe-keeping and handling of explosives. Proper
warning shall be given of all blasting operations. During operations involving the handling or use
of explosives, the Contractor shall be responsible for the safety of personnel, Site Works and
people or properties in the vicinity of the site. The Contractor shall make good at his own expense
any damage caused by the use or mishandling of explosives.
6. EXCAVATION AND BACKFILL

Excavation and backfill for foundations shall be in accordance with the relevant Code. The back
fill around the foundations shall be compacted according to Clause 6.7 for Compaction.
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.
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 faces shall measure not more than one metre 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 Engg Incharge (Divisional Engr.).
Rocks larger than ten centimetres 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.
6.1 Rock excavation
The rock to be excavated shall be classified under the following categories :
6.1.1 Ordinary rock
Rock which does not require blasting, wedging or similar means for excavation is considered as
ordinary rock.. This may be quarried or split with crowbars or pickaxes and includes lime stone,
sand stone, hard laterite, hard conglomerate and reinforced cement concrete below ground level.
It will also include rock which is normally hard requiring blasting when dry but can be excavated
without blasting, wedging or similar means when wet. It may require light blasting for loosening
materials, but this will not any way entitle the material to be classified as hard rock.
6.1.2
Hard Rock
Any rock or boulder for the excavation of which blasting is required, for example quartzite stone,
granite, basalt, reinforced concrete (reinforcement to cut through but not seperated from concrete)
below ground level.
6.1.3 Hard Rock (Blasting prohibited)
This shall cover any hard rock requiring blasting as described in above but where blasting is
prohibited for any reason and excavation has to be carried out by chieselling, wedging or any
other approved method.
6.1.4 Authority for classification
The classification of excavation shall be decided by the Engg Incharge (Divisional Engr.) and his
decision shall be final and binding on the Contractor. Merely the use of explosives in excavation
will not be considered as a reason for higher classification unless blasting is clearly necessary in
the opinion of the Engg Incharge (Divisional Engr.).
6.2 Excavations for foundations and other purposes

Excavations shall be of the minimum sizes necessary for the proper construction of the works,
and excavations shall not be kept open for periods longer than that reasonably required to
construct the works. The Contractor shall take all precautions necessary to ensure that the
bottoms of excavations are protected from deterioration and that the excavations are carried out in
such a manner that adjacent foundations, pipes or such like are not undermined, damaged or
weakened in any way. Any excavation taken out below the proper level without approval shall be
made good at the expense of the Contractor using concrete or other material as directed.
All excavated materials obtained from excavation shall remain OPTCL`s property. The useful
portion shall be seperated from the useless one and deposited in regular stacks at places indicated
and as directed by the Engg Incharge (Divisional Engr.).
6.3 Support of excavations
The Contractor shall be responsible for the stability of the sides of the excavations. Excavations
shall be close timbered or sheeted, planked and strutted as and when necessary during the course
of the work and shall ensure the safety of personnel working within them. If any slips occur, they
shall, as soon as practicable, be made good in an approved manner at the expense of the
Contractor. Shoring shall not be removed until the possibility of damaging the works by earth
pressure has passed. No payment for shoring or timber left in shall be made, unless agreed in
writing by the Engg Incharge (Divisional Engr.).
6.4 Works to be in dry
All excavations shall be kept free from water and the Contractor shall take whatever action is
necessary to achieve this. Pumping, well pointing and other means necessary to maintain the
excavations free from water shall be at the expense of the Contractor, and carried out in an
approved manner.
6.5 Backfill
As soon as possible after the permanent works are sufficiently hard and have been inspected and
approved, backfill shall be placed where necessary and thoroughly consolidated in layers not
exceeding two hundred (200) millimetres in depth.
On completion of structures, the earth surrounding them shall be accurately finished to the line
and grade as shown on the drawings. Finished surfaces shall be free of irregularities and
depressions.
The soil to be used for back filling purposes shall be from the excavated earth or from borrow
pits, as directed by the Engg Incharge (Divisional Engr.).
6.6 Disposal of surplus
Surplus excavated material not required or not approved for fill or backfill shall be loaded and
deposited either on or off site as directed. The Contractor shall not delay disposal of surplus
material after receipt of instructions from the Engg Incharge (Divisional Engr.). The contractor
shall arrange to transport the excavated earth by mechanical transport, not necessarily on Pucca
roads. The soil so transported shall be stacked and levelled neatly and dressed. The location
where the soil is to be stacked / disposed shall be as directed by the Engg Incharge (Divisional
Engr.).
6.7 Compaction
The method and equipment used to compact the fill material to a density that will give the
allowable soil bearing pressure required for the foundations, roads, etc. in each layer of fill
material. Each layer of earth embankment when compacted shall be as close to optimum
moisture content (OMC) as practicable. Embankment material which does not contain sufficient
moisture to obtain proper compaction shall be wetted. If the material contains an excess of
moisture, then it shall be allowed to dry before rolling. The rolling shall begin at the edges
overlaping 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 rockfills. No compaction shall be
carried out in rainy weather.
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.
The density to which fill material shall be compacted shall be as per relevant IS and as per
direction of Engg Incharge (Divisional Engr.). 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 subgrade for the roads and embankment filling shall be compacted to
minimum 95% of the Standard Proctor's density at OMC
6.8 Requirement for fill material under foundations
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.
Where compacted fill is required it shall consist of suitable sand, or other selective inorganic
material, subject to approval by the Engg Incharge (Divisional Engr.). The filling shall be done
with locally available sand. The filled in sand shall be kept immersed in water for sufficient time
to ensure compaction, if so desired by the Engg Incharge (Divisional Engr.).
7. SITE SURFACING
7.1 Scope of Work
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 Engg
7.2 General Requirement
The material required for site surfacing/gravel filling shall be free from all types of organic
materials and shall be of standard approved quality, and as directed by the Engg Incharge
(Divisional Engr.).
The Contractor shall furnish and install the site surfacing to the lines and grades as shown in the
drawing and in accordance with the requirements and direction of the Engg Incharge (Divisional
Engr.). The soil of the entire switchyard area shall be levelled before placing the site
surfacing/gravel fill material. After all the structures and equipment have been erected and
accepted the site shall be maintained to the lines and grades indicated in the drawing and rolled or
compacted by using three ton roller with suitable water sprinkling to form a smooth and compact
surface condition, which shall be matching with finished ground level of the switchyard area.
After due compaction of the surface of the entire switchyard area shall be provided with plain
cement concrete of 75 mm thickness after proper compaction, and antiweed treatment having
cement concrete ratio 1:4:8. Care shall be taken for proper gradient for easy discharge of storm
water.
After the PCC is applied and surface prepared to the required slope and grade a base layer of
uncrushed/crushed broken gravel of 20 mm nominal size shall be spread, rolled and compacted
by using 1/2 ton roller (30 width and 24 dia) with 4 to 5 passes and water sprinkling to form a
minimum 50 mm layer on the designed finished formation level of the entire switchyard area.
As a final surface course minimum 50 mm. uniform layers of uncrushed /crushed broken metals
(gravel) of 20 mm. nominal size shall be spread over the base layer/course. This final surface
course shall be applied in all areas exclusive of roadways and shall extend beyond the fenced area
as indicated in the drawing. This surface course shall then be compacted by light roller using 1/2
ton steel roller (width 30 x dia 24) and 4 to 5 passes or any other means with water sprinkling
as directed by the Engg Incharge (Divisional Engr.). Water shall be sprinkled in such a manner
that bulking does not take place. The 20 mm. nominal size (for both layers) shall pass 100%
through IS sieve designation 37.5 mm and nothing through 16.0 mm. IS sieve.
In areas that are considered by the Engg Incharge (Divisional Engr.) to be too congested with
foundations and structures for proper rolling of the site base course 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 structure or equipment during rolling or compaction.
Engg Incharge (Divisional Engr.) by no means shall relieve the contractor of their contractual
obligations as stipulated in General and Special Conditions of Contract.
7.3 Measurements
7.3.1 Payment of gravel filling
The measurement shall be based on square metre of finished area of minimum specified
compacted thickness of 100 mm above finished ground level. Nothing shall be paid extra for any
additional material labour etc. used for achieving the specified compacted thickness of 100 mm.
above finished ground level.
8. SITE DRAINAGE
8.1 General
Adequate site drainage system shall be provided by the Contractor. The Contractor shall obtain
rainfall data and design the storm water drainage system, (culverts, ditches, drains etc.) to
accommodate the most intense rainfall that is likely to occur over the catchment area in one hour
period on an average of once per ten years. The surfaces of the site shall be sloped to prevent the
ponding of water.
The maximum velocity for pipe drains and open drains shall be limited to 2.4m/sec and 1.8m/sec
respectively. However, minimum non silting velocity of 0.6m/sec shall be ensured. Longitudinal
bed slope not milder than 1:1000 shall be provided.
For design of RCC pipes for drains and culverts, IS 456 and IS 783 shall be followed.
The Contractor shall ensure that water drains are away from the site area and shall prevent
damage to adjacent property by this water. Adequate protection shall be given to site surfaces,
roads, ditches, culverts, etc., to prevent erosion of material by water.
The drainage system shall be adequate without the use of cable or pipe trenches.
For pipe drains, concrete pipes of class NP2 shall be used. However, for road crossings higher
strength pipe of class NP3 shall be provided. For rail crossings, pipes conforming to railway
loading standards or at least NP4 class shall be provided. Manholes shall be provided at 30 m
intervals, at connection points and at every change of alignment. All manholes deeper than 1.2 m
shall be provided with galvanised M.S. foot rests. Foot rests shall be of 20 mm M.S. square bars.
Open surface drains shall comprise walls with bricks of class designation 75 in cement mortar 1:4
and100 mm thick bed concrete of grade 1:3:6, and surface with 12 mm thick cement plaster 1:4
with a floating coat of neat cement on the drain bed and exposed sides. Design and drawings shall
have the approval of the Engg Incharge (Divisional Engr.). For expansive soils, the guide lines of
IS 9451 shall be followed.
In general, all plant effluent drainage shall be through buried concrete pipes and all storm water
drainage shall be through open drains/pipe drains. Open storm water drains shall be provided on
both sides of the roads and shall be designed to drain the road surface as well as all the free and
covered areas.
Pipe drains shall be connected through manholes at an interval of maximum 30 m. Plant effluents
shall be suitably treated by the Contractor to meet all the prevalent statutory requirements and
local pollution control norms and treated effluents shall be conveyed to the storm water drainage
system at a suitable location for their final disposal.
Invert of the drainage system shall be decided in such a way that the water can easily be
discharged above the High Flood Level (HFL) outside substation boundary at suitable location
and approved by Engg Incharge (Divisional Engr.). Pumping of drainage water, if required, shall
be provided by Contractor.
All internal site drainage systems, including the final connection and disposal to Engg Incharge
(Divisional Engr.) acceptance points shall be part of Contractor`s scope including all required
civil work, mechanical and electrical systems. The Contractor shall connect his drain(s) at one or
more points.
Precast manholes shall be preferred against cast-in-situ type. The drainage scheme may either
employ open drain system or underground pipe system or a combination of both. A man hole
shall be provided at every turn or corner in case of underground type in addition to the normal
requirement.
Suitable pumping arrangement shall be provided by the Contractor to pump out the water from
sump to the open channel; automatic float valve type pump shall be provided and installed by
Contractor.
The Contractor shall locate the outfall point outside the substation vicinity and the substation
storm drainage must be connected to this point.
The drainage scheme and associated drawings shall be subject to approval of the Engg Incharge
(Divisional Engr.).
8.2 Excavation and backfill
Trench excavations for drains shall be carried out with the minimum disturbance to adjacent
ground and in such a way that existing or new work shall not be undermined. No backfill shall be
placed until pipes, etc. have been inspected, tested and approved. Backfill shall be carefully
placed by hand tools round pipes, etc. and rammed in layers not exceeding one hundred
(100) millimetres thick in a manner which will not cause damage. When a minimum thickness of
three hundred (300) millimetres above the pipes has been so placed, normal methods of
backfilling and ramming may be adopted.
8.3 Laying Of Pipes
Pipes and fittings shall be of the types, qualities and sizes specified and shown on the approved
drawings. They shall be laid to the lines and levels shown, and the barrel of each pipe shall bear
firmly and uniformly on the trench bottom or prepared foundation bed, any projections in the
trench bottom which could cause damage to pipes being first removed. Pipes shall be kept clean
during and after laying, and open ends shall be provided with the temporary plugs to prevent
entry of foreign matter. Each pipe shall be accurately bonded to gradient between sight rails and
drain. Laying shall commence at the lowest end and proceed uphill. Pipes shall be laid with the
sockets leading uphill.
8.4 Testing of drains
All drains, other than open channels, stone filled drains and porous drains, shall be of watertight
construction, and all soil drains shall be subjected to a water test before backfilling of trenches is
commenced. Drains may be tested in sections, and manholes may be tested separately. The
Contractor shall submit to the Engg Incharge (Divisional Engr.) for approval his proposals for
testing. The drains shall withstand, without leakage, a water pressure of not less than one and one
half (1.5) metres at any point for a period of 20 minutes or such other time as the Engg Incharge
(Divisional Engr.) may direct. All necessary plugs, temporary connections and other equipment
and all labour required for the tests shall be provided by the Contractor and at the expense of the
Contractor. For testing of pipes in areas where an adequate supply of water is not readily
available, the Engg Incharge (Divisional Engr.) will accept an air (smoke) pressure test, provided
that the method of testing is approved by the Engg Incharge (Divisional Engr.). Further testing
may be called for after backfilling of trenches to ensure that pipes have not been damaged during
that operation.
8.5 Regulations
The regulations and recommendations of any relevant drainage or sanitary authority shall be fully
observed, and the Contractor shall be responsible for acquainting himself with any such
regulations.
9. SEWAGE SYSTEM
A sewage system shall be provided for all utility buildings including the Control room building
and other auxiliary buildings.
The Contractor shall construct suitable septic tank and soak pit for the discharge of effluents.
Sewers shall be designed for a minimum self cleansing velocity of 0.6m/sec and the maximum
velocity shall not exceed 2.4m/sec.
The sewage system shall consist of all necessary piping, pumps, if required, fittings, manholes,
clean - outs, piping connections and all other materials required for safe and efficient sewage
collection. Sewer pipes and fittings shall conform to the relevant Indian Standards.
Cast iron pipes shall be used below ground level for sewage disposal.
Manholes shall be provided at every 20 metres along the length, at connection points, and at
every change of alignment, gradient or diameter of a sewer pipe line.
10. ROADS AND CULVERTS

The Contractor shall be responsible for constructing approach roads, sub-station roads and service
roads etc. within the substation area. Layout of the roads shall be based on general details and
arrangement drawings for the substation. Parking areas shall be provided for Site personnel and a
minimum of twenty numbers of visitors at convenient locations. Adequate turning space for
vehicles shall be provided and bend radii shall be set accordingly. Roads to the transformer bays
shall be as short and straight as possible. Where the substation layout warrants headroom safety
barriers shall be installed to prevent vehicles coming into contact with overlying conductors. Such
barriers shall be included as part of the scope of the work.
All substation roads shall be constructed so as to permit transportation of all heavy equipment. A
minimum seven metres black topping with 1.6 m wide shoulders on either side of the road shall
be constructed for double lane roads. The other service roads shall be with 3.75 m black topping
and 1.3 m wide shoulders on either side of the road.
Finished top (crest) of roads shall be a minimum of 300 mm above the surrounding grade level
(Formation level).
Road construction shall be as per Indian Road Congress (I RC) standards.
Adequate provision shall be made for road drainage.
All culverts and allied structures required for road/rail, drain, trench crossings etc. shall be
designed for class AA loading as per IRC standard.
All roads shall be designed for class 'E' of traffic i.e. traffic intensity of 450-1500 vehicles per day
(heavy vehicles exceeding 3 tonnes laden weight) as per IRC-37-1984, Guide-lines for the design
of flexible pavements.'
California Bearing Ratio (CBR) method shall be followed for the design of roads. A detailed
CBR test which is an adhoc penetration test shall be carried out as per the procedure outlined in
IS 2720 (Part XVI).
The surface of the hardstanding shall be laid with falls to the drainage system. Care shall be
taken during the construction that no materials enter the drainage system.
At the junction of the hard standing and roads due to different thickness of foundations,
precautions shall be taken to ensure that sub-surface drainage from the hard standing does not
have a detrimental affect upon the road foundations.
A) CONCRETE ROAD:
All the roads except the main, approach and periphery roads shall be of concrete road. The side
shoulder of all the roads shall be with kerb stone at two sides. The kerb stones shall be painted
yellow and black alternatively. In case of switch yard road (concrete road) the shoulder would be
compacted earth 600 mm wide on the sides of the road. The concrete road shall have 100 mm
thick PCC (1:2:4 nominal ratio).Below it 100 mm thick PCC (1:4:8) shall be provided.300 mm
thick water bound macadam (WBM) in three equal layers of 100 mm each at the bottom.
PCC and WBM shall extend upto the shoulder width on both sides of the road out side switch
yard area as per drawing. In case of road within the switch yard area the PCC and WBM shall
placed only up to the width of the road. Polythene sheet of 125 microns shall be placed between
the RCC and PCC slab. Expansion joints (12mm thick) shall be provided at every 8 mtrs. In
addition, in case of 7 mtrs wide roads 100 mm Dia hume pipe (NP-3) shall be provided at every
100 mtrs interval across the length of the road for cable crossing.
B) BITUMINOUS ROAD:
The approach road, main road, periphery road and colony road shall be bituminous type. The
following procedure shall be followed for the construction of bituminous roads.
1. Compacted WBM at the bottom end of the road up to a thickness of 300 mm in three equal
layers 100 mm each. The compaction shall be done by laying stone aggregates of size 100mm.
each lair shall be laid and compacted with water spreading and using rollers as per the standard
practice adopted in the CPWD guide line.
2. Above, the compacted WBM 1st filing as stated under (!), 200 mm thick consolidated WBM in
two layers with stone aggregates of size 90 45mm shall be laid. Each layers shall be laid and
compacted with water spreading and using rollers as per recommended.
3. Above the compacted 2nd layer of WBM, 75 mm thick consolidated WBM in two layers with
stone aggregates of size 63mm-45mm shall be laid. Each layers shall be compacted with water
spreading and using rollers as per recommended.
4. Above the compacted 3rd layer of WBM, 75 mm thick consolidated WBM in two layers with
stone aggregates of size 53mm-22.4mm shall be laid. Each layers shall be compacted with water
spreading and using rollers as per recommended.
5. Above the 4th layer of compacted WBM, 25mm thick pre mix carpet surfacing has to be done.
The carpet surfacing shall be done with 2.25 cum and 1.12 cum of stone chippings of 13.2 mm
size and 11.2 mm size respectively per 100 sq mtrs and 52 Kgs of hot bitumen per cum of stone
chippings. Complete with paving ASPHALT 80/100 heated and thin mixed with solvent
@70g/Kg of ASPHALT. Hot bitumen of grade 80/100 shall be spread on road surface @750g/Kg
per sqmtr. There shall be shoulder on both side of the roads as per given data. The curvature of
the road shall be R=7M and additional metalling for turning has to be maintained. The shoulder
shall also be made compacted morrum filling and other as specified.
10.1 Periphery roads out side the fencing:
Periphery roads to be constructed out side the fencing. The width of the road is 3.5 mtrs having
borm of 1 mtr each at both sides of the roads. The roads shall be bitumen grading and as per
Indian Road congress standards.
10.2 The width and type of other roads are:
a) Bituminous road:-Approach and main roads shall be 7 mtr wide with both side shoulder
of 1.75 mtrs. The roads shall be of bitumen grade type.
b) Other roads shall be (peripheral and colony) 3.75 mtrs width having shoulder of 1.3 mtr
at both the side. The roads shall be of bituminous type.
11. AUTO TRANSFORMER / TRANSFORMER/REACTOR FOUNDATION, RAIL

TRACK / ROAD CUM
RAIL TRACK
11.1 General
The Contractor shall provide a permanent transfer track system integrated with the auto
transformer foundation to enable installation and the replacement of any failed unit with a spare
unit. The transfer track system shall be suitable to permit the movement of any failed unit fully
assembled (including OLTC, bushings) with integral radiators and oil, without the deenergization of any other equipment in the station. The system shall enable the removal of any
failed unit from its foundation to a repair area and the installation of a spare unit. The system
shall not interfere with the normal internal road and trench system. If trench or drain crossings are
required then suitable R.C.C culverts shall be provided in accordance with IRC Code and /or
relevant IS.
Rail tracks shall be of RCC, M20(1:1.5:3 mix) grade. The space between the tracks shall be
suitably filled with local sand and 75 mm thick PCC of grade 1:3:6 placed over sand filling. The
top of PCC shall be up to the formation level. In case of road cum rail track, 75mm thick PCC of
grade 1:1.5:3 shall be placed up to the road level. Suitable drainage system between the tracks
shall be provided.
The rails shall be first quality 52 kg/m medium manganese steel as per Indian Railway
specification T-12-64 and its subsequent revision, joined together by fish plates as per Indian
Railway specification T-1/57, and 27 mm diameter fish bolts.
A pylon support system shall be provided for supporting the fire fighting system by the
Contractor.
For design of foundation for transformer refer the weightage of the transformer indicated in the
BPS (civil works)
11.2 Oil Recovery System
11.2.1 General
An oil recovery system shall be provided for all transformers (containing insulating oil or any
flammable or polluting liquid) in order to avoid spread of fire by the oil, and for environmental
protection.
11.2.2 Description
Each auto transformer/transformer including oil conservator tank and cooler banks etc. shall be
placed in a transformer pit surrounded by retaining walls (pit walls). The clear distance of the
retaining wall from the transformer shall be 20% of the transformer height or 0.8 m whichever is
greater. The transformer pit thus formed shall have a capacity equal to volume of oil, usually
125%, in the transformers. The MS grating placed at the formation level shall be covered with
100mm thick gravel of 40 mm nominal size which acts as an extinguisher for flaming oil. The
bottom of the pit shall have an uniform slope towards the sump pit.
Each transformer pit shall be drained towards a common sump pit whose role is to recover the
infiltrating water and the drained oil from of the pit. The sump pit shall have sufficient capacity
to receive, without overflowing, the oil content of large transformers plus the water content of
any fixed fire fighting system and a certain quantity of rain water collected from the pit connected
to it. The system shall be provided with air vents large enough to avoid over-pressure during
operation. The whole internal surface of the sump pit should be impermeable.
11.2.3 Materials
The retaining walls which make up the transformer 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 15 cm above the finished level of the ground
to avoid ingress of water from outside.
The floor of the transformer pit shall be of plain cement concrete of concrete grade 1:2:4
11.2.4 Drainage
A device showing level of sump pit shall be fitted along with an automatic pumping system
which shall have sufficient capacity to evacuate the fire fighting and rain water from the sump pit.
The water/oil separation and drainage scheme shall be provided as described in the paper (2307/1972 Cigre Session) presented by working group 23.04 regarding oil pollution. The Contractor
may propose an alternative better scheme, which will be subject to the approval of the Engg
11.2.5 Particular Specification
If the height of the retaining walls which form the transformer pit exceed 60 cm, steps shall be
provided to facilitate access to the transformer or auto transformer and reactor
When designing the transformer pit, the movement of the auto transformer must be taken into
account.
It must be assured that the coefficient of crushed stone (granular material) penetration which fills
the transformer pit will be retained regardless of the climatic conditions.
12. FIRE PROTECTION WALLS
12.1 General
Fire protection walls shall be provided in accordance with Tariff Advisory Committee (TAC)
recommendations.
12.2 Application criteria
A fire wall shall be erected between the transformers and or the reactors if the free distance
between the various pieces of equipment is less than 10 m, to protect each one from the effects of
fire on another.
Fire walls shall also be erected between the transformers, reactors, and auxiliary services
transformers if the free distance is less than ten metres.
12.3 Fire resistance
The fire wall shall have a minimum fire resistance of three hours. Partitions which are made to
reduce the noise level of the transformers shall have the same fire resistance where they are also
used as fire walls. The walls of buildings which are used as fire walls, shall also have a minimum
fire resistance of three hours.
Fire walls shall be designed in order to protect against the effect of radiant heat and flying debris
from an adjacent fire. The column of the fire walls shall be type be RCC, M20 (1:1.5:3 mix).
12.4 Mechanical resistance
Fire walls shall have the mechanical resistance to withstand local atmospheric conditions. If the
wall is intended to serve as a support for equipment such as insulators etc., its mechanical rigidity
must be increased accordingly.
Connecting the walls by steel or other structures, which may produce a reversing torque if
overheated, shall be avoided.
12.5 Dimensions
Fire walls shall extend at least two metres on each side of the power transformers or reactors and
at least one metre above the conservator tank or safety vent.
These dimensions might be reduced in special cases, and if TAC permits so, where there is lack
of space. A minimum of two metres clearance shall be provided between the equipments e.g.
reactors, transformers and fire walls.
Building walls which act as fire walls shall extend at least one metre above the roof in order to
protect it.
12.6 Materials
Fire walls may be made of reinforced concrete (M20 grade), fire brick, concrete blocks or
corrugated iron on a steel structure as per the system requirements. Materials used must conform
to the standards of the National Fire Prevention Association and TAC norms.
12.7 BOUNDARY WALL/COMPOUND WALL:
The scope includes the design, engineering and construction of the boundary wall all along the
property line of the OPTCL on each sub-station.
The one and half brick wide boundary shall be constructed to a height of 2 mtrs above finished
ground level of the substation area and below virgin soil a minimum of 900 mm depth.
Galvanised barbed wire fencing shall be provided on top of the boundary wall to a height of 0.5
mtr. G.I Barbed wires(12 SWG) of 3-rows each limb of Y shaped frame (Total 6 nos) shall be
provided . A minimum length of 300 mm (bottom portion of the Y shaped frame) shall be grouted
and a clear height of 500 mm from the finished portion of the top of the wall shall be maintained
for the Y shaped frame with GI barbed wires. A 50mm height of finished concrete (ratio 1:2:4)
shall be provided on the top of the boundary wall.
A) The below mentioned brick works is for construction of pillar where the Y shaped frame shall
be grouted.
Inside the Virgin soil:The masonry work in foundation and plinth shall be done in 1:5 cement mortar above a
layer ( height of 75mm and width of 900 mm as per requirement) of cement concrete 1:3:6.The
Brick work shall be as per below.
1) First layer above the PCC of 75 mm: Height: 300mm & Width: 750 mm (as per
requirement)
2) Second layer above first layer brick: Height: 300mm & Width: 625 mm (as per
requirement)
3) Third layer above second layer brick: Height: 300mm & Width:500 mm (as per
requirement)
Above ground level:
1) DPC of 50 mm above the third layer of Brick work.
2) Brick work of thickness of 375 mm having height of 2 mtrs.
B) The below mentioned brick works is for the walls.

Inside the Virgin soil:The masonry work in foundation and plinth shall be done in 1:5 cement mortar above a
layer ( height of 75mm and width of 775 mm as per requirement) of cement concrete 1:3:6.The
Brick work shall be as per below.
1) First layer above the PCC of 75 mm: Height: 300mm & Width: 625 mm (as per
requirement)
2) Second layer above first layer brick: Height: 300mm & Width: 500 mm (as per
requirement)
3) Third layer above second layer brick: Height: 300mm & Width: 375 mm (as per
requirement)
Above ground level:
1) DPC of 50 mm above the third layer of Brick work.
2) Brick work of thickness of 250 mm having height of 2 mtrs.
The masonry work in super structure shall be done with 1:6 cement sand mortar, above 50 mm
thick layer of DPC at plinth level. Expansion joint shall be provided at 30 mtr interval of the
boundary wall.
The even face of the brick work shall be plastered with 12mm thick in 1:6 cement sand and
uneven face shall be plastered with 18mm thick in 1:6 cement sand (in two layers) above the
ground level.
Both faces of the walls shall be provided with two coats of cement painting (weather proof) using
approved quality of cement paint.
The Y post shall be galvanised one. The Y shape GI frame shall be grouted on the top of wall
inside a pocket of size 100 Sq mm X 300 mm deep with !:2:4 Cement concrete. The size of the
GI angle shall be 50X50X6 mm. The height of the Y shaped frame shall be
Boundary shall have one main gate as per stipulation elsewhere in the spec. The gate shall be
supported by gate pillars of RCC (1:1.5:3).A separate wicket gate shall be provided adjacent to
the main gate.
In case the stability of the boundary wall as mentioned is not suitable for the soil, the bidder has
to consider for putting RCC(1:1.5:3) tie beam to be rested on the RCC pillars. The size of the
beam and pillar has to be carried out as per the soil condition for proper stability of the boundary
walls.
13. CABLE AND PIPE TRENCHES
13.1 General
Cable trenches and pre-cast removable RCC covers (with lifting arrangement) shall be
constructed using RCC of M20 grade.
The cable trenches shall be designed for the following loads.
Dead load of 155 kg/ m length of cable support plus 75 kg on one tier at the end.
Triangular earth pressure plus uniform surcharge pressure of 2 tonnes per sq.metre.
Cable trench covers shall be designed for (i) self weight of top slab plus concentrated load
of 200 kg at centre of span on each panel and a surcharge load of 2 tonnes per sq. metre.
Cable trench crossings of road and rails shall be designed for class AA, class A and class 7OR
loading of IRC or relevant IS Code and should be checked for transformer loading.
Trenches shall be drained. Necessary sumps be constructed and sump pumps shall be supplied.
Cable trenches shall not be used as storm water drains.
The top of trenches shall be kept at least 250 mm above the finished ground level. The top of
cable trench shall be such that the surface rain water does 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(GI pipe and necessary G.I bends
and sockets)
A suitable clear gap shall be maintained between trench walls and foundations.
A clear ( vertical ) space of at least 300 mm shall be available for each tier in cable trench. From
trench bed to lowest tier, a minimum clearance of 200 mm shall be available for one tier trench
and 300 mm for trenches having more than one tier. The spacing between stands shall be 400mm.
The trench bed shall have a slope of 1/500 along the run and 1/250 perpendicular to the run.
All 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 expansion joints shall be
provided with approved quality PVC water stops of approximately 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 sand mortar.
Cable tray supports( all galvanised structures) shall be designed and constructed to be a single
complete fabrication or assembly such that every layer of the horizontal cable tray supports are
fixed, either bolted or welded, to a vertical steel support that is embedded in the concrete wall of
the cable trough. It shall not be permitted to embed a horizontal support beam directly into the
wall of the trough in order to use the concrete wall as a means of load bearing.
Concrete troughs shall be provided with concrete covers of suitable load bearing strength. Where
the cable troughs are run across or within 3 m of substation roads, the trough covers shall be
capable of bearing an accidental wheel load of 20 kN.
MORE ON CABLE TRENCH.
All the cable trenches shall be RCC type with mixing ratio 1:1.5:3.The size of MS rod to
be used for the same are of 8mm tor and 6mm.All the vertical rod shall be 8 mm
continuous and the wall and raft shall contain 2 nos 8 mm rods at two layers and spacing
shall be 150mm. The horizontal binders shall be of 6mm rod two nos in two layers and to
be placed at 200mm centre to centre for both on the wall and raft portion of the trench.
The mentioned rod placements are for section 1-1,2-2,and 3-3. For section 4-4 instead of
two 8mm and 6mm rods single rods can be used.
A frame of hot dip galvanized angles of size 50X50X6 mm having provision of
MS chairs on the grouting side on to the walls of the trench preferably at two locations(at
top and bottom) of the frame (these chairs have to be welded with the rods of the wall for
better rigidity). For section 1-1 there shall be of 4 tier mechanism for fixing of cable tray
having width of the angle 450mm (3 nos) and the top angle shall be of 300 mm, and the
quantity of such type of frame shall be 2 (for both way). For section 2-2 only one frame
of the above mentioned one shall be used. For section 3-3 there shall be one frame but
with three tier mechanism for fixing the cable trays. For section 4-4 two tier system of
angle width shall be 200 mm width at the bottom and 100 mm width at the top. Fixing of
the cable tray support stand (Frame) is to be fixed at a distance of 1 mtrs from one frame
to the other.
The thickness of the RCC wall of the trench shall be 100mm and thickness of the
raft shall be 75mm. All the frames for fixing of cable trays shall be of hot dip galvanized.
A running earth strip has to run all through the cable trench for proper earthing of the
cable trays and stand (frame).The size of the earth strip is of 50X6mm G.I flats. Welding
the GI flats to the frame to be carried out. Earthing strips to be welded with the running
earth mat at 10mtrs interval
The bidder also to supply and fix G.I perforated cable trays (of thickness 2mm) of
appropriate size before laying of cables on the cable tray stand.
The other dimensions of the cable trench are as below.
Sl
No
Section
No of
tiers in
each
frame/
and no
of
such
frame
Gap
Inside clearance Outside
betwee in mm
in mm
n the
two
angles
in mm
clearance Concrete
thickness in mm
Top to Wall
Botto
to wall
m
1275
1400
Top to Raft
bottom
width
of wall
1350
1750
Wall
Raft
100
75
1275
900
1350
1450
100
75
1075
900
1150
1450
100
75
545
250
620
350
75
75
1-1
Four
tiers/
Two
(both
way)
200
2-2
3-3
4-4
Four
200
tiers/si
ngle(o
ne
way)
Three/ 200
single
Two/si 200
nge
The covers of the slab are also of RCC with ratio mixing 1:1.5:3.The thickness of
the slab shall be 75mm for section 1-1(MS Rods to be used 10mm&8mm), section 2-2, 33 shall be 60mm (MS Rod to be used 8mm) and section 4-4 shall be 50mm(MS Rods to
be used 8mm&6mm). The MS rods to be used shall be placed at 100 mm centre to centre
both way and properly binded .The cover slab shall have provision of lifting hooks at two
points for easy lifting of the slabs. Slabs having lifting hooks shall be placed at every 10th
slabs. The lengths of the cable trench cover slabs are as below.
Section
1-1
2-2
3-3
4-4
Length of the slab

1600mm
1100mm
1100mm
400mm
Thickness of the slab

75mm
60mm
60mm
50mm
The covers for the cable trench inside the control room shall be provided with MS chequered
plate with MS angle stiffeners at the bottom for proper mechanical strength.
13.2 Excavation
Excavation for cable ducts shall generally be carried out in accordance with Clause no. 6.2 of this
specification.
13.3 Back fill
Except where ducts are to be encased in concrete, sand is to be packed and well tamped round the
duct until it is covered to a depth of 75 mm above the upper surface of the duct. Filling above
this level is to be with suitable excavated material free from large stones. In multiple duct runs the
interstices between the ducts are to be filled with sand and compacted. A cover of 75 mm above
the uppermost ducts shall be maintained. The sand used shall be the same quality as approved for
use in making concrete.
13.4 Laying of ducts
Telephone and electrical cable ducts shall be laid and jointed in accordance with the
Manufacturers instructions.
13.5 Multiple runs to ducts
Electrical cable ducts in multiple runs whether encased in concrete or not, shall be laid at
approved centres vertically and/or horizontally. The minimum concrete encasement where
required is to be 150 mm. The final jointing of ducts in multiple runs shall be done in the trench,
i.e. the duct shall be lowered and jointed singly not in groups, and duct joints shall be staggered
by approximately half the duct length in alternate lines.
13.6 Cutting of ducts
The Contractor shall carry out any necessary cutting of pipe ducts according to the requirements
of the work. Except where ducts enter the cable trench at an angle, they shall be cut at right
angles to the length of the duct. The inside edges of cut ducts shall be thoroughly rounded off or
so dressed before being placed in position so that there can be no possibility of damage to cables
from the edges of the ducts. All electrical ducts entering draw pits shall be provided with suitable
bellmouths.
13.7 Cleaning and testing of ducts
On completion of all electrical cable ducting, two mops of appropriate size connected one to each
end of an iron mandrel shall be passed twice through each way to clean the conduit and to remove
any foreign matter which may have entered. If any obstruction or other defect be discovered it
shall be removed or rectified forthwith.
13.8 Sealing of electrical ducts

As soon as every duct or set of ducts has been proved and its draw wire material installed, the
ends of the cut or its bellmouth where provided, shall be sealed to a depth of 5 mm with an
appropriate sealer, and a single coat of bitumastic paint shall then be applied over the end of the
ducts and the seal. The length of draw wire installed shall be such that at least one metre of draw
wire extends from each end of each duct. After the ends of ducts have been sealed the free ends of
draw wires shall be neatly coiled.
13.9 Concrete cable and pipe trenches
In-situ concrete trenches are to be provided inside and outside the Substation. The trenches are to
have falls in the floor and must be drained at regular intervals.
All trenches must have trench covers suitable for their location and loading. Any beams or
supporting covers must be as shallow as possible to avoid interfering with the pipes and cables in
the trench.
Once the trench covers have been made they are to be stored and not laid until all trench cabling,
piping, etc. is finished. Any covers laid before this time which become damaged shall be
replaced at the Contractors expense.
Trench covers and bridging beams for covers, except where heavy duty, shall be light enough for
two men to lift.
13.10 Buried cables
Cables are to be laid in neat lines and at suitable levels. Their depth below ground level will
depend upon the voltage associated with the cables but in all cases the excavation must provide a
clear trench. Sand filling below, around and above the cables will always be required and
protection covers or tiles will be placed in position over the sand filling before final backfilling to
the ground level. The line of the cable trenches shall be marked with suitable posts as required by
relevant section of this Specification.
14. FOUNDATION DESIGN
14.1 General
All foundations 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 M20
corresponding to 1:1.5:3 nominal mix ratio with 12-20 mm coarse aggregate. Higher grades of
concrete than specified above may be used at the discretion of the Bidder without any financial
implication to the owner.
Limit state method of design shall be adopted unless stated otherwise in the Specification.
For design and construction of steel-concrete composite beams IS 11384 shall be followed.
For detailing of reinforcement IS 2502 shall be followed. Cold twisted deformed bars (Fe= 415
N/sq mm) conforming to IS 1786 shall be used as reinforcement. However, in specific areas, mild
steel (Grade1) conforming to IS 432 can also be used. Two layers of reinforcement (on inner and
outer face) shall be provided for wall and slab sections having thickness of 150 mm and above.
Clear cover to reinforcement towards the earth face shall be minimum 40 mm.
RCC water retaining structures such as storage tanks, cooling water basin etc. shall be designed as
uncracked sections in accordance with IS 3370 (Part 1 to IV) by working stress method and shall
also be tested for water tightness at full water level. However, water channels shall be designed as
cracked sections with limited steel stresses as per IS 3370 (Part 1 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 produce the maximum stresses in the foundation or the foundation component,and as per
the relevant IS Codes of foundation design.The design calculations shall be submitted by the
bidder showing complete details of piles/pile groups proposed to be used.
All foundations shall rest below virgin ground level and the minimum depth of foundation below
the virgin ground level shall be maintained.
Design shall consider any sub-soil water pressure that may be encountered.
Necessary protection to the foundation work, if required, shall be provided to take care of any
special requirements for aggressive alkaline soil, black cotton soil or any other type of soil which
is detrimental or harmful to the concrete foundations.
RCC columns shall be provided with rigid connection at the base.
All building 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 as stated in relevant IS Codes or as stipulated elsewhere in the Specifications.
Earth pressure for all underground structures shall be calculated using coefficient of earth pressure
at rest, coefficient 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 substructures of any underground hollow enclosure etc., to allow for vehicular
traffic in the vicinity of the structure.
The following conditions shall be considered for the design of water tanks, pump houses,
channels, sumps, trenches and other underground concrete structures such as basements etc.
Full water pressure from inside and no earth pressure, ground water pressure and surcharge
pressure from outside (applicable only to structures which are liable to be filled 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.
Base slabs of any underground enclosures shall 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 underground enclosures such as water storage tank shall also be designed for the
condition of different combination of pump sumps being empty during maintenance stages with
maximum GWT. Intermediate dividing piers of such enclosures shall be designed considering
water in one pump sump only and the other pump sump being empty for maintenance.
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 foundation of the transformer and circuitbreaker 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 a factor of safety of 2.2 for normal
condition and 1.65 for short circuit condition against sliding,overturning and pullout. The same
factor shall be used as partial safety factor over loads in limit state design also.
All underground concrete structures such as basements, pump houses, water retaining structures
etc. shall have plasticizer cum water proofing cement additive conforming to IS 9103. In addition,
the limit on permeability as given in IS 2645 shall also be met. The concrete surface of these
structures in contact with earth shall also be provided with two coats of bituminous painting for
water /damp proofing.
In case of water leakage in the above structures, leakage repair shall be achieved by the injection
method.
14.2 Machine Foundations
All machine foundations shall be designed in accordance the provisions of the relevant parts of the
latest revisions of IS 2974, IS 456 and IS 2911.The provisions of DIN 4O24 (latest) shall also be
followed.
All block foundations resting on soil or piles shall be designed using the elastic half space theory.
The mass of the RCC block shall not be less than three times the mass of the machine. Dynamic
analysis shall be carried out to calculate natural frequencies in all the modes including coupled
modes, and to calculate vibration amplitudes. Frequency and amplitude criteria as laid down by
the relevant IS codes and/or machine manufacturers, shall be satisfied. Minimum reinforcement
shall be governed by IS 2974 and IS 456.
For the foundations supporting minor equipments weighing less than one tonne, or if the mass of
the rotating parts is less than one-hundredth of the mass of the foundation, no dynamic analysis is
necessary. However, if such minor equipment is to be supported on building structures, floors etc.
suitable vibration isolation shall be provided by means of springs, neoprene pads etc. and such
vibration isolation system shall be designed suitably.
14.3 Other Foundations
All foundations shall be designed in accordance with the provisions of the relevant parts of latest
revisions of IS 2911 and IS 456.
Type of foundation system i.e. isolated footing, raft or piling shall be decided based on the load
intensity and soil strata.
A minimum three piles shall be provided in any pile group.
Gantry and tower foundations shall be designed for an additional factor of safety of 1.1 for
normal/ broken wire conditions and for short circuit condition.
Circuit breaker foundations shall be designed for impact loading and shall be strictly in
accordance with the Manufacturer`s recommendations.
15. FOUNDATIONS AND R CC CONSTRUCTION

15.1 General
Work covered under this Clause of this Specification comprises the design, supply and
installation of foundations and other RCC constructions for switchyard structures, equipment
supports, trenches, rains, jacking pads, pulling blocks, fencing, control cubicles, bus supports,
transformers, marshalling kiosks, auxiliary equipments and systems, buildings and tanks, or for
any other equipment or service and any other foundation required to complete the work. This
clause is as well applicable to the other RCC constructions.
Concrete shall conform to the requirements of IS 456 and all the tests shall be conducted as per
relevant Indian Standard Codes.
If the site is sloping, the foundation height will be adjusted to maintain the exact level of the top
of structures to compensate for such slopes.
Switchyard foundation plinths and building plinths shall be minimum 300 mm and 500 mm
above finished ground level respectively.
A minimum of 75 mm thick lean mix concrete (1:3:6) shall be provided below all underground
structures, foundations, trenches etc. to provide a base for construction.
Concrete made with portland cement(OPC-43 grade) shall be carefully cured and special
consideration shall be given during the placing of concrete and removal of shuttering.
The design and detailing of foundations shall be done based on the approved soil data and subsoil conditions as well as for all possible critical loads and combinations thereof. Spread footing
foundations or pile foundations as may be required based on soil and subsoil conditions and
superimposed loads shall be provided.
If pile foundations are adopted, the same shall be cast-in-situ, driven, bored, precast or
underreamed type as per relevant IS. 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 contractor showing complete details of piles and pile
groups proposed to be used. Necessary initial load tests shall also be carried out by the contractor
at their entire cost to establish the pile design capacity. Only after the design capacity of piles has
been established, shall the Contractor commence of piling. All the design and testing work shall
be planned in such a way that these shall not cause any delay in project completion.
15.2 Cement
The cement to be used shall be the best quality of its type.
All cement shall be sampled and tested in accordance with Indian Standards.
The Portland cement(OPC-43 grade) used in concrete shall confirm to IS 269.
Requirement of sulphate resistant cement (SRC) for substructural works shall be decided in
accordance with the Indian Standards based on the findings of the detailed soil investigation to be
carried out by the contractor.
High Alumina cement shall NOT be used.
15.3 Delivery and storage of cement
Cement shall be delivered to the site in bulk or in sound and properly sealed bags and while being
loaded or unloaded whether conveyed in vehicles or by mechanical means, and during transit to
the concrete mixers, must be protected from the weather by effective coverings. Efficient screens
are to be supplied and erected to prevent wastage of cement during strong winds.
If the cement is delivered in bulk, the Contractor shall provide at his own cost approved silos of
adequate size and number to store sufficient cement to ensure continuity of work. The cement
shall be placed in these silos immediately it has been delivered on the site. Suitable precautions
shall be taken during unloading to ensure that the resulting dust does not constitute a nuisance.
If the cement is delivered in bags, the Contractor shall provide at his own cost perfectly
waterproof and well-ventilated sheds having a floor of wood or concrete raised at least 150 mm
above the ground. The sheds shall be large enough to store sufficient cement to ensure continuity
of work. Each consignment of each type of cement shall be stacked separately therein. On
delivery at site the cement shall at once be placed in these sheds and shall be used in the order in
which it has been delivered.
All cement shall be used within 3 months of the date of manufacture.
15.4 Aggregate
Coarse and fine aggregate shall conform to the requirements of IS 383-1970.
Sampling and testing of aggregates shall be in accordance with the relevant Indian Standard.
Fine and coarse aggregates shall be obtained from the same source and the Contractor shall
ensure that material from the source is known to have a good service record over a long period of
time.
Aggregate shall be hard and dense and free from earth, clay, loam and soft, clayey, shaley or
decomposed stone, organic matter and other impurities.
15.5 Storage of aggregates
Coarse and fine aggregates shall be stored on site in bins or on clean, dry, hard surfaces, and be
kept free from all sources of contamination. Aggregates of different gradings shall be stored
separately, and no new aggregate shall be mixed with existing stocks until tested, and approved
by the Engg Incharge (Divisional Engr.).
15.6 Approval of Supplies
As soon as possible after the Contract has been placed the Contractor shall submit a list giving
details of the sources from which he proposes to obtain concrete and mortar materials. Only
materials from approved sources shall be brought to site, but the Engg Incharge (Divisional
Engr.) will be prepared to extend his approval to other satisfactory sources of supply which may
be proposed by the Contractor. Approval of a source of supply shall not imply acceptance of
material found not to conform to this Specification
15.7 Water
Water used for mixing concrete and mortar shall be clean, fresh water obtained from an approved
source and free from harmful chemicals, oils, organic matter and other impurities. Normally
potable water may be considered satisfactorily for mixing and curing concrete and masonry work.
15.8 Steel bar reinforcement
Reinforcement shall comply with the appropriate Indian Standards.
All bar reinforcement shall be hot rolled steel except where the use of cold worked steel is
specified on the drawings or otherwise approved.
The bars shall be round and free from corrosion, cracks, surface flaws, laminations, rough, jagged
and imperfect edges and other defects.
The bar reinforcement shall be new, clean and of the lengths and diameters described on the
Drawings and Schedules. Bars shall be transported and stored so that they remain clean, straight,
undamaged and free from corrosion, rust or scale. Bars of different diameters shall be separately
bundled.
15.9 Bending of reinforcement
All steel bars are to be accurately bent cold to the shapes and sizes indicated on the Drawings and
Schedules unless otherwise approved. Re-bending of bars and bending in position in the works
shall not generally be allowed.
15.10
Welding of reinforcement
Spot or tack welding for positioning bars in heavily reinforced areas will only be allowed with the
express permission of the Engg Incharge (Divisional Engr.). Extension of lengths of
reinforcement by welding will not be permitted.
Welding will be approved only in low stress members, and lap welding will not be approved in
any circumstances.
15.11 Fixing of reinforcement
Before fixing in the works bars shall be seen to be free from pitting, mud, oil, paint, loose rust or
scale or other adherents harmful to the bond or strength of the reinforcement. Bars shall be fixed
rigidly and accurately in position in accordance with the working drawings, unless otherwise
approved by the Engg Incharge (Divisional Engr.). Reinforcement at all intersections shall be
securely tied together with 1.5 mm soft annealed tying wire the ends of which shall be cut and
bent inwards. Cover to the reinforcement shall be in accordance with Clause 15.12 of this
specification and sufficient spacers and chairs of precast concrete of approved design shall be
provided to maintain the specified cover and position. No insertion of bars in previously placed
concrete shall be permitted. Projecting bars shall be adequately protected from displacement.
The fixing of reinforcement in the works shall be approved by the Engg Incharge (Divisional
Engr.) before concrete is placed. Measurement will be based on the calculated weights of steel
actually used in tonnes corrected to second place of decimal.
15.12 Concrete cover to reinforcement
For durability the minimum concrete cover to any reinforcing bar shall be as follows:
Concrete above ground.
Internal faces of slabs
25 mm
Internal faces of beams and walls
30 mm
Exposed faces of slabs, beams and walls
50 mm
All faces of columns
50 mm
Concrete below ground (including piles).
Faces in contact with soil including blinding concrete

All other faces (i.e. internal faces of basement wall)
75 mm
50 mm
Only concrete or steel spacers shall be used to achieve the required minimum thickness of
concrete cover to reinforcement. Concrete spacers shall have non metallic ties. Timber blocks
for wedging the steel off the formwork will not be allowed.
15.13 Formwork
Formwork shall be constructed from timber, metal, lined as necessary for special finishes and
designed with the quality and strength required to ensure rigidity throughout placing, ramming,
vibration and setting of the concrete, without detrimental effect.
Formwork shall be erected true to line, level and shapes required using a minimum of approved
internal ties. Faces in contact with the concrete shall be true and free from defect, jointed to
prevent loss of water or fines, in panels or units which permit easy handling, and designed to
permit sideforms to be struck independently of soffit shuttering. Ties or spaces remaining
embedded shall have the minimum cover specified for reinforcement. Forms for exposed
concrete beams, girder casings and columns shall provide for a twenty five millimetre chamfer on
external corners.
Wedges and clamps shall be kept tight during vibration operations. Before commencement or
resumption of concreting, the interior of forms shall be cleaned and free of sawdust, shavings,
dust, mud or other debris and openings shall be formed to facilitate this cleaning and inspection.
The inside of the forms shall be treated with a coating of an approved substance to prevent
adhesion. Care shall be taken to prevent this substance being in contact with the reinforcement.
15.14 Grades of concrete
Concrete shall be either ordinary or controlled and in grades designated M10, M15, M20 and
M25 as specified in IS 456 (latest edition ). In addition, nominal mixes of 1:3: 6 and 1: 4: 8 of
nominal size 40 mm maximum, or as indicated on drawings, or any other mix without any
strength requirements as per mix design shall be used where specified.
15.15 Ordinary concrete
Ordinary concrete shall be used for all plain cement concrete work and where shown on drawings
or allowed by the Engg Incharge (Divisional Engr.). Ordinary concrete shall not require
preparation of trial mixes.
In proportioning concrete, the minimum quantity of cement shall be as specified in Table 15.15.1
of this clause and the amount to be used shall be determined by actual weight. The quantities of
fine and coarse aggregate may be determined by volume, but preferably by weight.
The water cement ratio shall not be more than those specified in IS 456.
Grade of
Concrete
Minimum cement content

per c.m. of finished concrete
M 10
236 kg
M 15
310 kg
M 20
360 kg
M 25
Table - 15.15
410 kg
Minimum Cement content.
15.16 Controlled concrete

15.16.1 Mix proportions
The mix proportions for all grades of concrete shall be designed to obtain strength corresponding
to the values specified in IS 456 for respective grade of concrete. Preliminary tests as specified in
the IS Code or as required by the Engg Incharge (Divisional Engr.), shall be carried out,
sufficiently ahead of the actual commencement of the work, with different grades of concrete
made from representative samples of aggregate and cement expected to be used on the job. The
purpose of this test is to ascertain the water cement ratio required to produce a concrete having
specified strength, and to demonstrate sufficient workability to enable it to be well consolidated
and to be worked into corners of shuttering and around the reinforcement.
15.16.2 Mix design
As a guide to perform the mix design properly, the relationship between water cement ratio,
aggregate to cement ratio, workability and strength of concrete will be as per relevant IS.
The cement /total aggregate ratio is not to be increased beyond 1: 9.0 without specific permission
of the Engg Incharge (Divisional Engr.). It should be noted that such high aggregate/cement ratios
will be required for concretes of very low slump and high water cement ratios which may be
required to be used in mass concrete work only.
The actual cement aggregate ratios are to be worked out from the specific gravities of coarse
aggregates and sand being used, and from trial mixes.
15.17 Strength requirements
The mix proportions for all grades of concrete shall be designed to produce the grade of concrete
having the required workability and a characteristic strength not less than the value given table
15.17.
Grade Designation
Characteristic Compressive
Strength at 28 days
M 10
10 N / sq. mm
M 15
15 N / sq. mm
M 20
20 N / sq. mm
M 25
25 N / sq. mm
Table - 15.17
Strength Characteristic
The strength of concrete given above is the 28 days characteristic compressive strength of 15 cm
cube.
15.18 Workability
The workability of concrete shall be checked at frequent intervals by slump test, where facilities
exist and if required by the Engg Incharge (Divisional Engr.), alternatively the compaction factor
test in accordance with IS 1199 shall be carried out.
15.19 Mixing of Concrete
Unless otherwise approved, concrete for foundations will be M 20 grade, corresponding

to nominal mix of 1:1.5:3 as per IS 456. The proportions of fine and coarse aggregate, cement
and water shall be as determined by the mix design or according to fixed proportions in case of
nominal mix concrete and shall always be approved by the Engg Incharge (Divisional Engr.). The
quantities of the cement, fine and coarse aggregates shall be determined by weight, the water
shall be measured accurately after giving proper allowance for surface water present in the
aggregate. Water shall be added to make a workable mix and it is important to maintain the
water-cement ratio at its correct value of 0.55 in accordance with the requirements of IS 456.
Water shall not be added to the mix until all the cement and aggregates constituting the batch are
already in the drum and dry mix for at least one minute. Mixing of each batch shall be continued
until there is uniform distribution of materials and the mass done for less than 2 minutes and at
least 40 revolutions after all the materials and water are in the drum.
When hand mixing is permitted by the Engg Incharge (Divisional Engr.) for concrete to be used
in unimportant locations it shall be carried out on a water tight platform and care shall be taken to
ensure that mixing is continued until the mass is uniform in colour and consistency. In case of
hand mixing, an extra 10% of cement shall be added to each batch and additional cost due to
extra cement will be borne by the Contractor.
15.20 Conveying Concrete

Concrete shall be handled and conveyed from the place of mixing to the place of final laying as
rapidly as practicable by approved means before the initial setting cement starts. Concrete should
be conveyed in such a way which will prevent segregation or loss of any of the ingredients. If
segregation does occur during the transport of concrete same shall be re-mixed. The
requirements to be fulfilled during trasportation are :

No segregation or seperation of materials in the concrete, and
Concrete delivered at the point of placing should be uniform and of proper
consistency.
15.21 Placing Concrete
Form work and reinforcement shall be approved in writing by the Engg Incharge (Divisional
Engr.) before concrete is placed. The forms shall be well wetted and all shavings, dirt and water
that may have collected at the bottom shall be removed before concrete is placed. Concrete shall
be deposited in its final position without segregation, re-handling or flowing. As far as possible
concrete shall be placed in the formwork by means approved by the Engg Incharge (Divisional
Engr.) and shall not be dropped from a height or handled in a manner which may cause
segregation. Any drop over 180 cm. shall have to be approved by the Engg Incharge (Divisional
Engr.). Once the concrete is deposited in its final position, it shall not be disturbed. Care should
be taken to avoid displacement of reinforcement or movement of formwork.
The placing of concrete shall be a continuous operation with no interruption in excess of 30
minutes between the placing of continuous portions of concrete. When fresh concrete is required
to be placed on previously placed and hardened concrete, special care should be taken to clean the
surface of all foreign matter. For securing a good bond and water tight joint, the receiving surface
should be made rough and a rich mortar placed on it unless it has been poured just before. The
mortar layer should be about 15 mm thick with cement and sand proportion as that of the mix in
use, and have the same water-cement ratio as the concrete to be placed.
After the concrete has been placed it shall be thoroughly compacted by approved mechanical
vibration to a maximum subsidence without segregation and thoroughly worked around
reinforcement or other embedded fixtures into the correct form and shape. Vibrators must be
operated by experienced men and over vibration shall not be permitted. Care should be taken to
ensure that the inserts, fixtures, reinforcement and formwork are not displaced or disturbed during
placing of concrete. No concrete shall be placed in open while it rains. If there is any sign of
washing of cement and sand, the concrete shall be entirely removed immediately. Slabs, beams
and similar structure shall be poured in one operation normally. In special circumstances with
the approval of Engg Incharge (Divisional Engr.) these can be poured in horizontal layers not
exceeding 50 cm. in depth. When poured in layers, it must be ensured that the under layer is not
hardened. Bleeding of under layer if any shall be effectively removed.
15.22 Compaction of Concrete
Compaction is necessary for production of good concrete. After the concrete has been placed it
shall be thoroughly compacted by approved mechanical vibrator to a maximum subsidence
without segregation and thoroughly worked around reinforcement or other embedded fixtures into
the correct form and shape. Vibrators must be operated by experienced men. Care should be taken
to ensure that the inserts, fixtures, reinforcement and formwork are not displaced or disturbed
during the vibration of the concrete. The Contractors shall provide standby vibrators. Vibration is
commonly used method of compaction of concrete, the use of mechanical vibrators complying
with IS 2505, IS 2506, IS 2514 and IS 4656 for compacting concrete is recommended
For all practical purposes, the vibration can be considered to be sufficient when the air bubbles
cease to appear and sufficient mortar appears to close the surface and facilitate easy finishing
operations. The period of vibration required for a mix depends upon the workability of the mix.
15.23 Curing of Concrete
In order to achieve proper and complete strength of the concrete, the loss of water from
evaporation should be prevented. Eighty to eighty five per cent of the strength is attained in the
first 28 days and hence this 28-day strength is considered to be the criterion for the design and is
called characteristic strength. The concrete after setting for 24 hours shall be cured by keeping the
concrete wet continuously for a period of 10 days after laying.
The curing increases compressive strength, improves durability, impermeability and abrasion
resistance. Failure to carry out satisfactory curing can lead to cracking in the concrete. This in
turn can lead to salt attack of the reinforcement and consequential failure of the structure. If
cracks occur in a structure which are severe enough to affect the structure, the Contractor shall
cut out and replace the defective concrete at his own cost. The Contractors attention is, therefore,
drawn to this particular aspect of proper and adequate curing.
15.24 Construction joints

Construction joints are a potential source of weakness and should be located and formed with
care and their number is kept to a minimum.
When the work is to be interrupted, the concrete shall be rebated at the joint to such shape and
size as may be required by the Engg Incharge (Divisional Engr.) or as shown on the drawings. All
vertical construction joints shall be made with water bars which are rigidly fixed and shall
provide a positive barrier against movement of water through the joint. Great care shall be taken
when placing concrete around water bars because the space is often congested. Concreting shall
be carried out continuously up to construction joints. Construction joints, if not described on the
drawings, shall be in accordance with the following:
In a column, the joint shall be formed about 75 mm below the lowest sofit of the beams
framing into it, at the meeting points of the columns and the raft, and at the point of
contraflexure in the columns.
Concrete in a beam shall be placed throughout without a joint. However if the provision of
a joint is unavoidable, the joint shall be vertical and at the middle of the span.
A joint in a suspended floor slab shall be vertical at one of the quarter points of the span
and at right angle to the principal reinforcement.
Additional reinforcements and shear keys shall be provided at the construction joints.
In forming a joint, concrete shall not be allowed to slope away to thin edge. The locations of
construction joints shall be planned by the contractor well in advance of pouring and be approved
by the Engg Incharge (Divisional Engr.).
Construction joints in foundation of equipment shall not be provided without the approval of
Engg Incharge (Divisional Engr.).
15.25 Expansion and separation joints
Expansion joints shall be as shown on the drawings or as specified in the schedules. Expansion
joint filler boards conforming to IS 1838 and sealing strips shall have minimum transverse joints.
Joints shall be vertical and straight except where otherwise approved and concrete surfaces and
faces shall be flush on bothsides of the joint.
Separation joints shall be with standard water proof paper or with as alkathene sheets about 1 mm
in thickness. Lap length and sealing of laps shall be to the satisfaction of the Engg Incharge
(Divisional Engr.).
15.26 Removal of formwork
Formwork shall be kept in position fully supported, until the concrete has hardened and gained
sufficient strength to carry itself and any loads likely to be imposed upon it. Stripping must be
effected in such a manner and at such a time that no shock or other injury is caused to the
concrete. The responsibility for safe removal rests with the Contractor but the Engg Incharge
(Divisional Engr.) may delay the time of striking if he deems it necessary.
Minimum periods, in the absence of agreement to the contrary, between completion of concreting
and removal of forms are given below but due regard must be paid to the method of curing and
prevailing conditions during this period.
Removal of shuttering to sides of rafts, walls, beams and columns
2 days
Removal of shuttering to slabs, beams and arches (props left under)
6 days
Removal of props to slabs, beams and arches
16 days
Lifting of precast members
16 days
15.27 Precast concrete members

Precast concrete members shall be used in the works only where specified on the Drawings or
approved by the Engg Incharge (Divisional Engr.).
The technical specifications for cement concrete, formwork and reinforcement covered under
earlier clauses shall form a part of these specifications and shall be followed for carrying out
precast concrete work.
Precast members shall not be disturbed or lifted until the minimum periods specified for
formwork removal have elapsed.
15.28 Load Test on Parts of Structures
The load test on concrete , if desired by the Engg Incharge (Divisional Engr.) shall be carried as
soon as possible after the expiry of 28 days from the time of placing of concrete as per the clause
16.5 to 16.6 of IS : 456.The structure shall be subjected to a load equal to full dead load of the
structure plus 1.25 times the imposed load for a period of 24 hours and then the imposed load
shall be removed. The entire cost of load testing shall be borne by the contractor and if any
portion of the structure found unacceptable under the relevant clause of IS : 456, the same shall
be dismantled and replaced by a new structure as per specification at no extra cost to the
Employer. If during dismantling any of the adjacent structure is damaged, the same shall be made
good free of charge by the contractor to the satisfaction of the Engg Incharge (Divisional Engr.).
15.29 Finish of concrete surface
15.29.1 Concrete cast against formwork.
The following finishes to concrete surfaces, unless otherwise specified or shown on the drawings,
shall be as follows
Class A1: All permanently exposed surfaces, including exposed sides of
foundations.
Class A2:
Surfaces to be covered by backfill, plasters or the like.
Class A1 surfaces shall be dense, fair, smooth, even, free from honeycombing, water and air holes
and other blemishes, true to line and surface and free from board or panel marking. They shall be
of uniform colour. Rendering of defective surfaces shall not be permitted, and, if ordered by the
Engg Incharge (Divisional Engr.), the Contractor shall at his own expense cut out to expose
reinforcement and make good any unsatisfactory work. All areas so treated shall be rubbed down
and kept moist for several days.
Class A2 surfaces shall be dense, even, free from honeycombing and true to line and surface.
Any special finishes will be to details or instructions given by the Engg Incharge (Divisional
Engr.).
15.29.2 Concrete not cast against formwork.
The following finishes shall be provided unless otherwise specified or shown on the drawings
Class B1:
All permanently exposed surfaces, including tops of equipment foundations, wall

copings, window sills, precast items (except paving flags ).
Class B2:
Paving flags and paths. Floors and slabs to be surfaced with blocks, tiles or
waterproofing materials.
Class B3:
Roads, buried concrete and floors or slabs to be covered by screed.
Class B1 surfaces shall first be levelled and screened to produce a true surface. After the
moisture film has disappeared, and the concrete has hardened sufficiently, the surface shall be
finished with a steel trowel under firm pressure to give a smooth, dense, even and hard surface
free from all marks and defects.
Class B2 surfaces shall be levelled and screened to produce a true surface, and be finished with
wooden or steel float to give a level surface free from screed marks. Excessive floating shall be
avoided.
Class B3 surfaces shall be levelled and screened to produce a true and uniform surface.
15.30 Holes, pockets, threaded inserts, etc.
The threaded inserts for casting into concrete shall be electro-galvanized and of malleable iron or
mild steel. Holes, cavities and fixings shall be provided in the works only at the positions
indicated on the drawings or as directed and they shall be incorporated as necessary during the
work of concreting. Unless otherwise agreed a tolerance in position of plus or minus five
millimetres shall be allowed. Inserts and bolts shall be fixed square in the works by means of
temporary bolts or nuts, and then concrete cast around them. The projecting portions of such
fixings, and concrete within fifty millimetres of them, shall be bitumastic painted and all threads
well greased on completion of the work. Holes and pockets shall be stripped down clean on
completion.
15.31 Blinding
Blinding concrete shall be made with nominal aggregate sizes of both 20mm and 40mm diameter.
They shall be referred to respectively as grade M 10/20 and M 10/40.
Under all foundations and elsewhere as indicated on the drawings a layer of concrete grade M10
(1:3:6) shall be laid immediately the excavation is carried down to foundation level. The blinding
surface shall be thoroughly cleaned before foundation concrete is deposited thereon. Sumps shall
be provided where necessary to facilitate the control of drained water. The grade shall be applied
as shown in Table 15.31.1
Location
Grade
Thickness of layer
Foundations and bases
M 10 / 1:3:6
75 mm
Floors of ducts, trough and reinforced

slabs not exceeding 100 mm
M 10 / 1:3:6
50 mm
Table 15.31.1. Blinding layer thickness values

15.32 Admixtures and 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 and additives shall be approved by the Engg Incharge
(Divisional Engr.).
The Contractor shall use an approved neutralized vinsol resin air-entraining agent in all concrete.
The Air entraining agent shall be supplied and batched as a solution with a solids content not
exceeding 15 percent by weight with suitable, stable and consistent pH.
The Contractor may propose and the Engg Incharge (Divisional Engr.) may approve 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 overcoming unusual
circumstances and placing conditions.
Water-reducing set-retarding admixture shall be an approved brand of lgno-sulphonate type
admixture.
Water proofing cement additives shall be used as required or advised by the Engg Incharge
(Divisional Engr.).
16. FENCING
16.1 General
Fencing shall be designed for the most critical loading combination taking into account wind
forces, stability, tension on wires, minimum requirements as per this clause and relevant IS
recommendations.
The un climbable or security, or anti-intruder fencing shall consist of chain link mesh, all as soon
on the drawings and as specified below, supported on approved sections of structural steel. The
posts shall be erected truly vertical, and all posts and struts shall be set in concrete block
foundations.
Concrete kerbing shall be provided between the fence posts as shown on the drawings.
16.2 Areas requiring fencing
Fencing shall be provided for the following areas:
Site fencing for the complete station, complete with barbed wires on top. Separate gates shall
be provided for men and equipment.
Internal fence surrounding the various equipments (if) mounted on ground or a height lower
than 2.5 m, without barbed wires on top. Necessary gates shall be provided for each area so
surrounded.
Wherever necessary anti-reptile fixture/arrangement shall be provided along with fencing.
16.3 Product materials
16.3.1 General
Chain Link fence fabric in accordance to IS :2721, and shall also meet the following
requirements.
Size of mesh
75 mm
Size of coated wire
3.15 mm diameter
Width of chain link
2000 mm
Class of zinc coating
medium
Zinc coated after weaving

Posts shall be as shown in Table.
The posts shall be of medium M.S tube of 50 mm diameter confirming toYst-22
(Kg / sq. mm ).The tubes shall be also confirm to IS:1161/IS 806.The length of the tubular
post shall be 3200mm.
An M.S base plate of size 160X160X6mm thick shall be welded with the tubular post.
The post shall be provided on the top with M.S plate.
The tubular post shall be welded with 8 numbers of M.S flat of size 50X6mm 75 mm
long. Two numbers of 13.5 mm dia holes on each cleats shall be provided to bolt the fence
fabric panel. The cleats shall be welded at equal spacing in such a way that 4 nos of cleats
are on the opposite side and remaining 4 nos cleats are on the opposite side of the post.
The cleats on the corner posts shall be welded in such a way that it suits the site
requirement.
The whole assembly of tubular post shall be hot dip galvanised. The zinc coating shall be
minimum 615 gram per sq mm. The purity of the zinc shall be 99.95% as per IS:209.
Fence fabric panel:
Chain link fencing shall be fabricated in the form of panel 2000X2928 mm. An
MS flat of at least 50X6 mm size shall be welded all round fence fabric to form a panel.
Four pairs of 13.5 mm diameter holes on the vertical MS flat matching the spacing of
holes in cleats fixed with pipe shall be provided to fix the fence panel with tubular posts.
A washer shall also be provided below each nut. 12 mm diameter bolts and nuts including
washers shall also be supplied. All bolts, nuts and washer shall be hot dip
galvanised. The fence panel shall be also of hot dip galvanised.
Installations:
Fence shall be installed along switch yard line as per the approved GA drawing.
Post holes shall be excavated by approved method.
All posts shall be 3 mtrs apart measured parallel to ground surface.
plain cement concrete block of minimum

0.4X0.4X1.2mtr depth. 75 mm thick PCC 1:4:8 shall be provided below concrete block.
Posts shall be set in 1:2:4
Fence posts shall be erected in vertical and kept for minimum 7 days curing
before fence fabri erection.
Fence fabric panel shall be fixed to the post at 4 nos. M.S flat each of 50X6
mm,75mm long through 2 nos of 12 mm dia bolts on each flat.
Paintings as per decision of the Engineer in charge have to be carried out.
Continuous running earth by using 50 X 6 mm GI flats to be provided for safety purpose.
A 345/380 mm thick (one and a half brick size) toe wall of Brick/Rubble masonry, or concrete
with notches shall be provided below all fencing and shall be minimum 200 mm above and 500
mm below finished ground level. All exposed surfaces for brick toe wall shall be provided with
15 mm 1:6 cement sand plaster and coated with two coats of water proofing snowcem cement
paint. In case if rubble masonry is provided suitable pointing shall be done.
GATES:
Gates shall be installed in locations shown on drawings. Next to the main gate, a men gate (1.25
m wide, single leaf) shall also be provided.
Bottom of gates shall be set approximately 40 mm above ground surface and necessary guiding
mechanism (with roller on the bottom of the gate and fixed guider in the road)shall be fitted to
avoid hanging of the main gate.
16.3.2 Gates
Gate frames shall be of galvanized steel of 40 mm dia main pipe and vertical pipes of 15mm dia
@ 125 mm spacing (pipe to relevant IS) welded to the main pipe for frames or Black steel pipe
to relevant IS for frames with welded joints and shall be painted with one coat of steel primer and
two coats of synthetic enamel paints.
Gates shall be fabricated with welded joints or other approved methods to achieve rigid
connections. The gate frames shall be hot dip galvanized after welding.
Gates shall be fitted with galvanized malleable iron hinges, latch and latch catch. Latch and latch
catch shall be suitable for attachment and operation of padlock from either side of gates. Hinges
shall permit gates to swing through 180 degree back against fence.
Gates shall be fitted with galvanized chain hook or gate hold back to hold gates open. Double
gates shall be fitted with centre rest and drop bolt to secure gates in closed position.
16.3.3 Patching
Damaged galvanized surfaces shall be repaired. Damaged surfaces shall be cleaned with wire
brush removing loose and cracked spelter coating. Two coats of approved zinc pigmented paint
shall be applied to damaged areas in accordance with manufacturers instructions.
There shall be one gate located on boundary wall as main gate having wicket gate and one gate as
switchyard gate, located on the fencing.
17. BUILDING
17.1 General
The scope includes the design, engineering and construction of control room and colony quarters
building. For control room and colony quarter building the tentative layout showing the facilities
to be provided is indicated some where and also to be proposed by the bidders for better utility
and aesthetic view. However, the size and layout of the building may be modified as per
requirements of Single Line Diagram (SLD) with the approval of the Engg Incharge (Divisional
Engr.).
17.2 Dimensions
An open space of one metre minimum shall be provided on the periphery of the rows of panels,
and equipment generally, in order to allow easy operator movement and access as well as
maintenance.
The building design shall also take into consideration the layout of the panels, switchboards,
switchgear and other equipment in order to allow enough area for the future extension of
switchyard depending upon the availability of substation area.
17.3 Design
The buildings shall be designed:
to the requirements of the National Building Code of India. and the standards quoted
therein
for the specified climatic and loading conditions
to adequately suit the requirements of the equipment and apparatus contained in the
buildings and in all respects to be compatible with the intended use and occupancy
with a functional and economical space arrangement
for a life expectancy of structure, systems and components not less than that of the
equipment which is contained in the buildings, provided regular maintenance is carried out
to be aesthetically pleasing. Different buildings shall show a uniformity and consistency in
architectural design
to allow for easy access to equipment and maintenance of the equipment
with, wherever required, fire retarding materials for walls, ceilings and doors, which would
prevent supporting or spreading of fire
with material preventing dust accumulation
Suitable expansion joints shall be provided in the longitudinal direction wherever necessary with
provision of twin columns.
Individual members of the building frame shall be designed for the worst combination of forces
such as bending moment, axial force, shear force, torsion etc.
Permissible stresses for different load combinations shall be taken as per relevant IS Codes.
All cable vaults shall be located above ground level i.e. cable vaults shall not be provided as
basements in the buildings.
The building lighting shall be designed in accordance with the requirements of relevant section.
The building auxiliary services such as air conditioning and ventilation systems, fire protection
and detection systems and all other miscellaneous services shall be designed in accordance with
the requirements specified in relevant sections of this Specifications.
The doors and windows of the building shall be of aluminium extruded channels, angles etc. The
windows shall be provided with sliding shuttering facilities and also to be provided with
aluminium make grills.
17.4 Design Loads
Building structures shall be designed for the most critical combinations of dead loads, superimposed loads, equipment loads, crane loads, wind loads, seismic loads, and temperature loads. In
addition, loads and forces developed due to differential settlement shall also be considered.
Dead loads shall include the weight of structures, complete finishes, fixtures and partitions and
should be taken as per IS:1911 (latest revision).
Super-imposed loads in different areas shall include live loads, minor equipment loads, cable
trays, small pipe racks/hangers, and erection, operation and maintenance loads. Equipment loads
shall constitute, if applicable, all load of equipments to be supported on the building frame.
For crane loads an impact factor of 30% and lateral crane surge of 10% of (lifted weight plus
trolley weight) shall be considered in the analysis of frame according to provisions of IS:875
(latest revision). The horizontal surge shall be 5% of the static wheel load.
For temperature loading, the total temperature variation shall be considered as two thirds of the
average maximum annual variation in temperature. The average maximum annual variation in
temperature for the purpose shall be taken as the difference between the mean of the daily
minimum temperature during the coldest month of the year and mean of daily maximum
temperature during the hottest month of the year. The structure shall be designed to withstand
stresses due to 50% of the total temperature variation.
Wind loads shall be computed as per IS:875. Seismic coefficient method shall be used for the
seismic analysis as per IS 1893 (latest revision), wind and seismic forces shall not be considered
to act simultaneously.
Floors/slabs shall be designed to carry loads imposed by equipment, cables, piping travel of
maintenance trucks and equipment and other loads associated with the building. In general,
floors shall be designed for live loads as per relevant IS and cable and piping loads not less than 5
kN/ sq.m hanging from the underside. In addition, beams shall be designed for incidental point
loads of 20 kN to be applied at any point along the beams. The floor loads shall be subject to the
approval of the Engg Incharge (Divisional Engr.).
For consideration of loads on structures, IS 875, Code of practice for structural safety of
buildings shall be followed. The minimum superimposed live loads shown in Table 17.4.1. shall
be considered for the design.
Roof
150 kg / sq m.
75 kg / sq m.
for accessible roofs.

for non - accessible roof.
R C C Floors.
500 kg / sq m.
for offices and minimum 1000 kg / sq m.

for equipment floors or actual requirement,
if higher than 1000 kg / sq m., based on
equipment component weight and layout
plans.
Stairs and balconies.
500 kg / m.
Toilet Rooms.
200 kg / m.
Chequered plate floor.
400 kg /sq. m
Walkways.
300 kg /sq. m.
Table 17.4.1.
Superimposed live loads
17.5 Submission of data for approval

The following information shall be submitted for review and approval to the Engg Incharge
(Divisional Engr.):
Design criteria for structural steel and reinforced concrete design. The criteria shall
comprise the codes and standards used, applicable climatic data including wind loads,
earthquake factors and maximum and minimum temperatures applicable to the building
locations, assumptions of dead and live loads, including equipment loads, impact factors,
safety factors and other relevant information.
Structural design calculations and drawings including those for construction and
fabrication for all reinforced concrete and structural steel structures.
Fully dimensioned floor plans, cross sections, longitudinal sections and elevations of each
building. These drawings shall be drawn at a scale not less than 1:50 and shall identify the
major building components.
Fully dimensioned drawings showing details and sections, drawn to scales of sufficient size
to clearly show sizes and configuration of the building components and the relationship
between them.
Product information of building components and materials, including walls, partitions,
flooring, ceilings, roofing, doors and windows and building finishes.
A detailed schedule of building finishes including colour schemes.
A door and window schedule showing door types and locations, door lock sets and latch
sets and other door hardware.
Approval of the above information shall be obtained before ordering materials or starting
fabrication or construction as applicable.
17.6 Electrostatic radio interference shielding
The building inside the energized area of the stations shall be electrostatically shielded to limit
the exposure of the equipment and personnel to specified electric field strengths. The shielding
system shall be grounded properly.
17.7 Control Room Building/Colony quarters
Design and construction, including anti termite treatment of control room building and colony
quarters for each substation or switchyard shall be in the scope of the contract. The control room
buildings and colony quarters shall be of RCC framed structure of concrete M20 grade. The
control room and some other rooms of the control room building shall be fully air conditioned.
17.8 Finish Schedule
The preliminary indicative finishing schedule is given in subsequent clauses. However, at the
time of detailed engineering, the Engg Incharge (Divisional Engr.) reserves the right to alter the
finishing schedule and specifications and such changes shall have no additional financial
implication whatsoever to the Employer.
17.9 Flooring (52 mm Thick)
5Omm thick cement concrete 1:2:4. & finishing with vitrified tiles in the main control room area,
conference room and MCCDB (AC & DC ) room. The other area flooring shall be with vitrified
tiles of reputed make. There shall be dado of 9 inches by the same. The toilets and bath rooms
shall be provided with antiskid ceramic tiles and the walls are also to be provided with ceramic
tiles of adequate height as per standard practice. The battery room floorings and walls (up to
3mtrs height) shall be provided with acid proof industrial based tiles. The left over portion of the
walls shall be painted with acid proof paints.
17.10 Walls
Control room buildings shall have framed superstructure. All walls shall be non-load bearing
walls. Minimum thickness of external walls shall be 230 mm with 1:6 cement sand mortar. A 50
mm thick DPC shall be provided at plinth level before starting masonary work.
17.11 Plastering
All internal walls shall have minimum 12mm thick 1:6 cement sand plaster. The ceiling shall
have 6mm thick 1:4 cement sand plaster.
17.12 External Finish
All external surfaces shall have painted with weather proof synthetic paints over 18mm thick
cement sand plaster in two layers. Under layer 12mm thick cement plaster 1:5 (1 cement:5 coarse
sand) and a top layer 6mm thick cement plaster 1:3 (1 cement:3 coarse sand) finished rough with
sponge.
All ceilings shall be white based plastic emulsion paints and the internal walls are also to be
provided with plastic emulsion synthetic paints. The outer of the building shall be provided with
weather seal coats of synthetic paints.
17.13 Roof
Roof of the building shall consist of cast in situ R.C.C. slabs. Extra heavy water proofing
treatment shall be done after grading underbed with 1:4 cement sand plaster of 25mm thickness.
The under bed shall be laid to provide an ultimate run off gradient of 1:120. The extra heavy
treatment shall be concrete based with water proof treatment as per the standard to protect the
roof from damage due to water logging. Proper slope and adequate no of water drains outlets
shall be provided for easy discharge of water from the roof. These drains shall be connected to the
main drain.
17.14 Glazing (glass)
Minimum thickness of glazing shall be 6 mm.The glazing for the control room area ,which will
be air-conditioned shall be provided with double toughned glass each of 6mm thickness.
17.15 False Ceiling
The control room and all other air conditioned areas shall have closed aluminium ceiling system
comprising 84mm wide, 12.5mm deep panels of approved colour with a recessed flange of
23.9mm roll formed out of 0.5mm thick aluminium alloy 5050/5052/3003 or equivalent, coated
with chromatised and stone enamelled on both sides, panels to be fixed on roll formed carriers 32
mm wide 39 mm deep out of minimum 0.9 mm thick aluminium alloy strip with cut outs to hold
panels in a module of 100mm minimum at maximum 1.6 mc/c carrier suspended from roof by
4mm diameter galvanised steel wire rod hangers with special height adjustment springs/clips
made out of spring steel at maximum spacing of 1.5 m c/c hangers fixed to roof, J'hooks and
nylon insert including providing laying and fixing 25mm thick resin bonded mineral wool of
approved quality, encased in 100 G black polythene and laid over top of places panels, all
complete. The system is subject to approval by the Engg Incharge (Divisional Engr.) before
installation.
.
17.16 Doors and Windows

The doors and windows of the control room building shall be of aluminium with aluminium grill
and all the frames of doors and windows also of aluminium sections in accordance with the
relevant IS Codes. Size and shapes shall be adequate for entering in to the room. In the Air
conditioned area shall be double glass (toughened) and doors suitably made to have efficient air
conditioning. The windows shall be of sliding type.
17.17 Plumbing And Sanitation
All plumbing and sanitation work shall be executed to comply with the requirements of the
appropriate bye laws, rules and regulations of the Local Authority having juridiction over such
matters. The Contractor shall arrange for all necessary formalities to be met in regard to
inspection, testing, obtaining approval and giving notices etc.
An overhead water tank of adequate capacity depending on the number of users for 24 hours
storage shall be provided.
Galvanised MS pipe of medium class conforming to IS : 1239 shall be used for internal piping
works for portable water supply.
Sand C I pipes with lead joints conforming to IS:1729 shall be used for sanitary works above
ground level.
A list of toilet fittings will be approved by the Engg Incharge (Divisional Engr.), before
procurement by the contractor and same will be inspected by the Engg Incharge (Divisional
Engr.) before installation. Sufficient nos of toilets and bath rooms including separate urinal
provision shall be provided at both ground and first floors. Required nos of wash basins (stand
type) with good quality mirrors and other accessories as required are also to be provided at both
ground and first floor of control room building. Same procedure for colony quarters also.
17.18 Building storm water drainage
The building design shall provide for the collection of storm water from the roofs. This water
shall be collected in junction boxes and these boxes shall drain to the main drainage system of the
station.
Cast iron rain water downcomers conforming to IS:1230 with water tight lead joints or medium
class galvanised mild steel pipes conforming to IS:1239/ IS:3589, shall be provided to drain off
the rain water from the roof. These shall be suitably concealed with masonry work of cement
concrete or cladding material. The number and size of downcomers shall be governed by IS:1742
and IS:2527.
All drains inside the buildings shall have minimum 40 mm thick grating covers and in areas
subject to movement heavy equipment loads, precast RCC covers shall be provided in place of
steel grating.
For all buildings, suitable arrangement for draining water collected from equipment blowdowns,
leakages, floor washings, fire fighting etc. shall be provided for each floor.
17.19 Flooring
Entire area around the control room building (out side)shall be provided with PCC paving starting
from the building upto 2 mtrs clear distance for the full length of the building.
The above specified PCC paving shall be with M15 mix grade concrete over suitable under bed
arrangement as specified for other ground floor slab.
Above the PCC paving suitable Cement pavers chequered plate of size as per the standard to be
provided. The colour of the chequered plate shall be fixed over the PCC paving by using cement
mortar and the colour of such plate shall be red.
The cable vault below the main control room shall have 50 mm thick smooth floor finish units of
cement concrete.
17.20 Provision of rooms in the control room building.
a) 220/132/33 KV S/S Building:
>The plinth area for the control room building shall be as below:Ground floor: 50mtrX25mtr
Ground floor portico: 5mtrX5mtr (at two locations)
First floor: 25 mtr X 25 mtr
i)Ground floor shall have cable vault, Battery room, Office rooms(3 nos),MCCB room,
Library, Conference room, Testing lab, Pantry room, Toilets and bath room(two nos
and one attached), Corridor with lounge, Portico at front and side, Ramp etc.
ii) First floor shall have control room, PLCC room, office room, toilets and bath room
etc.
* All internal walls shall 125 mm thick. (Excluding cement plastering)
* All external walls shall 250 mm thick. (Excluding cement plastering)
* For RCC works refer the relevant specification.
* The quarter shall be of framed RCC structure based.
* Concrete grade shall be 1:1.5:3 for all RCC works
* Reinforcement shall be Fe 415 Grade, confirming to IS:1786. All hooks,bands,laps shall be as
per IS:456-2000.All laps shall be staggered and minimum lap length shall be 50XDia of
Bar.
* Clear cover to main reinforcement for footing = 50mm,column=50mm,beam=25mm &
slab=20mm.
* Rain water pipes 100 sq mm to be provided at suitable location.
* The stair case width=1100mm, Tread=300mm, riser=148/150mm and suitable platform at
different level.
* The height of the ground floor of the building from the finished plinth level (0.5 mtr from the
finished ground level) shall be 3.9 mtrs and the height of the parapet wall shall be
750mm. The height of the first floor from the top of the roof of the first floor shall be 3.4
mtrs and the height of the parapet wall shall be 750mm.The stair case top shall be at a
height of 2.75 mtrs from the top of the parapet top.
* The stair case shall be RCC having Kotta stone fixing.
b) 132/33 KV & 220/33 KV S/S Building:
>The plinth area for the control room building shall be as below:Ground floor: 38mtrX11mtr
Ground floor portico: 5mtrX5mtr
First floor: 12 mtr X 11 mtr
i)Ground floor shall have Control room( also can be kept on the first floor for better
visibility of switch yard area),PLCC room, Battery room, MCCDB room, ,Toilets and
bath room, Verandah & Portico etc..
ii) First floor shall have office rooms (3 Nos), a Library, a Conference room, a Rest room,
,Pantry room ,toilets(2 No.) and toilet cum bath room (1 no.) etc.
Bar.
slab=20mm.
* The stair case width=1100mm,Tread=300mm, riser=148/150mm and suitable platform at
different level.
* The height of the ground floor of the building from the finished plinth level (0.5 mtr from the
finished ground level) shall be 3.9 mtrs and the height of the parapet wall shall be
750mm. The height of the first floor from the top of the roof of the first floor shall be 3.4
mtrs and the height of the parapet wall shall be 750mm.The stair case top shall be at a
height of 2.75 mtrs from the top of the parapet top.
17.21
Provision of rooms in the colony quarter (building).
a) D Type quarter: Tentative plinth area shall be 1075 sq ft (100 sq mtrs). D type quarter
shall have two bed rooms of size 3.6 mtrX3.6 mtr having porticos; one bed rooms of size
3.9 mtrX3.3 mtr having portico; one living room of size 4.2 mtrX3.6 mtr; one dining cum
lobby of size 4.2 mtrX4.7 mtr; one kitchen of size 2.75mtrX3.3 mtr; Two nos attached
toilet cum bath room of size 2.15 mtr X 1.5mtr, one no common toilet cum bath room of
size 1.5mtr X 2.2 mtr, Portico and space for vehicle parking. The kitchen shall have
provision of Kitchen platform (granite one) two sides of the wall with stainless steel sink
having water tap provision as per standard practice. Kitchen room shall have provision of
cupboard for storing the kitchen utensils and other items including locking arrangement
of the cup board. Provision of cup-boards in all other rooms as per standard practice shall
be provided. Shall have stair case to go to the top of the roof and have stair case head
room.
b) E Type quarter: Tentative plinth area shall be 650 sq ft (61 sq mtrs). E type quarter shall
have two bed rooms of size 3.3 mtrX3.3 mtr having porticos; one no attached toilet cum
bath room of size 2.15 mtr X 1.5mtr, one no common toilet cum bath room of size 1.5mtr
X 2.2 mtr, one living room of size 4.5 mtrX3.3 mtr Portico and space for vehicle parking.
The kitchen shall have provision of Kitchen platform (granite one) two sides of the wall
with stainless steel sink having water tap provision as per standard practice. Kitchen
room shall have provision of cupboard for storing the kitchen utensils and other items
including locking arrangement of the cup board. Provision of cup-boards in all other
rooms as per standard practice shall be provided. Shall have stair case to go to the top of
the roof and have stair case head room.
Bar.
slab=20mm.
* The stair case width=1100mm,Tread=300mm, riser=148/150mm and suitable platform at
different level.
* The height of the building from the finished plinth level (0.5 mtr from the finished ground
level) shall be 3.15 mtrs i.e. up to the terrace level. A clear 1.15 mtrs shall be above the
terrace and up to the top of the parapet. The stair case top shall be at a height of 2.75 mtrs
from the top of the parapet top.
18. MISCELLANEOUS GENERAL REQUIREMENTS
Dense concrete with controlled water cement ratio, preferably 0.45, shall be used for all
underground concrete structures such as pump-house, tanks, water retaining structures, cable and
pipe trenches etc. for achieving water-tightness.
All joints including construction and expansion joints for the water retaining structures shall be
made water tight by using PVC ribbed water stops with general 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 by sea shall be
provided with anti corrosives paint.
All mild steel parts used in the water retaining structure shall be hot-dip galvanised. The
minimum coating of the zinc shall be 750 gm/sq.m. for galvanised structures and shall comply
with IS:2629 and IS:2633. Galvanizing shall be checked and tested in accordance with IS:2629.
The galvanizing shall be followed by the application of an etching primer and dipping in black
bitumen.
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.
Bricks having minimum 75kg/sq.cm compressive strength can only be used for masonry work.
Bidder shall ascertain himself at site regarding the availability of bricks of minimum 75kg/ sq.cm
compressive strength before submitting his offer.
Monorails, monorail girders and fixtures shall be provided, wherever required.
Doors and windows on external walls of buildings other than areas provided with insulated metal
claddings shall be provided with a RCC sun-shade over the openings with 300 mm projection on
either side of the openings. Projection of sunshade from the wall shall be minimum 450 mm over
window openings and 750 mm over door openings.
All stairs shall have maximum riser height of 180 mm and a minimum tread width of 250 mm.
Minimum width of stairs shall be 1200 mm. There shall be provision of of stair case to the roof of
the building.
Angles of 50x50x6 mm minimum with lugs shall be provided for edge protection all round cut
out and openings in floor slab, edges of drains with grating covers, edges of RCC cable/pipe
trenches with covers, edges of manholes with covers, edges of precast covers and any other place
where breakage of corners of concrete is expected.
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.
Handrailing of a minimum height of 900 mm shall be provided around all floor or roof openings,
projections and balconies walk ways, platforms, steel stairs etc. All handrails and ladder pipes
shall be The railing of the staiarcase shall be made of proper aluminium sections. All rungs for
ladders shall also be of aluminium as per IS:.
For RCC stairs, also handrailing with aluminium sections are to be provided.
19. INTERFACING
Proper coordination and execution of all interfacing civil works activities such as fixing of
conduits in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of
supports/embedments, 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 such that dismantling, breakage etc. is reduced to minimum.
20. WATER SUPPLY
The Contractor shall be overall responsible for supply of water within switchyard for fire
fighting, drinking purposes and other miscellaneous purposes. Water shall be made available at a
single point by the Employer. The scope is also inclusive of supply and erection of all tanks,
pipes, fittings etc. required for the water supply to be taken from the terminal point to the
respective buildings. A scheme shall be prepared by the contractor indicating the layout and
details of water supply which shall subject to the approval of the Engg Incharge (Divisional
Engr.) before actual start of work. Any extra bore holes required shall be within the scope of the
contractor.
There shall be separate borewells for the control room building and colony quarters. There shall
be pump houses for the borewells and approach road to the pump houses shall be provided.
The Contractor shall have overall responsibility to provide a suitable arrangement for
permanent supply for and retention of water within switchyard building and to the yard
for watering to the earth pits, drinking purposes as well as for township and other
miscellaneous purposes. The scope is inclusive 0f supply and erection of all tanks, pipes,
fittings etc. required for the water supply to be taken from the terminal point/points to the
respective buildings. A scheme shall be prepared by the contractor indicating layout and
details of water supply which shall subject to the approval of the Engg Incharge
(Divisional Engr.) before commencement of work. Any extra bore holes required shall be
within the scope of this contract. The capacity of each submersible pump shall be 5 HP
and all control as per standard has to be provided. The no of bore holes shall be two nos ,
one for colony township and the other one for the switchyard building. Two nos pump
house as per standard are also within the scope of this contract. The height of the pump
house (LXW=3mtrsX3mtrs) shall be 3 mtrs and shall have RCC roof and brick walls
having MS doors. The capacity of RCC overhead tank for control room building shall be
2000 liters each .Two nos of overhead water tank for control room building and for
colony quarters each quarter shall have 1000 liters capacity.
There shall be interconnection between tow pump sections in order to meet any
exigencies.
21. STATUTORY RULES
The Contractor shall comply with all the applicable statutory rules pertaining to Factories Act (as
applicable for ORISSA State), Fire Safety Rules of Tariff Advisory Committee, Water Act for
pollution control etc.
Provisions for fire proof doors, numbers 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.
22. SECURITY WATCH TOWERS:
There shall be provision of security watch tower at the corners of the switch yard. These
watch towers shall be of RCC type. Standard practice in this effect shall be followed. The
maximum numbers of such towers shall be 4.The size of the tower platform shall be
2.5mtrsX2.5mtrs and height as per standard practice.
23. SECURITY SHED NEAR THE MAIN GATE.
There shall be one RCC type security shed near the main gate to be provided. The shed
shall have also provision of sitting arrangement for the guests. The shed shall be provided
with telephone internal, electrical lighting and ceiling fan facilities. There shall be
provision of gate lights. The size of the security cum guest shed shall be
5mtrsX3.5mtrsX3.5mtr(LengthXwidthXHeight).A portion of the shed shall be used for
the guest who comes for visit the sub-station. Adequate no of MS doors and windows are
also to be provided. Necessary paintings as per standard are also to be done.
24.
PROVISION OF STORE SHED, PLAT FORM, RAMP AND WINCH FOR LIFTING
MATERIALS & VEHICLE PARKING SHED.
24.1 One no store shed of size 15X15 mtr having brick walls and plastering
with RCC roof of 15X15 meters. The flooring shall be of 75 mm thickness PCC (mix
ratio1:2:4) over RR masonry works (as per standard practice of flooring). Provision of
adequate nos of MS racks (proper paintings also to be done as per the direction of site in
charge) for keeping the spare materials. The height of the shed shall be 4mtrs above the
plinth.
24.2 One no platform outside the store shed RR masonry (compacted) with
PCC at the top for storing the transformer bushings, Instrument transformers, transformer
oil drums etc. The size of the platform shall be 20mtrX15 mtr. Details of flooring as
mentioned under 24.1. The platform shall have top covers by using TATA GC sheets.
24.3 Provision of a RCC based ramp of adequate size for loading and unloading
of the materials from the lorry near the store shed.
24.4
A winch is to be provided near the ramp for lifting and lowering of
materials up to 5 tons capacity. The two side vertical pillars shall be by MS Rail/joist and
the top horizontal also of same type. A chain pulley of 5 ton capacity is to be provided at
the centre of the frame on the horizontal bar.
24.5 Erection of Isolator Mechanism Box.
Separate RCC foundation to be provided for the Isolator Mechanism boxes.
24.6 There shall be one no vehicle parking shed inside the sub-station area. The size of
the parking area shall be 15mtrs X 15 mtrs, out of the entire area there shall be provision
of shed for 5 mtrs X 15 mtrs and rest of the area shall be without shed. The flooring of
the entire area of the vehicle parking shall be as mentioned under 24.1.
25. ANTIWEED TREATMENT AND SITE SURFACING
SCOPE OF WORK
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 Engg Incharge (Divisional Engr.).
General Requirement
The material required for site surfacing/gravel filling shall be free from all types of
organic materials and shall be of standard approved quality, and as directed by the Engg
The Contractor shall furnish and install the site surfacing to the lines and grades as shown
in the drawing and in accordance with the requirements and direction of the Engg Incharge
(Divisional Engr.). The soil of the periphery area of the switchyard area shall be subjected
to sterilisation or anti-weed treatment before placing the site surfacing/gravel fill material
or strictly as per instruction or requirement of the manufacturer of the chemical required
for soil sterilisation or anti-weed treatment. After all the structures and equipment have
been erected and accepted, and soil sterilisation of the peripheral area (except the switch
yard area) as specified is complete, the site shall be maintained to the lines and grades
indicated in the drawing and rolled or compacted by using three ton roller with suitable
water sprinkling to form a smooth and compact surface condition which shall be
matching with finished ground level of the switchyard area.
Chemical to be used for soil sterilisation /anti-weed treatment:
The details of quantities and method of application of chemicals used for soil sterilisation
/and anti-weed treatment shall be as per manufacturer`s recommendations. Bidders are
required to submit the details of chemicals proposed to be used and recommendations of
manufacturer with required guarantee alongwith their bids for necessary approval of the
Engg Incharge (Divisional Engr.). Approval of the Engg Incharge (Divisional Engr.) by no
means shall relieve the contractor of their contractual obligations as stipulated in General
and Special Conditions of Contract.
26. PROVISION OF GARDEN INFRONT OF CONTROL ROOM BUILDING AND
PLANTATION OF PLANTS (FRUIT BEARING & OTHER SHOW PLANTS):
A garden in front of the control room building is to be developed. It includes treatment of

the land of size (30mtrsX10mtrs), manuring, and plantations of sufficient flower based,
show based, crotons and entire portion shall be provided with garden grass. Proper land
slope also to be maintained for better and aesthetic looking. Provision of water taps and
garden lights at different locations are to be provided for watering the plants and lighting
of the garden.
100 nos fruit bearing plants and 100 nos other show plants along the road side, near
colony quarters and near control room building are required to be planted. Treatment of
the soil and manuring are to be done before plantation of these plants. Water taps at
different locations are to be provided for watering the plants.
27. RAINWATER HARVESTING:

In addition to drainage of rainwater, the contractor shall make arrangement for rainwater
harvesting also.
Rainwater harvesting shall be done by providing two numbers recharge structures with
bore wells. The recharge structures shall be suitably located with in the S/S. Branch
drains from the main drain carrying rainwater from entire switchyard shall be connected
to the recharge structures.
The internal diameter of recharge shafts shall be 4.5 meter with 230mm thick lining of
brick work upto a depth of 2.0 meter from ground level and 345mm thick brickwork
below 2.0 meter depth. The brickwork shall be constructed with cement mortar 1:6 (1
cement : 6 coarse sand ). The overall depth of shaft shall be 5.0 meter below invert level
of drain. The shaft shall be covered with RCC slab for a live load of 300Kg. per Sq.m.
two openings of sizes 0.7X0.7 meter shall be provided in the RCC cover slab as shown in
the drawing. An iron cover made of 5mm thick chequered plate with hinges shall be
provided in the openings. Galvanized M.S. rungs of 20mm diameter at spacing of 300mm
shall be provided in the wall of the shaft below the opening of the RCC slab to facilitate
cleaning of shaft.
A 300mm diameter bore well shall be drilled in the centre of the shaft. The depth of bore
well shall be 5.0 meter more than the depth of the sub soil water.
A 100mm diameter medium duty MS pipe confirming to IS 1161 shall be lowered in the
bore well keeping bail plug towards bottom of bore well. The pipe shall have 1.58mm
holes for 4.0 meter length starting from 1.0 meter from bottom of bore well. Holes of
3.0mm dia. Shall be provided for a length of 2.0 meter starting from the bottom level of
coarse sand and downwards. The overall length of the pipe shall be equal to the total
depth of the bore well plus depth of shaft.
Gravel of size 3mm to 6mm shall be filled around 100 dia MS pipe in the bore well. The
shaft shall be filled with 500mm thick layers each from the bottom of shaft with boulders
of size 50mm to 150mm, gravel of size 5mm to 10mm, coarse sand having particle size
1.5mm to 2.0mm and boulders of size not less than 200mm respectively.

FOR
SWITCH YARD STRUCTURES
E7-SWITCHYARD STRUCTURE- Page 1 of 9
STRUCTURES FOR OUTDOOR EQUIPMENT

TABLE OF CONTENTS
1. GENERAL
2. SUPPORT STRUCTURES OF SWITCHYARD
3. INSPECTION BEFORE DESPATCH
4. ERECTION.
5. WIDTH & HEIGHT OF THE BUS AT S/S
1. GENERAL
1.1 Design of structures
Substation structures shall be designed in accordance with the requirements of IS 802. The wind
pressures for the substation sites shall be as per data in schedules and wind pressure map of the State of
Orissa.
Structures shall be designed to carry the equipment and associated connections, insulator sets, earth
conductors and all fittings under all specified conditions of service of operation and loading.
The substation gantry structures shall be designed to carry the downlead spans and the Contractor shall
be provided with the details and location of the terminal tower and the type of conductor used on the
overhead line in order to do so. All structures intended to carry equipment or materials on more than
one side of the structure shall be designed to cater for all possible stages of equipment erection,
installation and maintenance. The substation gantry structures shall be designed to terminate the
overhead line downlead spans which may enter 30 degrees horizontally and 15 degrees vertically.
1.2 Conductor spacing and clearances
Structures shall be dimensioned to maintain the specified minimum phase to earth, phase to phase and
insulation height clearances under conditions of maximum conductor swing and sag. The spacing
between individual phase conductors, and the clearance between clamps, arcing horns, jumper loops or
other live metal and the structure steelwork and other obstacles, under all specified conditions of
temperature and loading shall not be less than the specified values.
1.3 Applied loads
The assumed maximum simultaneous loadings on the substation structures shall be as follows
1.3.1 Wind loads
The normal wind load shall be given by the wind pressure, as stated in the Schedules, acting on the
whole projected area of the phase and earth conductors and, where applicable, the horizontal resultant
of the maximum line and earth conductor tensions, together with the wind pressure, as stated in the
Schedules, on 1.5 times the projected area of the members of one face of the structure plus the projected
area of the plant being supported.
1.3.2 Vertical loads
The normal vertical load shall be the mass of the line and earth conductors, insulators, the plant item,
insulator fittings, earth conductor fittings, spacers, line traps and ancillary apparatus where applicable.
For the overhead line terminating span it shall be assumed that the mass of the conductors and
earthwires shall include the actual total mass of the downlead span.
1.4 Electro mechanical loads
Electro dynamic forces due to short circuit conditions, snatch forces, aeolin vibration and other similar
loads shall be computed and applied for design of structures. The different mechanical effects due to
short circuit current etc. shall be estimated as per IEC 865 and CIGRE guide line No. 7
1.5 Construction
The structures shall be of an approved design and construction. All stressed members (tension and
compression) of steel structures shall consist of rolled steel sections unless otherwise approved.
The material used for the members shall not be less than 6 mm thick except for unstressed members
where the thickness may be reduced to 4 mm.
No bolt hole shall be more than 1.5 mm larger than the corresponding bolt diameter. As far as possible,
bolt heads, rather than nuts, shall be on the outer or upper faces of structure connections.
To facilitate inspection and maintenance, all tall structures shall be provided with step bolts and ladders
complete with hoops. Handrails, screens, guards and other appropriate facilities shall also be provided.
Where the structure is to terminate overhead transmission lines supplied under another contract,
suitable provisions shall be made to accept the transmission line insulator fittings and earth conductor
clamps.
Means shall be provided for fixing and bonding GI flat strip to the steelwork at a minimum of two
points. Earth connections shall be made to a vertical face, clear of the ground. Foundation bolts shall
not be used for their attachment. GI flats for earth connections, bolts, nuts washers etc.. shall be
included in the structures.
Gantry type structures which support more than one three phase circuit shall have suitable interbay
screens installed to prevent access along the beam from a dead to an energised circuit. The location of
the screens shall be agreed with the Engg Incharge (Divisional Engr.).
1.6 Material
All rolled steel sections, flats, plates and bolt and nut bars used shall consist of steel manufactured by
an approved process and shall be to the requirements of ISO 630 (minimum yield strength 255 N/mm2).
The steel shall be free from blisters, scales, laminations and other defects. Steel sections shall
preferably be British Standard or metric standard sections chosen with a view to avoiding delays in
obtaining material.
All members shall be cut to jig and all holes shall be drilled or punched to jig. All parts shall be
carefully cut and holes accurately located so that when the members are in position the holes will be
truly opposite to each other before being bolted up. Drifting or reaming of holes will not be allowed.
Built members shall, when finished, be true and free from all kinks, twists and open joints, and the
material shall not be defective or strained in any way.
If the structures are fabricated or galvanised by subcontractors, the Contractor shall, if required by the
Engg Incharge (Divisional Engr.), provide a resident inspector at the works of each subcontractor
during the time that the steelwork is being fabricated or galvanised.
All bolts and screwed rods shall be galvanised, including the threaded portions; all nuts shall be
galvanised with the exception of the threads, which shall be oiled.
Except where specified to the contrary, all iron and steel used in the construction of the Contract works
shall be galvanised after all sawing, shearing, drilling, punching, filing, bending and machining are
completed.
Galvanising of all material shall be in accordance with the requirements of this Specification. The
preparation for galvanising and the galvanising itself shall not adversely affect the mechanical
properties of the coated material.
Sheradizing or other similar process shall not be used.
2. SUPPORT STRUCTURES OF SWITCHYARD
2.1 General
The scope of works covers design, fabrication, proto -assembly, supply and erection of galvanised steel
structure for portals (columns, girders), lightning masts and equipment support structures.
Portals (columns, girders), lightning masts, and equipment support structures shall be lattice type
structures fabricated from structural steel conforming to IS 226/2062. The design of all support
structures for 400kV, 220kV, 132kV and 33kV equipment is within the scope of the Contractor. The
use of GI pipes conforming to IS 806 to support certain equipment will also be considered. However
approval of the Engg Incharge (Divisional Engr.) should be

commencement of detailed design.
obtained for the same before
It is the intent of the Employer to provide structures which allow interchangeability of equipment at a
later stage. Keeping this in view, the height of all the structures must be maintained as per approved
drawings. It is stressed that the Contractor has to provide minimum steel sections as per the standard
drawings. However, if a higher section is required from design point of view the same shall be
acceptable. Additional structures called stools shall be connected to the equipment and the bottom of
the stool shall be connected to the support structure where required.
The scope shall include the supply of all types of bolts, nuts, hangers, shackles, clamps, anticlimbing
devices, bird guards, climbing systems, inserts in concrete, gusset plates, equipment mounting bolts,
structure earthing bolts, foundation bolts, spring washers, fixing plates, angles and bolts for structure
mounted or ground mounted marshalling boxes (ACDC marshalling box and equipment control
cabinets), and any other items as required to complete the works.
The connection of all structures to their foundations shall be by base plates and embedded anchor and
foundation bolts. All steel structures and anchor or foundation bolts shall be fully galvanised. The
weight of the zinc coating shall in accordance with this Specification. One additional nut shall be
provided below the base plate which may be used for the purpose of levelling.
2.2 Design requirements
The minimum bolt diameter shall be 16 mm.
In order to facilitate inspection and maintenance, the structures shall be provided with climbing devices.
Each substation gantry structure shall be provided with step bolts not less than 16mm diameter and
175mm long spaced not more than 450mm apart, staggered on faces of one leg extending from about
2.5 metres above ground level to the top of the tower. The step bolts shall conform to IS 10238.
Ladders on lighting masts and other tall structures shall be provided with safety guards.
All structures shall be designed for the worst combination of dead loads, live loads, wind loads as per
code IS 802, seismic forces as per code IS 1893, loads due to deviation of conductor, load due to
unbalanced tension in conductor, torsional load due to unbalanced vertical and horizontal forces,
erection loads, short circuit forces including 'snatch' in the case of bundled conductors etc. Short circuit
forces shall be calculated considering a fault level of 40kA. IEC 865 and CIGRE Guide No. 7 may be
followed to estimate the various forces of conductor for structural design.
Substation gantry structures shall be designed in accordance with IS 802 for the three conditions i.e.
normal conditions, three conductors on one side broken, and broken wire condition and short circuit
force. The design of all structures shall be based on the condition where stringing is done only on one
side i.e. all the three (phase) conductors broken on the other side.
A factor of safety of 2.0 under normal and broken wire conditions and 1.5 under combined short circuit
and broken wire conditions shall be considered for the design of switchyard structures. For purpose of
design 110% of static tension pull and transverse reaction on the gantries as calculated for each span
shall be considered.
Vertical load of half the span of conductors/string and the earth wires on either side of the beam shall be
taken into account for the purpose of design. The weight of a man with tools shall be considered as 150
kg for the design of structures.
Torsional effect on towers and beams due to unbalanced forces may be taken care of as per American
Code DS-10.
Terminal line take off gantries shall be designed for a minimum conductor tension of four metric
tonnes per phase for 400kV and two metric tonnes per phase for 220kV & 132 kV. The distance
between terminal gantry and dead end tower shall be taken as 200 metres. The design of these terminal
gantries shall also be checked considering 30 degree horizontal and 15 degree vertical deviation of
conductor. The transmission line conductors would be either single ACSR conductor per phase on AC
side for all lines except for 400kV. For 400kV the line side conductor shall be twin ACSR.
The girders shall be connected with lattice columns by bolted joints.
All pipe supports used for supporting equipment shall be designed for the worst combination of dead
loads, erection load, wind load, seismic forces, short circuit forces and operating forces acting on the
equipment and associated busbars as per IS 806 and IS 1161. Minimum sections for 400kV, 220kV
and 132kV & 33kV structures shall be as per standard drawings approved by the Engg Incharge
(Divisional Engr.). However, the Contractor can increase the sections if required. The height of the
structures shall be as per standard drawings.
If lighting fittings are proposed to be fixed on gantries or towers, the proper loading for these shall be
considered in the design. Holes for fixing the brackets for lighting fittings should be provided wherever
required.
Foundation bolts and stubs shall be designed for the loads for which the structures are designed.
Lightning masts shall be designed as per IS 802 for diagonal wind condition for a height of 47.5 m for
lattice structures and 2.5m for MS pipe with conical head at top.
Lightning masts shall be provided with a structural steel ladder within its base up to a height of 25
metres. The ladder shall be provided with protection rings. Two platforms shall be provided one each
at 12.5m and 25m height for mounting of lighting fittings. The platforms shall also have protection
railing.
2.3 Design drawings, bill of materials and documents.
The fabrication drawings to be prepared and furnished by the Contractor shall be based on the design
approved by the Engg Incharge (Divisional Engr.). These fabrications drawings shall indicate complete
details of fabrication and erection including all erection splicing details and typical fabrication splicing
details, lacing details, weld sizes and lengths, bill of materials in the proforma approved by the Engg
Incharge (Divisional Engr.), bolt details and all customary details in accordance with standard structural
engineering practice whether or not given by the Contractor.
Fabrication work shall start only after the final approval of the design and fabrication drawings is
accorded by the Engg Incharge (Divisional Engr.).
Such approval shall, however, not relieve the Contractor of his responsibility for the safety of the
structure and good connections. Any loss or damage occurring due to defective fabrication, design, or
workmanship shall be borne by the Contractor.
2.4 Fabrication of steel
The Contractor shall bear all the expenditure at all stages on account of loading and unloading,
transportation and other miscellaneous expenses and losses and damages for all materials up to the
fabrication yard/shop and thereafter to the erection site including all other expenses till the erection of
work has been completed and accepted. His unit rates shall be deemed to be inclusive of all such
incidental expenses and no extra shall be payable on any account in this regard.
The fabrication and erection works shall be carried out generally in accordance with IS 802. A
reference however may be made to IS 800, in case of non stipulation of some particular provision in IS
802. All materials shall be completely shop fabricated and finished with proper connection material
and erection marks for ready assembly in the field.
2.5
Assembly
2.5.1 General
The component parts shall be assembled in such a manner that they are neither twisted nor otherwise
damaged and shall be so prepared that the specified camber, if any, is provided. In order to minimise
distortion in members the component parts shall be positioned by using clamps, clips, dogs, jigs and
other suitable means. Fasteners (bolts and welds) shall be placed in a balanced pattern if the individual
components are to be bolted, paralleled and tapered.
Sample towers, beams and lightning mast shall be trial assembled keeping in view the actual site
conditions, before erection in the fabrication shop and shall be inspected and approved by Engg
Incharge (Divisional Engr.) before mass fabrication. Necessary erection marks shall be made on these
components in the shop before disassembly and despatching.
2.5.2 Bolting
Every bolt shall be provided with a washer under the nut so that no part of the threaded portion of the
bolt is within the thickness of the parts bolted together.
All steel items, bolts, nuts and washers shall be hot dip galvanised.
2.0% extra nuts and bolts shall be supplied for erection.
2.5.3 Welding
The works shall be done in accordance with the General Technical Clauses (TS-GTC) and as per
approved fabrication drawing which shall clearly indicate various details such as joints to be welded,
type of weld, length and size of weld, and whether shop or site welded. Symbols for welding on
erection and shop drawings shall be according to IS 813. Efforts shall be made to reduce site welding
so as to avoid improper welding due to constructional difficulties.
Those welds which are considered to be critical to the design and the integrity of the construction of the
structure shall be subject to radiographic inspection.
The Contractor shall carry out non- destructive testing of all butt welds subject to tensile stresses.
Testing shall be carried out in the fabrication shop or on site as the case may be.
Unless otherwise approved, non- destructive testing shall be by radiographic examination.
2.6
Foundation bolts
Foundation bolts for the towers and equipment supporting structures and elsewhere shall be embedded
in first stage concrete while the foundation is cast. The Contractor shall ensure the proper alignment of
these bolts to match the holes in the base plate.
The Contractor shall be responsible for the correct alignment and levelling of all steel work on site to
ensure that the towers and structures are plumb.
All foundation bolts for all structures and supports are to be supplied by the Contractor.
All foundation bolts shall be fully galvanised in accordance with the General Technical Clauses of this
specification.
The contractor shall provide templates for all stanchion bolt spacing. Holding down bolts, assemblies,
templates, tubes and washers shall be delivered to the site in sufficient time to position and build them
into the foundations. Boxing out for bolts shall not be permitted. The projection of threaded portions of
bolts above the foundation level shall be adequate to properly secure the nuts.
2.7
Stub setting
Stub for towers and lightning mast shall be set in such a manner that the distance between the stubs and
their alignment and slope shall be exactly as shown in the fabrication drawings.
2.8
Stability of structure
The Contractor shall be responsible for the stability of the structure at all stages of its erection at site
and shall take all necessary measures by the additions of temporary bracings and guying to ensure
adequate resistance to wind and also to loads due to erection equipment and their operations.
2.9 Grouting
The method of grouting the column bases shall be subject to approval of Engg Incharge (Divisional
Engr.) and shall be such as to ensure a complete uniformity of contact over the whole area of the steel
base. The Contractor will be fully responsible for the grouting operations. The mix for the grouting
shall contain one part of cement and two parts of coarse sand. Non shrinkage admixtures of approved
quality and of standard make shall also be added in adequate proportion as specified by the
manufacturers of the admixtures.
2.10 Galvanising
All structural steel works and single pipe supports shall be galvanised after fabrication in accordance
with this Specification. The galvanising of structures having length not exceeding 6m for lattice type,
and 5m along with base plate size of 750x 750mm for other type, shall be made in one dip only.
The Contractor shall be required to make arrangements for frequent inspection by the Engg Incharge
(Divisional Engr.) as well as continuous inspection by a resident representative of the Engg Incharge
(Divisional Engr.), if so desired for this fabrication work.
2.11 Painting
Where members of steel structures are required to be painted it shall meet the requirements as specified
in relevant sections of this Specification.
The preparation, protection and painting systems selected for ferrous surfaces provided inside the
switchyard shall provide a life to first maintenance of 20 years and for doors, windows, louvres etc., it
shall provide life to first maintenance of 10 years. Finish colour will be selected as per relevant
sections of this Specification.
3. INSPECTION BEFORE DESPATCH
Each part of the fabricated steel work shall be inspected for correctness of physical parameters,
welding, joints, erection marks etc.. before it is despatched to the erection site. In any case the
Contractor shall be fully responsible for correctness, quality, adequacy and completeness of structures
being erected under the scope of this contract.
3.1 Testing and inspection
The Contractor shall give full access to the Engg Incharge (Divisional Engr.) at all times to the place of
fabrication and storage for the purpose of inspection and testing. Mill test certificates relating to the
material procured by the Contractor for works shall be forwarded to the Engg Incharge (Divisional
Engr.).
When so instructed by the Engg Incharge (Divisional Engr.), the Contractor shall provide samples of
the steel to be used in the works for tests to be carried out at an independent laboratory approved by the
Engg Incharge (Divisional Engr.). The cost of these independent tests shall be paid for by the
Contractor.
Should the works or any part thereof fail to pass any test or in the opinion of the Engg Incharge
(Divisional Engr.) fail to comply with the specification, the Contractor shall immediately take such
action as is necessary to ensure that the works comply with the specification at no extra cost to the
Employer.
All defective material and workmanship will be rejected and shall be replaced and reconstructed at the
Contractor`s expense.
No splice welding of members between connections shall be permitted without the prior approval of the
Engg Incharge (Divisional Engr.).
3.2
Despatch, handling and storage.
All bolts, nuts, washers, plates etc. shall be transported to site in properly marked and sealed containers,
suitably protected to prevent damage during transportation.
3.3 Test certificate.
Copies of all test certificate relating to material procured by the Contractor for the works shall be
forwarded to the Engg Incharge (Divisional Engr.).
4. ERECTION.
The Contractor should arrange his own erection plant and equipment, welding sets, tools and tackles,
scaffolding, trestles equipment etc. and any other accessories and ancillaries required for the work.
Finished structures shall be plumb, level and true to dimensions, within the tolerances specified.
4.1 Safety precautions.
The Contractor shall strictly follow at all stages of fabrication, transportation and erection of steel
structures, raw materials and other tools and tackles, the stipulations contained in Indian Standard Code
for erection for structural steel work, IS 7205.
4.2 Fire protection to steelwork.
The fire protection to steelwork shall be an approved intumnescent paint, spray or board system to give
two hours fire protection when tested. Fire protection shall only be required in the immediate vicinity of
potential fire sources.
If applicable, fire protection coatings shall be sprayed or painted onto previously primed steelwork.
Application to be made in strict accordance with product loading rates for base coat and top sealer
specified for two hours fire resistance in manufacturer`s product application notes. Suitable mesh
reinforcement shall be incorporated to prevent loss of insulation when subject to mechanical damage.
The coatings shall be applied by a specialist applicator strictly in accordance with the product
manufacturer`s recommendations. The whole of the fire protection proposals and application shall be in
accordance with the current Building Regulations and to the satisfaction of the Local Authority and the
Fire Authority.
Surfaces which are to receive a fire protective coating shall be delivered to site with travel coatings
applied and shall be suitably protected until immediately prior to the fire protective coatings or casings
being applied. The latter shall be applied as late as possible in the construction programme subject to
other trades and operations. Primer and travel coat shall be compatible with the fire protection coating.
5. WIDTH AND HEIGHT OF THE BUS AT SUB-STATION

VOLTAGE LEVEL
BAY EIDTH
BOTTOM BUS HEIGHT
TOP BUS HEIGHT
132 KV
11MTRS /
8.5 MTRS
5 MTRS
10.5 MTRS MIN FROM
5.5 MTRS FROM
TOP OF THE COLUMN
CENTER OF THE
FOUNDATION
BOTTOM BUS
13.1 MTRS
220KV
18MTRS
33KV
5.5MTRS
5.5 MTRS
4 MTRS
400KV
27 MTRS
>15
8 MTRS

FOR
MANUFACTURERS
DRAWING,
TEST
CERTIFICATES AND (O &M) MANUALS
E8-DRG,TEST CERT,O&M MANUALS-Page 1 of 16
SI.No.
1.
DESCRIPTION
DRAWINGS, TEST CERTIFICATES
PAGE No.
3
OPERATING AND MAINTENANCE

MANUAL.
2.
DRAWING
2.1
GENERAL
3.
DETAILED DRAWINGS
4.
RECORD DRAWING
5.
SPECIFIC REQUIREMENT
6.
SUBMISSION OF DRAWING
12
7.
TEST CERTIFICATE
12
7.1.1
ROUTIN TEST CERTIFICATES
13
7.1.2
OTHER DOCUMENTS
13
7.1.3
OPERATING AND MAINTENANCE

MANUALS
14
TECHNICAL SPECIFICATION FOR DRAWINGS, TEST CERTFICATE &

O&M MANUALS
1. DRAWINGS, TEST CERTIFICATES, OPERATING AND MAINTENANCE

MANUAL.
2. DRAWING
2.1 GENERAL
Separate drawings shall be prepared and submitted for equipment/installation

pertaining to each substation/site.
All drawings to be furnished by the Bidder shall be in standard size of sheets with
maximum size being A0. Drawings shall contain the following particulars in the
title block at lower right hand corner in addition to the Bidders name, date, scale,
drawing number title, etc.
a)
Client
OPTCL
b)
Project Title
PROJECT for System improvement for (*AS PER
PACKAGE DESCRIPTION)
A blank space of size 100 mm x 100 mm shall preferably be provided for the
Employers approval stamp and provision shall also be made by way of a block
for details of revisions to be recorded. The drawing number shall be marked with
a subsequent revision number every time the drawing is revised. The drawing title
shall also identify name of the substation/site.
The equipment/systems which are to be bought our from the sub vendors
are also required to be approved by the Employer prior to placement of order. The
relevant technical literature/drawings pertaining to such equipment/systems shall
be submitted for approval.
Six copies of each of the drawings are to be submitted for approval of

Employer. Bidder shall ensure that the contents of copies of drawings are legible
and are complete with all details. Drawings that are not legible or are incomplete
will not be reviewed.
Two copies of approved drawings will be furnished to the Bidder.

Drawings returned not approved/ approved with comments shall be
resubmitted with Revision No. for approved till the final approval is obtained.
Delays caused by submission of incomplete/ incorrect drawings shall be to

Bidder account.
Drawings submitted by sub-vendor/sub-contractor shall carry Bidders

approval stamp and the Bidder shall be responsible for their contents, accuracy
and completeness. These drawings shall also carry details indicated in this Clause
in addition to the Bidders name.
3. DETAILED DRAWINGS
The bidder shall submit to the Employer all working drawings, equipment
data and detailed drawings. These shall include general arrangement, details of
equipment, foundations, cable routing, openings in walls and floors, wiring
diagrams, cable schedules, interconnection diagrams etc. necessary for the
erection of plant. These drawings/data having been corrected or amended as
necessary based on the Employers comments shall become the approved
drawings/data to be used for manufacture and erection of plant.
Minimum details required on drawings of different categories are given

below:
Type of
Minimum details required.
Drawing.
List of Drawing
A detailed list of drawings which

The bidder proposes to prepare for
The substation in indicating therein
Drawing nos. and titles.
Programme:
1)
All activities from the start

Date up to commissioning shall
Be included. Separate
Programme shall be furnished
for each of the activities.
2)
Earliest and latest occurrence

of each activity.
3)
Constraints, if any.
The activities for each of the items shall essentially cover time-table for activities
such as placement of order with sub-vendors, Empowering, submission of
drawing, review and approval by the Employer, manufacture, inspection, delivery,
erection and commissioning. All events shall be represented in a proper in proper
sequence of occurrence with due consideration for inter-dependent activities and
all period shall be counted from the start date.
Type of Drawing
Minimum details required
Single line diagrams. 1.
All equipment connection with

ratings, polarities, protection
and metering details, etc.
2.
Cable details for all circuits.
3.
Details of relays, meters and

Major components associated
with each circuit.
4.
Busbar details, makes of equipment/

Components etc.
General Arrangement
5.
Reference Drawings.
1)
Dimensional layout drawings
(All equipment,
covering complete layout of
cabling earthing,
these items/systems.
lightning protection,
2)
lighting etc.)
Plans and sections as required

to show details, access space/
Clearances etc.
3.
Details of foundations, cutouts.

Openings, supporting/mounting
Details etc. indicating weight
on foundation.
4.
Bill of material and identification

of components/rooms/ areas etc.
5.
Reference drawings.
Installation Drawings
Details of installation for equipment, accessories, cabling, lighting, earthing and

lightning protection systems. These shall cover cross sectional details, cable
trays/cable layouts for cables directly buried/along cable trays/ in conduits/along

structures etc. details of marshalling boxes, embedment of conduits at building
entry points/between cable trenches and structures, mounting arrangements and
wiring for lighting fixtures, installation of earthing conductors directly
buried/along structures, jointing/terminations (between conductors and at
equipment ends), earth electrodes and pits, lightning shield wire, earth pads to be
provided at specific places etc.
4. RECORD DRAWING
Within 6 (six) weeks of successful commissioning tests, the Bidder shall

furnish the Record (As Built) drawings. Submission to and approval by the
Employer of the Record drawing shall be pre-requisite for the Taking Over
Certificate. The drawing shall show the whole sub-station as installed and shall
include electrical/mechanical and civil components with schematic and wiring
diagrams for all items of electrical equipment included in the works. Six sets of
recur drawings shall be furnished in neatly bound volumes. Reduced copies of the
relevant drawings shall be included in the operating and maintenance manual.
5. SPECIFIC REQUIREMENT
Following drawings shall be enclosed with the bid :
a) The programme shall be in the form of a network based on the principles of

PERT/CPM. Detailed to cover entire scope of the project showing all
activities (separately for each sub-station/site). Their durations start and finish
dates and their inter-relationships.
b) Dimensioned general arrangement drawings showing plan, elevation and

sections together with identification of parts/accessories, etc. for the major
plant items, viz. 132 KV/33 KV. Outdoor transformer and equipment, 415 V
A.C. and 220 V A.C. system equipment, control, relay and metering panels,
communication equipment, lighting equipment along with manufacturers
catalogues/literature, etc.
Following information/drawings shall be submitted after the award of

contract for approval of the Employer.
a)
Updated programme along with the list of drawings.
b)
Detailed design calculations for electrical, mechanical and civil equipment

and systems etc. including design calculation of earthing grid and
illumination system.
c)
33 KV/433 V transformer.
(i)
General arrangement drawing, showing plan, front and

side elevations and all accessories and fittings. Detailed dimensions, net
and shipping weights, crane lift for untanking, size of lifting lugs and eyes,
clearances between HV terminals, LV terminals and to ground and
between adjacent bushing identification for fittings and accessories, enter
lines in both the directions, details of anti-earthquake clamping device,
details of HV/LV bushings. LV box foundation details, detailed
manufacturers
catalogues/literature
of
accessories
actually
being
supplied.
(ii)
Rating and terminal marking plate, showing polarity

vector group and other details.
(iii)
GA drawing of OLTC and Marshaling Box.
(iv)
Control and wiring diagram for OLTC marshalling box

and cooler system.
d)
400KV,220KV,132KV
AND
33KV
outdoor
type
sub-station
equipment:
(i)
Detailed dimensional plan and sections for each equipment and for
the sub-station indicating therein salient features of equipment, detailed
bill of material for equipment, identification of clamps and connectors,
etc. including weight of different equipment.
(ii)
Cable trench, lighting, earthing and lightning protection drawings

for outdoor areas, control room drawings for equipment layout, cabling,
lighting and earthing systems.
(iii)
Detailed drawings for the sub-station structures, equipment and

clamps/ connectors.
(iv)
Foundation layout drawings.
(v)
Control and protection schematic diagrams.
(vi)
Detailed one-line diagrams.
(vii)
Block logic diagrams.
(viii)
Cable schedules and inter-connection wiring diagrams in detail

including all interlocking schematics.
(ix)
Typical installation detailed drawings.
(x)
Architectural and other civil drawings including that of state

quantum.
(xi)
Manufacturers catalogues/literature etc. of equipment being

supplied.
e)
400KV/220KV/132 KV/33 KV SF6 Circuit Breaker.
(i)
Complete assembly drawing of the Circuit Breaker

showing plan, elevation and control cable terminal blocks.
(ii)
Foundation plan showing the location of channel sills,

foundation bolts.
(iii)
Schematic diagram (AC and DC) for control protection,

indication, alarm and trip circuits, relays, instruments space heaters, etc.
(iv)
Complete
wiring
diagrams
of
Marshalling
Kiosk
including terminal wiring designation.
(v)
Cable terminal details with dimensions.
(vi)
Manufacturers catalogues/literature etc.
f)
Control, relay and metering panels, 415/V AC and 220 V DC distribution

boards, lighting panels, etc.
(i)
Fully dimensioned general arrangement drawings for

each of the above complete with plan, elevation and sectional views and
complete bill of material, foundation drawing and cable entry details.
(ii)
Schematic diagrams for all power, control, protection

and indication circuits.
(iii)
Alarm annunciation scheme drawings.
(iv)
Wiring diagrams.
(v)
Manufacturers catalogues/literature etc. for all items.
g)
220 V DC Battery and Battery Chargers.
(i)
Dimensioned general arrangement drawings of battery

and battery charges comprising plan, elevation and sectional views,
foundation details, etc.
(ii)
Complete schematic and wiring diagrams for battery

chargers.
(iii)
Detailed bill of material together with rating makes etc.
(iv)
Manufacturers catalogues/literature.
h)
LIGHTING SYSTEM
Lighting layout drawings for indoor and outdoor areas showing layout of
lighting fixtures, conduit/cables, lighting circuit distribution scheme, complete bill
of materials, locations of control switches, receptacles etc. and mounting details
for
fixtures,
switches
and
receptacles
as
well
as
manufacturers
catalogues/literature.
i)
EARTHING AND LIGHTNING PROTECTION SYSTEM
Layout drawings for earthing and lightning protection system showing

earthing
grid,
locations
of
earth
electrode3s,
routes
of
conductor,
interconnections, earth leads to various equipments, bill of materials, etc.
j)
MISCELLANEOUS SYSTEM
Detailed general arrangement, schematic and other drawings, bill of

material and manufacturers catalogues/literatures.
k)
TYPICAL INSTALLATION DRAWING
Cabling, lighting, earthing and lightning protection as well as

miscellaneous system drawings showing all, necessary details.
6. SUBMISSION OF DRAWING
The list of drawings and the programme shall be submitted within 30 days
from the start date.
All other drawings shall be submitted progressively thereafter within a maximum

period of 180 days as per approved sequence of drawings to be submitted with the
above period. But in no case the work progress should be hampered due to
wrong/unscheduled sequence of drawings submission.
7. TEST CERTIFICATE
Type test certificates for the following items shall be furnished.

a)
400KV,220 KV, 132 KV and 33KV
equipment like circuit Breaker,
isolators, CTs. VTs and CVTs. Line traps, insulators, bushings, LAs, etc.
b)
Cables
c)
Clamps, connectors and hardwires.
d)
Transformers, OLTC etc.
Type test certificates shall be furnished for tests carried out on similar type/design of
equipment. Type test to be carried out in presence of employers representative
for transformer.
7.1.1
ROUTIN TEST CERTIFICATES
Routine test certificates for all the plant items and accessories shall be
furnished.
Routine test certificates shall be furnished in addition to test reports which

will be collected at the time of inspection.
Routine test certificates shall be furnished for review by the Employer

within seven (7) days after completion of inspection of relevant item or as
instructed by the Employer in case of items for which witnessing of tests is
waived.
Test certificates should be approved by the Employer for obtaining

dispatch clearance of any material.
Six (6) copies of approved test certificates should be submitted for record.
7.1.2
OTHER DOCUMENTS
Technical catalogues, descriptive literature, characteristic curves, write-up

on schemes where required in support of relevant control/annunciation drawings
etc. shall be furnished for all the items of plant and accessories/components.
Documents pertaining to cables shall, in addition, include current ratings,

de rating factors, physical and electrical data, recommended bending radii etc.
Documents in respect of lighting systems equipment shall include data in

respect of each type of lighting fixture/switch, receptacles/miniature circuit
breaker and wires to be used in circuit wiring. Data on lighting fixtures shall
include dimensional drawings, cable facility, mounting details and weight, light
distribution diagrams, light absorption and utilization factors, lamp data etc.
Bidder shall note that the documents mentioned above shall be made
available along with relevant drawings (listed in Clause 11.4 above items/
accessories components etc. as supporting documents to facilitate expeditious
review of such drawings.
7.1.3
OPERATING AND MAINTENANCE MANUALS
The Contractor shall provide five bound sets of approved manuals written
in English language. All descriptive leaflets, instruction sheets, charts, lists,
pamphlets and other documents that are used in compiling each manual shall be
contained in one or more bundle designed to prevent loss of contents. Each
binding shall be titled with a name of the Employer, the name of the project the
Contract Number, the name of the Bidder and with information to identify the
subject matter and shall include a detailed index to all the literature contained
therein.
The manuals shall be initially approved in draft form by the Employer and
shall cover all items of the works. For this purpose, three (3) draft copies shall be
submitted to the Employer. Final submission of manuals shall be done after

satisfactory completion of commissioning tests. A mere collection of
manufacturers descriptive leaflets, will not be acceptable in satisfaction of this
clause. The manuals shall comprise both operating instructions and maintenance
instructions. The operating manual should also highlight operation of the Plant in
conjunction with the system. Thus, a general tie-up between system and
equipment shall be available in the manuals.
A separate section of a manual shall be devoted to each size and type of

equipment. It shall contain a detailed description of its construction and operation
and shall include all relevant pamphlets and a list of parts with procedure for
ordering spares. Operation of electrical equipment shall be described step by step
giving the complete sequence of operation. The detailed sections of the manual if
necessary, shall contain further maintenance instructions and fault location charts.
The manuals shall be printed on A4 size sheets and shall be bound.

Reduced copies of record drawings shall also be included in the manuals.
Step to step of the plant to work, listing all adjustment necessary for the
correct functioning of the plant alarms giving possible causes for alarm initiation
and sequence of remedial actions to be taken.
Instructions on monitoring of plant performance and sample log sheet for
each plant item, to be filled by operators on a routine basis.
Dos and Donts in plant operations. Operations attention shall be drawn

to all operations considered to be dangerous to operators or likely to cause
damage to the plant.
The maintenance instructions shall include the following.
Checking, testing and replacement procedures to be carried out on all plant

items on a daily, weekly and monthly basis or at longer intervals to ensure trouble
free operation.
Fault locations and remedy charts to facilitate tracing the cause of

malfunctions or breakdown and correcting faults.
A spares schedule which shall consist of a complete list of itemized spares

for all plant items with ordering references and part numbers.
Full instructions to cover the complete dismantling and reassembly of all

items of plant.
Part list and drawings or exploded diagrams for such items of plant
showing manufacturing tolerances, matching clearances between machined
components at the time of supply, maximum wear and clearances permitted to
facilitate replacement.
Complete list of recommended lubricants and lubricating charts insulating

oil and insulation checking/replacement chart.
ORISSA POWER TRANSMISSION

CORPORATION
LIMITED

FOR
ELECTRICAL EQUIPMENT
INSTALLATION AND
COMMISSIONING
E9-ELEC. EQPMT. INST. & COMM. Page 1 of 12
SI.No.
1.
DESCRIPTION
PAGE No.
ELECTRICAL EQUIPMENT INSTALLATION

AND COMMISSIONING
1.1
SCOPE
1.2
CODES AND STANDARDS
1.3
GENERAL
2.
INSTALLATION WORK SCOPE
2.1
POWER AND INSTRUMENT TRANSFORMERS
2.2
SWITCHGEAR, CONTROL/RELAY PANELS
2.3
BATTERY AND CHARGERS
3.0
SWITCHYARD
3.1.
GENERAL REQUIREMENTS OF INSTALLATION

FOR CONDUITS, PIPES AND DUCTS.
3.2

FOR EARTHING AND LIGHTNING PROTECTION
SYSTEMS
4.0
SCOPE AND INSTALLATION
4.1`
EARTHING CONNECTIONS
4.2
EARTH ELECTRODES
5.0
TESTING OF EARTHING SYSTEM
5.1

FOR LIGHTING SYSTEM AND POWER
RECEPTACLES
10
5.2
TESTING AND COMMISSION
10
6.0
COMPLETION CHECKS
11
6.1
COMMISSIONING TEST
11
ELECTRICAL EQUIPMENT INSTALLATION AND COMMISSIONING
1.1 SCOPE
This chapter describes board guidelines for installations, testing and
commissioning of electrical equipment. The work shall, however, be carried out
strictly as per the instruction of the MANUFACTURER / EMPLPOYER.
1.2 CODES AND STANDARDS

The electrical installation work shall comply with the latest applicable
standards, regulations, electricity rules and safety codes of the locality where the
installation is carried out. Nothing in this specification shall be construed to
relieve the CONTRACTOR OF HIS RESPONSIBILITY
1.3 GENERAL
The CONTRACTOR shall transport the equipments where required in actual
position. Erect, assemble all parts of the equipments and test and commission the same.
The CONTRACTOR shall furnish all tools, welding equipment, rigging materials,
testing equipment, test connections and kits, etc. required for complete installation,
testing and commissioning of the items included in the contract work.
The EMPLOYER may engage specialist Employer to supervise the installation,
testing and commissioning of their equipment. The CONTRACTOR shall extend full cooperation to these Employers and carry out the works as per their instructions. The
CONTRACTORS work shall include minor rewiring modifications as may be
necessitated during commissioning. Providing such assistance shall be deemed to be
included in the CONTRACTORS basic scope.
The CONTRACTOR shall co-operate through the EMPLOYER with other
contractors at site, in all matters of common interest, so as not to abstract operation of
others and to ensure the safety of all personnel and works covered under this
specification.
It will be the CONTRACTORS responsibility to assist the OWNER to obtain
approval/ clearance from local statutory authorities including electrical inspector,
wherever applicable, for conducting any work or for installation carried out which comes
under the purview of such authorities.
The work shall be carried out strictly as per the instructions and layout drawings
of the EMPLOYER/ manufacturer. In case of any doubt/ misunderstanding as to correct
interpretation of the drawings or instructions, necessary clarifications shall be obtained
from the EMPLOYER. The CONTRACTOR shall be held responsible for any damage to
the equipment consequent to not following the MANUFACTURERS instructions
correctly. All necessary drawings. MANUFACTURERS instructions correctly. All
necessary drawings. MANUFACTURERS equipment manuals will have to be arranged
by the contractor as this is a Turn-key contract.
All thefts of equipment/component parts till the including executed portion

handed over to the EMPLOYER shall be made good by the CONTRACTOR.
The CONTRACTOR shall have a separate cleaning gang to clean all equipment
during erection and as well as the work area and the project site at regular intervals to the
satisfaction of the EMPLOYER. In case the cleaning is not to the Employers
satisfaction, he will have the right to carry out the cleaning operations and any
expenditure incurred by the OWNER in this regard will be the CONTRACTORS
account.
In order to avoid hazards to personnel moving around the equipment such as
switcher etc. which is kept charged after installation before commissioning, such
equipment shall be suitably cordoned off to prevent any one accidentally going near it.
Safety of the Contractors personnel engaged in erection and commissioning job
will be Contractors responsibility.
The CONTRACTOR shall carry out touch-up painting on any equipment
indicated by the EXMPLOYER if the finish paint on the equipment is soiled for marred
during installation handling.
The CONTRACTOR shall ensure workmanship of good quality and shall assign
qualified supervisors/Employers and competent labour who are skilled, careful and
experienced in their several trades in similar works. The EMPLOYER shall reserve the
right to reject non-competent persons employed by the CONTRACTOR, if the
workmanship is not of good order.
It shall be the responsibility of the CONTRACTOR to obtain necessary
Licence/Authorisation, Permit for work from the Licensing Board of the Locality/ state
where the work is to be carried out. The persons deputed by the CONTRACTORS firm
should also hold valid permits issued or recognized by the Licensing Board of the
locality/State where the work is to be carried out. A list of the personnel engaged in
erection and commissioning work should be submitted to the Employer before
commencement of the work.
2. INSTALLATION WORK SCOPE
Equipment shall be installed in neat, workmanlike manners so that it is
level, plump, square and properly aligned and oriented. Tolerances shall be
established in the Manufacturers drawings or as stipulated by the EMPLOYER.
No equipment shall be permanently bolted down to foundation or structure until
the alignment has been checked and found acceptable by the EMPLOYER.
Care shall be exercised in handling to avoid distortion to stationary structures, the
marring of finish, or damaging of delicate instruments or other electrical parts.
Adjustment shall be made as necessary to the stationary structures for plumb and
level, for the sake of appearance or to avoid twisting of frames, binding of hanged
members, etc.
The CONTRACTOR shall move all equipment into the respective building
through the regular doors or floor opening provided specially for lifting the
equipment.
All external cabling including end connections and earthling shall also be carried
out.
2.1 POWER AND INSTRUMENT TRANSFORMERS
Physical inspection on receipt, storage, installation, testing and commissioning of
transformers shall be in accordance with the specified code of practice and
Manufacturers instructions.
Transformer may be delivered without oil filled with inert gas and without
bushings and external mounted accessories. As applicable, the CONTRACTOR
shall.
a) Assemble the transformers with all fittings such as bushings, cooler banks,
radiator, conservators, valves, piping, cables boxes, marshalling boxes OLTC,
cooling fans/pumps, etc.
b) Arrange for vacuum and oil filtration of the transformers. Oil filtration shall
be done as per the standard practice. Oil tanker in this effect are to be used
and filtration to be done while the oil is inside the tanker. On getting the
standard value of the oils the same shall be pushed into the main tank and
other portion of the transformer. Final filtration to be done after entire oil is
filled in the transformer. Prior to that vacuum treatment of the tank of the
transformer with the windings are to be taken up.
c) Provide wedges/clamps to rigidly station all transformers on rails.
d) Connect up the transformers terminals.
e) Lay and terminate cables/ conduits between all the accessories mounted on the
transformer tank/cooler and the transformer-marshalling kiosk and RTCC
panels etc.
f) Pre commissioning checks shall be carried out as per relevant standards and
Employers instructions.
The CONTRACTOR shall arrange the oil filtration equipment.
Care shall be taken during handling of insulating oil to prevent ingress of
moisture or foreign matter. In the testing, circulating, filtering or otherwise
handling of oil, rubber hoses shall not be used, circulation and filtering of oil, the
heating of oil by regulated short-circuit current during drying runs and sampling
and testing of oil shall be in accordance with the MANUFACTURERS
instructions and specified Code of Practice.
2.2 SWITCHGEAR, CONTROL/ RELAY PANELS
Switchgears and control relay panels/desks shall be installed in accordance
with specified Code of Practice and the Manufacturers instructions. The
switchgear panels shall be installed on finished surfaces or concrete or steel sills.
The CONTRACTOR shall be required to install and align and channel sills
which form part of the foundations. In joining shipping sections of the
switchgear/panels /control centers together with adjacent housing or panes

sections provided shall be bolted together after alignment has been completed.
Power bus, enclosures, ground and control splices of conventional nature shall be
cleaned and bolted together, being drawn up with torque wrench of proper size or
by other approved means. Tape or compound shall be applied where called for by
the MANUFACTURERS drawings.
The CONTRACTOR shall take utmost care in handling instruments.
Relays and other delicate mechanisms. Wherever the instruments and relays are
supplied separately, they shall be mounted only after the associated control
panel/desks have been erected and aligned. The blocking materials/mechanism
employed for the safe transit of the instruments and relays shall be removed after
ensuring that the panels/desks have been completely installed and no further
movement of the same would be necessary. Any damage to relays and
instruments shall be immediately reported to the EMPLOYER.
Pre-commissioning checks on relays have to be carried out on all relays in
accordance with manufacturers instruction and in presence of Employer.
2.3 BATTERY AND CHARGERS

Installation and testing of battery and battery chargers shall be done in
strict compliance with the manufacturers instructions. Each cell shall be
inspected for break ate and condition of cover seals as soon as received at site.
Each cell shall be filled with electrolyte in accordance with the
MANUFACTURERS instructions. Battery shall be set up on racks as soon as
possible after receipt, utilizing lifting devices supplied by the
MANUFACTURER. The cells shall not be lifted by the terminals. Contact
surfaces of battery terminals and inter-cell connectors shall be cleaned, coated
with protective grease and assembled. Each connection shall be properly
tightened. Each cell shall be tested with hydrometer and results logged.
Freshening charge, if required, shall be added. When turned over to the
EXPLOYER, the battery shall be fully charged and electrolyte shall be at full
level and of specified specific gravity.
Battery shall be put in commercial use only after carrying out
charge/discharge cycle as per Manufacturers instruction.
3.0 SWITCHYARD
The CONTRACTOR shall carry out switchyard installation as required as
per approved plan and elevation drawings of switchyard showing bus bar
configurations, sizes, tensions, insulator details, etc. All equipment including
connectors (unless otherwise specified) will be supplied by the VENDOR. The
bus bar arrangement shall be two Bus system, main Bus-1 and main Bus-2 for 220
KV side and Main bus and transfer bus arrangement for 132 KV side.
The CONTRACTOR shall install complete set of bus bars and all bays
conductors, complete with tension with tension suspension insulator strings, buspost insulators, equipment connections, bus bar connections to equipment,
lightning shield wires including down comers up to a height of 1000 mm. From
ground level where they shall be connected to the Employers test links.
Installation work of breakers and isolators shall include adjustment/
alignments necessary for proper operation of circuit breakers, isolators and their
operating mechanisms. All insulators and bushings shall be protected against
damage during installation. Insulators and bushings damaged due to negligence or
carelessness of the CONTRACTOR shall not be in any way accepted and shall be
replaced by him at his expense.
i)
General requirements of Installation of Cabling:

The supplier shall install, test and commission the cables. Cables shall be
laid on cable trays and supports, in conduits and doctor or bare on walls,
ceiling, etc. as required. The suppliers scope of work includes laying,
fixing, jointing, bending and terminating cables. The supplier shall also
supply necessary materials and equipment required for jointing and
terminating of cables. The supplier shall prepare detailed layout drawing
for cable trenches, cable tray layouts for approval by Employer and
construct cable routes strictly according to these drawings.
ii)
Sharp bending, twisting and kinking of cables shall be avoided. The

bending radius for various types of cables shall not be less than those
specified by cable manufacturer.
iii)
In each cable run, some extra length shall be kept at a suitable point to
enable one or two straight through joints to be made. Should the cable
develop fault at a later date.
iv)
Cable joints in the middle of the run for control cables will not be a
accepted.
v)
All cable terminations shall be made in a neat. Workmanlike manner.

Terminations shall be made for each type of wire or cable in accordance
with instructions issued by cable manufacturers and the Employer.
vi)
Metal sheath and Armour of the cable shall be bounded to the earthing
system of the sub-station.
3.1.GENERAL REQUIREMENTS OF INSTALLATION FOR CONDUITS,

PIPES AND DUCTS.
i)
The supplier shall supply and install conduits pipes(PVC thick but flexible
suitable for taking inside the roof and walls) and ducts as necessary for the
lighting system. All accessories/fittings required for making installation
complete. Including but not limited to ordinary and inspection tees and
elbows, check nuts, make and female reducers and enlargers, wooden
plugs, caps, squat headed male plugs, nipples, gland sealing fittings,
motion boxes, pull boxes, conduit outlets, outlet boxes, splice boxes,
terminal boxes, glands, gaskets and box covers, saddles and all steel
supporting work shall be supplied. Conduit fittings shall be of the
galvanized one. Flexible metallic conduits shall be used for termination of
connections to equipment such as motors or other apparatus to be
disconnected at periodic intervals.
ii)
Conduits(thick and flexible PVC) and accessories shall be adequately

protected against mechanical damage as well as corrosion.
3.2.GENERAL REQUIREMENTS OF INSTALLATION FOR EARTHING

AND LIGHTNING PROTECTION SYSTEMS
4. SCOPE OF INSTALLATION
i)
The supplier shall install steel conductors(GI flats) and braids, as required
for system and individual equipment earthing. All work such as cutting,
bending, supporting, painting coating drilling, brazing/soldering/welding,
clamping, bolting and connection on to structures, equipment frames,
terminals, rails or other devices shall be in the scope of work. All
incidental hardware and consumables such as fixing cleats/clamps. Anchor
fasteners, lugs, bolts, nuts, washers, bituminous compound, anticorrosive
paints as required for the complete work shall be deemed to to be included
as part of the installation work.
ii)
The quantities, sizes and material of earthing conductors and electrodes to

be installed and routes of the conductors and location of the electrodes
shall be as per specification mentioned elsewhere and approved drawings
for the optimal capacity of the Sub-station taking the future requirement in
to account..
iii)
The scope of installation of earth conductors in outdoor areas, buried in

ground shall include excavation in earth at least upto 700 mm. Deep and
450 mm, wide (unless otherwise stated), brazing/welding as required of
main grid conductor joints as well as risers of 500 mm. Length above
ground at required locations and backfilling. Backfilling material to be
placed over buried conductor shall be free from stones and other harmful
mixtures. Backfill shall be placed in layers of 150 mm, uniformly spread
along the ditch and tempered utilizing pneumatic tempers or other
approved means.
vii)
The scope of installation of earth connection leads to equipment and risers

on steel structures/walls shall include laying the conductors, welding/
cleating, at specified intervals, welding/brazing to the main earth grids
risers, bolting at equipment terminals and coating welded/brazed joints by
bituminous paint. Galvanized conductors shall be touched up with zinc
rich paint, where holes are drilled at site for holding to equipment/
structure.
viii)
The electrodes shall be installed either directly in earth or in constructed

earth pits as shown in approved drawings.
ix)
The scope of installation of lightning conductors on the roof of buildings

shall include laying, anchoring, fastening and cleating of horizontal
conductors, grouting of vertical rods where necessary, laying,
fastening/cleating/welding of the down comers on the walls/columns of
the building and connection to the test links above the ground level.
x)
The scope of installation of the test links shall include mounting of the
same at specified height on wall/column by suitable brackets and
connections of the test link to the earth electrodes.
4.1 Earthing connections:

i)
All connections in the main earth conductors buried in earth/concrete shall
be welded/brazed type,. Connection between main earthing conductor and
earth leads shall also be of welded/brazed type.
ii)
Welding and brazing operations and fluzes/alloys shall be of approved
standards.
iii)
All connections shall be of low resistance. Contact resistances shall also
be minimum.
iv)
All bi-metallic connections shall be treated with suitable compound to
prevent moisture ingress.
4.2 Earth Electrodes:
i)
Electrodes shall as far as practicable, be embedded below permanent
moisture level.
ii)
Some electrodes shall be housed in test pits with concrete covers for
periodic testing of earthing resistively. Installation of rod/pipe plate
electrodes in test pits shall be convenient for inspection, testing and
watering.
iii)
Earth pits shall be treated with salt and charcoal.
iv)
Soil, salt and charcoal placed around the electrode shall be finely graded
free from stones and other harmful mixtures. Backfill shall be placed in
the layers of 250 mm. Thick uniformly spread and compacted. If
excavated soils are found unsuitable for backfilling, the contractor shall
arrange for a suitable soil from outside.
5. TESTING OF EARTHING SYSTEM

The Supplier shall ensure the continuity of all conductors and joints. The
Purchaser may ask for earth continuity tests, earth resistance measurements and
other tests, which in his opinion are necessary to prove that the system is in
accordance with the design, specifications and code of practices. The supplier
shall have to bear the cost of all such tests.
5.1.GENERAL REQUIREMENTS OF INSTALLATION FOR LIGHTNING
SYSTEM AND POWER RECEPTACLES
i)
The supplier shall supply, install, test and commission complete lighting
system and power receptacles in accordance with relevant Standards.
Concealed conduit wiring (thick flexible PVC pipes suitable for taking
inside the roof and walls) shall be adopted for the control building.
ii)
Wiring shall be colour-coded so as to enable easy identification of phase

and neutral conductors, and DC wire (colour-coded as follows white
phase wire, black neutral wire, grey / DC wires.)
iii)
There shall be switch on each live conductor of supply mains at the point
of entry. The wiring throughout the installation shall be such that there is
no break in neutral wire in the form of switch or fuse unit.
iv)
Fixtures shall be ground by 1.5sq mm .flexible PVC copper wires(green

colour) and taken to earth strips.
v)
All fixtures, associated accessories, conduits, wires, junction boxes,

cables, switches, switch boxes, etc. required for complete wiring of the
lighting system as per approved drawings shall be supplied.
5.2.TESTING AND COMMISSION

All checks and tests as per the Manufacturers drawings/manuals, relevant
code of installation/erection practices and commissioning checks for various types
of equipment e.g. transformers, breakers, isolators, CTs, PTs, motors, relays,
meters, etc. shall be carried out by the CONTRACTOR as part of the installation
work.
The owner may ask for such additional tests on site as in his opinion are
necessary to determine that the works comply with the specification,
Manufacturers guarantee/instructions or the applicable code of installation. The
CONTRACTOR shall carry out such additional tests also.
The CONTRACTOR shall perform operating tests on all switchgear and
panels to verify operation of switchgear/panels and correctness of the interconnections between various items of the equipment. This shall be done by
applying normal AC or DC voltage to the circuits and operating the equipment for
functional checking of all control circuits e.g. closing, tripping, control interlock
supervision and alarm circuits. All connections in the switchgear shall be tested
from point for possible ground or short circuit.
Insulation resistance tests shall be carried out by following rating megger :
a)
Control circuits up to 220 V :
By 500 V Megger
b)
Power circuits, busbars
:
By 5000 Motor
c)
connections for 132 KV.

Power circuits, busbars
connections above 220 KV.
Operated Megger.
By 5000 V Motor
Operated Megger.
The Employers authorized representative shall be present during every test as

called for by the EMPLOYER. The CONTRACTOR shall record all test values
and furnish the required copies of the test data to the EMPLOYER. Electrical
circuits and equipments shall be energized or used at nominal operating voltage
only after such reports have been accepted as satisfactory by the EMPLOYER.
6. COMPLETION CHECKS
a)
Name plate details according to approved drawings/ specifications.
b)
Any physical damage or defect and cleanliness.
c)
Tightness of all bolts, clamps and connections
d)
Oil leakages and oil level.
e)
Condition of accessories and their completeness.
f)
Clearances.
g)
Earthing connections.
h)
Correctness of installation with respect to approved drawings/

specifications.
i)
Lubrication Moving parts.
j)
Alignment.
k)
Correctness and condition of connections.
6.1 COMMISSIONING TESTS

a)
b)
c)
d)
e)
f)
g)
h)
i)
Insulation resistance measurement of equipment, accessories,

cabling/ wiring. etc.
Dielectric tests on equipment, accessories, cabling/wires. etc.
Phase sequence and polarity.
Voltage and current ratios.
Vector group.
Resistance measurement of winding. Contacts, etc.
Continuity tests.
Calibration of indicators, meters, relays.etc.
Control and interlock checks.
j)
k)
l)
m)
n)
o)
Settings of equipment accessories.

Checking of accuracy/error.
Checking of operating characteristics, pick/up voltages and
currents. Etc.
Operational and functional tests on equipment, accessories, control
schemes, alarm/trip/indication circuits, etc.
Measurement of guaranteed/approved design values including
lighting levels, earth resistance measurements, etc.
Complete system commissioning checks.
FOR
GENERAL EQUIPMENT AND SUBSTATION ACCESSORIES
E10-GEN. EQPMT. & SS ACCESSORIES- Page 1 of 25
GENERAL EQUIPMENT AND SUBSTATION ACCESSORIES

TABLE OF CONTENTS
1. MOTORS
2. CABLE BOXES
3. TERMINAL BOARDS AND TERMINAL BLOCKS
4. FUSES AND LINKS
5. COMMUNICATIONS CABLES
6. MARSHALLING KIOSKS AND CONTROL CABINETS
7. AUXILIARY SWITCHES
8. MINIATURE OR MOULDED CASE CIRCUIT BREAKERS
9. SPACE HEATERS
10. LVAC CABLES
11. BUSHINGS
11
12. BUSHINGS, HOLLOW COLUMN INSULATORS, SUPPORT INSULATORS
11
13. CIRCUIT BREAKERS
12
14. RELAYS
13
15. CONTACTORS
14
16. INSTRUMENT TRANSFORMERS
14
17. INDICATING INSTRUMENTS
14
18. CONTROL AND SELECTOR SWITCHES
15
19. AIR BREAK SWITCHES
16
20. PUSH BUTTONS
16
21. INDICATING LAMPS
17
22. FUSES
17
23. NAME PLATES AND LABELS
18
24. ELECTRIC MOTORS (LV)
18
25. JUNCTION BOXES
24
26. CONDUIT AND CONDUIT ACCESSORIES
25
1.
MOTORS
1.1
General
All motors shall comply with IEC 34 / IS 335 and dimensions with IEC 72, however they shall be
capable of operating continuously under actual service conditions without exceeding the specified
temperature rises, determined by resistance, at any frequency between 48 and 51.5 Hertz together with
any voltage between 10 per cent of the nominal value.
All motors shall be totally enclosed, and if situated in the open they shall be weatherproof and suitable
for outdoor working. They shall be provided with a suitable means of drainage to prevent accumulation
of water due to condensation and with suitable means of breathing.
Motors operating in an ambient temperature not exceeding 40C shall have insulation to at least Class B
and preferably Class F standards. The temperature rise shall be restricted to that associated with
Class B insulation. Where the motor may be appreciably affected by conducted heat the class of
insulation shall be to approval.
All motors shall be suitable for direct starting at full voltage.
Motors shall have sealed ball or roller bearings.
The three line connections of AC motors shall be brought out to a terminal box. The terminal
arrangement shall be suitable for the reception of aluminium cable. Terminal markings shall be made
in a clear and permanent manner and shall comply with IEC 34. A permanently attached diagram or
instruction sheet shall be provided giving the connections for the required direction of rotation. All
terminal boxes shall be of the totally enclosed type designed to exclude the entry of dust and moisture
and sealed from the internal air circuit of the motor. All joints shall be flanged with gaskets of
neoprene or other approved material. Natural rubber insulation shall not be used.
Motors rated above 1 kW shall be three phase motors. Where single phase motors are employed the
motors shall be grouped so as to form an approximately balanced three phase load.
1.2
Motor control gear
Control gear shall comply with the requirements of IEC 292, the control gear being rated according to
the duty imposed by the particular application.
Motor contactors shall comply with IEC 158 class of intermittent duty 0-3 with type 52 enclosure
protection. Apparatus shall be capable of switching the stalled current, and shall have a continuous
current rating of at least 50 per cent greater than the full load current of the motors they control.
The operating currents of overload trips fitted to motor contactors shall be substantially independent of
ambient temperature conditions, including the effect of direct sunlight on the enclosure in which the
contactors are installed.
Where small motors are connected in groups, the group protection shall be arranged so that it will
operate satisfactorily in the event of a fault occurring on a single motor. The control and protection
equipment shall be accommodated in the control cabinet or marshalling kiosk.
Each motor or group of motors shall be provided with control gear for starting and stopping by hand
and automatically. Overload and single-phasing protection shall be provided.
2.
CABLE BOXES
Cable boxes shall be suitable for cables entering from above or below as may be required. They shall
be weatherproof, rodent and insect-proof and be complete with all gaskets, compression glands, wiping
glands and all associated fittings as may be required to make-off the cables.
Gland plates shall be insulated from the cable boxes and, in the case of single core cables, shall be of
non-magnetic or insulating material. If metallic gland plates are used, single core cable glands shall be
insulated from the gland plate. Gland plate insulation shall be capable of withstanding a dry high
voltage test of 2000 volts ac for one minute.
Where cable boxes are provided for three core cables, the sockets on the outer phases shall be inclined
towards the centre to minimise opening of the cable cores. Cable sockets shall be supplied under this
Contract.
Cable boxes for voltages up to and including 11 kV shall be suitable for PVC or XLPE insulated steel
wire-armoured PVC served cables. The boxes shall be air insulated and designed to accommodate all
the fittings required by the cable manufacturer. Front covers and gland plates shall be removable and a
12 mm diameter breathing hole covered with a wire gauze shall be provided.
Cable boxes shall be capable of withstanding on site the cable high voltage test level in accordance with
IEC 502.
The drilling of gland plates, supply and fitting of compression glands and connecting up of power
cables not included in the Contract scope of work shall be carried out under a separate contract.
Connection of the power cables included in the Contract scope of works shall be carried out under this
Contract.
3.
TERMINAL BOARDS AND TERMINAL BLOCKS
Terminal boards shall be of good quality non-flammable insulating material with a comparative
tracking index (CTI) of not less than 500 to IEC 112.
Terminal boards shall be spaced not less than 150 mm apart. For relay panels, they shall be mounted at
the sides of the cubicle, and set obliquely towards the rear doors to give easy access to termination and
to enable ferrule numbers to be read without difficulty.
Studs of stud type terminal boards shall be locked in the base to prevent turning and all connections
shall be made on the front of the terminal board using lock nuts or lock washers. Where crimped type
termination are provided at least two sets of crimping tools for each size of crimp must be supplied for
each installation.
Terminals shall be of the insertion clamp type incorporating captive pressure screws which do not bear
directly on the wire but on a serrated clamping plate. The pressure screws shall have an inherent
locking feature.
Where connections are to be made between multi-core cables and telephone type multi-pair cables, the
terminal blocks shall be of the insulation displacement type and shall have a withdrawable insulated
link in order to facilitate isolation (or busy out in the case of the apparatus associated with the telephone
system) of the individual circuits. These terminals shall also be provided with facilities for the insertion
of test probes on both sides of the link.
All terminations shall be numbered for identification and grouped according to function. Engraved
white on black labels shall be provided on the terminal blocks.
Terminals for connections which exceed 110 Volts shall be separated from those of other circuits and
shall be fitted with insulating screens and DANGER notices.
The use of terminal blocks as junction points for wires which are not required in the associated cubicle
shall be avoided wherever practicable.
All termination racks shall have a minimum of 20 per cent spare terminals blocks. At least 20% spare
terminals shall be provided on each panel and these spare terminals shall be uniformly distributed on all
terminal blocks.
All internal wiring to be connected to external equipments shall terminate on terminal blocks,
preferably vertically mounted on the side of each panel. Terminal blocks shall be 650 V grade and have
10A continuous rating. Terminal blocks shall be moulded in one piece, complete with insulated
barriers, stud type terminals, washers, nuts and lock nuts. Terminal blocks shall include a white fibre
marking strip with clear plastic, slip-on/clip-on terminal covers. Markings on the terminal strips shall
correspond to terminal numbers on the wiring diagrams.
Terminal blocks for current transformer and voltage transformer secondary leads shall be provided with
test links and isolating facilities. Current transformer secondary leads shall be provided with short
circuiting and earthing facilities.
All terminal blocks shall be suitable for terminating on each side, two by 2.5 mm2 standard copper
conductors.
Wherever duplication of a terminal block is necessary it shall be achieved by solid bonding links.
Unless otherwise specified, terminal blocks shall be suitable for connecting the following conductors
on each side :
All CT and VT circuits
Minimum of two 2.5 mm2 copper stranded.
AC/DC power supply circuits
One 16 mm2 aluminium.
All other circuits
Minimum of one of 2.5 mm2 copper stranded
There shall be a minimum clearance of 250 mm between the first row of terminal blocks and the
associated cable gland plate or panel side wall, as per the terminal block mounting arrangement
adopted. Also the clearance between the edges of two rows of terminal blocks shall be minimum of
150 mm.
Arrangement of the terminal block assemblies and the wiring channel within the enclosure shall be
such that a row of terminal blocks is run in parallel and close proximity along each side of the wiring
duct to provide for convenient attachment of internal panel wiring. The side of the terminal blocks
opposite the wiring duct shall be reserved for external cable connections. All adjacent terminal blocks
shall also share this field wiring corridor. All wiring shall be provided with adequate support inside
the panels to hold it firmly and to enable free and flexible termination without causing strain on
terminals.
All necessary cable terminating accessories such as gland plates, supporting clamps and brackets,
wiring troughs and gutters etc. including glands and lugs for cable shall be in Contractors scope of
supply.
4.
FUSES AND LINKS
Carriers and bases for fuses and links shall be in accordance with IEC 269 and colour coded to permit
identification of the circuit rating.
The fuses and links mounted in cubicles for tripping circuits and protective gear test links shall be
mounted on the front of the panel. Other links and fuses shall be accommodated within the cubicle or
above the cubicle doors. Fuses and links shall be grouped and spaced according to their function in
order to facilitate identification.
All incoming circuits in which the voltage exceeds 125V shall be fed through insulated fuses and/or
links, the supplies being connected to the bottom terminal. The contacts of the fixed portion of the fuse
or link shall be shrouded so that accidental contact with live metal cannot be made when the moving
portion is withdrawn.
Main supply fuse links shall be of the high rupturing capacity cartridge type.
Where fuse carriers are mounted vertically the incoming (supply) side shall be the bottom terminal.
Where either fuses or circuit breakers are used it should be ensured that proper discrimination between
main and sub-circuits is maintained.
5.
COMMUNICATIONS CABLES
All cables and wiring shall have copper conductors and PVC insulation and shall comply with IEC 227.
Telephone type cables shall comply with IEC 96 and IEC 189.
Cabling and wiring installations shall be arranged to minimise the risk of fire and damage which may
be caused in the event of fire.
For telephone type cables conductor wires with a cross sectional area of less than 0.2 mm2 shall not be
used. Where twin or quad make up is required in any cable the cores shall be uniformly twisted and the
lays arranged such that crosstalk is reduced to a minimum.
No conductor smaller than 32/0.2 mm (1 mm2), or having less than three strands shall be used for
interconnecting cabling except in the case of telephone cables. All cables shall have insulation which
will withstand the highest temperature to be experienced in service.
Each conductor of a multi-core cable shall be readily identified by a numbered marker tape or, in the
case of telephone type cables, colour coded insulation.
The Contractor shall submit full details of all loading on cables and in the case of interposing current
transformer connections, the loop resistance of each circuit.
Apparatus cubicles, cabinets, racks and panels shall be provided with gland plates and all necessary
equipment for the termination of cables. The Contract Works shall include for the checking,
termination and ferruling of the cable cores and their lacing into cable forms and connection to the
equipment terminal boards or tag blocks using claw washers. Crimping ferrules shall be used for each
conductor.
6.
MARSHALLING KIOSKS AND CONTROL CABINETS
The Contractor shall provide within every bay of the switchyard a bay marshalling kiosk to which all
incoming and outgoing connections to and from the associated bay equipment will be run. The terminal
blocks within the kiosks shall be grouped together by function and shall be properly labelled and
segregated. Transformer and circuit breaker control/marshalling kiosks will be provided under a
separate contract, but it shall be the Contractors responsibility to cable up to the control/marshalling
kiosks as provided by the transformer and circuit breaker suppliers. The Contractor shall provide a
separate stand alone kiosk for busbar protection CT marshalling and the kiosk shall house the CT
shorting and switching relays required for the correct function of the busbar protection scheme.
All outdoor cabinets and kiosks shall be protected in accordance with Class IP55 of IEC 947-1 and shall
be insect and rodent proof. The minimum sheet steel thickness for all cubicles, kiosks and panels shall
be not less than 2 mm cold rolled or 2.5 mm hot rolled sheet steel. The top of the outdoor boxes/kiosks
shall be provided with Aluminium alloy sheets having 2 mm thick with proper sloping for easy
discharge of water.
Anti-condensation heaters, 240V AC single phase, shall be provided and shall be controlled by a
watertight switch mounted externally. Ventilation louvres shall be provided, suitably lined internally
with a mesh screen, and divisions between compartments shall be perforated.
Control cabinets shall be illuminated with a switch operated and fused 240V CFL tube. Control
cabinets shall be provided with a switch operated single phase 240V 15A power socket.
All cables shall enter cabinets and kiosks at the base.
Each compartment of all kiosks and cabinets shall be provided with access doors at the front and rear.
Doors and access covers shall not be secured by nuts and bolts but shall be fastened with integral
handles with provision for locking with a padlock.
Doors for kiosks shall be of the lift off and hinged type and shall be provided with glazed windows of
adequate size to facilitate reading of indicators from outside the kiosk. Facilities shall be provided to
permit removal of the temperature indicators without the need to pass the capillary tubing and bulb
through the various compartments.
Doors and covers under 15 kg mass may be of the slide on pattern, but above this mass hinged doors
shall be used. Door shall be provided with padlocking facilities.
When three phase connections rated at 380V and above are taken through cabinets or kiosks, the
terminal blocks shall be adequately screened, insulated and suitably marked with the phase colour;
DANGER notices shall be affixed to the terminal blocks and a DANGER notice stating the voltage
shall be fixed on the inside and outside of the kiosk or cabinet. Exterior DANGER notices shall be
stove enamelled and shall be written in English and Oriya and shall be of an approved class/grade.
A durable copy of the circuit wiring diagram shall be affixed to the back of the kiosk door and labels
shall be provided inside each kiosk or box to describe the functions of the various items of equipment.
When the marshalling kiosks are positined in side the switchyard , flood water shall not ingress in to the
marshalling kisok. The contractor may achieve the same either positioning the marshallingh kiosk
appropriately or providing adequate water proof arrangement.
CT, CVT & IVT outdoor kiosks shall be of Aluminium alloy sheets having 3mm thickness. It shall
have proper slop canopy for easy drainage of water.
7.
AUXILIARY SWITCHES
With each disconnector, contactor and earthing device, there shall be supplied all necessary auxiliary
switches and mechanisms for indication, protection, control, interlocking, supervisory and other
services as specified. Not less than four spare auxiliary switches of each type shall be provided.
All auxiliary switches shall be wired up to a suitable terminal board on the fixed portion of the
switchgear whether they are in use or not in the first instance, and shall be arranged in the same
sequence on all similar items of equipment. Switches shall be provided to interrupt the supply of
current to the tripping mechanism of the circuit breakers and latched contactors. All such switches and
mechanisms shall be mounted in accessible positions clear of the operating mechanism, and shall be
adequately protected.
The contacts of all auxiliary switches shall be strong and be capable of adjustment in relation to the
movement of the circuit breaker or other item of equipment. Auxiliary switches and auxiliary circuits
shall be capable of carrying a continuous current of 10 Amps.
8.
MINIATURE OR MOULDED CASE CIRCUIT BREAKERS
Miniature or moulded case circuit breakers (MCBs or MCCBs) shall be designed and tested in
accordance with IEC 157 and supplementary requirements of this specification. They shall be suitable
for use over the full range of expected voltage variation as specified in the Schedules.
MCBs and MCCBs shall be suitably rated for both the continuous and short circuit loading of the
circuits they are protecting under all service and atmospheric conditions stated in the specification. The
Contractor shall ensure that correct discrimination is maintained between main and sub-circuits.
For three phase circuits, the miniature circuit breakers shall be of the three pole type; for single phase
circuits they shall be of the single pole type and for dc circuits they shall be of the double pole type.
Where miniature circuit breakers are used in circuits containing inductive loads, e.g. operating coils, it
is essential that they are suitable for satisfactory operation in the circuit in which they are used, i.e.
account is taken of the circuit time constant.
All miniature circuit breakers shall be provided with an auxiliary contact for remote indication of circuit
breaker operation.
Means shall be provided to prevent the miniature circuit breakers being inadvertently switched to the
OFF position.
Miniature circuit breakers shall be mounted in such a manner so as to give easily visible indication of
breaker position and shall be grouped and spaced according to their function in order to facilitate
identification and easy replacement.
9.
SPACE HEATERS
Heaters shall be suitably designed to prevent any contact between the heater wire and the air. They shall
consist of coiled resistance wire centred in a metal sheath and completely encased in a highly
compacted powder of magnesium oxide or other material having equal heat conducting and electrical
insulation properties, or they shall consist of resistance wire wound on a ceramic and completely
covered with a ceramic material to prevent any contact between the wire and the air.
Alternatively, they may consist of a resistance wire mounted into a tubular ceramic body built into an
envelop of stainless steel or the resistance wire wound on a tubular ceramic body and embedded in
vitreous glaze. The surface temperature of the heaters shall be restricted to a value which will not
shorten the life of the heater sheaths or that of insulated wire or other component in the compartments.
10.
LVAC CABLES
10.1
General
LVAC power cables shall have aluminium conductors with XLPE insulation, galvanised steel wire
armour and PVC oversheath and shall comply with the requirements of IEC 227, 228 and 502 as
applicable. Cables shall be sized to carry the highest anticipated load under the worst case ambient
conditions. Where a three, three and a half or four core power cable is provided, the cores shall be
coloured to distinguish the relevant phases.
All sheaths shall be free from defects and impervious to water.
10.2
1.1kV grade power and control cables
10.2.1 Codes and Standards

The design, manufacture, testing and performance of cables covered under this specification shall
comply with latest edition of the standards including amendments as indicated in the relevant schedules
attached to this specification.
10.2.2
Technical requirements
The cables shall be suitable for laying in racks, ducts, trenches, conduits and underground buried
installation with uncontrolled backfill and chances of flooding by water.
They shall be designed to withstand all mechanical, electrical and thermal stresses under steady state
and transient operating conditions. The XLPE insulated LV power cables shall withstand without
damage a three phase fault current of at least 45 kA for a minimum of 0.12 seconds, with an initial
peak of 105 kA in one of the phases. The armour for XLPE insulated power cables shall be capable of
carrying 45 kA for at least 0.12 seconds without exceeding the maximum allowable temperature of
PVC outer sheath.
Progressive sequential marking of the length of cable in metres at every one metre shall be provided on
the outer sheath of all cables.
Strip wire armouring following method (a) of the relevant IS shall not be accepted for any of the cables.
For control cables round wire armouring only shall be used.
Cables shall have outer sheath of a material with an oxygen index of not less than 29 and a temperature
index of not less than 250C.
All the cables shall pass fire resistance test as per IS 1554 (Part-I)
The normal current rating of all PVC insulated cables shall be as per IS 3961.
Repaired cables shall not be accepted.

10.3
LV XLPE power cables
XLPE insulated cables shall conform to IS 7098 (Part-I) and its amendments read along with this
Specification. The conductor shall be stranded aluminium circular/sector shaped and compacted. In
multi-core cables, the core shall be identified by red, yellow, blue and black coloured strips or colouring
of insulation. A distinct inner sheath shall be provided in all multi-core cables even if they are unarmoured. For armoured or unarmoured cables, the inner sheath shall be of extruded PVC to type ST-2
of IS 5831. When armouring is specified for single core cables, the same shall consist of aluminium
wires/strips.
10.4
LV XLPE power cables
PVC (70C) insulated 1100V grade power cables shall conform to IS 1554 (Part-I) and its amendments,
read along with this Specification and shall be suitable for a steady conductor temperature of 70C .
The conductor shall be stranded aluminium. Insulation shall be extruded PVC to type-A of IS 5831. A
distinct inner sheath shall be provided in all multi-core cables. For multi-core armoured cables, the
inner sheath shall be of extruded PVC. The outer sheath shall be extruded PVC to Type ST-1 of IS
5831 for all cables.
10.5
LV PVC control cables
The 1100V grade control cables shall conform to IS 1554 (Part-1) and its amendments, read along with
this specification. The conductor shall be stranded copper. The insulation shall be extruded PVC to
type A of IS 5831. A distinct inner sheath shall be provided in all cables whether armoured or not. The
oversheath shall be extruded PVC to type ST-1 of IS 5831 and shall be grey in colour except where
specifically advised by the Project Manager to be black.
Cores shall be identified as per IS 1554 (Part-1) for cables up to five cores and for cables with more
than five cores the identification of cores shall additionally be done by printing legible alphabets on all
cores. The alphabets shall be white and shall be printed at approximately 100 mm intervals along the
cable length. Cables without such core identifications will not be accepted.
10.6
Cable drums
Cables shall be supplied non-returnable wooden or steel drums of heavy construction. Wooden drums
shall be properly seasoned sound and free from defects. Wood preservative shall be applied to the entire
drum.
Standard lengths for each size of power and control cables shall be 500/1000 meters. The cable length
per drum shall be subject to a tolerance of plus or minus 5% of the standard drum length. The Project
Manager shall have the option of rejecting cable drums with shorter lengths. However, the total quantity
of cables after taking into consideration of all cable drums for each size shall be within the tolerance of
2%.
A layer of water proof paper shall be applied to the surface of the drums and over the outer most cable
layer.
10.7
Tests
All cables shall conform to all type, routine and acceptance tests listed in the relevant IS.
The temperature index tests shall be carried out as per ASTM-D-2863.
All cables shall meet the fire-resistance test as per IS 1554 (Part-I)
10.8
Cable sizes
Following standard sizes of cables shall be considered by Bidder for various power distribution and
protection,control and metering purposes in the system:
XLPE power cables:
1c 630 mm2, 1c 300 mm2, 3 1/2c 300 mm2. (armoured)
LV XLPE power cables: (armoured)1c 150 mm2, 31/2 c70 mm2, 31/2c 35 mm2, 4c 16 mm2, 4c 6
mm2,
2c 6 mm2.
PVC control cables:
2c 2.5 mm2, 3c 2.5 mm2, 5c 2.5 mm2, 7c 2.5 mm2, 10c 2.5 mm2,
14c 2.5 mm2, 19c 2.5 mm2, 27c 2.5 mm2

11.
BUSHINGS
All bushings shall comply with the requirements of IEC 137 and the associated barrel porcelains shall
comply with IEC 233 together with the requirements of this Specification. Provision shall be made for
the fitting of arcing horns.
Transformer bushings rated at 66 kV and above shall be either of the oil impregnated paper or resin
impregnated type. When filled with transformer oil there shall be no connection with the oil in the
transformer and an oil gauge shall be provided. The visible oil levels in the gauge shall correspond to
the range of average oil temperatures, from the minimum ambient stated in the Schedules to plus 70C.
The oil level at 15C shall be marked. Connections from the main windings to bushings shall be flexible
and shall be such that undue mechanical stresses are not imposed on them during assembly on site.
Terminal clamps shall be supplied with each bushing for flexible or rigid busbars as may be required.
The material of the clamps shall be as stated in the Schedules.
12.
BUSHINGS, HOLLOW COLUMN INSULATORS, SUPPORT INSULATORS
Bushings shall be manufactured and tested in accordance with IS 2099 and IEC 137 while hollow
column insulators shall be manufactured and tested in accordance with IEC 233/IS 5621. The support
insulators shall be manufactured and tested as per IS 2544/IEC 168 and IS 2099/IEC 273. The
insulators shall also conform to IEC 815 as applicable.
The Contractor may also offer composite silicon insulators conforming to IEC 36.
Support insulators, bushings and hollow column insulators shall be manufactured from high quality
porcelain. Porcelain used shall be homogeneous, free from laminations, cavities and other flaws or
imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified
tough and impervious to moisture.
Glazing of the porcelain shall be uniform brown in colour, free from blisters, burrs and other similar
defects.
Support insulators, bushings and hollow column insulators shall be designed to have ample insulation,
mechanical strength and rigidity for the conditions under which they will be used.
When operating at normal rated voltage there shall be no electric discharge between the conductors and
bushing which would cause corrosion or injury to conductors, insulators or supports by the formation of
substances produced by chemical action. No radio interference shall be caused by the insulators or
bushings when operating at the normal rated voltage.
Bushing porcelain shall be robust and capable of withstanding the internal pressures likely to occur in
service. The design and location of clamps and the shape and the strength of the porcelain flange
securing the bushing to the tank shall be such that there is no risk of fracture. All portions of the
assembled porcelain enclosures and supports other than gaskets, which may in any way be exposed to
the atmosphere shall be composed of completely non hygroscopic material such as metal or glazed
porcelain.
All iron parts shall be hot dip galvanised and all joints shall be air tight. Surface of joints shall be trued
up, porcelain parts by grinding and metal parts by machining. Insulator and bushing design shall be
such as to ensure a uniform compressive pressure on the joints.
12.1
Tests
In accordance with the requirements stipulated above bushing, hollow column insulators and support
insulators shall conform to type tests and shall be subjected to routine tests in accordance with IS 2099
and IS 2544.
All routine tests shall be conducted on hollow column insulators as per IEC 233. In addition the
following tests shall also be conducted
1. Ultrasonic test as a routine test.
2. Pressure test as a routine test.
3. Bending load test in four directions at 50% specified bending load, as a routine test.
4. Bending load test in four directions at 100% specified bending load, as a sample test on each lot.
5. Burst pressure test as a sample test on each lot.
6. Hollow porcelain insulators should be in one integral piece in green and fired stage. No jointed
porcelain will be acceptable.
12.2
Technical parameters of bushings, hollow column insulators and support insulators:

Parameter
420kV
245kV
145kV
36kV
420
245
145
36
Impulse withstand (wet and dry) kVp
1425
1050
650
170
Switching surge withstand (wet and dry) kVp
1050
630
460
275
70
10500
6125
3625
900
Rated voltage kV
Power frequency withstand (wet and dry) kVrms

Total creepage distance mm
Pollution level shall be Class III Heavy as per IEC 71, and as specified in Schedules for all classes of
equipment.
Insulators shall also meet the requirements of IEC 815 for 420kV, 245kV and 145kV systems as
applicable having alternate long and short sheds.
13.
CIRCUIT BREAKERS
13.1
General
Circuit breakers shall be of three pole air break design, horizontal draw out type in accordance with
IEC 947-2. In particular, evidence shall be provided of the performance when switching currents in the
critical current range. They shall be capable of the ratings specified in the Schedules, when mounted in
the switchboard.
Circuit breakers shall be fitted with trip-free, spring-operated mechanisms of the independent manually
operated type and be provided with making and over current release facilities. A push-button shall be
provided to trip the breaker electrically.
The breaker shall be provided with ÒPEN'. `CLOSE', `SERVICE', `TEST' and `SPRING
CHARGED' position indicators and shall be provided with the necessary number of auxiliary contacts
for interlocking, indication and tripping purposes plus two spare.
Each incoming circuit shall be provided with thermal overload relays and short circuit protection relays;
they shall also be provided with an undervoltage relay to trip breaker in the event of a supply failure.
There shall be `SERVICE', `TEST' and fully withdrawn positions for the breakers. It shall be possible
to close the door in TEST position.
Movement of a circuit breaker between SERVICE and TEST positions shall not be possible unless
it is in OPEN position. Attempted withdrawal of a closed circuit breaker shall not trip the circuit
breaker.
Closing of a circuit breaker shall not be possible unless it is in SERVICE, TEST
withdrawn positions.
or fully
A breaker of particular rating shall be prevented from insertion in a cubicle of a different rating.
Circuit breakers shall be provided with electrical anti-pumping and trip free feature.
Means shall be provided to slowly close the circuit breaker in withdrawn position if required for
inspection and setting of contacts. In service position slow closing shall not be possible.
Circuit breakers shall be provided with the following mechanism as specified in the Bill of Material.
13.2
Power operated mechanism
Power operated mechanism shall be provided with a universal motor suitable for operation 220V DC
control supply with voltage variation from 90% to 110% rated voltage. Motor insulation shall be class
È' or better.
The motor shall be such that it requires not more than 30 seconds for fully charging the closing spring.
Once the closing springs are discharged, after the one closing operation of circuit breaker, it shall
automatically initiate, recharging of the spring.
The mechanism shall be such that as long as power is available to the motor, a continuous sequence of
closing and opening operations shall be possible. After failure of power supply at least one open-closeopen operation shall be possible.
Provision shall be made for emergency manual charging and as soon as this manual charging handle is
coupled, the motor shall automatically be mechanically decoupled.
All circuit breakers shall be provided with closing and tripping coils. The closing coils shall operate
correctly at all values of voltage between 85% to 110% at rated control voltage. Tripping coils shall
operate satisfactorily under all values of supply voltage between 70% to 110% of rated control voltage.
Provision for mechanical closing of the breaker only in `TEST' and withdrawn positions shall be made.
14.
RELAYS
All relays and timers in protective circuits shall be flush mounted on panel front with connections from
the inside. They shall have transparent dust tight covers removable from the front. All protective
relays shall have a drawout construction for easy replacement from the front. They shall either have
built-in test facilities, or shall be provided with necessary test blocks and test switches located
immediately below each relay. Auxiliary relays and timers may be furnished in non-drawout cases.
All AC relays shall be suitable for operation at 50 Hz with 110 volts VT secondary and 1A or 5A CT
secondary.
All protective relays and timers shall have at least two potential free output contacts. Relays shall have
contacts as required for protection schemes. Contacts of relays and timers shall be silver faced and
shall have a spring action. Adequate numbers of terminals shall be available on the relay cases for
applicable relaying schemes.
All protective relays, auxiliary relays and timers shall be provided with hand reset operation indicators
(flags) for analysing the cause of operation.
All relays shall withstand a test voltage of 2kV (rms) for one minute.
Motor starters shall be provided with three element, ambient temperature compensated, time lagged,
hand reset type terminal overload relays with adjustable settings. The setting ranges shall be properly
selected to suit the motor ratings. These relays shall have a separate black coloured hand reset push
button mounted on compartment door and shall have at least one changeover contact.
All fuse protected, contactor controlled motors shall have single phasing protection, either as a distinct
feature in the overload relays (by differential movement of bi-metallic strips), or as a separate device.
The single phasing protection shall operate with 80% of the set current flowing in two of the phases.
15.
CONTACTORS
Motor starter contactors shall be of air break, electromagnetic type rated for uninterrupted duty as per
IS 2959.
Contactors shall be double break, non-gravity type and their main contacts shall be silver faced.
Direct line starter contactors shall be of utilisation category AC2. These contactors shall be as per IS
1822.
Each contactor shall be provided with two normally open (NO) and two normally close (NC) auxiliary
contacts.
Operating coils of contactors shall be of 240V AC unless otherwise specified elsewhere. The
Contactors shall operate satisfactorily between 85% to 110% of the rated voltage. Contactors shall drop
out at 70% of the rated voltage.
16.
INSTRUMENT TRANSFORMERS
All current and voltage transformers shall be completely encapsulated cast resin insulated type suitable
for continuous operation at the temperature prevailing inside the switchgear enclosure, when the
switchboard is operating at its rated condition and the outside ambient temperature is 50C.
All instrument transformers shall be able to withstand the thermal and mechanical stresses resulting
from the maximum short circuit and momentary current ratings of the associated switchgear.
All instrument transformer shall have clear indelible polarity markings. All secondary terminals shall
be wired to a separate terminal on an accessible terminal block where star-point formation and earthing
shall be done.
Current transformers may be multi or single core type. All voltage transformers shall be single phase
type. Busbar VTs shall be housed in a separate compartment.
All VTs shall have readily accessible HRC current limiting fuses on both primary and secondary sides.
17.
INDICATING INSTRUMENTS
All indicating and integrating meters shall be flush mounted on panel front. The instruments shall be of
at least 96 mm square size with 90 degree scales, and shall have an accuracy class of 2.5 or better. The
covers and cases of instruments and meters shall provide a dust and vermin proof construction.
All instruments shall be compensated for temperature errors and factory calibrated to directly read the
primary quantities. Means shall be provided for zero adjustment without removing or dismantling the
instruments.
All instruments shall have white dials with black numerals and lettering. Black knife edge pointer with
parallax free dials will be preferred.
Ammeters provided on motor feeders shall have a compressed scale at the upper current region to cover
the starting current.
Watt-hour meters shall be of three phase, three element type. Maximum demand indicators need not be
provided.
18.
CONTROL AND SELECTOR SWITCHES
Control and instrument switches shall be rotary operated type with escutcheon plates clearly marked to
show the function and positions. Switches shall be suitable for flush mounting with only switch front
plate and operating handle projecting from the panel front. Switches shall be of sturdy construction
suitable for mounting on panel front. Switches with shrouding of live parts and sealing of contacts
against dust ingress shall be preferred. Handles of different shapes along with suitable inscriptions on
switches shall be provided as an aid to switch identification. The selection of operating handles for the
different types of switches shall be as follows :
Switch Type
Application
Specification
Switchgear control switches
For closing and opening of

breakers and isolators.
Pistol grip, black, three position type.
Synchronising
For synchronising check bypass

facilities
Oval, black, keyed (common removable handle, or with

locking facility and common key).
Selector switches
Auto, manual, local, remote and

test facilities
Oval or knob, black
Instrument switches
Phase or meter selection
Round, knurled, black
Transfer of protection.
Pistol grip, lockable and black.
Protection
transfer
switches
switch
TABLE 18.1
Switch operating handles
The control switches of breakers and isolators shall be of spring return to neutral type. The control
springs shall be strong and robust enough to prevent inadvertent operation due to light touch. The
spring return type switch shall have spring return from close and trip positions to after close and
after trip positions respectively. They shall have at least two (2) contacts closing in close positions,
and two (2) contacts closing in Trip positions unless specified otherwise.
Circuit breaker selector switches for breaker controlled motors shall have three stay put positions
marked AUTO, MANUAL and TEST respectively. They shall have two contacts each of three
positions and shall have black, pistol grip handles.
Instrument selection switches shall be of maintained contact stayput type. Ammeter selection switches
shall have make-before-break type contacts so as to prevent open circuiting of CT secondaries when
changing the position of the switch. Voltmeter transfer switches for AC shall be suitable for reading all
line-to-line and line-to-neutral voltages for non effectively earthed systems, and for reading all line to
line voltages for effectively earthed systems. Ammeter and voltmeter selector switches shall have four
stayput positions with an adequate number of contacts for three phase four wire systems. These shall
have black oval handles
Synchronising switches shall be of maintained contact stayput type having a common removable
handle for a group of switches. The handle shall be removable only in the OFF position and it shall
be co-ordinated to fit in to all the synchronising switches. These switches shall be arranged to connect
the synchronising equipment when turned to the ON position. One contact of each switch shall be
connected in the closing circuit of the respective breaker so that the breaker cannot be closed until the
switch is turned to the ON position.
Lockable type switches which can be locked in particular positions shall be provided when specified.
The key locks shall be fitted on the operating handles.
The contacts of all switches shall preferably open and close with snap action to minimise arcing.
Contacts of switches shall be spring assisted and contact
faces shall be with rivets of pure silver
or silver alloy. Springs shall not be used as current carrying parts.
The contact combination and their operation shall be such as to give completeness to the interlocking
and function of the scheme. The contact rating of the switches shall be as follows :
Contact rating in Amps

Description
220V DC
50V DC
240V AC
Make and carry continuously
10A
10A
10A
Make and carry Make and carry for

0.5 sec.
30A
30A
30A
3A
20A
7A
0.2A
Break
Resistive load
Inductive Load with L/R=40ms
TABLE 18.2
19.
Contact ratings of switches
AIR BREAK SWITCHES
Air breaker switches shall be of the heavy duty, single throw group operated, load break, fault make
type complying with IS 4064.
The Bidder shall ensure that all switches are adequately rated so as to be fully protected by the
associated fuses during all abnormal operating conditions such as overload, locked motor, short circuit
etc.
Switch operating handles shall be provided with padlocking facilities to lock them in ÒFF' position.
Interlocks shall be provided such that it is possible to open the cubicle door only when the switch is in
ÒFF' position and to close the switch only when the door is closed. However suitable means shall be
provided to intentionally defeat the interlocks explained above.
Switches and fuses for AC/DC control supply and heater supply wherever required shall be mounted
inside and cubicles.
20.
PUSH BUTTONS
Push-buttons shall be of spring return, push to actuate type. Their contacts shall be rated to make,
continuously carry and break 10A at 240V and 0.5A (inductive) at 220V DC.
All push-buttons shall have one normally open and one normally closed contact, unless specified
otherwise. The contact faces shall be of silver or silver alloy.
All push-buttons shall be provided with integral escutcheon plates marked with the appropriate
function.
The colour of the button shall be as follows :
GREEN
For motor START, breaker CLOSE, valve /damper OPEN
RED
For motor TRIP, breaker OPEN, valve /damper CLOSE
BLACK
For overload reset, all annunciator and miscellaneous functions.
All push-buttons on panels shall be located in such a way that red push buttons shall always be to the
left of green push buttons.
21.
INDICATING LAMPS
Indicating lamps shall be of the panel mounting filament type and low watt consumption. Lamps shall
be provided with series resistors, preferably built-in the lamps assembly. The lamps shall have
escutcheon plates marked with its function, wherever necessary. Lamps shall have translucent lamp
covers of colours appropriate to the application as indicated in Table 21.1
Colour
Indication
RED
For motor ON, breaker/isolator CLOSED, valve/damper OPEN
GREEN
For motor OFF, breaker /isolator OPEN, valve/damper CLOSE
WHITE
For motor Auto-Trip
BLUE
For all healthy conditions (e.g. control supply) and also for 'SPRING CHARGED"
AMBER
For all alarm conditions (e.g. overload) Also for `SERVICE' and `TEST' positions indicators.
TABLE 21.1
Indicating lamp colours
Indication lamps should be located just above the associated push buttons/control switches. Red lamps
shall invariable be located to the right of green lamps. In case a white lamp is also provided, it shall be
placed between the red and green lamps along with the centre line of control switch/push button pair.
Blue and amber lamps should normally be located above the red and green lamps.
When associated with push-buttons, red lamps shall be directly above the green push button, and green
lamps shall be directly above the red push-button.
The wattage and resistance of the lamps shall be as follows:
220/250V
5 - 10W
4000 - 8000 ohms
110V
5 - 10W
1000 - 2000 ohms
Neon indicating lamps or LEDs shall be provided when specified. The wattage of the neon lamp shall
be 0.25 to 0.5W.
Bulbs and lenses shall be interchangeable and easily replaceable from the front of the panel. Tools, if
required for replacing the bulbs and lenses shall also be included in the scope of supply.
All indicating lamps shall be suitable for continuous operation at 90 to 110% of their rated voltage.
22.
FUSES
All fuses shall be of HRC cartridge fuse link type. Screw type fuses shall not be accepted. Fuses for
AC circuits shall be of Class 2 type, 20kA (RMS) breaking current at 415V AC, and for DC circuits
Class 1 type 4kA breaking current.
Fuses shall have visible operation indicators.
Fuses shall be mounted on fuse carriers, which are mounted on fuse bases. Wherever it is not possible
to mount fuses on carriers, they shall be directly mounted on plug in type bases. In such cases one set
of insulated fuse pulling handles shall be supplied with each switchgear.
Fuse ratings shall be chosen by the Contractor depending upon the circuit requirements and these shall
be subject to approval of Project Manager.
23.
NAME PLATES AND LABELS
All switchgears and ACDC distribution boards etc. shall be provided with prominent, engraved
identification plates. The module identification plate shall clearly give the feeder number and feeder
designation. For single front switchboards, similar panel and board identification labels shall be
provided at the rear also. Language shall coform to the requirements stipulated elsewhere in the
technical specification..
All name plates shall be of non-rusting metal or 3-ply lamicoid with white engraved lettering on black
back ground. Inscriptions and lettering sizes shall be subject to Project Managers approval.
Suitable plastic sticker labels shall be provided for easy identification of all equipment, located inside
the panel or module. These labels shall be positioned so as to be clearly visible and shall give the
device number as mentioned in the module wiring drawings.
24.
ELECTRIC MOTORS (LV)
24.1
Codes and Standards
All motors shall conform to the latest revisions of the relevant IEC, Indian Standards, British Standards
given in the schedules, except where modified or supplemented by this Specification.
The design, manufacture, installation and performance of motors shall conform to the provisions of
latest Indian Electricity Act and Indian Electricity Rules. Nothing in these specifications shall be
construed to relieve the contractor of his responsibility in this regard.
In case of contradiction between this specification and IS or BS or IEC, the stipulations on this
specification shall prevail.
National Electrical Code for Hazardous locations and relevant NEMA standard shall also be applicable
for motors located in hazardous location.
24.2
Service conditions and temperature rise
Unless otherwise specified, machines shall be designed for a maximum ambient air temperature of 50C.
Accordingly the temperature rise of the stator winding by resistance method over the ambient air
temperature shall not exceed 70C.
For applications where the motor temperatures may be appreciably affected by conducted or radiated
heat, the amount of heat must be specified by the Contractor and the appropriate temperature rises
agreed.
24.3
AC Motors
24.3.1 General
All AC motors shall be of squirrel cage type, unless otherwise specified and shall be suitable for direct
on line starting.
Each motor shall be assigned a maximum continuous rating (MCR) corresponding to 70C temperature.
Maximum continuous motor rating shall be at least ten percent above the maximum load demand of the
driven equipment at designed capacity.
Rated voltage for AC motors shall be as given below for various MCRs of the motor, unless specified
otherwise:
From 0.2 kW to 220 kW
415 V, three phase, 50 Hz
Below 0.2 kW
240 V, single phase, 50 Hz
Voltage and frequency variations shall be as per clause 3.3 of IS 325.
The lowest voltage at the motor terminals throughout the starting period, with which the driven
equipment shall satisfactorily start up even under the most arduous conditions specified, shall be 85%
for motors rated up to 110 kW, and 80% for motors rated above.
The accelerating torque at any speed with the lowest starting voltage shall be at least ten (10) percent of
rated full load torque of the motor.
The motors shall be suitable for two starts in succession under the specified conditions of load, torque
and inertia, with the motor initially at its normal running temperature.
The ratio of locked rotor kVA at rated voltage to rated kW (MCR corresponding to 70C temperature
rises) shall not exceed the following (without any further tolerance):
Motor MCR kW
Start kVA/Rated kW
Up to 110kW
1.0
Above 110kW
10.0
When tests to determine the breakaway starting current of cage induction motors are taken at reduced
voltage, due allowance shall be made for the effect of saturation. The estimated value of breakaway
starting current at rated voltage shall be given on all test certificates.
All motors shall be so designed that the maximum inrush currents and locked rotor and pull out torque,
developed by them at 110% of the rated voltage, do not endanger the motor or the driven equipment.
The pull out torque at rated voltage shall not be less than 200 percent of the full load torque.
Motors for reciprocating compressors etc. shall be specially designed/rated to withstand the torque
pulsation produced by the driven equipment.
24.3.2 Transient recovery
The motors shall be capable of resuming normal operation after a system disturbance causing
temporary loss of supply voltage for periods of up to 0.2 second (fault clearance time), followed by
sudden restoration to 70 percent rated voltage. From this voltage the motors shall be capable of
acceleration and ultimate recovery under the most arduous load conditions.
24.4
DC Motors
DC motors shall comply with IS 4722 and shall be shunt wound type rated for 220V. Motor MCR kW
rating at 50C ambient shall be at least ten percent higher than the power requirement of the driven
equipment under the most onerous operating conditions foreseen during the plant's life.
DC motors which are to operate from batteries shall be capable of operating continuously under actual
service conditions at any voltage between 190V and 240V.
DC motors supplied from rectifier equipment connected to AC power supplies shall meet the voltage
and frequency variations specified for AC motors.
Rectifier equipment shall be capable of meeting the condition of transient recovery given above for AC
motors and shall be provided with the necessary current limiting devices.
The pull-out torque of DC motors at the rated voltage shall not be less than 200 percent of the full load
torque.
24.5
Enclosure and method of cooling
The following types of enclosure may be supplied:

Totally enclosed, fan ventilated.
Totally enclosed, closed air circuit, integral heat exchanger.
Totally enclosed, closed air circuit, machine mounted heat exchanger.

In all cases protective enclosure and method of cooling of motors shall be IP 54 and IC 0141 in
accordance with IS 4691 and IS 6362 respectively.
Cooling fans shall be directly driven from the motor shaft.
Motors situated outdoors or exposed to the weather shall be weather protected (IPW-55).
All totally enclosed type of motors shall have a dust tight construction with suitable means of breathing
and of drainage to prevent accumulation of water from condensation. Drain holes shall exclude bodies
greater than 6 mm diameter.
24.6
Constructional features
All components shall be of adequate mechanical strength and robustness and shall be constructed of
metal unless otherwise approved. Glass fibre or plastic components, where employed, shall be of
adequate design and robustness taking into account the conditions of service required and the effects of
operating temperatures, ageing and thermal stability of the material. The material shall be resistant to
flame propagation.
Rotors shall be so designed as to keep the combined critical speeds with the driven equipment away
from the running speed by at least 20%.
Motors and their major components such as stators, rotors, terminal boxes, bearings and heat
exchangers shall be designed to be readily interchangeable as integral units.
All motor rotors shall be dynamically balanced.
The enclosures shall be designed to provide an effective sealing between the primary and secondary air
circuits.
The radial air gap between stator and rotor shall have an adequate margin to minimise the possibility of
rubbing between the stator and rotor due to eccentric positioning, play and wear, shaft deflection due to
rotor weight and unbalanced magnetic pull etc. The minimum radial air gap for all motors shall be in
accordance with Clause 5.1.5 of IS 6381.
All requirements of clause 5.1.4 of IS 6381 shall also be complied with.
All the induction motors shall be capable of running at 75% of rated voltage for a period of 5 minutes.
Induction motors shall be designed to be capable of withstanding the voltage and torque stresses
developed due to the difference between motor residual voltage and incoming supply voltage equal to
150% of the rated motor voltage during fast changeover of buses. The necessary features incorporated
in the design to comply with this requirement shall be clearly indicated in this proposal.
24.7
Variable speed motors
Variable speed motors shall be such that the speed can be continuously adjusted over the required
range. The speed control gear shall be provided with an interlock to ensure that the motor can only be
started when its control sequence is at the correct setting. When the motor is switched off, the speed
control sequence shall automatically return to this position.
24.8
Brush gear, commutators and slip-rings
Brush gear, commutators and slip-rings shall be designed to operate without injurious sparking and to
run for at least three months without the need for adjustment or replacement of brushes.
Brushes shall be of electrographite or metal graphite type. Adequate precautions shall be taken to
protect the windings, commutators, slip-rings and brush gear against deposits of entrained carbon dust.
Removable covers shall be fitted to provide access to the brush gear, commutators and slip-rings. For
totally enclosed type motors, windows shall be provided to permit observation of the brush gear whilst
the motor is running.
Brush holders shall be of non-ferrous materials and located securely to accurately position the brushes
on the commutator. Means for adjusting brush pressure and brush assembly shall be provided.
24.9
Internal electric heaters
Internal electric heaters shall be provided on motors rated above 30 kW, to maintain the windings in a
dry condition during periods of standstill. The heater shall be suitable for use on a 240V, 50 Hz, AC
supply.
24.10
Lifting facilities
All heavy parts of the motors shall be provided with adequate arrangements for lifting or handling
during erection or overhaul.
All material used for equipment construction including castings and forging etc. shall be of tested
quality as per relevant codes and standards. No welding shall be carried out on cast iron components
for repair or any other purpose.
24.11
Winding and insulation
Winding insulation shall be of class B or better and of proven high quality and reliability.
All winding insulation shall be non-hygroscopic, oil resistant and of materials resistant to flame
propagation. All windings shall be impregnated and suitably processed to effectively seal them to
prevent deterioration from adverse environmental conditions at site during the installation period and
also during normal operation.
All winding overhangs and leads shall be adequately supported, braced and blocked to provide
sufficient rigidity during all normal conditions of service.
Cage windings and all joints shall be designed to give an adequate safety factor on fatigue due to
thermal and mechanical stresses, taking into account the specified starting and running conditions. The
short-circuiting and rings shall be of joint less construction. All electrical joints and connections shall
be of brazed or welded construction.
Motors shall be designed to give a life endurance of at least 18000 starts.
24.12
Bearings
Bearings shall be of rolling type. Vertical motors shall normally have rolling type guide and thrust
bearings.
Bearings shall be designed to prevent ingress of dust and water and shall be sealed against leakage of
lubricant along the shaft.
When the motor shaft is not located axially by its own bearings, it shall be permanently marked to
indicate its normal running position and the extent of float in either direction.
Bearings shall comply with the relevant Indian or International Standards. The bearing housing shall be
correctly packed with lithium based grease at the time of assembly. Construction shall be such that the
bearings can be dismantled without risk of damage.
For direct drives, bearings shall have an expected life of at least 40,000 running hours. For motors with
significant external radial or axial loads, e.g. belt drives, bearing shall have a life of at least 15000
running hours. The bearing assembly shall be provided with a grease relief device to eject any surplus
grease in to a separate container.
Lubrication shall be possible without removal of the guarding. All grease nipples, oil cups and dip
sticks shall be readily accessible.
24.13
Heat exchangers
An adequate margin shall be included in the design of heat exchangers to allow for fouling of cooling
tubes or ducts under service conditions. Provision shall be made for the easy cleaning of the cooling
tubes or ducts, preferably on load.
The cooling tubes or ducts shall be adequately braced and supported to prevent vibration and premature
fatigue or fracture.
24.14
Noise level
Noise levels shall comply with BS 4999, Part-51.

24.15
Vibration level
The double amplitude of vibrations as measured at motor bearings shall be within the limits specified in
IS 4729, and the limits specified for the driven equipment.
24.16
Earthing terminals
Two independent earthing points shall be provided in accordance with IS 3043(1966), on opposite sides
of the motor for bolted connection of Employer's earthing conductor.
24.17
Terminal boxes and associated fittings
Terminal boxes for motors rated above 110 kW shall be capable of withstanding a system fault level of
31 MVA for 0.12 seconds.
Unless otherwise approved, the terminal box shall be capable of being turned through 360 degrees in
steps of 90 degrees.
415 volt terminals shall be suitable for receiving 1.1 kV grade PVC or XLPE, unarmoured or armoured
power cables.
Only three line terminals need be brought out from each three phase primary winding. All inter phase
connections whether star or delta shall be made inside the machine.
Marking of all terminals shall be in accordance with IS 4728.
Leads from terminals to the windings shall be adequately sized and braced to withstand heating and
forces produced by maximum fault current.
Cable boxes and terminations shall be designed to enable easy disconnection and replacement of cables.
All joints other than those on cable glands shall be gasketted with neoprene, neoprene bonded cork or
other approved material.
For single core cables, gland plates shall be effectively non-magnetic.
The following shall be supplied along with each motor :
1. Crimping type tinned copper lugs for power cables, with all necessary hardware.
2. Compression type tinned brass cable glands for power cables (to be supplied loose).
3. Removable type undrilled gland plate.
4. Terminal boxes shall of weather proof construction with a degree of protection of IP-55. At least
one motor of each batch shall be type tested to comply with the following : the terminal boxes
shall be subject to an internal air pressure of 0.207 bar g for 12 hours. After this period the
pressure shall not be less than 0.104 bar g (after correcting for any change in temperature).
24.18
Rating plate
In addition to the requirements as called for in General Technical Clauses and relevant IS, the rating
plate shall indicate the following:
Maximum continuous rating in kW for 70C temperature rise.
Bearing identification numbers (in case of ball or roller bearings) and recommended lubricant.
24.19
Paint and finish
All external parts shall be finished and painted to produce a neat and durable surface which would
prevent rusting and corrosion. The equipment shall be thoroughly degreased, and sharp edges and
scales removed and treated with one coat of primer and two coats of grey enamel paint. Motor colour
codes shall comply with the requirements indicated elsewhere in this Specification.
All fasteners used in the construction of the equipment shall be either of corrosion resistant material or
electro galvanised to service condition 4. Current carrying fasteners shall be either of stainless steel or
high tensile brass or copper.
24.20
Tests
Induction motors shall be subjected to the following routine and type tests.
24.20.1 Routine Tests
Visual Checks of the following:
Marking on rating plates
Appearance and painting
Location and details of terminal boxes and accessories.
In order to observe compliance to degree of protection, following test will be performed. It shall
not be possible to insert a feeler gauge of 1 mm thick in the enclosure or flange faces.
Dimensional checks
Measurement of Insulation Resistance (IR) of windings, and space heaters.
Measurement of winding resistance, and space heater resistance at ambient temperature.
High voltage test on main windings, and space heaters.
IR measurement after HV test in main windings, and space heaters.
No load running test (reading of current, voltage input and speed measurement).
Measurement of bearing temperature during steady state conditions.
Vibration measurement at rated speed and rated voltage, also measurement of vibration during coasting
down.
Reduced voltage running test at no load
Locked rotor test.
Phase sequence polarity check and check for terminal markings.
Overspeed test
Measurement of air gap
Functional check on auxiliaries
24.20.2 Type Tests
All tests as listed under routine tests
Measurement of noise at no load

Locked rotor test - measurement of VA power input
Momentary overload test
Temperature rise test at rated conditions as well as at maximum input conditions (during heat run test,
measurement of bearing temperature, winding temperature, core temperature, coolant flow and coolant
temperature). In case the temperature rise test is carried at other load than rated load, specified
approval for the test method and procedure shall be obtained from the Project Manager.
Degree of protection test for the enclosure followed by IR, HV and no load run test.
Terminal box - fault level withstand test and pressure test.
Pull out torque measurement
Measurement of no-load starting time.
24.20.3 DC motors
DC motors shall be subjected to all routine and type tests as per IS 4722. In addition, following tests
shall be carried out:
Noise level measurement as type test.
Vibration measurement as routine test
Degree of protection test as per IS 4691 as type test.
24.21
Junction boxes and cables
Design and selection of all the components shall be made with a good margin of safety factor.
The equipment shall be installed indoor.
The reference ambient temperature outside the equipment shall be taken as 50C and relative humidity
as 100%.
25.
JUNCTION BOXES
25.1
Construction
Contractor shall supply and install junction boxes complete with terminals as required.
Junction boxes shall be suitable for mounting on walls, columns, structures etc. The brackets, bolts,
nuts, cable-glands, screws and all other accessories required for the erection shall be included in the
Bidders scope.
Junction boxes shall be of square or rectangular type of 2.0 mm CRCA sheet steel and shall have bolted
cover with good quality gasket lining.
Junction box and covers shall be hot dip galvanised.
All the terminals blocks of ESSEN make or equivalent shall be rated for 1100V and shall be of stud
type. Each terminal shall be suitable for connecting two 2.5 mm2 copper conductor.
All terminals shall be complete with insulated barriers, terminals studs, washers, nuts, locknuts,
identification strips etc.
Junction boxes located inside shall have IP-54 protection as per IS 2147. Junction boxes located outside
shall have IP-55 protection as per IS 2147.
Junction boxes shall be provided with one earthing terminal suitable for galvanised steel conductor.
The general arrangement, cross sectional details and other technical details are to be submitted in the
form of drawing for Project Managers approval.
25.2
Interconnecting cables
All cables between junction box and field devices shall be stranded copper conductor, PVC insulated,
extruded PVC inner sheathed, single galvanised steel wire armoured and overall PVC sheathed 1.1 kV
grade and shall conform to IS 1554. The minimum size of cable used shall be 2.5 mm2 copper
conductor. All cables shall be supplied by the Contractor.
26.
CONDUIT AND CONDUIT ACCESSORIES
The contractor shall supply and install all rigid steel conduit, flexible conduits, Hume pipes etc.
complete with accessories such as tees, bends, adaptors and couplings as required for cabling work
between various field devices to junction boxes.
All conduits shall be seamed by welding and shall be heavy gauge hot dip galvanised.
Each piece of conduit shall be straight, free from any defects and conform to IS 1653. The
manufacturers name shall be stamped on each piece.

FOR
420,245, 145, & 36 KV
CIRCUIT BREAKERS
E11-CIRCUIT BREAKER- Page 1 of 55
FOR
420,245 & 145 KV SF6 & 36 KV VCB

CIRCUIT BREAKER
I- 420 KV SF6 CIRCUIT BREAKER

II-245KV SF6 CIRCUIT BREAKER
III-145 KV SF6 CIRCUIT BREAKER
IV 36 KV VCB
TECHNICAL SPECIFICATION FOR

420/245/145 KV CIRCUIT BREAKERS
1.0
SCOPE :
1.1
This specification provides for the design, manufacture, inspection and testing before dispatch,
packing and delivery F.O.R. (destination) By Road transport only and supervision of erection,
testing and commissioning, of outdoor SF6 circuit breakers along with structures, all the
accessories and auxiliary equipment and mandatory spares, described herein, required for their
satisfactory operation in various substations of the state.
1.2
The circuit breaker shall conform in all respects to high standards of engineering, design,
workmanship and latest revisions of relevant standards at the time of offer and purchaser shall
have the power to reject any work or material, which, in his judgement, is not in full accordance
therewith.
2.0
2.1
STANDARDS
Except as modified in this specification, the circuit breakers shall conform to the latest revisions
with amendments thereof, of following standards.
SL.
NO.
1.
2.
3.
4.
STANDARD
TITLE
IEC-62271-100
IS12729:2004/IEC60694
High Voltage Alternating Current Circuit-Breaker

Common Specification for High Voltage Control gear &
Switchgear standard
IS-14658/IEC1633
H.V Alternating Current Ckt Breaker-Guide for Short

Ckt & Switching Test Procedures for metal enclosed &
dead tank Circuit Breaker
IS14674:1999/IEC1166:1993
H.V Alternating Current Ckt Breaker-Guide for Seismic

qualification of HV A.C Circuit Breaker
5.
IEC-56 / IS13118
6.
IS-325
Specification for three phase induction motors
7.
IS-375
Marking and arrangement for switchgear bus-bar, main

connections and auxiliary wirings.
9.
IS-802
(Part-1)
Code of practice for use of structural steel in overhead

trans. Line towers.
10.
IS-2099
High voltage porcelain bushings.
11.
IS-2147
Degree of protection provided for enclosures for low

voltage switchgear and control gear.
Specification for alternating current circuit breakers
12.
IS-2629
Recommended practice for hot dip galvanizing of iron

and steel.
13.
IS-4379
Identification of the contents of Industrial Gas

Cylinders.
14.
IS-7311
Seamless high carbon steel cylinders for permanent and

high pressure liquefied gases.
2.2
Equipment meeting with the requirements of any other authoritative standards, which ensures
equal or better quality than the standard mentioned above shall also be acceptable. If the
equipment offered by the Bidder conforms to other standards, salient points of difference
between the standards adopted and the specific standards shall be clearly brought out in relevant
schedule. Two copies of such standards with authentic English Translations shall be furnished
along with the offer.
2.3
The standards mentioned above are available from:

Reference/Abbreviation
IS
IEC
3.0
Name and address from which the standards are

available
Bureau of Indian Standards,
Nanak Bhawan,
9-Bahadur Shah Zafar Marg,
New Delhi-110 001
INDIA
International Electrotechnical Commission
Bureau Central De la Commission
Electro Technique International
1,Rue De Verembe
Geneva, Switzerland
AUXILIARY POWER SUPPLY

Auxiliary electrical equipment shall be suitable for operation on the following supply system.
(a)
Power Devices like drive

Motors of rating 1 KW
and above.
415 V, 3 phase 4 wire 50Hz, neutral

grounded AC supply.
(b)
Lighting, space heaters and

Fractional KW motors.
240 V, single phase, 50 Hz neutral

grounded AC supply.
(c)
Alarm, control and

Protective devices.
220 V DC, 2 wire
Each of the foregoing supplies shall be made available by the Purchaser at the terminal point for
each circuit breaker for operation of accessories and auxiliary equipment. Suppliers scope
include supply of interconnecting cables, terminal boxes etc. The above supply voltage may vary
as below and all devices shall be suitable for continuous operation over entire range of voltages.
4.0
i)
AC supply : voltage 10% frequency 5%
i)
DC supply : - 15% to + 10%
PRINCIPAL PARAMETERS
The breakers shall conform to the specific technical requirements specified hereunder:
Sl.
Item
Requirements
No.
145 KV
245KV/420KV
1.
Rated voltage (KV rms) 145
245/420 KV
frequency (Hz)
50HZ
50HZ
2.
3.
4.
5.
6.
7.
8.
9.
Continuous current rating (A) 3150

3150/3150
rms
Type
Outdoor SF6
Mounting
Hot dip galvanized lattice steel support
structure to be supplied by the Bidder
Number of Poles
3
Type of Operation
Gang Operated
Individually
Operated Single
poles.
Phase to phase spacing in the
2150
4500/7000
switchyard
i.e.
interpole
spacing for breaker (mm)
Required ground clearance
from the lowest live terminal
(mm):
i.
If both the terminals
4800/7000
are not in the same
horizontal plane
ii.
If both the terminals
4600
6500/7000
are in the same
horizontal plane
Height of concrete plinth (to
300
300
be provided by the Owner)
mm.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Minimum height of the lowest

part of the support insulator
from ground level (mm)
Operating Mechanism
Autoreclosing duty
Rated operating duty cycle
First pole to clear factor
Type of tripping
Max. closing time(ms)
Max. BREAK TIME (ms)
1.2/50 microsecond impulse
withstand voltage: (dry)
i.
To earth(kvp)
ii.
Across the open contacts
with impulse on one
terminal and power
frequency voltage on
opposite terminal
(kvp/kv rms)
1 minute power frequency
withstand voltage (kv rms)
(wet)
Max.
radio
interference
voltage (micro volts) at 1.1
times maximum phase voltage
Min. corona extinction voltage
(kv rms)
Rated
breaking
current
capacity:
i.
Line charging at rated
voltage at 90 deg.
Leading power factor
(A) rms
ii. Small inductive current
(A) rms
iii. Short circuit current
a) AC component (kA)
b) % DC component
Rated short circuit making
current capacity (kA)
Permissible
limit
of
temperature rise
Max. acceptable difference in
the instant of closing/opening
of contacts
i) Within a pole (ms)
2550
2550/3500
spring charged(Spring-Spring)
FOR 420 KV HYDRAULISPRING/SPRING-SPRING/
Single Phase
0-0. 3 sec-co-3 min-co
1.3(As per IEC-62271-100)
Trip free
60
30 4
50/40
650
750
1050/1550
1200/1665
275
460/610
500
500/1000
105
176/320
50
125/600
------------0.5 to 10------------without switching o/v exceeding 2.3 p.u.

40
25%
79
40/63
40%/as per
IEC62271-100
100
As per Clause 5.29
5/2.5
ii) Between poles (ms)

26.
27.
28.
29.
30.
31.
10
10/3.3 for opening

&5 for closing
6,125/10500
Min. creepage distance of

3,625
support insulator(mm)
Short time current carrying
31.5
40
capability for one second (kA)
Rating of auxiliary contacts
----10A at 220 V D.C.---Breaking capacity of auxiliary 2 A DC with the circuit time constant not
contact
less than 20 ms
Noise level at base and upto
-----140 dB (max.)---------50 metres
Seismic acceleration
--------0.3 g --------------
5.0
Note:-Purchaser may accept the phase to phase, or phase to earth spacing of the breakers
&structure heights basing on the firms type test reports or he may ask the firm to manufacture
the breakers as per the dimensions indicated in this specification. .
GENERAL TECHNICAL REQUIREMENTS
5.1
Circuit breaker offered shall be sulphur hexaflouride (SF6) type only.
5.2
Any part of the breaker, especially the removable ones, shall be freely interchangeable without
the necessity of any modification at site.
5.3
Circuit breaker shall comprise of three identical single pole units. If the circuit breaker not meant
for single pole reclosure, these units shall be linked together electrically . Complete circuit
breaker with all the necessary items for successful operation shall be supplied, including but not
limited to the following:
5.3.1 Breaker assemblies with bases, support structure for circuit breaker as well as for control cabinet,
Ladder, central control cabinet and foundation bolts for main structure as well as control cabinet
and central control cabinet (except concrete foundations), terminals and operating mechanisms.
5.3.2 Compressed SF6 gas, spring operated systems complete including piping, fittings, valves and
controls and etc.
5.3.3 One central control cabinet for each breaker and one control box for each pole with all the
required electrical devices mounted therein and the necessary terminal blocks for termination of
interpole wiring. The necessary interpole cabling at site shall be done by the Purchaser based on
the schematic, wiring diagram and termination schedule to be supplied by the Supplier.
5.3.4
Instruments, pressure gauges and other devices like gas density monitor, temp. monitor & etc. for
SF6 gas pressure supervision.
5.3.5
All necessary parts to provide a complete and operable circuit breaker installation such as main
equipment, terminal, control parts, connectors and other devices, whether specifically called for
herein or not.
5.4
The circuit breaker shall be designed for high speed single and three pole reclosing with and
operating sequence and timing as specified in clause 4.0 Principal Parameters.
5.5
The support structure of circuit breaker as well as that of control cabinet shall be hot dip
galvanized. The minimum weight of zinc coating shall be 610 gm/sq.m and minimum thickness
of coating shall be 86 microns for all items thicker than 5 mm.
5.6
Circuit breaker shall be suitable for hot line washing.
5.7
All breakers shall be supplied with terminal connectors. The exact requirement of terminal
connectors would be intimated to the supplier during the course of detailed engineering(during
drawing approval).
5.8
Terminal pads shall have silver plating of atleast 50 microns thickness.
5.9
CONTACTS
5.9.1
All making and breaking contacts shall be sealed free from atmospheric effects. Contacts shall be
designed to have adequate thermal and current carrying capacity for the duty specified and to
have a life expectancy so that frequent replacements due to excessive burning will not be
necessary. Provision shall be made for rapid dissipation of heat generated by the arc on opening.
5.9.2
Main contacts shall be first to open and the last to close so that there will be little contact burning
and wear. If arcing contacts are used they shall be first to close and the last to open. Tips of
arcing contacts and main contacts shall be silver plated or made of superior material like
graphite.
5.9.3
Any device provided for voltage grading 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 comparable to that of the breaker as a whole.
5.9.4
Breakers shall be so designed that when operated within their specified rating, the temperature of
each part will be limited to values consistent with a long life or the material used. The
temperature shall not exceed that indicated in IEC-56 under specified ambient conditions.
5.9.5
Contacts shall be kept permanently under pressure of SF6 gas. The gap between the open
contacts shall be such that it can withstand atleast the rated phase to ground voltage continuously
at zero gauge pressure of SF6 gas due to its leakage.
5.9.6
If multibreak interrupters are used these shall be so designed and augmented that a uniform
voltage distribution is developed across them. Calculations/test reports in support of the same
shall be furnished along with the bid. The thermal and voltage withstands of the grading elements
shall be adequate for the service conditions and duty specified.
5.10
PORCELAIN HOUSING
5.10.1 The porcelain housing shall be of single piece construction without any joint or coupling. It shall
be made of homogeneous, vitreous porcelain of high mechanical and dielectric strength. Glazing
of porcelain shall be uniform brown or dark brown colour with a smooth surface arranged to shed
away rain water or condensed water particles (fog). The type and profile of the porcelain
insulator sheds shall be in accordance with IEC-815 joints as per IEC-233.
5.11
ADDITIONAL REQUIREMENTS :
a)
The circuit breakers shall be single pressure type, the design and construction of the
circuit breaker shall be such that there is minimum possibility of gas leakage and entry of
moisture. There should not be any condensation of SF6 gas on the internal insulating surface of
the circuit breaker.
b)
All gasketed surfaces shall be smooth, straight and reinforced, if necessary to minimize
distortion and to make a tight seal, the operating rod connecting the operating mechanism to the
arc chamber (SF6 media) shall have adequate seals, Double 0ring seals and test holes for
leakage test of the internal seal shall be provided on each static joint.
c)
In the interrupter assembly there shall be an absorbing product box to eliminate SF6
decomposition products and moisture. The material used in the construction of the circuit
breakers shall be fully compatible with SF6 gas.
d)
Each pole shall form an enclosure filled with SF6 gas independent of two other poles. The
SF6 density of each pole shall be monitored and regulated by individual pressure switches.
e)
The SF6 gas density monitor shall be adequately temp. compensated. The density monitor
shall meet the following requirements:
i)
It shall be possible to dismantle the density monitor for checking/replacement without
draining the SF6 gas by using suitable interlocked non-return couplings.
ii)
It shall damp the pressure pulsation while filling the gas in service so that the flickering of
the pressure switch contacts does not take place.
iii)
A pressure indicator (pressure gauge) shall also be supplied.
f)
Means for pressure relief shall be provided in the gas chamber of circuit breaker to
avoid the damages or distortion during occurrence of abnormal pressure increase or shock waves
generated by internal electric fault occurs. The position of vents, diaphragms and pressure relief
devices shall be so arranged as the minimize danger to the operators in the event of gas or vapour
escaping under pressure.
g)
Facility shall also be provided to reduce the gas pressure within the breaker to a value
not exceeding 8 millibars within 4 hours or less. Each circuit breaker shall be capable of
withstanding this degree of vacuum without distortion or failure of any part.
h)
Sufficient SF6 gas shall be provided to fill all the circuit breakers installed. In addition to
this 20% of the total gas requirement shall be supplied in separate cylinders as spare
requirement.
i)
Provisions shall be made for attaching an operation analyzer after installation at site to
record contact travel, speed and making measurement of operation timings, preinsertion timing of
closing resistor, synchronization of contacts in one pole.
5.12
SULPHUR HEXAFLUORIDE GAS (SF6 GAS) :

a) The SF6 gas shall comply with IEC-376, 376A and 376B and be suitable in all respects for
use in the switchgear under the worst operating conditions.
b) The high pressure cylinders in which the SF6 gas is shipped and stored at site shall comply
with requirements of the following standards and regulations:
IS:4379 Identification of the contents of industrial gas cylinders.
IS: 7311 Seamless high carbon steel cylinders for permanent and high pressure liquifiable
gases.
The cylinders shall also meet Indian Boiler regulations.
c) Test: SF6 gas shall be tested for purity, dew point, break down voltage, water contents as per
IEC-376, 376A and 376B and test certificates shall be furnished to owner indicating all the
tests as per IEC-376 for each lot of SF6 gas.
5.13
PREINSERTION RESISTOR (PIR)

DELETED
5.14
DUTY REQUIREMENTS
5.14.1 The circuit breaker shall be totally restrike free under all duty conditions. Opening resistors shall
not be used.
5.14.2 The circuit breaker shall meet the duty requirements for any type of fault or fault location, for
line charging and dropping when used on an effectively grounded system and perform make and
break operations as per stipulated duty cycles satisfactorily. It shall withstand the maximum
expected dynamic loads (including the seismic) to which the circuit breaker may be subjected
during its 45 years service life.
5.14.3 The circuit breaker shall be capable of:
i)
ii)
iii)
iv)
v)
Interrupting the steady and transient magnetizing current corresponding to 420 kv/245
KV and 145 KV class transformers of 100 MVA, 160 MVA ratings respectively.
Interrupting line charging current as given in clause 4.0, Principal Parameters of this
specification with a temporary overvoltage as high as 1.5 p.u. without restrikes.
Clearing short line faults (Kilometric faults) with source impedance behind the bus
equivalent to symmetrical fault current specified.
Breaking inductive currents of 0.5 to 10A without switching overvoltage exceeding 2.3
p.u.
Breaking 25% of the rated fault current at twice rated voltage under phase opposition
condition.
5.14.4 The critical current, which gives the longest arc duration at lockout pressure of extinguishing
medium and the arc duration shall be indicated.
5.14.5 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 ALSO
WITHSTAND THE VOLTAGE SPECIFIED IN CLAUSE 4.0 principal Parameters of this
specification.
5.15
TOTAL BREAK TIME
5.15.1 The Total Break Time as specified in clause 4.0, Principal Parameters of this section shall
not be exceeded under any of the following duties:
i)
ii)
Test duties 1,2,3,4,5 (with TRV as per IEC-62271-100)/as per related IS.
Short line fault L90, L75 (with TRV as per IEC-62271-100) /as per related IS.
5.15.2 The Bidder may please note that there is only one specified break time of the breaker which shall
not be exceeded under any duty conditions specified such as with the combined variation of the
trip coil voltage, (70-110%) spring-spring operation and arc extinguishing medium pressure etc.
while furnishing the proof for the total break time of complete circuit breaker, the Bidder may
specifically bring out the effect of non-simultaneity between contacts within a pole or between
poles and show how it is covered in the guaranteed total break time.
5.15.3 The values guaranteed shall be supported with the type test reports.
5.16
OPERATING MECHANISM AND ASSOCIATED EQUIPMENTS
5.16.1 The circuit breaker shall be designed for electrical local as well as remote control. In addition
there shall be provision for local mechanical control (emergency trip).
5.16.2 SPRING OPERATED MECHANISM:
The operating mechanism for 245 KV / 145 KV class breakers shall be of spring spring type
only operated by electrical control. The mechanism shall be adequately designed for the specified
tripping and reclosing duty. The entire operating mechanism control circuitry & etc as required, shall be
housed in an outdoor type, hot dip galvanized steel enclosure. This enclosure shall conform to the degree
of protection IP-55 of IS- 2147. The enclosure shall be invariably mounted on a separate concrete plinth.
5.16.3 All working parts in the mechanism shall be of corrosion resistant material. All bearings which
require greasing, shall be equipped with pressure grease fittings.
5.16.4 The design of the operating mechanism shall be such that it shall be practically maintenance free.
The guaranteed years of maintenance free operation, the number of full load and full rated short
circuit current breaking/operation without requiring any maintenance or overhauling, shall be
clearly stated in the bid. As far as possible the need for lubricating the operating mechanism shall
be kept to the minimum and eliminated altogether if possible.
5.16.5 The operating mechanism shall be non-pumping (and trip free) electrically and mechanically
under every method of closing. There shall be no rebounds in the mechanism and it shall not
require any critical adjustments at site. Operation of the power operated closing device, when the
circuit breaker is already closed, shall not cause damage to the circuit breaker or endanger the
operator, provision shall be made for attaching an operation analyzer to facilitate testing of
breaker at site.
5.16.6 A mechanical indicator shall be provided to show open and close position of the breaker. It shall
be located in a position where it will be visible to a man standing on the ground level with the
mechanism housing closed. An operation counter shall also be provided in the central control
cabinet.
5.16.7 The supplier shall furnish detailed operation and maintenance manual of the mechanism along
with the operation manual for the circuit breaker.
5.17
CONTROL
5.17.1 The close and trip circuits shall be designed to permit use of momentary contact switches and
push buttons.
5.17.2 Each breaker pole shall be provided with two (2) independent tripping circuits, valves and coils
each connected to a different set of protective relays.
5.17.3 The breaker shall normally be operated by remote electrical control. Electrical tripping shall be
performed by shunt trip coils. However, provisions shall be made for local electrical control. For
this purpose a local/remote selector switch and close and trip push buttons shall be provided in
the breaker central control cabinet. Remote located push buttons and indicating lamps shall be
provided by purchaser.
5.17.4 The trip coils shall be suitable for trip circuit supervision. The trip circuit supervision relay would
be provided by the purchaser. Necessary terminals shall be provided in the central control cabinet
of the circuit breaker by the supplier.
5.17.5 Closing coil shall operate correctly at all values of voltage between 85% and 110% of the rated
voltage. Shunt trip shall operate correctly under all operating conditions of the circuit breaker
upto the rated breaking capacity of the circuit breaker and at all values of supply voltage
between 70% and 110% of rated voltage. However, even at 50% of rated voltage, the breaker
shall be able to perform all its duties. If additional elements are introduced in the trip coil circuit
their successful operation and reliability for similar applications on outdoor circuit breakers shall
be clearly brought out in the additional information schedules. In the absence of adequate details
the offer is likely to be rejected.
5.17.6 Suitable relay for monitoring of DC supply voltage to the control cabinet shall be provided. The
pressure switches used for interlock purposes shall have adequate contact ratings to be directly
used in the closing and tripping circuits. In case the contacts are not adequately rated and
multiplying relays are used then the interlock for closing/opening operation of breaker shall be
with No logic of the relay i.e. if the DC supply to the interlock circuit fails then operation lockout
shall take place.
5.17.7 For all types of operating mechanism a local manual closing device which can be easily operated
by one man standing on the ground shall also be provided for maintenance purposes and direction
of motion of handle shall be clearly marked.
5.17.8 The auxiliary switch of the breaker shall be preferably positively driven by the breaker operating
rod and where due to construction features, same is not possible a plug in device shall be
provided to simulate the opening and closing operations of circuit breaker for the purpose of
testing control circuits.
5.18
MOTOR COMPRESSED SPRING CHARGING MECHANISM

Spring operated mechanism shall be complete with motor, opening spring, closing spring and
all other necessary accessories to make the mechanism a complete unit. Breaker operation shall
be independent of motor which shall be used solely for the purpose of charging the closing
spring. Motor rating shall be such that it requires only 15 seconds for fully charging the closing
spring. Closing operation shall compress the opening spring and keep ready for tripping. The
mechanism shall be provided with means for charging the spring by hand. This operation shall be
carried out with the doors of the cubicle open. During the process no electrical or mechanical
operation of the mechanism shall endanger the operator or damage the equipment. A mechanical
indicating device shall be provided to indicate the state of the charge spring and shall be visible
with the door of the cubicle closed. An alarm shall be provided for spring failing to be charged
within a pre-set time after circuit breaker closing. The spring mechanism shall be fitted with a
local manual release, preferably by a push button to avoid inadvertent operation. Means shall be
provided for discharging the spring when the circuit breaker is in the open position without
circuit breaker attempting to close.
Opening spring and closing spring with limit switches for automativ charging and other
necessary accessories to make the mechanism a complete operating unit shall also be provided.
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 suplly to the motor one close open operation shall be possible with
the energy contained in the operating mechanism.
Breaker operations 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 the breaker shall compress the opening spring ready for tripping.
When closing spring are discharged after closing a breaker, closing spring shall
automatically charged for the next operation and an indication of this shall be provided in the
local and remote control cabinet.
The spring operating mechanism shall have adequate energy stored in the operating
spring to close and latch the circuit breker against the rated making current also to provide the
required energy for the tripping mechanism in case the tripping energy is derived from the
operating mechanism.
Provision shall be made to prevent a closing operation of the breaker when the spring is in
the partial charged condition. Mechanical interlocking shall be provided in the operating
mechanism to prevent discharging of closing spring when the breker is alredy in the closed
position.
5.18.1 HYDRAULIC OPERATED MECHANISM.
The operating mechanism for 420 KV circuit breakers shall be Hydraulic/spring operated
mechanism.
The Hydraulic operated mechanism shall comprise of operating unit with power
cylinder,control valves,high and low pressure reservoir.
The hydraulic oil used shall be fully compatible for the specified temperature range.
The oil pressure switch controlling the oil pump and pressure in the high pressure
reservoir shall have adequate number of spare contacts to be used for continuous monitoring of
low and high pressure etc.
The mechanism shall be suitable atleast two close open operation after failure of AC
supply to the motor starting at pressure equal to the lowest pressure of auto recluse duty plus
pressure drop for one close open operation.
The mechanism shall be capable of operating the circuit breaker correctly and performing
the duty cycle specified under all conditions with the pressure of hydraulic operated fluid in the
operating mechanism at the lowest permissible pressure before make up. The opening time at the
lowest pressure for a particular operation shall not exceed the guaranteed operating time within
any value of trip coil supply voltage as specified.
Trip lockout shall be provided to prevent operation of the circuit breaker below the
minimum specified hydraulic pressure. Alarm contacts for loss of Nitrgen shall be provided.
All hydraulic joints shall have no oil leakage under the site conditions and joints shall be
tested at factory against oil leakage at a minimum of 1.5 times maximum working pressure.
5.19
OPERATING MECHANISM HOUSING
The operating mechanism housing/control cabinet shall conform to the requirement specified in
clause 5.29. The entire operating mechanism control circuitry & etc as required, shall be housed
in an outdoor type, made out of aluminium plates of 3mm thickness or, hot dip galvanized steel
enclosure. This enclosure shall conform to the degree of protection IP-55 of IS- 2147. The
enclosure shall be invariably mounted on a separate concrete plinth.
5.20
INTERLOCKS
It is proposed to electrically interlock the circuit breaker with purchasers associated air break
isolating switches in accordance with switchyard safety interlocking scheme. The details of the
scheme will be furnished to the supplier. All accessories required on breaker side for satisfactory
operation of the scheme shall be deemed to be included in the scope of supply of this
specification.
5.21
SUPPORT STRUCTURE
The supplier shall indicate the price of support structure along with the foundation bolts required
separately in the bid proposal sheets and these shall be considered in evaluation. Purchaser
reserves the right to procure these from the supplier or through separate contract. However, in
case the equipment offered have integral support structure or the specialities of the breaker are
such that support structures have to be provided by the supplier, the prices of these support
structure shall be included in the price of the equipment and same shall be indicated clearly in the
bid proposal sheet. The support structure shall meet the following requirements:
5.22
1)
The minimum vertical clearance from any energized metal part to the bottom of the circuit
breaker (structure) base, where it rests on the foundation pad, shall be 5.5 mtrs for 245KV
& 4.6 mtrs. for 145 KV.
2)
The minimum vertical distance from the bottom of the lowest porcelain part of the
bushings, porcelain enclosures or supporting insulators to the bottom of the circuit breaker
base, where it rests on the foundation pad shall be 2.55 mtrs. for all voltages.
3)
The minimum clearance between the live parts and earth shall be 2.4 mtrs for 245 KV and
1.5 meters for 145 KV.
FITTINGS AND ACCESSORIES
5.22.1 Following is a partial list of some of the major fittings and accessories to be furnished by supplier
in the central control cabinet. Number and exact locations of these parts shall be indicated in the
bid.
a)
Central control cabinet in accordance with clause no. 5.29 complete with
i)
ii)
iii)
iv)
Cable glands.
Local/remote changeover switch.
Operation counter.
SF6 pressure gauges.
v)
vi)
vii)
5.23
Control switches to cut off control power supply.

Fuses as required.
The number of terminals provided shall be adequate enough to wire out all
contacts and control circuits plus 24 terminals spare for owners use.
b)
Anti-pumping relay.
c)
Rating and diagram plate in accordance with IEC / IS incorporating year of manufacture.
PAINTING, GALVANISING AND CLIMATE PROOFING
5.23.1 All interiors and exteriors of tanks and other metal parts shall be thoroughly cleaned to remove
all rust, scales, corrosion, greases or other adhering foreign matter and the surfaces treated by
phosphating (e.g. seven tank phosphating sequence). All steel surfaces in contact with insulating
oil, as far as accessible, shall be painted with not less than two coats of heat resistant, oil
insoluble, insulating paint.
5.23.2 All metal surfaces exposed to atmosphere shall be given, in addition to the treatment described in
clause 5.23 two primer coats of zinc chromate and two coats of epoxy paint with epoxy base
thinner. All metal parts not accessible for painting shall be made of corrosion resisting material.
All machine finished or bright surfaces shall be coated with a suitable preventive compound and
suitably wrapped or otherwise protected. All paints shall be carefully selected to withstand
tropical heat and extremes of weather within the limits specified. The paint shall not scale off or
wrinkle or be removed by abrasion due to normal handling. All external paintings shall be as per
shade no. 697 of IS:5.
5.23.3 Paint inside the metallic housing shall be of anti-condensation type and the paint on outside
surfaces shall be suitable for outdoor installation.
5.23.4 All components shall be given adequate treatment of climate proofing as per IS:3202 so as to
withstand corrosive and serve service conditions.
5.24
GALVANISING
All ferrous parts including all sizes of nuts, bolts, support channels, structures, etc. as also the
mechanism housing shall be hot dip galvanized conforming to latest version of IS:2629. Spring
washers shall be electrogalvanised.
5.25
EARTHING
The operating mechanism housing, control cabinets, dead tanks, support structure etc. shall be
provided with two separate earthing terminals suitable for bolted connection to 50X8 mm mild
steel flat to be provided by the Purchaser for connection to station earth mat.
5.26
NAME AND RATING PLATES:

Circuit breaker and its operating device shall be provided with a rating plate or plates marked
with but not limited to following data:
a)
b)
c)
d)
e)
Manufacturers name or trade mark.

Serial Number or type designation making it possible to get all the relevant information
from the manufacturer.
Year of manufacture.
Rated voltage.
Rated insulation level.
f)
Rated frequency.
g) Rated normal current.
h) Rated short circuit breaking current.
i)
First pole to clear factor.
j)
Rated duration of short circuit.
k) Rated auxiliary D.C. supply voltage of closing and opening devices.
l)
Rated pressure of compressed air gas for operation and interruption.
m) Rated out of phase breaking current.
n) Rated supply voltage of auxiliary circuits.
o) Rated supply frequency of auxiliary circuits.
p) Number of closing & Tripping coils
q) Opening time & closing time
Other informations are as per IS 12729/IEC 60694 .
The coils of operating devices shall have a reference mark permitting the data to be obtained
from the manufacturer.
The rating plate shall be visible in position of normal service and installation. The rating plate
shall be weather proof and corrosion proof.
5.27
LIMITS OF TEMPERATURE RISE

The temperature rise on any part of equipment shall not exceed the maximum temperature rise
specified below under the conditions specified in test clauses. The permissible temperature rise
indicated is for a maximum ambient temperature of 50 deg. C. If the maximum ambient
temperature rises, permissible values shall be reduced accordingly.
Sl.
No.
Nature of the part or of the liquid
Maximum Value of
Temp.
1.
2.
3.
4.
5.
Contacts in air, silver-faced copper, copper 105

alloy or aluminium alloy [see notes (i) and
(ii)]
Bare copper or tinned aluminium alloy.
Contacts in oil:
Silver-faced copper, copper alloy
aluminium alloy (see note ii)
75
25
90
40
or
Bare copper or tinned aluminium alloy

80
Terminals to be connected to external 105
conductors by screws or bolts silver faced
(see note iii)
Metal parts acting as springs
See
Note
iv
Metal parts in contact with insulation of the
Temp. rise at a
max. ambient air
temp.
not
exceeding 50 deg.
C.
55
30
55
See note iv
following classes:
Class Y: (for non-impregnated materials)
6.
7.
40
Class A: (for materials immersed in oil or

100
impregnated)
50
Class E: in air
in oil
120
100
70
50
Class B: in air
in oil
130
100
80
50
Class F: in air
in oil
155
100
105
50
Enamel: Oil base

Synthetic, in air
Synthetic, in oil
100
120
100
50
70
50
Any part of metal or of insulating material 100

in contact with oil, except contacts
Oil
90
50
Notes:
5.28
90
40
(i)
When applying the temperature rise of 55 deg. C, care should be taken to ensure
that no damage is caused to the surrounding insulating materials.
(ii) The quality of the silver facing shall be such that a layer of silver remains at the
points of contact after the mechanical endurance test. Otherwise, the contacts shall
be regarded as bare.
(iii) The values of temperature and temperature rise are valid whether or not the
conductor connected to the terminals is silver-faced.
(iv) The temperature shall not reach a value whether the elasticity of the material is
impaired. For pure copper, this implies a temperature limit of 80 deg. C.
TERMINAL CONNECTORS
5.28.1 The terminal connectors shall meet the following requirements:

a)
Terminal connectors shall be manufactured and tested as per IS: 5561.
b)
All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp
edges and corners shall be blurred and rounded off.
c)
No part of a clamp shall be less than 10 mm thick.
d)
All ferrous parts shall be hot dip galvanized conforming to IS: 2633.
e)
For bimetallic connectors, copper alloy liner of minimum thickness of 2 mm shall be cast
integral with aluminium body.
5.29
f)
Flexible connectors shall be made from tinned copper.
g)
All current carrying parts shall be designed and manufactured to have minimum contact
resistance.
h)
Connectors shall be designed to be corona free in accordance with the requirements

stipulated in IS: 5561.
SPECIFICATION FOR CONTROL CABINETS:

1.
Control cabinets shall be of the free standing floor mounting type.
2.
Control cabinet of the operating mechanism shall be made out of 3 mm thick aluminium
alloy plate or casting. Hinged door shall be provided with padlocking arrangement.
Sloping rain hood shall be provided to cover all sides. 15 mm thick neoprene or better
type of gaskets shall be provided to ensure degree of protection of at least IP55 as per IS:
2147.
3.
Bus bars shall be of tinned copper of adequate cross-section to carry the normal current,
without exceeding the permissible temperature rise over an ambient temperature of 50
deg. C outside the cubicle. The buses shall be braced to withstand forces corresponding to
short circuit current of 25 KA.
4.
Motors rated 1 kw and above being controlled from the control cabinet would be suitable
for operation on a 415 V, 3 phase 50 Hz system. Fractional KW motors would be suitable
for operation on a 240 V, 1-phase, 50 Hz supply system.
5.
Isolating switches (MCBs) shall be group operated units ( 3 pole for use on 3-phase
supply systems and 2 pole for single phase supply systems) quick make quick break type,
capable of breaking safely and without deterioration, the rated current of the associated
circuit. Switch handle shall have provision for locking in both fully open and fully closed
positions.
6.
Push buttons shall be rated for not less than 6 Amps, 415 V A.C. or 2 Amps, 220 V D.C.
and shall be flush mounted on the cabinet door and provided with appropriate name
plates. Red, Green and Amber indicating lamps shall be flush mounted.
7.
For motors upto 5 KW, contactors shall be direct-on-line, air break, single throw type and
shall be suitable for making and breaking the stalled current of the associated motor
which shall be assumed equal to 6.5 times the full load current of the motor at 0.2 p.f. For
motors above 5 KW, automatic star delta type starters shall be provided. 3 pole contactors
shall be furnished for 3 phase motors and 2-pole contactors for single phase motors.
Reversing contactors shall be provided with electrical interlocks between forward and
reverse contactors. If possible, mechanical interlocks shall also be provided. Contactors
shall be suitable for uninterrupted duty and shall be of duty category class AC4 as defined
in IS: 2959. The main contacts of the contactors shall be silver plated and the insulation
class for the coils shall be class E or better. The dropout voltage of the contactors shall
not exceed 70% of the rated voltage.
8.
Contactors shall be provided with a three element, positive acting, ambient temperature
compensated, time lagged, hand reset type thermal overload relay with adjustable setting,
hand reset button shall be flush with the front door of the cabinet and suitable for resetting
with starter compartment door closed.
9.
Single phasing preventer relay shall be provided for 3 phase motors to provide positive
protection against single phasing.
10.
Mini starters shall be provided with no volt coils whenever required.
11.
Purchasers power cables will be of 1100 volts grade stranded aluminium conductor. PVC
insulated, PVC sheathed single steel wire armoured and PVC jacketed. All necessary
cable terminating accessories such as glands, crimp type tinned copper lugs etc. for power
as well as control cables shall be included in suppliers scope of supply. Suitable brass
cable glands shall be provided for cable entry.
12.
Wiring for all control circuits shall be carried out with 1100 volts grade PVC insulated
tinned copper stranded conductors of sizes not smaller than 2.5 sq. mm. Atleast 10%
spare terminal blocks for control wire terminations shall be provided on each panel. The
terminal blocks shall be of non-disconnecting stud type. All terminals shall be provided
with ferrules indelibly marked or numbered and these identifications shall correspond to
the designations on the relevant wiring diagrams. The terminals shall be rated for
adequate capacity which shall not be less than 10 Amps.
13.
Separate terminal blocks shall be provided for terminating circuits of various voltage
classes. CT loads shall be terminated on a separate block and shall have provision for
short circuiting the CT secondary terminals.
14.
Control cabinet shall be provided with 240 V, 1-phase 50 Hz, 20 W CFL TUBE light
fixture and a suitably rated 240 V, 1-phase, 5 amps, 3 pin socket for hand lamps.
15.
Strip heaters shall be provided inside each cabinet complete with thermostat (preferably
differential type) to prevent moisture condensation. Heaters shall be controlled by
suitably rated double pole miniature Circuit Breakers.
Signal lamps provided shall be of neon screw type with series resistors, enclosed in
backelite body. Each signal lamp shall be provided with a fuse integrally mounted in the
lamp body.
16.
5.30
17.
Electric measuring instruments shall be of moving iron type. Ammeters for measuring
current upto 30 Amps shall be directly connected while those for measuring above 30
Amps shall be connected through suitable CBs. Ammeters shall be provided with selector
switches.
18.
Items inside the cabinet made of material shall be coated with a fongus resistant varnish.
MOTORS :
Motors shall be squirrel cage three phase induction motors as per IS:325 of sufficient size
capable of satisfactory operation for the application and duty as required for the driven
equipment.
6.1.1
TESTS
Type Tests
All the equipments offered shall be fully type tested as per the relevant standards(IEC-62271100,IEC-60694/IS-12729 with latest amendments ) & tests as indicated below. The bids
offering equipments not type tested will be rejected. In case, the equipment of the type &
design offered has already been type tested, the bidder shall furnish four sets of the type test
reports along with the offer. The test must have been conducted not latter than five years
from the date of opening of the bids. The purchaser reserves the right to demand repetition of
some or all the type & additional type tests in the presence of his representative. For this purpose,
the bidder may quote unit rates for carrying out such type tests. For any change in the design/type
already type tested the design/type offered against this specification, the purchaser reserves the
right to demand repetition of tests without any extra cost or reject the bid without any
intimation.
Type Tests:--( As per IEC-62271-100 with lattest amendments)
1) Dielectric Test(LI Voltage,PF Voltage Withstand(Dry&Wet)& etc)
2) RIV Test
3) Measurement of resistance of the main circuit
4) Temperature rise Test
5)Short Time withstand current & Peak withstand current Test
6) Tightness Test
7) Mechanical Operation Test, Mechanical endurance test
8)Short Circuit making & Breaking Test
9) Capacitive Current, Switching Test , Line charging current breaking Test
10)Test to verify degree of protection
11)EMC Test
Routine Tests:1)Dielectric Tests on the main Circuit ,auxiliary & control circuits
2)Measurement of resistance of the main circuit.
3) Tightness Test
4) Design & Visual Checks
5) Mechanical operation Test
6) Operating time of the device, motor Characteristics, measurement of coil current & resistance ,
Sf6 gas pressure monitoring , control Circuit , antipumping,
dimensions,nameplate details , contact travel & timing checks .
The following additional type tests are proposed to be conducted. The type test charges for these
tests shall be quoted along with other type tests(AS indicated above) as per IEC/ IS in the
relevant schedule & the same shall be indicated in the total bid price.
1)
2)
3)
Corona extinction voltage Test(As per Annexure-I)

Out of phase closing testas per IEC
Line charging breaking current test
4)
Seismic Withstand test in unpressurised condition(as per Annexure-I)
6.1.2
The prices quoted by the bidder towards conductance of type tests & additional type tests shall be
taken in to consideration for bid evaluation.
6.2
TYPE, ACCEPTANCE AND ROUTINE TESTS
6.2.1 All acceptance and routine tests as stipulated in IEC-62271-100,IEC-60694/IS-12729, IS 13118

with its latest amendments & routine tests as indicated above shall be carried out by the supplier
in the presence of purchasers representative. Also type test on one unit may be carried out by the
supplier in the presence of purchasers representative if purchaser decides & if such facility will
be available either in the manufacturers laboratory or in the CPRI. Rates for these tests must be
indicated in the Annexure-IV, V, of Section-III of this tender specification. If the manufacturer
wants to do the above tests in free of cost, then he may indicate the rates as NIL. Purchaser
reserves the right to conduct type test or may not insist for this test.
6.2.2
In addition to the mechanical and electrical tests specified by IEC, the following shall also be
performed.
Speed curves for each breaker shall 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, pressure etc.).
The tests shall show the speed of contacts directly at various stages of operation, travel of
contacts, opening time, closing time, shortest time between separation and meeting of contacts at
break/make operation etc. This test shall also be performed at site for which the necessary
operation analyzer along with necessary transducers, cables, console, etc. shall be furnished as
mandatory maintenance equipment.
6.2.3 Immediately after finalization of the programme of type/acceptance/routine testing, the supplier
shall give sufficient advance intimation (20 days) to the purchaser to enable him to depute his
representative for witnessing the tests.
6.3
ADDITIONAL TESTS
The purchaser reserves the right for carrying out any other tests of a reasonable nature at the
works of the supplier/laboratory or at any other recognized laboratory/research institute in
addition to the above mentioned type, acceptance and routine tests at the cost of the purchaser to
satisfy that the material complies with the intent of this specification.
7.0
INSPECTION
7.1
The inspection may be carried out by the purchaser at any stage of manufacture. The supplier
shall grant free access to purchasers representative at a reasonable time when the work is in
progress. Inspection and acceptance of any equipment under this specification by the purchaser
shall not relieve the supplier of his obligation of furnishing equipment in accordance with the
specification and shall not prevent subsequent rejection if the equipment is found to be defective.
The supplier shall keep the purchaser informed in advance, about the manufacturing programme
so that arrangement can be made for inspection. Before offering for inspection, the supplier shall
furnish shop routine test certificates and calibration reports of the equipments/instruments to be
used during testing. After acceptance of these calibration reports and shop routine test certificate,
inspecting officer of the purchaser will be deputed for witnessing such inspections.
7.2
The purchaser reserves the right to insist for witnessing the acceptance/routine testing of the
bought out items.
7.3
No material shall be dispatched from its point of manufacture unless the material has been
satisfactorily inspected and tested or unless the same is waived by the purchaser in writing.
8.0
QUALITY ASSURANCE PLAN:

The bidder shall invariably furnish following information along with his offer, failing which his
offer, shall be liable for rejection.
i)Statement giving list of important raw materials including but not limited to:
(a)
Contact Material
(b)
Insulation
(c)
Porcelain
(d)
Oil
(e)
Sealing material
(f)
Contactor, limit switches, etc. in control cabinet.
Names of sub-suppliers for the raw materials, list of standards according to which the raw
materials are tested, list of test normally carried out on raw materials in presence of
Bidders representative, copies of test certificates.
ii)
Information and copies of test certificates as in (i) above in respect of bought out
accessories.
iii)
List of areas in manufacturing process, where stage inspections are normally carried out
for quality control and details of such tests and inspections.
iv)
Special features provided in the equipment to make it maintenance free.
v)
List of testing equipment available with the Bidder for final testing of breakers vis--vis,
the type, special, acceptance and routine tests specified in the relevant standards. These
limitations shall be very clearly brought out in the relevant schedule i.e. schedule of
deviations from specified test requirements.
The supplier shall, within 30 days of placement of order, submit following information to
the purchaser.
i)
List of raw materials as well bought out accessories and the names of subsuppliers selected from those furnished along with offer.
ii)
Type test certificates of the raw material and bought out accessories.
iii)
Quality assurance plan (QAP) with hold points for purchasers inspection (if
purchaser will desires).
The supplier shall submit the routine test certificates of bought out items and raw
material, at the time of routine testing of the fully assembling breaker
9
DOCUMENTATION
9.1
All drawings shall conform to relevant International Standards Organization (ISO)

Specification/ISS. All drawings shall be in ink and suitable for micro filming. All dimensions and
data shall be in S.I. Units.
List of Drawings and Documents:
9.2
The Bidder shall furnish four sets of relevant descriptive and illustrative published literature
pamphlets and the following drawings/documents for preliminary study along with the offer.
a)
General outline drawings showing dimensions and shipping weights, quantity of

insulating media, air receiver capacity etc.
b)
Sectional views showing the general constructional features of the circuit breaker
including operating mechanism, arcing chambers, contacts with lifting dimensions for
maintenance.
c)
Schematic diagrams of breaker offered for control supervision and reclosing.
d)
Structural drawing, design calculations and loading data for support structures.
e)
Foundation drilling plan and loading data for foundation design.
f)
Type test reports .
9.3
The supplier shall, within 2 weeks of placement of order submit four sets of final version of all
the above drawings for purchasers approval. The purchaser shall communicate his
comments/approval on the drawings to the supplier within reasonable period. The supplier shall,
if necessary, modify the drawings and resubmit four copies of the modified drawings for
purchasers approval within two weeks from the date of comments. After receipt of purchasers
approval, the supplier shall, within three weeks, submit 15 prints and one good quality
reproducibles of the approved drawings for purchasers use.
9.4
The supplier shall also furnish fifteen copies of manuals covering erection, commissioning,
operation and maintenance instructions and all relevant information and approved drawings
pertaining to the main equipment as well as auxiliary devices. Marked erection drawings shall
identify the component parts of the equipment as shipped to enable purchaser to carry out
erection with his own personnel. Each manual shall also contain one set of all the approved
drawings, type test reports as well as acceptance reports of the corresponding consignment
dispatched.
9.5
The manufacturing of the equipment shall be strictly in accordance with the approved drawings
and no deviation shall be permitted without the written approval of the purchaser. All
manufacturing and fabrication work in connection with the equipment prior to the approval of the
drawing shall be at the supplier risk.
9.6
TEST REPORTS
10
i)
Four copies of acceptance test reports and type test reports shall be furnished to the
purchaser as per the inspection of testing. One copy will be returned, duly certified by the
purchaser and only there afterwards shall the material be dispatched.
ii)
All records of routine test reports shall be maintained by the supplier at his works for
periodic inspection by the purchaser.
iii)
All test reports of tests conducted during manufacture shall be maintained by the supplier.
These shall be produced for verification as and when requested for by the purchaser.
PACKING AND FORWARDING

The equipment shall be packed in suitable crates so as to withstand handling during transit. The
supplier shall be responsible for any damage to the equipment during transit, due to improper and
inadequate packing and handling. The easily damageable materials shall be carefully packed and
marked with the appropriate caution symbols. Wherever necessary, proper arrangement for lifting
such as lifting hooks etc. shall be provided. Any material found short inside the packing cases
shall be supplied by the supplier without any extra cost.
Each consignment shall be accompanied by a detailed packing list containing the following
information:
a)
b)
c)
d)
e)
f)
g)
h)
Name of the consignee.

Details of consignment.
Destination.
Total weight of consignment.
Sign showing upper / lower side of the crate.
Handling and unpacking instructions.
Bill of material indicating contents of each package and spare material.
Manuals containing approved drawings & test reports
The supplier shall ensure that the packing list and bill of material are to be supplied in advance
to the purchaser & to the consignees before dispatch.
11.0
SUPERVISION OF ERECTION, TESTING AND COMMISSIONING (ET&C)

The erection, testing and commissioning of the breakers shall be supervised, by trained personnel
(Engineer) of the supplier who shall direct the sequence of ET&C and make the necessary
adjustments to the apparatus and correct in the field any errors or omissions in order to make the
equipment and material properly perform in accordance with the intent of this specification. The
Engineer shall also instruct fully(up to the satisfaction) to the plant operators, in the operation
and maintenance of equipment furnished. The supplier shall be responsible for any damage to the
equipment, on commissioning the same, if such damage results from faulty or improper ET&C
procedure. Purchaser shall provide adequate number of skilled/semi-skilled workers as well as all
ordinary tools and equipment and cranes required for breaker erection, at his own expense. Apart
from the above, the purchaser shall not be responsible for any other expenses incurred by the
supplier and against personal injuries to the Engineer etc., shall be to suppliers account. Special
tools, if required for erection and commissioning shall be arranged by the supplier at his cost and
on commissioning these shall be supplied to the purchaser, free of cost, for future use.
12.0
QUANTITY AND DELIVERY RERQUIREMENTS

i)
The scope of supply shall include a supply of 25% extra-quantity of bolts, nuts, washers,
split pins, cotter pins and such other small loose items free of cost.
SCHEDULE A
TECHNICAL PARTICULARS AND GUARANTEES
1. Topographical and Meteorological site conditions
Location
Altitude
State of Orissa
m
1000
Minimum
Maximum
55
maximum daily average
32
per cent
100
Air Temperatures
Humidity variation
Pollution level to IEC 815
Heavy
Airborne contamination, if any

Isoceraunic level
Seismic withstand factor (all equipment)
Maximum wind pressure
Wind velocity - (Wind Zone to IS 875)
Average annual rain fall
Highly polluted
day/annum
70
0.3
kg/sq. m
80.84
m/sec
50
cm
150
SYSTEM DETAILS
kV
400
220
132
2.1
Rated system voltage
kV
420
245
145
2.2
Earthing of system neutral
solid
solid
solid
2.3
System frequency
Hz
50
50
50
INSULATION LEVEL (at site altitude)
3.1
Lightning impulse voltage withstand level,

positive and negative polarity
kVp
1425
1050
650
Switching impulse voltage withstand level

of insulation to ground, positive and
negative polarity
dry
wet
kVp
kVp
1050
1050
Power frequency withstand voltage

dry
wet
kV
kV
520
520
460
460
275
275
Voltage below which corona shall not be

visible
kV
320
176
105
Maximum radio interference voltage level

measured at 1.1 times Us/3 at 1 MHz
<1000
<500
<500
25
25
25
3.2
3.3
3.4
3.5
3.6
Minimum creepage to earth over

insulation on rated service voltage (to
IEC 815)
mm/kV
Us is rated system voltage
Creepage distance across interrupter chambers shall be at least 10 percent greater than the
creepage distance to earth and shall comply with the pollution conditions of IEC 815.
2. - SWITCHGEAR DETAILS
Item
No
Description
Particulars
kV
TYPE OF SWITCHGEAR
4.1
Type of switchgear
420
GIS or Open terminal

Installation
SHORT TIME CURRENT CAPACITY
5.1
All equipment 3 seconds
5.2
Maintenance earthing devices, 3 seconds
CIRCUIT BREAKER
6.1
Normal current rating
6.2
Fault rating
6.2.1
Making current
6.2.2
Breaking current (symmetrical)
6.2.3
Breaking current (asymmetrical)
Outdoor
Outdoor
Outdoor
Outdoor
kA
63
40
40
kA
63
40
40
3150
3150
3150
kAp
100
100
100
kA
63
40
40
IEC 56
IEC 56
IEC 56
<50%
<50%
<50%
kA
10
10
10
600
125
50
as per
IEC
as per
IEC
250
160
as per
IEC
as per
IEC
% DC/kAp
6.2.4
Breaking current under out of phase conditions
6.2.5
Rated line charging current
Rated cable charging current
6.2.7
Rated inductive current
6.2.8
Maximum overvoltage factor on any switching

duty
pu
6.3
Operating sequence
6.3.1
Normal
145
Open terminal
4.2
6.2.6
245
600
1 to 10 - 50 - 100 200
<2.0
<2.0
<2.0
0-0.3 s - CO-3 min CO
Item
No
Description
6.3.2
Auto reclosing
6.3.3
Delayed three phase auto reclose cycle

adjustable dead time range
6.3.4
6.3.5
Particulars
0-0.3 s - CO-3 min CO
High speed single phase auto reclose cycle

adjustable dead time
Number of closing operations under out
of synchronous conditions
2-30
2-30
2-30
kV
420
245
145
0.3-20
0.3-20
1.3
1.3
1.5
s
(2.0 pu)
6.4
Transient recovery voltage
6.4.1
First phase to clear factor
6.4.2
Recovery voltage parameter for 3 phase

unearthed terminal fault
IEC 56
IEC 56
IEC 56
6.4.3
Short line fault parameter
IEC 56
IEC 56
IEC 56
6.4.4
Surge impedance for short line fault test
ohms
450
450
450
6.4.5
Minimum voltage to earth when switching

capacitive currents, (1.4 times rated phase to
earth voltage)
kV
340
198
117
Voltage across circuit breaker under out of

phase switching conditions
pu
6.4.6
6.5
Electro mechanical performance
6.5.1
Maximum total break time throughout complete

rating, ie trip coil initiation to final arc
extinction
ms
40
50
50
Maximum time interval between closure of first

and last phase of three phase circuit breakers
ms
Maximum time interval between closure of

interrupters of one phase of the circuit breaker
ms
ms
3.3
3.3
3.3
ms
6.5.2
6.5.3
6.5.4
6.5.5
Maximum time interval between opening of

first and last phase of three phase circuit breaker
Maximum time interval between opening of
interrupters of one phase of the circuit breaker
6.6
Insulation level (IEC 694)
6.6.1*
Lightning impulse withstand

(1.2/50 wave) - positive and negative
kV
420
245
145
kVp
1425
1050
650
1425
+(240)
1200
-
750
-
1050
1050
900
+(345)
520
460
275
610
530
315
a. To earth, closed contacts

b. Across, open contacts
kVp
kVp + kVACp
6.762*+
Switching impulse withstand (250/

2500 wave) - positive and negative
c. To earth, closed contacts
kVp
d. Across, open contacts

kVp
kVp + kVACp
6.6.3+
Power frequency withstand

e. To earth, closed contacts - 1 minute
f.
Across, open contacts - 1 minute
Dry/wet
kV
kV
6.7
Ancillary equipment
6.7.1
Number of trip coils required
6.7.2
Number of closing coils required
6.7.3
Degree of protection
IP 55
IP 55
IP 55
Biased tests (Impulse + ACp), required on switchgear for 300 kV and above.
Wet tests are required on outdoor open-terminal switchgear.
Specifcation for 145kV, 245kV and 420kV open terminal air insulated SF6 circuit breakers
TABLE 1. - 420KV CIRCUIT BREAKERS

(A) TERMINAL FAULT REQUIREMENTS - FOUR PARAMETER TRV
Current
kA (rms)
First test
voltage
U1 (kV)
Time
co-ord
t1 (s)
TRV peak
value
Uc (kV)
Time
co-ordt2
(s)
Time delay
td (s)
Volt co-ord
u (kV)
Time
co-ord
t (s)
Rate of rise
U/t kV
(kV/s)
10% symmetrical
787
88
11
262
8.9
30% symmetrical
15
446
89
669
668
5(22)
223
50(67)
5.0
60% symmetrical
30
446
149
669
671
2(37)
223
76(111)
3.0
100% symmetrical
50
446
223
624
669
223
113
2.0
100% Asym.
**
446
223
624
669
223
113
2.0
Asynchronous
12.5
686
446
857
1338
100% closing
125
Fault duty
**
Dependent on circuit breaker opening time
***
100% Sym and Assym duties shall either include ITRVs of Table III of IEC 56 or the SLF duties have been performed with tdL = 0
(B) SHORT LINE FAULT REQUIREMENTS
Source side
50
343
171
480
513
UL
tL
tdL
171
88
2.0
UL/tL
Line side
L 90
45
54.9
6.1
0.5
Line side
L 75
37.5
137.3
18.4
0.5
7.46
Line side
L 60
30
219
36.5
0.5
TABLE 2 - 245 kV CIRCUIT BREAKERS
Current
kA (rms)
First test
voltage
U1 (kV)
Time
co-ord
t1 (s)
TRV peak
value
Uc (Kv)
Time
co-ordt2
(s)
Time delay
td (s)
Volt co-ord
u (kV)
Time
co-ord
t (s)
Rate of rise
U/t kV
(kV/s)
10% symmetrical
459
66
153
30
7.0
30% symmetrical
15
300
60
450
450
5(15)
150
35(45)
5.0
60% symmetrical
30
260
87
390
392
2(22)
130
45(65)
3.0
100% symmetrical
50
260
130
364
390
130
67
2.0
100% asymmetrical
**
260
130
364
390
130
67
2.0
Asynchronous
12.5
400
260
500
780
1.54
100% closing
125
Fault duty
**
***
Source side
50
200
100
280
300
UL
tL
tdL
100
52
2.0
UL/tL
Line side
L 90
45
32
3.6
0.5
8.9
Line side
L 75
37.5
80
10.6
0.5
7.55
Line side
L 60
30
128
21.3
0.5
TABLE 3 - 145 kV CIRCUIT BREAKERS
Current
kA (rms)
First test
voltage
U1 (kV)
Time
co-ord
t1 (s)
TRV peak
value
Uc (kV)
Time
co-ordt2
(s)
Time delay
td (s)
Volt co-ord
u (kV)
Time
co-ord
t (s)
Rate of rise
U/t kV
(kV/s)
10% symmetrical
272
45
91
21
6.0
30% symmetrical
12
178
36
266
270
5(9)
89
23(27)
5.0
60% symmetrical
24
178
59
266
266
2(15)
89
32(44)
3.0
100% symmetrical
40
178
89
249
267
89
46
2.0
100% asymmetrical
**
178
89
249
267
89
46
2.0
Asynchronous
10
296
178
370
534
1.67
100% closing
100
Fault duty
**
***
Source side
40
118
59
166
177
UL
tL
tdL
59
32
2.0
UL/tL
Line side
L 90
36
18.9
2.6
0.2
7.3
Line side
L 75
30
47.4
7.9
0.2
6.0
Line side
L 60
24
75.9
15.8
0.2
4.8
Specifcation for 145kV, 245kV and 420kV open terminal air insulated SF6 circuit
breakers
Item
No
Description
Particulars
kV
420
245
145
MINIMUM FACTORS OF SAFETY

FOR SWITCHGEAR
7.1
Complete insulators based on electromechanical test
2.5
2.5
2.5
7.2
Insulator metal fittings based on elastic

limit
2.5
2.5
2.5
7.3
Steel structures based on elastic limit of

tension members and on crippling loads
of compression members
2.5
2.5
2.5
7.4
Foundations for structures against

overturning or uprooting under
maximum simultaneous working
loadings
2.5
2.5
2.5
Sr. G.M CPC-TN-41/08-09
TS-CB-Page 34 of 55
breakers
8. CLEARANCES*
8.1 Clearances for busbars and connections
RATED SYSTEM VOLTAGE kV
36
145
245
420
1050
1425
BIL
kVpK
170
650
SIL
kVpK
Minimum Clearance between Live metal and

Earth
0.32
1.3
2.0
3.4
Minimum Clearance between Live metal of

Different Phases
0.43
1.5
2.4
3.9
Safety Working Clearance Horizontal
2.3
3.2
3.3
5.4
Safety Working Clearance Vertical
2.9
3.7
4.5
6.4
Minimum height to base of insulation
2.4
2.4
2.6
2.7
1050
Based on BS 7354: 1990

Clearances apply only to equipment not subject to impulse voltage type tests.
They apply to conditions of maximum conductor swing and sag.
Sr. G.M CPC-TN-41/08-09
TS-CB-Page 35 of 55
breakers
Item
Description
FINISH OF EQUIPMENT
9.1
Outdoor equipment
9.1.1
Porcelains
9.1.2
Structures
9.1.3
Cubicles and enclosures
10
LVAC EQUIPMENT
10.1
Rated system voltage
10.2
Rated frequency
10.3
Method of earthing system neutral
10.4
Type of equipment required (switchfuses,

MCCBs, air circuit breakers etc)
10.5
Voltage limits for correct operation of

circuit breakers
11
DC AUXILIARY SUPPLIES
11.1
11.2
Particulars
Outdoor
Outdoor
Outdoor
Brown
Brown
Brown
Hot dip galvanized

As specified
415 V-30
240 V-10
415 V-30
240 V-10
415 V-30
240 V-10
Hz
50
50
50
Solidly earthed
Air circuit breaker
MCCBs
%V
%
10
5
10
5
10
5
Nominal voltage of system
220
220
220
Voltage limits for correct operation of

equipment
10
5
10
5
10
5
12
NOMINAL VOLTAGE OF
AUXILIARY SUPPLIES
12.1
Supply for electrical operation of circuit

breakers
12.1.1
Closing initiation
V dc
220
220
220
12.1.2
Tripping
V dc
220
220
220
12.2
Power supply for compressor equipment
415
415
415
12.3
Power supply for spring and hydraulic

charging motors
V ac
240
240
240
12.4
Supply for indication and alarm circuits
V dc
220
220
220
Sr. G.M CPC-TN-41/08-09
TS-CB-Page 36 of 55
breakers
ANNEXURE I
(CIRCUIT BREAKERS)
CORONA, RIV AND SEISMIC TEST PROCEDURES
Corona and Radio Interference Voltage (RIV) test:
1)
General:
Unless otherwise stipulated, all equipment together with its associated
connectors, where applicable, shall be tested for external corona both by
observing the voltage level for the extinction of visible corona under
falling power frequency voltage and by measurement of radio interference
voltage(RIV).
2)
Test Levels:
The test voltage levels for measurement of external RIV and for corona
extinction voltage are listed under the relevant clauses of the specification.
3)
Test Methods for RIV
3.1
RIV tests shall be made according to measuring circuit as per International

Sub-Committee on Radio Interference Publication 1- 1972 second edition.
The measuring circuit shall preferably be tuned to frequency of 0.5 MHz
but other frequencies in the range of 0.5 MHz to 2 MHz may be used. The
measuring frequency shall be recorded. The results shall be in microvolts.
3.2
Alternatively, RIV tests shall be conducted in accordance with NEMA

standard publication No. 107-1964 except as otherwise noted herein.
3.3
In measurements of RIV only standard fittings of identical type supplied

with the equipment and a simulation of the connections as used in the
actual installation will be permitted in the vicinity within 3.5 metres of
terminals.
3.4
Ambient noise shall be measured before and after each series of tests to
ensure that there is no variation in ambient noise level. If variation is
present, the lowest ambient noise level will form basis for the
measurement. RIV levels shall be measured at increasing and decreasing
voltages of 85%, 100%, 115% and 130% of the specified RIV test voltage
for all equipments unless otherwise specified.
3.5
The metering instruments shall be as per CISPR recommendation or

equipment device so long as it has been used by other testing authorities.
Sr. G.M CPC-TN-41/08-09
TS-CB-Page 37 of 55
breakers
B.
3.6
The RIV measurement may be made with a properly tuned noise meter.
4.0
Test Methods for Visible Corona:
4.1
The purpose of this test is to determine the corona extinction voltage of

apparatus and connectors, the test shall be carried out in the same manner
as RIV test described above with the exception that RIV measurements are
not required during test and a search technique shall be used near the onset
of extinction voltages, when the test voltage is raised and lowered to
determine their precise values. The test voltage shall be raised to 130% of
RIV test voltage and maintained there for five minutes. The voltage will
then be decreased slowly until all visible corona disappears. The voltage
will then be raised slowly again to the same maximum voltage. The
procedure shall be repeated at least 4 times with corona inception and
extinction voltage recorded each time. The corona extinction voltage for
purposes of determining compliance with the specification shall be the
lowest of the four values at which visible corona (negative or positive
polarity) disappears. Photographs with laboratory in complete darkness
shall be taken under test conditions, at all voltage steps i.e., 85%, 100%,
115% and 130%. Additional photographs shall be taken at corona
inception and extinction voltages. At least two photographs shall be taken
in each case.
4.2
The test to determine the visible corona extinction voltage need not be
carried out simultaneously with test to determine RIV levels. However,
both tests shall be carried out with the same test set up and as little time
duration between tests as possible. No modifications or treatment of the
sample between tests will be allowed. Simultaneous RIV and visible
corona extinction voltage testing may be permitted at the discretion of
owners inspector if, the same, in his opinion, will not prejudice other
tests.
Seismic Withstand Test:

The seismic withstand test on the complete equipment shall be carried out along
with the supporting structures etc. The seismic level specified shall be applied at
the base of the structure. The accelerometers shall be provided at the terminal pad
of the equipment and any other point as agreed by the purchaser. The seismic test
shall be carried out in all possible combinations of the equipment. The detailed
seismic test procedure shall be furnished for approval to the purchaser ,before
offer for inspection.
Sr. G.M CPC-TN-41/08-09
TS-CB-Page 38 of 55
breakers
FOR
36 KV VACCUM CIRCUIT BREAKERS

(OUT DOOR TYPE)
Sr. G.M CPC-TN-41/08-09
TS-CB-Page 39 of 55
breakers
TECHNICAL SPECIFICATION FOR 36 K.V. VACCUM

CIRCUIT BREAKERS
(OUTDOOR TYPE)
1.01
SCOPE:
36 K.V. 1430 MVA Circuit Breakers are intended to be purchased for installation at
different Sub-stations. Some of the Sub-stations for which equipment are tendered
are situated in coastal areas where saline climate prevails. The base structure of
the circuit breakers must be galvanized.
1.02
POWER SUPPLY TO AUXILIARIES :

A.C. supply to auxiliaries will be 3 phase, 3 wire, 430 volt or single phase
250 volts at 50 C/s. The voltage variation will be within 10% and the frequency
variation 5%.
1.03
33 K.V. CIRCUIT BREAKERS TYPE AND RATING :
The circuit breakers shall be vacuum type suitable for outdoor operation under the
climatic conditions specified without any protection from sum and rain.
The circuit breaker shall have the following ratings :
1.
Number of poles
3 (One unit with three phase

making and breaking).
2.
Frequency.
50 C/s.
3.
33 KV rms.
4.
Highest system voltage
36.0 KV rms.
5.
Basic insulation level
170 KVP
6.
7.
Power frequency test

Voltage (wet).
Nominal Current.
:
:
75 KV (rms.)
1250 Amps rms.
7a.
First pole to clear factor
8.
Breaking capacity.
(a)
Symmetrical.
Sr. G.M CPC-TN-41/08-09
1.5
25 KA/1430 MVA.
TS-CB-Page 40 of 55
breakers
(b)
A symmetrical.
9.
Making capacity.
62.5 KA Peak.
10.
Continuous current rating.
11.
Operating Duty.
12.(a) Break time
33 KA Peak.
1250 Amps (RMS)
0-0.3 Sec-CO-3 Min-CO.
3 Cycles
(b)Make time
5 Cycles.
(c )Minimum reclosing time
15 Cycle.
(d)Minimum dead time for reclosing :
15 Cycle
13. Dry one minute power frequency withstand test

a) Between line terminal
b)Between line and body :
voltage
75 KV rms.
75 KV rms.
14. Impulse withstand test voltage ;

a)Between terminal
170 KV (Peak)
with C.B. open.

b)Between body & terminal :
170 KV (Peak)
15. Insulator or bushing

a)Dry one minute power
Frequency voltage,
75 KV
b)Wet one minute power
75 KV
580 mm (Minimum)
Frequency withstand Voltage.

c) Creepage distance
16.Short time current
:
rating for 3 seconds.
17.Control circuit voltage
1.04
Not less than 25 KA for

3 seconds.
:
220 V D.C
STANDARDS :
The circuit breakers shall comply with the requirements of latest issue of IEC-62271100,IEC-60694/IS12729:2004,IS-13118:1991, except wherein specified otherwise. Where
the equipment offered confirm to any other standard the silent points of difference between
the standard adopted and the IS or IEC recommendations shall be brought out in the tender.
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breakers
Equipment meeting any other authoritative standard which ensures an equal or better
quality than the standard mentioned above is also acceptable.
CLIMATIC CONDITIONS :
The climatic conditions at site under which the equipment shall be operated
satisfactorily are as follows :
Peak ambient air temperature
50 C
Maximum temperature attainable by

an object exposed to sun.
60C
Minimum temperature of the air

in shade.
0C
Maximum yearly weighted average

ambient Temp.
32 C
Maximum daily average ambient temp
Maximum humidity.
Average number of thunder storm :

Average number of rainy days per
Annum.
35deg C
100%
70 Days per annum.
120
Average annual rainfall.
1500 mm
Number of months of tropical

Monsoon conditions per annum.
Maximum wind pressure.
260 kg/Sq.m.
Altitudes not exceeding.
1000 M
For the purpose of the specification, the limit of ambient temperature shall
be50 C peak and 45 C average over a 24 hours period.
Some of the breakers to be purchased against this specification are
intended to be installed on the sea coast having extremely saline climate.
Necessary anticorrosive provisions need be incorporated.
1.05
GENERAL :
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breakers
1.06
The circuit breakers shall be of vacuum type. The breakers shall be
furnished as a complete unit with all accessories and equipment in place and all
internal wiring installed and terminated in the mechanism.
1.07
The circuit breakers shall provide rapid and smooth interruption of current
under all conditions, completely suppressing all undesirable phenomena even

under the most severe and persistent short circuit conditions or when interrupting
small currents of leading or lagging reactive current. The details of any device
incorporated to limit or control the rate of rise of restricting voltages across the
circuit breaker contacts shall be stated. The over voltages caused by the circuit
breaker switching on inductive or capacitive load shall not exceed, 2.5 times the
normal phase to neutral voltage. The total break time for the circuit breakers
throughout the range of their operating duty shall be stated in the tender and
guaranteed.
1.08
CONSTRUCTIONAL FEATURES :
Each circuit breaker shall comprise 3 identical poles complete with a gang
operated mechanism for specified duty. All these poles of the C.B. shall be linked
together Electrically, Mechanically for specified duty.
The breaker shall be capable of interruptions of low reactive current
(lagging/leading) without undue over voltage and restrike.
1.09
CONTROL CUBICLE :
A common control cubicle shall be furnished to house electrical controls,

monitoring devices and all other accessories. The cubicle shall be of gasketed
weather proof construction, fabricated from sheet Aluminum alloy sheet having
minimum 3 mm thick.
1.10
The cubicle shall have front access door with lock and keys and removable
gland plate at the bottom for owners cable entry. Thermostat controlled space
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breakers
heater, internal illumination lamp, 5 A 3 pin socket with individual on off switches
shall be provided in the cubicle.
1.11
MOUNTING :
The circuit breakers shall be suitable for mounting on steel galvanized structures.
The prices of necessary frames for mounting the circuit breaker shall be included
with the offer.
1.12
The circuit breakers shall consist of three identical single phase units with a
common operating mechanism. All joints shall be welded so as to have adequate

mechanical strength. The breaker porcelain shall be capable of withstanding all
pressure resulting from any specified performance of the breaker.
The circuit breaker shall be supplied complete with the necessary lifting tools,
foundation bolts and other accessories.
1.13
TEMPERATURE RISE :
The maximum temperature attained by any part of the equipment when in-service
at site under continuous full load conditions and exposed to direct rays of sun shall
not exceed the permissible limits fixed by approved specifications.
When the
standards specifies the limits of temperature rise these shall not exceed when
corrected for the difference between ambient temperature at site and the ambient
temperature specified in the approved specification. The corrections proposed
shall be stated in the tender and shall be subject to approval of the purchaser.
1.14
INSULATION OF THE CIRCUIT BREAKERS :
1.15
The insulation to ground, the insulation between open contacts, the
insulation between phases of the completely assembled circuit breakers, should be

capable of withstanding satisfactorily die-electric test voltages corresponding to
basic insulation level specified in clause-1.03.
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breakers
1.16
The clearance in open air shall be as follows, unless the apparatus is
impulse tested after complete assembly.

i)
Minimum clearance between phase :
505 mm
ii)
Phase to Earth.
305 mm
iii)
Minimum clearance between live :
1400 mm
Parts and grounded objects.

iv)
Minimum ground clearance to live:
3700 mm
part.
1.17
BUSHING AND INSULATIONS :
The basic insulation level of the insulating porcelains shall be as specified and
shall be suitable for installation in contaminated atmospheres. The porcelains used
shall be homogenous and free from cavities and other flaws. They shall be
designed to have ample insulation, mechanical strength and rigidity for satisfactory
operation under conditions specified above. The puncture strength of the bushings
shall be greater than the flashover value. The bushings shall be entirely free from
radio disturbance when operating at a voltage 10% above rated voltage and also
be free from external corona.
Adequate means shall be provided to accommodate conductor expansion and
there should not be any undue stressing of any part due to temperature change.
1.12
OPERATION
MECHANISM :
1.12.1 The operating mechanism shall be spring operated type. In case of spring
operating mechanism it shall be of motor operated having provision of hand
operated spring charging type of by local/remote electric control under normal
operation. The mechanism shall be trip from electrically and mechanically. All
working parts in the mechanisms shall be corrosion resistant material and all
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breakers
bearings which require greasing shall be equipped with pressure grease fittings.
The mechanism shall be strong, positive, quick in action and shall be removable
without disturbing the other parts of the circuit breakers. The mechanisms of
breaker shall be such that the failure of any spring will not prevent tripping.
1.12.2 The operating mechanism along with its accessories shall be mounted in a
weather proof cabinet with hinged doors located near the breakers. A local control
switch and the breaker position indicator shall be provided in the cabinet.The
circuit breakers shall also be provided with means for manual operation for
maintenance purposes.
1.12.3 The control circuits shall be designed to operate on 220V. d.c. It shall be
possible to adopt to work on other voltages by simply changing the operating coils.
The closing and operating coils shall be designed to operate satisfactorily at any
control voltage from 70% to 115% of the normal rated voltage. A heater shall be
provided in the cabinet to prevent moisture condensation.
1.12.4 Necessary cable glands for the cables of the operating mechanism shall be
provided.
1.13
TERMINAL CONNECTORS :
Technical connectors suitable for all Aluminum Alloy Conductor zebra shall
be provided, Suitable terminal earth connector for earthling connections shall also
be supplied.
1.14
AUXILIARY SWITCHES :
Adequate number of auxiliary switches (contacts) both of the normally open
and normally closed types shall be provided on each circuit breaker for use in the
remote indication and control scheme of the circuit breaker and for providing safety
interlocking. Special contact for use with trip coil and single short reclosing
operation which permits relative adjustment with respect to the travel of the moving
contact of the circuit breaker shall also be provided. There shall be provision to add
more auxiliary switches at the later date if required.
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breakers
1.15
COMPLETENESS OF EQUIPMENT :
Any fittings, accessories or apparatus which may not have been specifically
mentioned in those specification but which are usual or necessary in the

equipment of similar plant shall be deemed to be included in the contract and shall
be supplied by the contractor without extra charges. All plant and equipment shall
be complete in all details whether such details are mentioned in the specification or
not. The detail bill of materials list to the furnished along with the tender.
1.16
AFTER SALES SERVICE :
1.16.1 The supplier should guarantee for after sales service for a minimum period
of one and half years from the date of receipt of the equipment or one year from
the date of commissioning of the equipment whichever is earlier.
1.16.2 The supplier also should guarantee after sales service beyond the free
service period.
1.16.3 Supplier also should provide after sales service within 15 days of receipt of
intimation from the field Engineer-in-charge of the equipment or the purchaser.
1.16.4 COMMISSIONING :
The manufacturers shall render all help for commissioning of the breakers.
Supervision of erection , testing & Commissioning charges per breaker to be
quoted in the schedule of prices (Annexure-v) for evaluation of the Price bid or else
it will be presumed that the charges towards Supervision of erection , testing &
Commissioning per Breaker are included in the unit price offered.
1.17
EXPERIENCE :
The list of supplies already made by the supplier/manufacturers are to be
enclosed along with the tenders.

1.18
RECOMMENDED SPARES AND TOOLS :
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breakers
For 5 (five) years operation, price are to be enclosed along with the tenders
for each item of spares and special tools.
2.0
TEST :
2.1
Type test : - All the equipment offered shall be fully type tested as per the
relevant standards. In case the equipment of the type and design offered, has
already been type tested in an Govt. Approved test Laboratory, the bidder shall
furnish four sets of type test reports along with the offer. These tests must not
have been conducted earlier than five years from the date of opening of bids.
The purchaser reserves the right to demand repetition of some or all the type tests
in the presence of owners representative. For this purpose the bidder may quote
unit rates for carrying out each type test. These prices shall be taken into
consideration for bid evaluation. For any change in the design/type offered against
this specification, if accepted by the purchaser, the purchaser reserves the right to
demand repetition of tests without any extra cost. Reports of Type tests as
stipulated in relevant IS along with Impulse and short circuit test documents
conducted shall be supplied along with the tender. All the test reports should be
submitted and shall be approved by the purchaser before dispatch of the material.
Note :-
Tender not accompanying with the
type test reports alongwith
Impulse and short circuit tests are liable for rejection.

Type Tests:--( As per IEC-62271-100)
1) Dielectric Test(LI Voltage,PF Voltage Withstand(Dry&Wet)& etc)
2) RIV Test
3) Measurement of resistance of the main circuit
4) Temperature rise Test
5)Basic short circuit duty test ,Short Time withstand current & Peak withstand current Test
6) Mechanical Operation Test, Mechanical endurance test
7)Out of phase / Short Circuit making & Breaking Test
8) Capacitive Current, Switching Test ,a) cable charging current Test b)Single capacitor Bank
current switching test
9)Test to verify degree of protection
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Routine Tests:1)Dielectric Tests on the main Circuit ,auxiliary & control circuits
2)Measurement of resistance of the main circuit.
3) Design & Visual Checks(Dimensions,clearances&etc)
4) Mechanical operation Test
5) Operating time of the device, motor Characteristics, measurement of coil current & resistance ,
Sf6 gas pressure monitoring ,electrical scheme,control Circuit,antipumping, vaccum
interrupter(type,make&etc),dimensions, name plate details , contact travel & timing checks
.
Acceptance and Routine Tests.
2.1.1
All acceptance and routine tests as stipulated in the relevant standards
& above shall be carried out by the supplier in presence of owners representative.
2.1.2
Immediately
after
finalization
of
the
programme
of
type/acceptance/routine testing, the supplier shall give twenty days advance

intimation to the purchaser, along with the shop routine test certificate and valid
calibration certificates of the equipments/instruments calibrated in a govt. approved
test house ,to be used during testing for scrutiny,to enable him to depute his
representative for witnessing the tests.
3.0
INSPECTION :The inspection may be carried out by the purchaser at any
stage of manufacture. The successful tendered shall grant free access to the
purchasers representative at a reasonable time when the work is in progress.
Inspection and acceptance of any equipments under this specification by the
purchaser, shall not relieve the supplier in his obligation of furnishing equipment in
accordance with the specification and shall not prevent subsequent rejection if the
equipment is found to be defective.
The supplier shall keep the purchaser informed in advance, about the
manufacturing programme so that arrangement can be made for inspection.
The
purchaser
reserves
the
right
to
insist
for
witnessing
the
acceptance/routine testing of the bought out items.
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4.0
QUALITY ASSURANCE PLAN :
4.1 The tenderer shall invariably furnish following information along with his offer,
failing which his offer shall be liable for rejection. Information shall be separately
given for individual type of equipment offered.
(i)
Statement giving list of important raw materials names of sub-suppliers for
the raw materials, list of standards according to which the raw materials are tested.
List of tests normally carried out on raw materials in presence of tenderers
representative, copies of test certificates.
(ii)
Information and copies of test certificates as in (i) above in respect of
bought out accessories.

(iii)
List of manufacturing facilities available.
(iv)
Level of automation achieved and list of areas where manual processing
exists.
(v)
List of areas in manufacturing process, where stage inspections are
normally carried out for quality control and details of such tests and inspections.
(vi)
(vii)
List of testing equipments available with the tenderer for final testing of
equipment specified and test plant limitation. If any, vis-avis the type, special
acceptance and routine tests specified in the relevant standard. These limitations
shall be very clearly brought out in schedule of deviations from specified test
requirements.
4.1 The successful tendered shall within 30 days of placement of order, submit
following information to the purchaser.
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breakers
(i)
List of raw materials as well as bought out accessories and the names of
sub suppliers selected from those furnished along with offer.

(ii)
(iii)
Quality assurance plan (QAP) with hold points for purchasers inspection.
The quality assurance plan and purchasers hold points shall be discussed between
the purchaser and supplier before the QAP is finalized.
4.3
The successful bidder shall submit the routine test certificates of bought
out accessories and central excise passes for raw material viz. oil, copper,
aluminum, conductors, insulating materials, core material at the time of routine
testing of the fully assembled equipment.
5 DOCUMENTATION :
5.1 All drawing shall conform to International Standards organization (ISO). A
series of drawing sheet/Indian standards specification IS.656. All drawings shall be
in ink and suitable for micro filming. All dimensions and data shall be in S.I. Units.
5.1 List of drawings and documents.
The bidder shall furnish four sets of following drawings along with his offer.
a)
General outline and assembly drawings of the equipment.
b)
Graphs showing the performance of equipments
c)
Sectional views showing :-
i)
General Constructional features.
ii)
The materials/gaskets/sealing used.
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iii)
iv)
method of connections.
Porcelain used and its dimensions along with the mechanical and electrical
characteristics.
d)
Arrangement of terminals and details of connection studs provided.
e)
Name Plate.
f)
Schematic drawing :-
g)
Type test reports in case the equipment has already been type tested.
h)
Test reports, literature, pamphlets of the bought out items, and raw material.
5.2
The successful tender shall, within 2 weeks of placement of order, submit
four sets of final version of all above said drawings for purchasers approval. The
purchaser shall communicate his comments/ approval on the drawings to the
supplier within four weeks. The supplier shall, if necessary modify the drawings
and resubmit three copies of the modified drawings for owners approval within two
weeks from the date of owners comments. After receipt of owners approval, the
supplier shall within two weeks, submit. 15 prints and two good quality reproducible
of the approved drawings for purchasers use.
5.3
Six sets of the type test reports, duly approved by the purchaser, shall be
submitted by the supplier for distribution before commencement of supply.

Adequate copies of acceptance and routine test certificates, duly approved by the
purchaser, shall accompany the dispatched consignment.
5.4
The manufacturing of the equipments shall be strictly in accordance with
the approved drawings and no deviation shall be permitted without the the written
approval of the purchaser. All manufacturing and fabrication work in connection
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with the equipment prior to the approval of the drawing shall be at the suppliers
risk.
5.5
15 sets of nicely printed and bound volumes of operation, maintenance and
erection manuals in English language for each type and rating of equipment
supplied shall be submitted by the supplier for distribution, prior to the dispatch of
the equipment. The manual shall contain all the drawings and information required
for erection, operation and maintenance of the equipment. The manual shall also
contain a set of all the approved drawings, type test reports etc.
5.6 Approval of drawings/work by purchaser shall not relieve the supplier of his
responsibility and liability for ensuring correctness and correct interpretation of the
drawings for meeting the requirement of the latest revision of applicable standards,
rules and codes of practices. The equipment shall conform in all respects to high
standards of engineering design workmanship & latest revisions of relevant
standards at the time of ordering &purchaser shall have the power to reject any
work or materials which in his judgement is not in full accordance therewith.
6 PACKING AND FORWARDING
6.1 The equipments shall be packed in crates suitable for vertical/horizontal
transport as the case may be, and suitable to withstand handling during transport
and outdoor storage during transit. The supplier shall be responsible for any
damage to the equipment during transit, due to improper and inadequate packing.
The easily damageable material shall be carefully packed and marked with the
appropriate caution symbol. Wherever necessary, proper arrangement for lifting,
such as lifting books etc. shall be provided. Any material found short inside the
packing cases shall be supplied by supplier without any extra cost.
6.2 Each consignment shall be accompanied with a detailed packing list
containing the following information.
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a)
b)
c)
Destination
d)
e)
Sign showing upper/lower side of the crate.
f)
g)
Bill of material indicating contents of each package.

The supplier shall ensure that the packing list and bill of material are
approved by the purchaser before dispatch.

TOPOGRAPHICAL AND METEOROLOGICAL SITE CONDITIONS
Location of installations
State of Orissa
Altitude
1000 m
Maximum Temperature
60C
Minimum Temperature
0C
Maximum daily average temperature
35C
Maximum humidity
100%
Pollution level
Heavy
Airborne contamination, if any
Highly Polluted
Seismic withstand factor
0.3 g
260 kg/m
Wind velocity
50m/sec
Maximum rainfall per annum
2000 mm
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Average rainfall per annum
1500 mm
Average no. of thunder-storm days/annum
70
Average no. of dust storm days per annum
20
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ORISSA POWER TRANSMISSION CORPORATION

LIMITED
FOR
CURRENT
TRANSFORMERS.
I: - 33KV CT
a) RATIO-400-200A-100/1-1-1A
b) RATIO-800-400-200A/1-1-1A
II: - 132 KV CT
a) RATIO-800-400-200A/1-1-1-1A
b) RATIO-600-300-150A/1-1-1-1A
c) RATIO-400-200A-100/1-1-1-1A
d) RATIO-200-100/1-1-1-1A
III: - 220 KV CT
RATIO-1200-600-300A/1-1-1-1-1A
IV:- 400 KV CT
RATIO:2000-1000-500/1-1-1-1-1A
E12-CURRENT TRANSFORMER- Page 1 of 37
TECHNICAL SPECIFICATION FOR 33KV, 132KV, &

220KV & 400 KV CURRENT TRANSFORMERS WITH
METERING CORES OF ACCURACY CLASS 0.2
1.0
SCOPE :
1.1.
The specification covers the design, manufacture, assembly, inspection and testing
at the manufactures work, packing and delivery F.O.R. (destination) of the outdoor
mounted dead tank type, single phase, single unit type current Transformers and
CT console( one CT console per 3 CTs) for protection and metering services in
33KV, 132KV, & 220KVand 400 KV solidly grounded system.
Current transformers shall be supplied with common marshalling box in a batch of three
CTs along with terminal connectors and other fittings for forming necessary interphase and
control room interconnections. The CT console shall be of Aluminum alloy sheets having 3 mm
thickness.
1.2. The current transformers shall be of the outdoor type, single phase, 50 C/S, oil
immersed, self cooled, hermetically sealed and suitable for operating in the tropical
conditions with maximum ambient temperature upto 500C. The C.TS should be
suitable for use in the areas subject to heavy lightning storms and highly polluted
conditions.
1.3.
Followings are the list of documents constituting this specification.

[i]
[ii]
Technical specification(TS)
Technical Requirements
Appendix I
[iii]
Quantity and Delivery
Appendix II
Schedule (Appendix II)
1.4
[iv]
Guaranteed Technical Particulars
[v]
[vi]
Calibration Status of testing equipments and Annexure B

meters / Instruments
Check-List towards Type Test Reports
Annexure-C
[vii]
Check-List for Delivery Schedule
Note :
Annexure- A, B, C & D are to be filled up by the Bidder
Annexure A
Annexure-D
The current transformer shall conform in all respects to high standards of

engineering, design, workmanship and latest revisions of relevant standards at the
time of offer and purchaser shall have the power to reject any work or material
which in his judgment is not in full accordance therewith.

1.5
Bidders are required to quote for 0.2 accuracy class of metering cores with the
following data / informations etc.
[a]
Guaranteed Technical particulars.
[b]
[c]
Technical literatures, brochures and drawings as per this specification.

Type Test Reports.
[d]
List of orders, executed and Users certificates, failing submission of the above
particulars with the offer, the tender may not be considered for evaluation.
2.0
STANDARDS
2.1
Except to the extent modified in the specification, the C.TS shall conform to the
latest editions and amendments of the standards listed hereunder.
Sl. No.
Standard Ref. No.
1
2.
3.
4.
5.
6.
7.
8.
9.
10.
IEC-44
IEC-60
IEC-171
IEC-185
IEC-270
IEC-8263
IS-335
IS:2071
IS:2099
IS:2147
11.
IS:2165
12.
IS:2705
[Part-I to IV)
IS:3347
IS:5621
13.
14.
15.
16.
17.
18.
2.2
IS:4201
IS:13072 of1991
IEC:60376
Title
Instrument transformer-measurement of PDS
High Voltage Testing Technique.
Insulation co-ordination
Current Transformers.
Partial Discharge Measurement
Method for RIV Test on High Voltage Insulators.
Insulating oil for Transformers
Method of High Voltage Testing
High Voltage porcelain Bushings
Degree of Protection Provided by Enclosures for Low
Voltage Switchgear and Control.
Insulation Co-ordination for equipment of 100KV and
above
Current Transformers
Dimensions of Porcelain Transformer Bushing
Specification for Large Hollow Porcelain for use in
Electrical installation.
Application guide for CTS
Indian Electricity Rules, 1956
SF6 Gas (for 220kv SF6 gas filled CTs only)
SF6 Gas(for 220kv SF6 gas filled CTs only)
Current Transformers with the requirements of other authoritative standards, which

ensure equal or better quality than the standards, mentioned above, shall also be acceptable,
Where the equipment, offered by the supplier conforms to other standards, salient points of
difference between the standards adopted and specified standards shall be brought out in th
offer. 4 (four) copies of the reference standards in English language shall be furnished along
with the offer.

2.3
The supplier is to furnish the latest edition of the standards as mentioned above
from SI.1 to Sl.15 with their amendments, if any, at their own cost, if required by the
Purchaser.
2.4
All the above alongwith amendments thereof shall be read and interpreted together.
However, in case of a contradiction between the Technical Specification and any
other volume, the provisions of this specification will prevail.
3.0
CLIMATIC & SERVICE CONDITIONS :
3.1
The current Transformers are required to operate satisfactorily under the following
conditions.
[a]
Maximum ambient temperature
500C
[b]
Minimum ambient temperature
00C
[c]
Maximum daily average ambient air
450C
temperature
3.2
[d]
Maximum relative humidity
100%
[e]
Average no. of rainy days in a year.
120 days
[f]
Average annual rainfall
150 cm
[g]
260 Kg/Sq.m
[h]
Altitude not exceeding
1000 m
EARTHOUAKE INCIDENCE
The current Transformers are to be designed to withstand earthquakes of an
intensity equivalent to seismic acceleration of 0.3g in the horizontal direction and
0.15g in the vertical direction, where gstands for acceleration due to gravity.
3.3
The current Transformers covered under this specification shall be suitable for
outdoor installation.
4.0
PUCHASERS AUXILIARY POWER SUPPLY :

4.1
Following power supplies shall be made available at site.
(a)
A.C. Three phase, 415V, 50HZ earthed
(b)
A.C. Single Phase, 240V, 50HZ earthed.
(c)
220 V D.C. ungrounded.
4.2
All the equipments and devices shall be capable of continuous satisfactory

operation on AC and DC supplies of normal voltage mentioned above with the
variation given below.
[a]
AC voltage variation
+ 10%
[b]
Frequency variation
+ 5%
[c]
Combined voltage and + 10%

frequency variation
[d]
4.3
DC Voltage Variation
190V to 240V
The supplier shall make his own arrangements for the power supplies other than
those specified under clause 4.1 above.
5.0
GENERAL TECHNICAL REQUIREMENTS :
5.1
The C.T. shall be of dead tank design and shall be so constructed that it can be
easily transported to site within the allowable limitation and in horizontal position if
the transport limitations so demand. The 400 KV CTs may be of live tank design.
5.2
For compensation of variation in the oil volume due to ambient variation, nitrogen
cushion / metal bellows shall be used. Rubber diaphragms shall not be permitted for
this purpose.
5.3
The C.T. secondary terminals shall be brought out in a weather proof terminal box.
The terminal box shall be provided with removable gland plate and gland (s)
suitable for 1100 volts grade PVC insulated, PVC sheathed, multicore 4 Sq. mm
stranded copper conductor cable. The terminal blocks shall be stud-type and
provided with ferrules, indelibly marked or numbered. The terminals shall be rated
for not less than 10 Amps. The terminal box shall be dust and vermin proof. Suitable
arrangements shall be made for drying of air inside the secondary terminal box. The
dimensions of the terminal box and its openings shall be adequate to enable easy
access and working space with the use of normal tools.
5.4
Polarity shall be indelibly marked on each primary and secondary terminal. Facility
shall be provided for short-circuiting and grounding of the C.T. secondary terminals
inside the terminal box.
5.5
The C.T. shall be provided with non-corrosive, legible name plate with the
information, specified in the relevant standards, duly engraved/punched on it.
5.6
The current Transformer shall be vacuum filled with oil after processing and
thereafter hermetically sealed to eliminate breathing and to prevent air and
moisture from entering the tanks. Oil filling and / or sampling cocks, if provided to
facilitate factory processing should be properly sealed before despatching the C.T.,
The method adopted for hermetic sealing shall be described in the offer
5.7
The castings of base, collar etc. shall be diecast and tested before assembly to
detect cracks and voids, if any.
5.8
The instrument security factor of metering core shall be low enough and not greater
than 5. This shall be demonstrated on all the ratios of the metering core in
accordance with procedure, specified in IEC-185 OR IS:2705. In case the
instrument security factor of 5 or less is not possible to be achieved on higher ratios,
auxiliary CTS of ratio1/1 and 0.2 accuracy class shall be deemed to be included in
the suppliers scope of supply. This shall also be specifically brought out by the
supplier in his offer. However, all parameters, specified shall have to be met treating
auxiliary CT/ reactor as an integral part of the current Transformer. The auxiliary
C.TS/reactor shall be inbuilt construction of the C.TS.
5.9
Current transformers guaranteed burdens and accuracy class are to be intended as

simultaneous for all cores.
5.10
For 245 KV, 145 and 36 KV Current Transformers, characteristics shall be such as
to provide satisfactory performance for burdens ranging from 25% to 100% of rated
burden over a range of 5% to 120% of rated current in case of metering CTS and
upto accuracy limit factor / knee point voltage in case of relaying C.TS.
5.11
Current Transformers shall be designed so as to achieve the minimum risk of

explosion in service. The Bidder shall bring out in his offer, the measures taken to
achieve this.
5.12
PRIMARY WINDING
5.12.1 Primary winding may be either ring type or hair pin type or the type, which has been
type tested.. For 220KV, 132KV, and 33KV class C.Ts, the rated extended primary
current shall be 120% on all cores of the C.Ts, specified in tables.
5.12.2 The primary windings of current transformers shall be constructed of high purity,
annealed,
high
conductivity
electrolytic
copper/Aluminium
meeting
to
the
requirements of IEC 28/IS:2705.

5.13
SECONDARY WINDINGS:
Suitably insulated copper wire of electrolytic grade shall be used for secondary
windings. Type of insulation, used shall be described in the offer. The secondary
taps shall be adequately reinforced to withstand handling without damage.
The rating of the Current Transformers secondary winding shall be 1 (One)
Amp.The secondary terminals shall be brought out in a compartment for easy
access.
5.14
PRIMARY TERMINALS
The primary terminals shall be heavily tinned electrolytic copper or Aluminium alloy
of 99.9% conductivity. The minimum thickness of tinning shall be 1.5 microns.
5.15
SECONDARY TERMINALS
5.15.1 Secondary terminal studs shall be provided with at least three nuts and adequate
plain and spring washers for fixing the leads. The studs, nuts and washers shall be
of brass, duly nickel plated. The minimum outside diameter of the stud shall be 6
mm. The length of at least 15 mm shall be available on the studs for inserting the
leads. The horizontal spacing between the centers of the adjacent studs shall be at
least 1.5 times the outside circum-dia of the nuts.
5.15.2 The current transformer shall be provided with suitable test tap for measurement of
capacitance, tan delta as well as partial discharges. Provision shall be made on a
screw cap for solid and secured earthing of the test tap connection, when not in
use. A suitable caution plate shall be provided duly fixed on the cover of the
secondary terminal box indicating the purpose of the test tap and the necessity of its
solid earthing as per prescribed method before energising the Current Transformer.
5.15.3 The secondary terminals shall be provided with shorting arrangements.
5.16
CORE
Each core of the Current Transformer shall be of torroidal shape. Core laminations
shall be of cold rolled grain oriented silicon steel or other equivalent alloys of low
hysteresis and eddy current losses, high permeability to ensure high accuracy at
both normal and over-current conditions. The cores used for protection shall
produce undistorted secondary current under transient conditions at all ratios, with
specified Current Transformer parameters. The core material, thickness of
lamination, the relevant graphs showing the characteristics of the core material shall
be submitted alongwith the offer.
5.17
TANK
5.17.1 Both expansion chambers and the tanks of the Current Transformers shall be made
up of high quality steel ,which should be able to withstand full vacuums and
pressure occurring during transit and thermal and mechanical stresses resulting
from maximum short circuit current during operation. The tanks alongwith all ferrous
parts shall be galvanised as per relevant standard.
5.17.2 The metal tanks shall have bare minimum number of welded joints so as to
minimise possible locations of oil leakage. Welding in horizontal plane is to be
avoided as welding at this location may give way due to vibrations during transport
resulting in oil leakage. Supplier has to obtain specific approval from purchaser for
any horizontal welding used in the bottom tank.
5.18
SECONDARY TERMINAL BOX :
5.18.1 Secondary Terminal Boxes shall be weather proof with a rating not less than IP 55
5.18.2 All secondary terminals shall be brought out in a compartment on one side of each
current transformer for easy access.
5.18.3 The exterior of this terminal box shall be of aluminium sheets of minimum 3 mm
thickness.
5.18.4 A terminal board which shall have arrangement for series / parallel connection and
arrangement for shorting of secondary terminals shall be provided.. For 220KV and
132KV C.Ts, at least one of the ratios should be achieved through secondary
tapping(s). i,.e
primary re-connection is allowed for two ratios where as third ratio is to be achieved
by provision of secondary tapping or alternatively all the stipulated ratios may be
achieved through secondary tappings. For 132KV C.T. of ratio-400-200A/1-1-1-1A,
the specified ratios may be obtained by. Series parallel connection or by secondary
tapping.
5.18.5
The terminal box shall be provided with a removable cable gland plate at bottom for
mounting cable glands for 1.1KV PVC sheathed 4 x 4 Sq. mm stranded copper
conductor cables.
5.18.6
The terminal box shall be provided with a door in front so as to have easy access of
secondary terminals. The door shall have a sealing / locking arrangement and shall
be suitable to prevent penetration of moisture and rain water.
5.18.7
All terminals shall be clearly marked with identification number to facilitate

connection to external wiring.
5.18.8
The secondary box of the CTs also of high quality steel materials with galvanizing
as per standard (IS).
5.18.9
The CT console to be provided (one per 3 CTs) is also of high quality steel with
proper galvanization.
5.19
PORCELAIN HOUSING
5.19.1
The housing shall be made up of homogeneous, vitreous porcelain of high

mechanical and dielectric strength, Glazing of procelain shall be of uniform brown or
dark brown colour with a smooth surface, arranged to shed away rain water or
condensed water particles (fog.) The details of location and type of joint, if provided
on the porcelain, shall be furnished by the Bidder along with the offer.
5.19.2
The bushings of the Current Transformers shall conform to the latest edition of
IS:2099. The hollow porcelain insulator shall conform to the latest edition of
IS:5621.
5.19.3
The insulators shall be cemented with Portland cement to the flanges resulting in
high mechanical, tensile and breaking strength.
5.19.4
The bushings shall have ample insulation, mechanical strength and rigidity for the
condition under which they shall be used and shall be designed to prevent
accumulation of explosive gases and provide adequate oil circulation to remove the
internal heat.
5.19.5
Cast metal end caps for the bushings shall be of high strength, hot dip glavanised
malleable iron. They shall have smooth surface to prevent discharge taking place
between the metal parts and porcelain as a result of ionisation.
5.19.6
The insulation of bushings shall be coordinated with that of the current transformer
such that the flashover, if any, will occur only external to the Current Transformer.
5.19.7
Oil level gauge and convenient means of filling, sampling and draining of oil should
be provided.
5.19.8
End shields should be provided for distribution of stresses.
5.19.9
Corona shields for bushings, if required should be provided.
5.20
INSULATING MEDIUM ( OIL TYPE)

The quantity of insulating oil for the filling and the complete specification of the
insulating oil shall be stated. The oil shall comply in all respects with the provisions
of latest edition of IS: 335. The current Transformers shall be supplied, filled with
purified oil completely.
PREVENTION OF OILLEAKAGE AND ENTRY OF MOISTURE :
5.20.1
The supplier shall ensure that the sealing of the Current Transformer is properly
achieved. In this connection, the arrangement provided by the supplier at various
locations including the following ones shall be described, supported by sectional
drawings.
5.20.2
(a)
locations of emergence of primary and secondary terminals.
(b)
Interface between porcelain housing and metal tank/s
(c)
Cover of the secondary terminal box.
Nuts and bolts or screws, used for fixation of the interfacing porcelain bushings for
taking out terminals shall be provided on flanges, cemented to the bushings and not
on the porcelain.
5.20.3
For gasketed joints, wherever used, nitrite butyl rubber gaskets shall be used. The
gasket shall be fitted in properly machined groove with adequate space for
accommodating the gasket under compression.
5.21
FITTINGS AND ACCESSORIES :

Fittings and accessories, listed below shall be supplied with each Current
Transformer. Any fitting, required essential other than those listed below shall also
be supplied alongwith each Current Transformer without any extra cost to the
purchaser :
(a)
Oil level gauge.
(b)
Oil filling hole and cap.
(c)
Pressure relieving device.
(d)
Phase terminal connectors.
(e)
Lifting lugs for core and windings, bushings and complete Current
Transformers.
(f)
Tank earthing pads/terminals with necessary nuts, bolts and washers for
connecting to purchasers earth strip.
(g)
5.21.1
Name / Rating plate.
(A) OIL LEVEL GAUGE :

An oil level gauge shall be provided to indicate the oil level in the Current
Transformer. This gauge shall be mounted in such a way that the oil level can be
seen from ground level. If metal bellow is used, a ground glass window shall be
provided to monitor the position of the metal bellow. The metal below shall be
tested in accordance with relevant standards. The details shall be to the approval of
the purchaser.
5.21.2 PRESSURE RELIEVING DEVICE :

Each Current Transformer shall be provided with a pressure relieving device so as
to protect bushing of the Current Transformer even under unfavorable
conditions. In case of non provision of the PRD, the same should be brought out
clearly in the offer with detailed explanation and proof.
5.21.3 (A) OIL DRAIN COCK :
An oil drain cock alongwith a stop cock shall be provided in the bottom flange so as
to permit taking of oil samples for testing, if required.
5.21.4 EARTHING :
Metal tank of each Current Transformer shall be provided with two separate
earthing terminals for bolted connection to 50mm X 6mm and 75X10 mm flat, to be
provided by the purchaser for connection to station earth-mat.
5.21.5 LIFTING ARRANGMENT :
The Current Transformer shall be provided with suitable lifting arrangement to lift
the entire unit. The lifting arrangement shall be clearly shown in the general
arrangement drawing. Lifting arrangement (lifting eye) shall be positioned in such a
way so as to avoid any damage to the porcelain housing or the tanks during lifting
for installation / transport. Necessary string guides shall be offered which shall be of
removable type.
5.21.6 NAME PLATE & MARKING :
5.21.6.1 The Current Transformer shall be provided with non-corrosive, legible name
plate
with
the
information
specified
in
relevant
standards,
duly
engraved/punched On it.
5.21.6.2 A schematic drawing indicating the connections shall be provided in the interior
of the Terminal box.
5.21.7 TERMINAL CONNECTORS :
All the Current Transformers shall be provided with bimetallic solderless clamp type,
rigid type terminal connectors, suitable for
(i)
33KV C.T. ACSR MOOSE conductor.
(ii)
132KV C.T. ACSR MOOSE conductor.
(iii)
220 KV C.T. ACSR MOOSE conductor & also suitable for AC tube of 4
inchs.
(iv)
400 KV CT suitable for Al tube of 4 inch or more
Each terminal connector shall be of universal type, suitable for both horizontal and
vertical connections to the transmission line conductors / station bus bars.
5.21.7.1 Terminal connectors shall be manufactured and tested as per IS:5561.
5.21.7.2 All castings shall be free from blow holes, surface blisters, cracks and cavities.
All sharp edges and corners shall be blurred and rounded off.
5.21.7.3 No part of a clamp shall be less than 10mm thick.
5.21.7.4 All ferrous parts shall be hot-dip galvanised conforming to relevant standard.
5.21.7.5 For bimetallic connectors, copper alloy linear of minimum thickness of 2 mm
shall be cast integral with aluminium body.
5.21.7.6 All current carrying parts shall be designed and manufactured to have minimum
contact resistance.
5.21.7.7 Connectors shall be designed to be corona free in accordance with the
requirements, stipulated in IS:5561.
6.0 TEST :
6.1
TYPE TESTS & SPECIAL TESTS:-
The current transformers, offered should have been subjected to the following type
tests and Special Tests in Government approved test laboratory. The bidder shall
furnish four sets of type test and Special Tests reports alongwith the offer for 0.2
accuracy class CTs. These tests should not have been conducted earlier than five
years from the date of opening of the bid. For any change in the design/type already
type tested and the design/type offered against this specification, the purchaser
reserves the right to demand repetition of some or all type & special tests without
any extra cost to OPTCL in the presence of OPTCLs representative(s) at the cost
of the supplier.
(a)
Lightning Impulse Voltage Test.
(b)
High Voltage power frequency wet withstand voltage Test.
(c)
Short time current test.
(d)
Temperature rise test.
(e)
Determination of errors or other characteristics according to the requirements

of the appropriate designation and accuracy class as per individual parts of
IS:2705.
(f)
Instrument Security Factor Test.
(g)
IP-55 Test on Secondary Terminal Box.
(In addition to the above tests, following type tests/special tests should have been
conducted exclusively for 220KV/400 KV C.T)
(h)
Radio Interference voltage test.
(i)
Corona Extinction test.
(j)
Thermal stability test.
(k)
Thermal Co-efficient test.
(l)
Fast transient test.
(m)
Seismic withstand test.
(n)
Mechanical terminal load on bushing.
(o)
Magnetisation and internal burden tests..
(p)
Effectiveness of sealing tests.
(q)
capacitance and dielectric loss angle test. (For 400 KV ,220KV & 132KV
C.Ts.)
N.B :
Lightning Impulse Test, switching Impulse Voltage test and High Voltage power
frequency wet withstand voltage Tests should have been carried out on the same
current transformer.
After the current transformers have been subjected to lightning Impulse Test, and High
Voltage power frequency wet withstand voltage tests, these must have been subjected
to all the routine tests as per IS:2705 (Part-I to IV).
6.2
ROUTINE TESTS :
The following routine tests shall be conducted on each Current Transformer in the
presence of OPTCLs representative(s) for which no charges will be payable by
OPTCL. No sampling will be allowed.
(i)
Appearance and Dimensional Check.
(ii)
Verification of Terminal Marking and polarity.
(iii)
Verification of all individual parts / components of the Current Transformer so

as to ensure to have complied the above specification.
(iv)
Measurement of Insulation Resistance.
(v)
Power Frequency Dry withstanding Test on Primary and Secondary winding

including primary intersections.
(vi)
Over Voltage Interturn test.
(vii)
Partial discharge Test for 400 KV,220 KV and 132KV C.TS
(viii)
Knee point voltage and Excitation current measurement for PS class cores.
(ix)
Secondary winding resistance measurement.
(x)
Determination of errors.
(xi)
ISF Test.
(xii)
Leakage Test.
(xiii)
Magnetization Characteristics of the Current Transformers.
(xiv)
Turn ratio error on PS class cores.
(xv)
Measurement of capacitance for 400 KV,220KV and 132KV C.TS.
(xvi)
Measurement of tan delta at 0.3, 0.7, 1.0 and 1.lU/3 for 400 KV,220KV &
132KV C.Ts.
(xvii) Checking of SF6 gas Pressure.(for SF6 gas filled CTs)
The Method For Conducting Partial Discharge Test.

The test circuit for the measurement of partial discharge (PD) should have been in
accordance with sub-clause 4.2 of IEC-270. The applied voltage should be raised to
the rated voltage of the Current Transformers and should have been maintained for a
period greater than or equal to 10 seconds. The voltage should have been reduced to
measuring voltage of
1.1 X145/245/400KV rms/phase
3
to ground and maintained for a period greater than or equal to 1 minute. The PD
should not exceed 10 picco-coulombs.
7.0
7.1
INSPECTION :
The purchaser shall have access at all times to the works and all other places of
manufacture, where the Current Transformers are being manufactured and the
supplier shall provide all facilities for unrestricted inspection of the suppliers works,
raw materials, manufacture of all the accessories and for conducting the necessary
tests.
7.2
The supplier shall keep the purchaser informed in advance of the time of starting
and of the progress of manufacture of equipment in its various stages so that
arrangement could be made for inspection.
7.3
No material shall be despatched from its point of manufacture unless the material
has been satisfactorily inspected, tested and despatch clearance
issued. However, the purchaser reserves the right to alter the despatch schedule,
attached to this specification without any extra financial liability to OPTCL.

7.3.1 The acceptance of any quantity of equipment shall in no way relieve the supplier of
his responsibility for meeting all the requirements of this specification and shall not
prevent subsequent rejection, if such equipments are found to be defective.
8.0
8.1
The Bidder shall invariably furnish following information alongwith his offer.
(i)
Statement giving list of important raw materials, names of sub-suppliers for

the raw materials, list of standards, according to which the raw materials are
tested, list of tests, normally carried out on raw material in presence of Bidders'
representative, copies of test certificates.
(ii)
Information and copies of test certificates as in (i) above in respect of bought

out items.
(iii)
(iv)
Level of automation achieved and list of areas where manual processing

exists.
(v)
List of areas in manufacturing process where stage inspections are normally

carried out for quality control and details of such test and inspections.
(vi)
(vii)
List of testing equipments, meters available with the Bidder for final testing of
equipment specified and test plant limitation, if any, vis--vis the type,
acceptance and routine tests, specified in the relevant standards. These
limitations shall be very clearly brought out in the offer.
(viii)
All the testing equipments, meters etc, should have been calibrated in a
Government approved laboratory. The Bidder must submit the list of
testing equipments and meters test-wise as per Annexure B of the
Technical Specification.
8.2
The supplier shall within 30 days of placement of order submit the following
information to the purchaser.
(i)
List of raw materials as well as bought out accessories and the names of the
materials as well as bought-out accessories and the names of sub-suppliers,
selected from those, furnished alongwith the offer.
(ii)
Type Test Certificates of the raw material and bought out accessories.
(iii)
Quality Assurance plan (QAP) with hold points for the purchasers inspection.
The QAP and hold points shall be discussed between the purchaser and the
supplier before the QAP is finalized.
8.3
The supplier shall submit the routine test certificate of bought-out items and raw
materials at the time of acceptance testing of the fully assembled equipment.
9.0
DOCUMENTATION :
9.1
All drawings shall conform to relevant Indian Standard as per relevant IS. All
drawings shall be in ink and suitable for microfilming. All dimensions and data shall
be in S.I. units.
9.2
The supplier shall furnish four sets of following drawings/documents along with his
offer for 0.2 accuracy class metering core CTs.
(a)
General outline and assembly drawings of the Current Transformers.
(b)
Sectional views showing.

(i)
General constructional features.
(ii)
Materials / gaskets / sealing used.
(iii)
The insulation of the winding arrangement, method of connection of

the primary / secondary winding to the primary / secondary terminals
etc.
(c)
Schematic drawing
(d)
Rating and Diagram plate.
(e)
Secondary Terminal Box.
(f)
Assembly Sectional view of Primary Terminal
(g)
Assembly drawing for secondary terminal.
(h)
The detailed dimensional drawing of Porcelain Housing such as ID, OD,

thickness and Insulator details such as height, profile of petticoats, angle of
inclination and gap between successive petticoats, total creepage distance
etc.
(i)
Sectional view of Pressure Release device.
(j)
Drawing showing details of Oil level Indicator.
(k)
All type and special test reports relating to tests, as mentioned at CI. No.
6.1 of this Technical Specification.
(l)
Ratio and phase angle error curves for CTS.
(m)
Magnetization characteristic curves such as B-H curves and sp.loss vs. flux
density curves.
(n)
Drawings for Terminal Connector.
10.0
TEST REPORTS :
(i)
Four copies of type test and special test reports shall be furnished to the
purchaser with the tender offer for 0.2 accuracy class metering core CTs.
(ii)
Copies of acceptance test reports and routine test reports shall be furnished to the
purchaser. One copy will be returned, duly certified by the purchaser and only
thereafter shall the materials be despatched.
(iii)
All records of routine test reports shall be maintained by the supplier at his
works for periodic inspection by the purchaser.
(iv)
All test reports of tests, conducted during manufacture shall be maintained by

the supplier. These shall be produced for verification as and when required
for by the purchaser.
11.0
SPARE PARTS
A list of spare parts recommended for five years operations for each Current
Transformer shall be furnished with the tender. The purchaser will decide the actual
quantities of spare parts to be ordered on the basis of the list and the item wise
price of spare parts.
12.0
The necessary galvanized flanges, bolts etc. for the base of the Current
Transformers shall be supplied without any extra cost to the purchaser.
13.0
PACKING AND FORWARDING :
13.1
The equipment shall be packed in suitable crates so as to withstand handling during

transport and outdoor storage during transit. The supplier shall be responsible for
any damage to the equipment during transit, due to improper and inadequate
packing. The easily damageable material shall be carefully packed and marked with
the appropriate caution symbols. Wherever necessary, proper arrangement for
lifting such as lifting hooks
etc. shall be provided. A material found short inside the packing cases shall be supplied by
supplier without any extra cost.
13.2
informations :(a) Name of the consignee
(b) Details of consignment

(c) Destination
(d) Total weight of consignment
(e) Sign showing upper / lower side of the crate
(f) Handling and unpacking instructions
(g) Bill of materials indicating contents of each package.
13.2.1 The supplier shall ensure that the bills of materials are approved by the purchaser before
despatch.
13.3
Any tender without complete information, as asked for in the above specification, is likely to
be rejected.
APPENDIX-I
TECHNICAL REQUIREMENT FOR 33 KV, 132 KV & 220 KV

CURRENT TRANSFORMERS
The Current Transformers under this specification shall conform to the parameters given
below :-
Sl.
No.
1
2
3
4
5
6
7
8.
9
10
Item.
Type of CT/Installation.
Type of mounting.
Suitable for system
frequency.
Rated voltage (KV rms)
(KV rms)
(KV rms)
Current ratio (A/A)
Specification
36 KV
145 KV
245KV
Single phase, dead tank, oil filled, hermetically sealed,
outdoor, self-cooled.(For 220KV SF6 gasfilled CTs-Single
phase, live tank, hermetically sealed, out door,self-cooled)
Pedestal type
50 HZ 5 %
33
33
132
132
220
220
36
145
245
a)800-400-200A/
1-1-1-1A
b)600-300-150A/
1-1-1-1A
c)400-200A-100/
1-1-1-1A
d)200-100/
1-1-1-1A
Solidly Effectively earthed.
a)400-200A-100/
1-1-1A
b)800-400-200A/
1-1-1A
1200-600-300A/
1-1-1-1-1
Method of earthing the

system where the current
transformer will be
installed.
Rated continuous
120 % of rated primary current
thermal current (A)
Acceptable limit of temperature rise above 50C ambient temperature for continous
operation at rated continuous thermal current.
(a)
Winding
(b)
Oil
45C
40C
(c)
11
12.
13.
14.
15.
16.
17.
18.
19.
20.
External surface of the

core, metallic parts in
contact with or adjacent
to, insulation.
Acceptable partial
discharge level
Maximum radio
interference voltage at l. l
times the maximum rated
voltage.
l.2/50 micro second
lightning impulse
withstand voltage (KVP)
(dry)
45C
Less than 10 picco coulombs

Less than 500 micro volts
170
1 minute dry power

frequency withstand
70
voltage primary (KV rms)
Switching Impulse with
-stand and voltage (KVP)
l Minute dry power
frequency withstand
3
voltage secondary (KV
rms)
Minimum creepage
distance of porcelain
900
Housing (mm)
Rated short time withstand
25KA
current for l second at all
ratios (KA rms)
Instrument security factor
at all ratios for metering
core.
Minimum rated short time
thermal current density of
the primary winding at all
ratios (A/mm2)
650
1050
275
460
3625
6125
31.5 KA
40KA
Not more than 5.0
As per clause No9.6.3- Note of IS: 2705 (Part-I)/l992
21.
22.
23.
24.
25.
Application, current ratio,

Enclosed in separate sheets for each rating of the Current
output burden, accuracy
class, minimum knee point Transformers.
voltage, secondary
winding resistance,
maximum excitation
current at minimum knee
point voltage etc.
Type of core
Torroidal type
Seismic acceleration
0.15g (Vertical)
0.3g (Horizontal)
Dielectric dissipation
factor at 245/1.732KV (for
220KV C.T) &
145/.1.732KV
( for 132 KV C.T.) at
ambient temperature
Accuracy class of standard
C.T. to be used during
testing towards
determination of ratio
errors and phase angle
errors for metering cores.
0.005 or less
0.05 or better.
400 KV Current transformer Selection philosophy

The following shall be adopted for selecting the type of current transformers:
Insulation
Oil impregnated paper/ porcelain.
Type
Live /Dead Tank type
Voltage Class
400kV
Application
Outdoors
IMPORTANT: ALSO REFER THE SPECIFICATION OF CT,S MENTIONED IN ABOVE

SECTIONS.
General
Current transformers shall comply with IEC 60044-1/ IS 2705.
Current transformers shall be supplied with common marshalling box in a batch of three CTs along
with terminal connectors and other fittings for forming necessary interphase and control room
interconnections.
Current transformers shall operate satisfactorily in system with high X / R ratio.(Tp=100ms)

Current transformer tanks along with top metallic parts shall be hot dip galvanised.Spray galvanisation
as per IS-5905 with 250 micron thickness of Zinc followed by finishing coats of a suitable primer with
sealer.
The impregnation details along with tests and checks to ensure successful completion of impregnation
cycle shall be furnished for Project Managers approval.
Bellows if used for expansions of insulating oil shall be tested in accordance with relevant standards.
The details shall be to the approval of the Project Manager.
The instrument transformers shall be designed for use in geographic and meteorological condition as
stipulated (GTR)
The secondary windings of current transformers shall be as stated in the schedules and shown in the attached
single line diagrams; the secondary windings shall meet the requirements stated in the tables attached under this
section of this Specification.
Each current transformer secondary winding circuit shall be earthed at one point only i.e. in the control room.
Terminal boxes shall be weather proof with a rating not less than IP 55. The terminal box shall be provided with
a gland plate suitable for PVC insulated PVC sheathed 10 core, 2.5 mm2 stranded copper conductor cables.
Where adequate earth screens are fitted between the primary and secondary windings earthing of the secondary
winding shall be via a link mounted in the related protection or instrument cubicle. Where such earth screens are
not fitted a separate earth system may be necessary.
Wherever possible the connection to earth shall be on the side of the S2 terminals.
Necessary markings for connections shall be provided on each CT at load termination end points and at the
associated terminal blocks. Provision shall be provided for short circuiting and grounding of the CT secondary at
the terminal blocks.
Different ratios specified shall be achieved by secondary taps only and primary reconnection shall not be
accepted.
Core laminations shall be of cold rolled grain oriented silicon steel or other equivalent alloys. The cores used for
protection shall produce undistorted secondary current under transient conditions at all ratios, with specified CT
parameters.
The expansion chamber at the top of the porcelain insulators should be suitable for expansion of oil.
Facilities shall be provided at terminal blocks in the marshalling box for star delta formation, short circuiting and
grounding of CT secondary terminals.
A wiring diagram plate for the interconnections of the three single phase CTs shall be provided inside the
marshalling box.
The physical disposition of the secondary cores shall preferably be in the same order as that given in the tables in
this section of the specification.
Current transformers shall be suitable for mounting on lattice support structure as stipulated elsewhere in this
Specification.
technical specification of current transformers

Current transformers guaranteed burdens and accuracy class are to be intended as simultaneous for all cores.
For 400 kV class CT's the rated extended primary current of the CT's shall be 200 % of rated primary on all
except 2000/1 tap ratio. On 2000/1 ratio the rated extended primary current shall be 120%. However, at
2000/1 ratio the CT shall be thermally rated for 200 % for 15 minutes and 120 % continuous.
For 420kV current transformers, characteristics shall be such as to provide satisfactory performance for burdens
ranging from 25 % to 100 % of rated burden over a range of 10 % to 100 % of rated current in case of metering
CTs, and up to the accuracy limit factor / knee point voltage in case of relaying CTs.
Current transformers shall be suitable for horizontal transportation. It shall be ensured that the CT is able to
withstand all the stresses imposed on it while transporting and there shall be no damage in transit.
For 420 kV CTs the instrument security factor at all ratios shall be less than five (5) for metering cores. If any
auxiliary CTs or reactors are used in the current transformers then all parameters specified shall have to be met
treating auxiliary CTs or reactors as an integral part of the current transformer. The auxiliary CTs or reactors
shall preferably be inbuilt construction of the CTs. In case these are to be mounted separately they shall be
mounted in the central marshalling box suitably wired up to the terminal blocks.
Current transformers shall be designed so as to achieve the minimum risks of explosion in service. The Bidder
shall bring out in his offer, the measures taken to achieve this.
420 kV and 245 kV current transformers shall be suitable for high speed auto reclosing.
Oil impregnated current transformers

Post type current transformers using oil impregnated paper as the insulant may be of the bar, single or multi-turn
primary and shall be hermetically sealed and conform to the requirement of IEC 185.
In case bar primary inverted type current transformers are offered the manufacturer will meet
additional requirements :
following
The secondary shall be totally encased in metallic shielding providing a uniform equipotential surface for
even electric field distribution.
The lowest part of the insulation assembly shall be properly secured to avoid any risk of damage due to
transportation stresses.
The upper part of insulation assembly resting on primary bar shall be properly secured to avoid any
damage during transportation.
Nitrogen if used for hermetic sealing should not come in direct contact with oil.
The primary windings of current transformers shall be constructed of high purity, annealed, high conductivity
copper or electrolytic grade aluminium meeting to the requirements of IEC 28. secondary windings shall be
constructed out of copper only.
Each current transformer shall be impregnated and filled with oil of the grade specified in IEC 296.
The following facilities shall be provided:
Visual means of determining the level of oil within the transformers from ground level.
Oil drain cock and sampling device where applicable.
Earth terminal of adequate dimensions so arranged that the earth connection cannot be inadvertently
removed.
The creepage and flashover distances of the support insulator shall be dimensioned to suit the outdoor service
conditions specified in the schedules.
Technical parameters
In addition to meeting the system technical parameters the parameters given in the following tables
shall apply.
SPECIFIED PARAMETERS FOR KPV,

SEC. WDG. RESISTANCE, EXCITATION
CURRENT FOR PS CLASS CORES
AND
BURDEN, ISF FOR METERING CORES

OF
ACC.CLASS 0.2
FOR
33KV, 132KV & 220 KV C.TS
REQUIREMENT FOR 245 KV CURRENT TRANSFORMERS OF RATIO

1200-600-300/1-1-1-1-1A
No. of
Cores
Core
No.
1
5.
2
1
2
3.
4.
5.
Application
Current ratio
Output
burden
in VA
Accuracy
class as
per IS:
2705
Minimum
knee
point
voltage
(Vk) at all
ratios in
volts.
Maximum
CT
resistance
RCT in
ohms at 75
0
C at all
ratios
3
4
Bus different 1200/1
oil check
600/1
300/1
Bus
1200/1
differential
600/1
main
300/1
Metering
1200/1
600/1
300/1
30
30
30
PS
PS
PS
PS
PS
PS
0.2
0.2
0.2
Transformer
back up / line
protection
Transformer
back up/line
protection
PS
PS
PS
PS
PS
PS
1200/1
600/1
300/1
1200/1
600/1
300/1
Maximu
m
excitati
on
current
at Vk in
mA at
all
ratios.
9
600
5.0
40
600
5.0
40
1200
5.0
40
5.0
40
1200
Instrument
security factor
10
1200/1::-5or less
600/1::-5 or less
300/1::-5 or less

a) 800-400A-200A/1-1-1-1A
No. of
Cores
Core
No.
1.
Application
3
Protection
2.
Metering
3.
Back up
4.
For
owners
future use.
Current
Ratilo
4
800/1
400/1
200/1
800/1
400/1
200/1
800/1
400/1
200/1
800/1
400/1
200/1
Output
burden
in VA
Accuracy
class as per
IS: 2705
Minimum
knee point
voltage (Vk)
at all ratios
in volts.
Maximum
excitation
current at Vk
in mA at all
ratios.
Instrument
security
factor at all
ratios
Maximum
CT
resistance
RCT in
ohms at 75
0
C at all
ratios
8
5
30
30
30
-
6
PS
PS
PS
0.2
0.2
0.2
PS
PS
PS
PS
PS
PS
10
400
30
400
30
400
30
5 or less
5 or less
5 or less

b) 600-300A-150A/1-1-1-1A
No.
of
Core
s
1
4
Cor
e
No.
Application
2
1.
3
Protection
2.
3.
4.
Current
Ratilo
4
600/1
300/1
150/1
Metering
600/1
300/1
150/1
Back up
600/1
300/1
150/1
For owners 600/1
future use.
300/1
150/1
Maximum
excitation
current at Vk
in mA at all
ratios.
Instrument
security
factor at all
ratios
Maximum
CT
resistance
RCT in
ohms at 75
0
C at all
ratios
8
10
500
60
500
60
500
60
Output
burden
in VA
Accuracy
class as per
IS: 2705
Minimum
knee point
voltage (Vk)
at all ratios
in volts.
5
30
30
30
-
6
PS
PS
PS
0.2
0.2
0.2
PS
PS
PS
PS
PS
PS
5 or less
5 or less
5 or less

c) 400-200A-100/1-1-1-1A
No.
of
Core
s
1
4
Cor
e
No.
Application
2
1.
3
Protection
2.
3.
4.
Current
Ratilo
4
400/1
200/1
100/1
Metering
400/1
200/1
100/1
Back up
400/1
200/1
100/1
For owners 400/1
future use.
200/1
100/1
Maximum
excitation
current at Vk
in mA at all
ratios.
Instrument
security
factor at all
ratios
Maximum
CT
resistance
RCT in
ohms at 75
0
C at all
ratios
8
10
800
30
Output
burden
in VA
Accuracy
class as per
IS: 2705
Minimum
knee point
voltage (Vk)
at all ratios
in volts.
5
-
6
PS
PS
PS
0.2
0.2
0.2
PS
PS
PS
PS
PS
PS
30
30
30
-
5 or less
5 or less
800
30
800
30

c) 200A-100/1-1-1-1A
No.
of
Core
s
1
4
Cor
e
No.
Application
2
1.
3
Protection
2.
3.
4.
Current
Ratilo
Maximum
excitation
current at Vk
in mA at all
ratios.
Instrument
security
factor at all
ratios
Maximum
CT
resistance
RCT in
ohms at 75
0
C at all
ratios
8
10
800
30
Output
burden
in VA
Accuracy
class as per
IS: 2705
Minimum
knee point
voltage (Vk)
at all ratios
in volts.
4
200/1
100/1
5
-
6
PS
PS
200/1
100/1
30
30
0.2
0.2
200/1
100/1
PS
PS
800
30
For owners 200/1

future use.
100/1
PS
PS
800
30
Metering
Back up
5 or less
5 or less
REQUIREMENT FOR 36KV CURRENT TRANSFORMERS OF RATIO

a)
No.
of
Core
s
Core
No.
1
3.
2
1
2.
3.
Application
3
Protection
Metering
Protection
Current
Ratio
4
400/1
200/1
100/1
400/1
200/1
100/1
400/1
200/1
100/1
Output
burden
n VA
5
30
30
30
-
400-200A-100/1-1-1A
Accurac
y class
as per
IS: 2705
Minimum
knee point
voltage (Vk)
at all ratios
in volts.
6
PS
PS
PS
0.2
0.2
0.2
PS
PS
PS
7
400
Maximum
CT
resistance
RCT in
ohms at 75
0
C at all
ratios
8
5.0
Maximum
excitation
current at
Vk in mA at
all ratios.
9
10
25
400
5.0
25
Instrument
security
factor
5 or less
5 or less
5 or less
-
REQUIREMENT FOR 36KV CURRENT TRANSFORMERS OF RATIO

b)
No.
of
Core
s
Core
No.
1
3.
2
1
2.
3.
Application
3
Protection
Metering
Protection
Current
Ratio
4
800/ 1
400/1
200/1
800/1
400/1
200/1
800/1
400/1
200/1
Output
burden
n VA
5
30
30
30
-
800-400-200A/1-1-1A
Accurac
y class
as per
IS: 2705
Minimum
knee point
voltage (Vk)
at all ratios
in volts.
6
PS
PS
PS
0.2
0.2
0.2
PS
PS
PS
Maximum
CT
resistance
RCT in
ohms at 75
0
C at all
ratios
8
Maximum
excitation
current at
Vk in mA at
all ratios.
9
10
450
10
40
450
10
40
Instrument
security
factor
5 or less
5 or less
5 or less
-
ANNEXTURE B.
CALLIBRATION STATUS OF TESTING EQUIPMENTS AND INSTRUMENTS / METERS
Name
of the
Test
Meters &
Equipments
required for
the
correspondi
ng test with
range
accuracy,
make &
Sl.No.
Date of
Calibrati
on
Due
Date of
Calibra
tion
Name of
the
Calibrating
Agency
Whether
Calibrating
Agency is
Govt.
approved
Whether
documen
-ts
relating
to Govt.
approval
of the
calibratin
g Agency
furnished
Whether
the
meters /
equipme
n-ts fulfill
the
accuracy
class as
per
calibratio
n report
Whether
the
calibrating
agency
has put
any
limitation
towards
the use of
the
particular
meter /
equipment.
If yes state
the
limitations.
Whether
green
sticker or
Blue
Sticker or
Yellow
Sticker has
been
affixed on
the body of
the
particular
equipment
/ meter.
State the
colour of
the affixed
sticker
10
Signature of the tenderer with seal & date
Inspite of Reimposed marks

limitation
s,
whether
the
particular
meter /
equipme
nt can
still be
used ?
Justify its
use for
correspo
nding test
(s)
11
12
ANNEXURE C
CHECK-LIST TOWARDS TYPE TEST & SPECIAL TEST REPORTS
Name
Date of
of the Test.
Type
Test &
special
test
Name of the
Laboratory
where
the
Test
has
been
conducted
Whether the
Laboratory is
Government
approved
Whether the
Test report is
valid as per
Cl.No. 6.1 of
TS
Whether
the copy of
test report
in
complete
shape
alongwith
drawings
etc.
furnished
or not ?
Whether the
tested
Current
Transformer
s fulfill the
technical
requirements
as per TS
If the tested Current Remarks

Transformer does not
fulfill
the
technical
requirements as per
this
specification,
whether
the
bidder
agrees to conduct the
particular
type
test
again at their own cost
without any financial
liability to OPTCL in the
presence of OPTCLs
representative(s) within
the specified delivery
period.
8
9
Signature of the Tenderer with seal and date
ANNEXURE
Requirements for 420kV current transformers

No. of
cores
Core
No.
Application
Bus
differential
Check
Bus
differential
Main
Metering
Current ratio
Output
burden
in VA
Accuracy
class as
per IEC 185
Minimum knee
point voltage Vk
corresponding
to tap position
in Volts
Maximum CT
resistance RCT
in
corresponding
to tap position
Maximum
excitation Current
at Vk in mA
corresponding to
tap position
2000/1
1000/1
...
...
PS
PS
2000
1000
10
5
30 on 2000/1 tap
60 on 1000/1 tap
2000/1
1000/1
...
...
PS
PS
2000
1000
10
5
30 on 2000/1 tap
60 on 1000/1 tap
2000/1
1000/1
500/1
Transformer / 2000/1
line Protection 1000/1
500/1
Transformer
2000/1
back up / line 1000/1
Protection
500/1
60
60
60
...
...
...
...
...
...
0.2
0.2
0.2
PS
PS
PS
PS
PS
PS
...
...
...
4000
2000
1000
4000
2000
1000
10
5
2.5
10
5
2.5
10
5
2.5
...
...
...
30 on 2000/1 tap
60 on 1000/1 tap
120 on 500/1 tap
30 on 2000/1 tap
60 on 1000/1 tap
120 on 500/1 tap
REMARKS: THE BIDDERS ARE ALSO TO FILL-UP THE GTP FOR 400 KV CTS AS PER THE STANDARD FORMAT OF OPTCL
MENTIONED ABOVE FOR OTHER CLASS CT,S. SAME GTP TO BE FILLED-UP.
Remarks

LIMITED

FOR
400,220, 132 & 33 KV ISOLATORS
E13-ISOLATORS- Page 1 of 16
FOR
A) 220KV SINGLE ISOLATOR WITHOUT
EARTH SWITCH.
B) 220KV SINGLE ISOLATOR WITHEARTH
SWITCH
C) 220 KV TANDEM ISOLATOR
D) 132 KV DOUBLE ISOLATOR WITH
EARTH SWITCH.
E) 132 KV SINGLE ISOLATOR WITH
EARTH SWITCH.
F) 132 KV SINGLE ISOLATOR WITHOUT
EARTH SWITCH.
G) 132 KV TANDEM ISOLATOR
H) 33 KV DOUBLE ISOLATOR WITH
EARTH SWITCH
I) 33 KV SINGLE ISOLATOR WITHOUT
EARTH SWITCH
J) 400KV SINGLE ISOLATOR WITH
SINGLE EARTH SWITCH
K) 400KV SINGLE ISOLATOR WITH
DOUBLE EARTH SWITCH
1.
TECHNICAL SPECIFICATION FOR 220 KV. 132 KV & 33 KV ISOLATOR
Type:
1. Main switch
220 KV
132 KV
33 KV
Double end break centre post
rotating, gang operated
2. Service
---------------- Outdoor -------------------
3. Applicable standard
- IS : 9921 / IEC-129/IEC-62271-102.
4. Pole :
3 pole gang operator ----------------
5. Rated voltage nominal /

maximum
220/245
6. Rated requency
------------ 50 HZ + 5%---------------------
7. System earthing
----------- effectively earthed -------
8. Temperature rise
As per relevant IS/IEC publication
132/145
33/36
9. Insulation level
impulse with stand voltage :
a) Across Isolating distance
(kV peak)
1200
750
195
b) To earthed & between poles

(kV Peak)
1050
650
170

(kV Peak)
530
315
80

(kV Peak)
460
275
70
11.
Rated current
2000
1250
800
12.
Short time current for 3 sec.
40 KA
31.5 KA
25KA
13.
Operating mechanism
Motor
Motor
Motor
10.
1 minute power frequency with

stand voltage
14.
15.
Auxiliary voltage
220 KV
132 KV
a) Control & Inter lock
------- 220V DC 80% to 110% -------
b) Motor voltage & heater, lamp

& socket
---- Single phase 240 V 50HZ-----
Safe duration of overload

a) 150% of rated current
-------- 5 minute -------
b) 120% of rated current
-------- 30 minute -------
33 KV
16.
Minimum creepaye distance of support and

Rotating insulator
-----6125mm------3625 mm ---900mm
17.
Mounting structure
-------- Upright on steel structure ------
18.
Terminal connector type
Bimetallic clamp size as per

Requirement
19.
20.
Control
Operating time
----------Local / Remote--------------12 sec, or less(for 220 & 132KV)
REMARKS:
1) The operating mechanism for earth switch of 33 KV only shall be
manual operated.
2) 220 KV Tandem Isolators shall be individual-pole or gang
operated. The operating mechanism of the three poles shall be
well synchronized and interlocked.
2.
TECHNICAL SPECIFICATION FOR 400 KV ISOLATOR
Type:
1. Main switch
400 KV
Double end break centre
rotating, gang operated
2. Service
---------------- Outdoor -------------------
3. Applicable standard
- IS: 9921 / IEC-129/IEC-62271-102.
4. Pole :
3 pole gang operator ----------------
5. Rated voltage nominal /

maximum
6. Rated requency
post
400/420
------------ 50 HZ + 5%---------------------
7. System earthing
----------- effectively earthed -------
8. Temperature rise
As per relevant IS/IEC publication
9. Insulation level
impulse with stand voltage :
a)Across Isolating distance

(kV peak)
b)To earthed & between poles
(kV Peak)
11.
1550
1425
1 minute power frequency with

stand voltage
(kV rms)
610

(kV rms )
520
11.
Rated current
3600 Amp
12.
Short time current for 3 sec.
40 KA
13.
Operating mechanism
Motor
17.
Auxiliary voltage
a) Control & Inter lock
------- 220V DC 80% to 110% -------
b) Motor voltage & heater, lamp

& socket
18.
19.
---- Single phase 240 V 50HZ-----
Safe duration of overload

a) 150% of rated current
-------- 5 minute -------
b) 120% of rated current
-------- 30 minute -------
17.
Minimum creepaye distance of support and

Rotating insulator
10500 mm
Mounting structure
-------- Upright on steel structure ------
18.
Terminal connector type
Bimetallic clamp size as per

Requirement
19.
Control
----------Local / Remote---------------
20.
Operating time
12 sec, or less
** Insulator for 400/220/132/33 kv Isolators:

Top PCD: 127mm/127mm/127/76mm
No of holes: 4XM16
Bottom PCD: 300mm/254mm/254/76mm
No of holes: 8X18 dia/4xM16
3.
SCOPE
This specification provides for design, manufacturer, testing at

manufacturers Works and delivery ,supervision of erection, commissioning(if
required )of outdoor station type 400 KV/220KV /132KV /33KV, 3 phase triple pole
double break gang operated centre rotating type (Single / Double) Isolator with /
without earth switches, with electrical inter lock, insulators and complete in all respect
with bimetallic connectors arcing horns operating mechanism, auxiliary switches,
indicating devices, fixing detail etc. as described hereinafter.
4.STANDARDS
Disconnecting switches covered by this specification shall conform to latest
edition IEC-129/IEC 62271-102 I.S.1813 and IS: 9921,IS-325,and unless specifically
stated otherwise in this specification.
5.TYPE
The 220&132 &33 KV Isolators shall be outdoor type with three phase double
break centre rotating type [Single (SI) / Double (DI) ] Isolators suitable for electrical
as well as manual operation and local/remote operation. They shall have crank and
reduction gear mechanism.
All Isolators offered shall be suitable for horizontal upright mounting on steel
structures. Each pole unit of the multiple Isolators shall be of identical construction
and mechanically linked for gang operation.
Each pole of the Isolator shall be provided with two sets of contacts to be operated in
series and the moving contact blades shall rotate in horizontal plane.
The design shall be such that the operating mechanism with the linkages shall be
suitable for mounting on any of the outer pole ends without much difficulty and with
minimum shifting of parts.
Moving contacts of all isolators shall rotate through 90 deg from their fully closed
position to fully open position so that the break is distinct and clearly visible from
ground level.
The Isolators offered by the Bidder shall be designed for Normal rating current for
Isolator
400 KV 220 kV 132 kV
33kV
3600A 2000A 1250A
800 amp
It should suitable for continuous service at the system voltages specified
herein. The Isolators shall be suitable to carry the rated current continuously and full
short circuit current of 40/31.5/25 KA for 400 and 220/132/33 KV respectively for 3
second at site condition without any appreciable rise in temperature. These shall also
be suitable for operation at 110% rated (normal) voltage. The Isolators shall be
suitable for Isolating low capacitive / inductive currents of 0.7amp at 0.15 power
factor. The isolators shall be so constructed that they dont open under the influence
of short circuit conditions.
The Isolators and earthing switches are required to be used on electrically
exposed installation and this should be taken into account while fixing the clearance
between phases and between phase and earth.
6.
MAIN CONTACTS
All Isolators shall have heavy duty, self aligning and high pressure line type
contacts made of high conductivity, corrosion resistant, hard-drawn electrolytic
copper strips of proper thickness and contact area. Fixed contact should consist of
loops of above copper strips suitable for 3600 Amps,2000 Amps, 1250 Amps, and
800 Amps ratings for400 KV, 220 KV, 132 KV and 33 KV Isolators respectively. The
hard dawn electrolytic copper strips should be silver plated 10 micron thickness or
more as per the requirement and fixed contacts should be backed by powerful
phosphor bronze/stainless steel springs of suitable numbers. However, the thickness
and contact area of the contact should conform to the drawing approved during type
test.
These fixed and moving contacts shall be able to carry the rated current continuously
and the maximum fault current of 40/31.5/25 KA for 400 and 200/132/33KV
respectively for 3 seconds without any appreciable rise in temperature. The Isolator
blades shall retain their form and straightness under all conditions of operation
including all mechanical stress arising out of operation as well as under rated short
circuit condition.
Fixed guides shall be provided so that even when the blades are out of alignment by
one inch (maximum), closing of the switches, proper seating of the blades in between
contacts and adequate pressure to give enough contact surface is ensured. Wherever
possible, the blades shall be counter balanced by weights and springs. The contact
shall be self cleaning by the wiping action created by the movements of the blades.
The surface of the contacts shall be tendered smooth and silver plated.
The Isolator shall be self cleaning type so that when isolator remain closed for
long periods in a heavily polluted atmosphere, binding does not occur. No undue wear
or scuffing shall be evident during the mechanical endurance tests, contacts and
springs shall be designed so that adjustment of contact pressure shall not be necessary
throughout the life of the isolator. Each contact or part of contacts shall be
independently sprung so that full pressure is maintained on all contact at all times.
7.
ARCING HORN AND GRADING HORN
Suitable arcing horn made of tinned electrolytic copper which are required for
guiding contacts shall be provided on the fixed and moving contacts of all Isolators.
The contacts shall be of make before and break after type.
8.
ELECTRICAL INTERLOCK / MECHANICAL INTERLOCK
The disconnecting switches whenever required shall be with an approved type
electrical interlock for interlocking with the associated circuit breakers and earth
switch. Electrical interlock assembly should be more right in construction and
properly mounted to ensure reliable operation. The design should be such that the
electrical circuit for the interlocking mechanism will only remain energised during
operation of the switches.
9.
AUXILIARY SWITCHES
All isolators and earthing switches shall be provided with 220VDC auxiliary switches
for their remote position indication on the control board and for electrical interlocking
with other equipment. The auxiliary switch shall be provided with a minimum of
auxiliary contacts-10 normally open and 10 normally closed and 10 normally open
and 10 normally closed for earth switch. Separate auxiliary switches shall be provided
for isolating and earth switches. 6 additional NO and NC contact to be provided as
spare in each case.
The auxiliary switches and auxiliary circuits shall have a continuous current carrying
capacity of at least 10 Amps. Auxiliary switches shall not be used as limit switches.
Details of make, rating and type of limit switch shall be furnished in the offer.
10.
EARTH SWITCH
Line earth switch shall consist of three earthing blades for Isolator which normally
rest against the frame when the connected Isolator is in closed position. The earthing
blades for three phase shall be mechanically linked to a coupling shaft which shall be
capable of being fitted on either side of the Isolator. The earthing blades shall match
and be similar to the main switch blades and shall be provided at the hinge; with
suitable flexible conductors with terminal lugs for connecting to the station ground
bus. The earthing blades shall be operated by a separate mechanism but shall be
mechanically interlocked with the main switch so that the earthing blades can be
closed only when the main switches are in open position and vice-versa. The earthing
blades shall be gang operated and all the three blades will operate simultaneously.
11.
OPERATING MACHANISM
The operating mechanism shall be simple and shall ensure quick and effective 1000
operation. The design shall be such as to enable one man to operate it with nominal
effort. The operating mechanism box shall be made out of Aluminum extruded
(Aluminum Alloy) sections of minimum 3mm thickness.
The Isolator blades shall be in positive continuous control throughout the entire cycles
of operation. The operating rods and pipes shall be rigid enough to maintain positive
control under most adverse conditions and to withstand all torsional and bending
stresses arising from operation. Operation of the switches at any speed should not
result in improper functioning, in displacement of parts / machines after final
adjustment has been made. All holes in cranks, linkages etc. having moving pins shall
be drilled and fitted accurately so as to prevent slackness and lost motion.
Provision shall be made for padlocking the operating mechanism of disconnecting and
earth switches in both open and closed positions.
Bearings shall be ball and roller type shall be protected from weather and dust by
means of cover and grease retainers. Bearings pressures shall be kept low to ensure
long life and care of operation.
Each power operated isolator shall be motor driven as well as manually operated and
shall be complete with local / remote selector switch and open / close push buttons.
The function of all control facilitates operating isolators.
Provision shall be made in the control cabinet to disconnect power supply to prevent
local / remote power operation. Limit switches for open and close positions of reisolations and earth switches.
12.
DESIGN, MATERIALS AND WORKMANSHIP
The live parts shall be designed to eliminate sharp points, edges and similar corona
producing surfaces, where this is impracticable, adequate shields to be provided. All
ferrous metal parts shall be hot dip galvanized, as per IS 2629.All metal parts shall be
of such materials or treated in such a way so as to avoid rust, corrosion and
deterioration due to continued exposure to atmosphere and rain. All current carrying
parts shall be made from high conductivity electrolytic copper / aluminium.
Bolts, screws and pins shall be provided with standard locking device viz. Locknuts,
spring washers, keys etc. and when used with current carrying parts, they shall be
made of copper silicon or other high conductivity and wear resistant alloys.
The switches should not need lubrication of any parts except at very long interval of
five year minimum.
13.
PROTECTIVE COATINGS
All ferrous parts including bolts, nuts and washers of the switches assembly shall be
galvanised to withstand at least six one minute dips in copper sulphate solution of
requisite strength (Prece tests) except the threaded portions which should withstand
four dips.
14.
Insulators Support insulators for all type of isolators shall be of solid core
type.The insulator shall be made of homogeneous and vitreous porcelain of high
mechanical and dielectric strength. It shall have sufficient mechanical strength to
sustain electrical and mechanical loading on account of wind load, short circuit forces
etc. Glazing of the porcelains shall be of uniform dark brown colour with a smooth
surface arranged to shed away raise water. The porcelain shall be free from
laminations and other flaws or imperfections that might affect the mechanical or
dielectric quality. It shall be thoroughly vitrified, tough and impervious to moisture.
The porcelain and metal ports shall be assembled in such a manner and with such
material that any thermal differential expansion between the metal and porcelain parts
throughout the range of temperature specified in this specification shall not loosen the
parts or create under internal stresses which may affect the mechanical or electrical
strength or rigidity. The assembly shall not have excessive concentration of electrical
stresses in any section or across leakage surfaces. The cement used shall not give rise
to chemical reaction with metal fittings. The insulator shall be suitable for water
washing by rain or artificial means in service condition. Profile of the insulator shall
also conform to IEC-815. Insulator shall have a minimum cantilever strength of 800
kgs. Caps to be provided on top of the insulator shall be of high grade cast iron or
malleable steel casting. It shall be machine faced and hot dip galvanized. The cap
shall have four numbers of tapped holes spaced on a pitch circle diameter of 127mm.
The holes shall be suitable for bolts with threads having anti corrosive protection. The
effective depth of threads shall not be less than the nominal diameter of the bolt. The
cap shall be so designed that it shall be free from visible corona and shall have radio
interference level within 500 micro volts.Casing shall be free from blow holes cracks
and such other defects.
15.
Control Cabinet : The control cabinet of the operating mechanism shall be
made out of aluminium sheet of minimum 3mm thickness. Hinged door shall be
provided with pad locking arrangement. Sloping rain hood shall be provided to cover
all sides. 15 mm thick neoprene or better type of gaskets shall be provided to ensure
degree of protections of at least IP 55 as per IS 2147/IS-3947. The cabinet shall be
suitable for mounting on support structure/or on a separate plinth foundation with

adjustment for vertical, horizontal and longitudinal alignment. Details of these
arrangements shall be furnished along with the offer.
16.
Motor : Motors rated 1 Kw and above shall be suitable for operation on 3
phase, 415 V, 50 HZ supply. Motors of lower rating shall be single phase type
suitable for 240V, 50HZ system. It shall be totally enclosed type if mounted outside
the control cabinet. The motor shall withstand without damage stalled torque for
atleast 3 times the time lag of tripping device. The motor shall, in all other respects,
conform to the requirement of I.S. 325.
17.
Gear : The dis-connector / isolator may be required to operate occasionally,
with considerably long idle intervals. Special care shall be taken for selection of
material for gear and lubrication of gears to meet this requirement. The gear shall be
made out of aluminium bronze or any other better material lubricated for life with
graphite or better quality non-drawing and non-hardening type grease. Wherever
necessary automatic relieving mechanism shall be provided suitable relay, Device
shall be provided to prevent over loading of the motor. Single phase preventer (for 3
phase meter) shall be provided to operate on open circuiting of any phase and shall
trip off the motor. Complete details of the devices shall be furnished in the offer.
18.
Space heaters : Space heaters with thermostat auto control suitable for 1
phase 240V AC supply shall be provided for each motor operated operating
mechanism to prevent condensation and shall be operated by MCB.
19.
Terminal block and Wirings Each operating mechanism shall be provided
with 1100V grade stud type terminal block. All auxiliary switches, interlocks and
other terminals shall be wired upto terminal block. The terminal block shall have at
least 20% extra terminals. All wiring shall be carried out with 1.1KV grade insulated
2.5 sqmm copper wires.
20.
Interior Illumination : A light fixture suitable for a 240 V CFL tube light
shall be provided in each of the motor operated mechanism of three poles & shall be
door operated type.
21.
Control and auxiliary supply A 3 phase switch with MCB for phases and
link for neutral, shall be provided for power supply and a 2 pole MCB shall be
provided for control supply.
22.
Position indicator : A position indicator to show the isolator is in ON or
OFF position to be provided.
23.
Name plate : Isolator, earthing switches and their operating devices shall be
provided with name plate. The name plate shall be weather proof and corrosion proof.
It shall be mounted in such a position that it shall be visible in the position of normal
service and installation. It shall carry the following informations duly engraved or
punched on it.
A.
Isolator Base
Name : OPTCL
Name of manufacturer
Order No.
Type Designation
Manufacturers serial No.
Rated voltage
Rated normal current
Rated short time current (rms) and duration
Rated short time peak current (KAP)

Weight
B.
B. Earthing Switch
Name : OPTCL
Order No.
Type Designation
Manufacturers serial No.
Rated voltage
Rated normal current
Rated short time current (rms) and duration
Rated short time peak current (KAP)
Weight
C.
Operating Device
Name OPTCL
Order No.
Type Designation
Reduction gear ratio
AC motor
i)
Rated auxiliary voltage
ii)
Starting current
iii)
Designation of AC motor as per I.S 4722/325
iv)
Starting torque at 80% of supply voltage
v)
Over travel in degrees after cutting off supply
Total operating time in seconds
i)
Close operation Electrical
ii)
Open operation electrical
Open operation manual
All components shall be given adequate treatment of climate proofing as per IS:3202
so as to withstand corrosive and severe service conditions.
All metal parts not suitable for painting such as structural steel, pipes, rods ,levers,
linkages, nuts and bolts used in other than current path etc. shall be hot dip gaivanised
as per IS -2629
Complete details of painting, galvanising and climate proofing of the equipment shall
be furnished in the offer.
24. TESTS
Type Tests
Isolators offered, shall be fully type tested as per the relevants standards. The Bidder
shall furnish Three sets of the following valid type test reports for their different type
of offered Isolators alongwith the offer. The Purchaser reserves the right to demand
repetition of some or all the type tests in the presence of purchasers representative.
For this purpose the Bidder may quote unit rates for carrying out each type test and
this will be taken during bid price evaluation ,if required.
a)short time withstand & peak withstand current test for Isolator & Earth Switch.
b)power frequency (Dry & Wet),Lightening Impulse dry withstand Test
c) Mechanical endurance Test
d) IP-55 test
During type tests the isolator shall be mounted on its own support structure or
equivalent support structure and installed with its own operating mechanism to make
the type tests representative. Drawing of equivalent support structure and mounting
arrangements shall be furnished for Purchasers approval before conducting the type
tests.
The type tests shall be conducted on the isolator along with approved insulators and
terminal connectors.
Mechanical endurance test shall be conducted on the main switch as well as earth
switch of one isolator of each type
Acceptance and Routine Test :
All acceptance and routine test as stipulated in the relevant standards shall be carried
out by the supplier in presence of Purchasers representative.
Mechanical operation test (routine test) shall be conducted on isolator (main switch
and earth switch) at the suppliers works as well as purchasers substation site.
Immediately after finalisation of the programme of type / acceptance, routine testing
the supplier shall give sufficient advance intimation (clear 20 days advance
intimation), along with shop routine test certificates, valid calibration reports from
Govt. approved test house for the equipments, instruments to be used during testing
for scrutiny by the purchaser to enable him to depute his representative for witnessing
the tests. If there will be any discrepancies in the shop routine test certificates and
calibration reports furnished by the firm then after settlement of the discrepancies
only, purchasers representative will be deputed for witnessing the tests.
Special tests proposed to be conducted (if decided to conduct ) as type test on
isolators, are given at Annexure- II. These special type test charges shall be quoted
alongwith all other type tests as per relevant IEC standard and these charges shall be
included in the total bid price.
Test certificates of various items including but not limited to the following shall be
furnished at the time of routine tests.
a)
Chemical analysis of copper alongwith a copy of excise certificate
indicating genuine source of procurement of electrolytic grade copper.
b)
Bearings
c)
Fasteners
d)
Universal / swivel joint coupling
e)
Insulators
f)
Motor
g)
Gears
h)
Auxillary switch
i)
Limit switch
j)
Timer
k)
Overload / single phase preventer relay
l)
Interlocking devices
m)
Terminal block
n)
Any other item
25. INSPECTION
i)
The Purchaser shall have access at all times to the works and all other
places of manufacture, where the disconnectors, earth switches and associated
equipment are being manufactured and the supplier shall provide all facilities for
unrestricted inspection of the works raw materials manufacture of all the accessories
and for conducting necessary tests as detailed herein.
ii)
The supplier shall keep the purchaser informed in advance of the time
of starting of the progress of manufacture of equipment in its various stages so that
arrangements could be made for inspection.
iii)
No material shall be dispatched from its point of manufacture unless
the material has been satisfactorily inspected and tested.
iv)
The acceptance of any quantity of the equipment shall in no way
relieve the supplier of his responsibility for meeting all the requirements of this
specification and shall not prevent subsequent rejection if such equipment are later
found to be defective.
26
QUALITY ASSURANCE PLAN
The Bidder shall invariably furnish following information alongwith his offer, failing
which his offer shall be liable for rejection.
(i)
Names of sub suppliers for raw materials, list of standards according to
which the raw materials are tested, list of tests normally carried out on raw materials
in presence of Suppliers representative, copies of test certificate
(ii)
Information and copies of test certificates as in (I) and (ii) above in
respect of bought out accessories.
(iii)
List of manufacturing facilities available
(iv)
Level of automation achieved and list of areas where manual
processing still exists.
(v)
List of areas in manufacturing process, where stage inspections are
normally carried out for quality control and details of such tests and inspections.
(vi)
List of testing equipments with calibration certificates from Govt.
approved test house available with supplier for final testing equipment and test plant
limitation if any, vis--vis the type, special acceptance and routine test specified in the
relevant standards. These limitations shall be very clearly brought out in the specified
test requirements.
The supplier shall within 30 days of placement of order, submit following information
to the purchaser.
i)
List of raw material as well as bought out accessories and the names
of sub-suppliers selected from the lists furnished alongwith offer.
ii)
Type test certificates of the raw material and both bought out
accessories.
iii)
Quality Assurance Plan (QAP) with hold points for purchasers
inspection.
The supplier shall submit the routine test certificates of bought out accessories and
raw material viz. Copper, aluminium conductors, lubricating material, gear material
etc. at the time of routine testing of the fully assembled isolator.
27.
DOCUMENTATION
All drawings shall conform to relevant international standards organisation (ISO). All
drawings shall be in ink and suitable for micro filming. All dimensions and data shall
be in S.I. Units.
List of Drawings and Documents
The Bidder shall furnish four sets of following drawings / documents

along with
his offer.
a)
General outline and assembly drawings of the dis-connector operating
mechanism, structure, insulator and terminal connector.
b)
Sectional views and descriptive details of items such as moving blades,
contacts, arms contact pressure, contact support bearing housing of bearings,
balancing of heights, phase coupling pipes, base plate, operating shaft, guides, swivel
joint operating mechanism and its components etc.
c)
Loading diagram
d)
Drawings with structure for the purpose of type tests.
e)
Name plate.
f)
Schematic drawing.
g)
Type test reports.
h)
Test reports, literature, pamphlets of the bought out items and raw
material.
The supplier shall within 2 weeks of placement of order submit four sets of final
versions of all the above said drawings for Purchasers approval. The purchaser shall
communicate his comments / approval on the drawings to the supplier. The supplier
shall, if necessary, modify the drawings and resubmit four copies of the modified
drawings for Purchasers approval within two weeks from the date of comments.
After receipt of approval the supplier shall within three weeks submit 15 prints and
two good qualities re-producible of the approved drawings for purchasers use.
Six sets of the type test reports, duly approved by the Purchaser shall be submitted by
the supplier for distribution, before commencement of supply Adequate copies of
acceptance and routine test certificates, duly approved by the Purchaser shall
accompany the despatched consignment.
The manufacturing of the equipment shall be strictly in accordance with the approved
drawings and no deviation shall be permitted without the written approval of the
purchaser. All manufacturing and fabrication work in connection with the equipment
prior to the approval of the drawing shall be at the supplier risk.
28.
INSTRUCTION MANUALS :
Fifteen copies of the erection, operation and maintenance manuals in English be
supplied for each type of disconnector one month prior to despatch of the equipment.
The manual shall be bound volumes and shall contain all drawings and information
required for erection, operation and maintenance of the disconnector including but not
limited to the following particulars.
(a)
Marked erection prints identifying the component parts of the
disconnector as shipped with assembly drawings.
(b)
Detailed dimensions and description of all auxiliaries.
(c)
Detailed views of the insulator stacks, metallics, operating mechanism,
structure, interlocks, spare parts etc.
29.
PACKING AND FORWARDING.
The equipment shall be packed in crates suitable for vertical / horizontal transport, as
the case may be and suitable to withstand handling during transport and outdoor
storage during transit. The supplier shall be responsible for any damage to the
equipment during transit, due to improper and inadequate packing. The easily
damageable material shall be carefully packed and marked with the appropriate
caution symbols. Wherever necessary, proper arrangement for lifting, such as lifting
hooks etc. shall be provided. Any material found short inside the packing cases shall
be supplied by supplier without any extra cost.
Each consignment shall be accompanied by a
detailed packing list containing the following information:
(a)
(b)
(c)
Destination.
(d)
(e)
(f)
Bill of material indicating contents of each package.
The supplier shall ensure that the bill of material is approved by the purchaser before
despatch.
30.
SUPERVISION OF ERECTION TESTING AND COMMISSIONING
(ET & C)
Purchaser proposes to utilize the services of the supplier for supervision of
testing and commissioning of the equipment being supplied by him, if it is required.
For this purpose, the supplier should make available the services of trained personnel
(Engineers) who shall correct in the field, any errors or omissions in order to make the
equipment and material properly perform in accordance with the intent of this
specification. The Engineer shall also instruct the plant operators in the operation and
maintenance of the commissioned equipment. The supplier shall be responsible for
any damage to the equipment on commissioning the same, if such damage results for
the faulty or improper ET&C. Purchaser shall provide adequate number of skilled /
semi skilled workers as well as ordinary tools and equipment and cranes required for
equipment errection, at his own expenses. Apart from the above, the Purchaser shall
not be responsible for providing any other facilties to the supplier. Special tools if
required for erection and commissioning shall be arranged by the supplier at his cost
and on commissioning these shall be supplied to the purchaser free of cost for future
use.
31.
QUATITITY AND DELIVERY REQUIREMENTS :
(i)
The scope of supply shall include a supply of 2.5% extra quantity of gal
vanised bolts, nuts, washers, split pins, cotter pins and such other small loose items
free of cost.
ANNEXURE I
(Isolators)
LIST OF SPECIAL TESTS TO BE CARRIED OUT IF DECIDED BY THE
PURCHASER
Sl. No. Name of the Test
Standard to which it
conforms.
1.
Test for visible Corona and Radio NEMA Pub No. 107-1964
interference voltage (RIV) on disconnectors ISRI Pub No. 1-1972
and teminal connector
2.
Tests on insulators
IS-2544 IEC. 168
3.
Tests on terminal connectors
IS:5561
4.
Tests on galvanised components
IS:2633
5.
Stalled torque test on motor operating At 110% of supply voltage

mechanism
LIST OF MANDATORY SPARES (AS PER SPARE LIST SEPARATELY

ENCLOSED)
Sl. No.
Item
Quantity
1.
Copper contact fingers for male and female 2sets each for each Type
contact per Isolator
of Isolators
(400/220/132/33KV)
2.
Relay, power contactors, switch fuses for 2sets each for each Type
electrical control circuit per Isolator (Indicate of
(400/220/132/33KV)
the nos of relay, power contactors, switch Isolators
fuses used in the electrical circuit of each type
of isolators)
3.
Support insulator stack for one pole of the 2 stacks (for each type of
isolator
Isolators)
4.
Terminal pad
2 Nos. each (for each type
of isolators)
5.
Limit switch and Auxiliary switch per 2sets (for each type of
Isolator(Indicate the nos of each switch used in 400kv,220KV,132 & 33
each type of isolators)
KV Isolators)
6.
Terminal connectors per Isolator
2 sets for each type of
isolators.
FOR
250 KVA & 1 MVA, 33/0.433 KV STATION
TRANSFORMER
E14-STATION TRANSFORMER- Page 1 of 18
TECHNICAL SPECIFICATION FOR 250 KVA & 1 MVA

33/0.433 KV STATION TRANSFORMER
TECHNICAL SPECIFICATION FOR 250 KVA, 33/0.433 KV

STATION TRANSFORMER
1.
& 1
MVA, 33/0.433 KV
TYPE:
The Transformers shall be of the out door core type double wound oil immersed self cooled type
ON and conform to ISS 1183/1964 and 2026/1977 with up-to-date amendments.
All the transformers shall be suitable for operation in humid atmosphere in the
ambient temperature ranging from 50 to 60 C.
2.
tropical place with
STANDARD
The transformers shall comply with ISS 2026/1977 , 1183/1964 & the latest version thereon &
CBIP standards with Class-A materials specified therein and should be designed taking
ambient temp. as 50 C.
3.
RATING
The transformer shall have core type copper wound construction, oil immersed ON suitable for
out-door service as a step down transformer. The rating and electrical characteristics of the
transformers shall be as follows:
250KVA
1MVA
i)
Frequency
------------50 Hz 5% -------ii)
Continuous rating
250 KVA
1MVA
iii)
Rated HT/LT voltage
----------33/0.433 KV-----------iv)
Number of phase
----------3 phases
-----------v)
Connection HT
-------------Delta
------------vi)
Connection LT
-------------Star
-------------vii)
Vector group
-------------Dyn 11-------------viii) Taps
-5% to +7.5% in steps 2.5% in
high voltage side.
ix)
Percentage impedance at
----- +5% (Minimum)-------Continuous maximum
(No negative tolerance is allowed)
Rating at 75 C
x)
Type tap changer for transformer
(Rotary type, off load control
tap changing gear)
xi)
BIL
---------------170 KVP-----------xii)
Terminal connection
Bimetallic clamp suitable for
ACSR conductor as per system
Requirement.
xiii) Maximum flux density at normal
Voltage & normal frequency 1.4 Tesla
4.
The primary-winding shall be connected Delta and secondary winding star as per vector
symbol Dyn-II(IS:2026/1977). The terminal arrangement shall be out door bushing suitable
for bare ACSR Twin Zebra conductors for 33 KV side and to suit 3 x300 mm armoured
PVC cable with cable end box for 433volt side.
The temperature rise should not exceed the limits stated in relevant standards. The
transformer shall be capable of withstanding thermal and mechanical effects, of a short
circuit on the terminals of any winding with full voltage maintained on other windings for a
duration of at least five seconds.
5.
INSULATION
5.1
5.2
5.3
6.
VOLTAGE RATIO
6.1
6.2
7.
The electric strength of the winding insulation and of bushings shall conform to the values
given in the IS:2026/1977.
For rated system voltage of 33 kV the impulse test voltage is 170 kV (Peak).
All windings of the transformer shall have uniform insulations.
The transformers shall be for the rated kV specified on the HV side and on the LV side.
The insulation and magnetic circuit shall be suitable for working continuously at 10% in
excess of the normal voltage and at the same time at a frequency of 3% below the normal.
CURRENT DENSITY
The current density in windings shall be kept within 2.4 A/sq.mm.
8.
FLUX DENSITY
The maximum induction with maximum system voltage i.e. 36 kV& frequency, and the type of
steel used for core laminations should be stated in the tender. Flux density at maximum
system voltage i.e. 36 kV and lowest frequency 48.5 C/S shall not exceed 1.6 Tesla.
9.
FRERQUENCY
The transformers shall be suitable for continuous operation with a frequency variation of plus or
minus 3% from the normal frequency of 50 Hz without exceeding the temperature rise
specified in clause 17.
10.
TERMINAL ARRANGEMENTS
HT side Bimetallic clamp type, suitable for ACSR conductor as per requirement and
layout.
LT side cable connection, 3 x 300 mm armoured PVC aluminium cable. The neutral of
the star end brought to a separate insulation terminal for earthing purpose.
11.
TAPPINGS
Tappings range shall be 12.5% in steps of 2.5% and it shall be off load type with local
control. The taps shall provide for voltage adjustment on the high voltage side from 5% to
+7.5% of the rated voltage, the tappings being located on higher voltage winding.
The transformer shall be so designed that the temperature rise is maintained within limits,
specified in relevant standards when operated at full output or constant primary service
voltage on any primary tappings irrespective of the tapping corresponding to the service
voltage.
An externally operated off circuit tapping switch shall be provided to enable changing of
taps without removing the transformer cover or lowering of the oil level. The transformer
shall give full rated KVA output of each winding at all the taps.
The switch mechanism shall be so designed as to prevent the entry of moisture into the tank.
The design of the switch mechanism shall ensure that the switches are making full contact
and then only it shall be possible to look the operating mechanism. The tap mechanism shall
be provided with a locking device.
12.
BUSHING TERMINALS
All main winding and neutral leads shall be brought out through outdoor type bushing
suitable for bare copper or ACSR conductors for 33 kV side and to suit for 3 x 300 mm
armoured PVC cable for 433 volt side & so located that the full flash over strength will be
utilized.
Each bushing shall be so coordinated with the transformer insulation that all flashovers will
occur outside the tank. The porcelain used for the bushings shall be of the wet processed
type, homogenous and free from cavities or other defects. The glaze of the porcelain parts
shall be uniform in colour and free of blisters, burns and other defects.
The bushings should conform to IS:2099/73 and with 3347(Part-I & II Section 1 & 2) with
its latest amendments.
13.
FLASHOVER CHARACTERISTICS OF BUSHINGS

The spacing between the bushings must be adequate to prevent flash over between phases
under all condition of operation. Special adjustable coordinating gaps should be provided on
the high-tension terminals and the gap setting adjusted with reference to the impulse
coordination of the system. The tenderer is requested to give the guaranteed withstand
voltage for the impulse and flash over values of the bushings.
14.
SUPPRESSION OF HARMONNICS
The transformers shall be designed with particular attention for suppression of harmonic
voltages especially the 3rd and 5th so as to eliminate wave form distortion and any possibility
of high frequency distortion and any possibility of high frequency disturbances, inductive
factor or of circulating current between neutral point at the different transformer station
reaching such a magnitude as to cause, interference with post office or other communication
circuits.
15.
CENTRE OF GRAVITY
The center of gravity of the assembled transformer shall be low and as near the vertical
centerline as possible. The transformer shall be stable with or without oil. If the center of
gravity is eccentric to the vertical line either with or without oil, its location shall be shown
on the outline drawing.
16.
VIBRATIONS AND NOISE

The transformers shall operate without undue vibration and noise and shall comply with
NEMA publication TR 1.
17.
TEMPERATURE RISE
Each transformer shall be capable of operating continuously at this normal rating without
exceeding temperature rise limits as specified below:
i)
Winding 55C by resistance measurement.

ii)
Top oil 50C by thermometer measurement.
The above limits are with an ambient temperature of 50 maximum. All transformers shall comply
with requirement of IS:2026/77 & its latest amendments as regard the rating and
temperature rise.
18.
EFFICIENCY
The efficiencies of the transformer corresponding to 25%, 50%, 75%, 100% and 125% load may be
specified. Maximum efficiency should occur at 50% load.
19.
PERCENTAGE IMPEDENCE
The transformer offered must be designed for a minimum impedance of +5% at 75 C. No negative
tolerance on impedance is allowed.
20.
LOSSES
The no load & load losses shall not exceed the values given in the following table.
Ratings
NO LOAD LOSS IN LOAD

LOSS
WATTS
WATTS
75DEGREE C
NORMAL TAP
KVA(Copper 620 FIRM
3700 FIRM
250
wound)
1MVA(Copper
Wound)
2200 FIRM
11500 FIRM
IN PERCENTAGE
AT IMPEDANCE AT 75
AT DEGREE
C
AT
NORMAL TAP
5 (Minimum)
5 (Minimum)
The above losses are maximum allowable losses & there shall not be any + ve
tolerance
on the losses for the transformers. Bid evaluation will be done taking in to consideration the
quoted no load & load loss figures. The purchaser reserves the right to reject the whole lot of
supply in case the loss figures exceed the limit given in above table at the time of testing.
21.
PARALLEL OPERATION
The transformers with similar connection shall be capable of operating in parallel on corresponding
taps and of sharing loads in proportion to their ratings subject to the tolerances of
impedance.
22.
WINDING AND INSULATION

All permanent current carrying joints shall be welded or brazed.
All threaded connections shall be provided with locking facilities.
The assembled core and coils shall be properly dried before impregnation. The process of
impregnation should be stated.
All leads from the winding shall be rigidly supported to prevent injure isolation due to vibration.
Flexible tubes shall be used where practicable.
- The HT and L:T winding of all transformers shall be of the fully insulated type.
a. Special attention should be given to provisions of adequate insulation and clearances
between HT and LT windings and live parts must be adequate for normal voltage of
operation plus 10%.
b. The end turn insulation of the transformers shall inconformity with latest practice.
c. Windings shall be circular and concentric with the HT windings on the outside. All
similar coils shall be inter changeable.
d. The insulation of the transformer winding and connection shall be free from
insulating compound which may so often coagulate shrink or collapse during service.
None of the materials used shall shrink, disintegrate, carbonized or become brittle
under the action of hot oil when the transformer is operated continuously with the
conductors at any temperature which may be reached at the specified loading
conditions.
The finished width of any oil ducts shall be such and the clamping arrangement shall be so
designed as not to impede the free circulation of oil through the ducts.
23.
BRACING OF WINDINGS
Windings connections and tappings of the transformers shall be braced to withstand the
shocks, which may occur during transport and during service due to short circuit, switching
or other transient condition. No mechanical movement of coils shall be possible with dead
short circuit on either side of the transformer. The short circuit rating shall be as per Clause
9.1 ISS: 2026/1977.
24.
MAGNETIC CIRCUITS
The transformers core shall be of high grade non-ageing, electrical silicon steel cold-rolled
laminations each coated with hot oil proof, lead enamel insulation clamped together firmly
to the frame to ensure even pressure over the whole of the core laminations and to prevent
undue vibration and noise. After being sheared the laminations shall be treated to remove all
burns and shall be reannealed to remove all strains.
Paper or varnish insulation shall not be accepted. The joints in the core shall be inter leaved
and in no account will Butt Joints be accepted. Suitable axial cooling ducts suitable
proportioned to prevent excessive temperature rise must be provided to ensure, free
circulation of oil and efficient cooling of the core. The clamping structure shall be so
constructed with MS Channels, and insulated bolts and so designed that eddy currents is
minimum and hood must not be used for the purpose. The core shall be designed and build
up in such a manner as to avoid accidental or slow development of short circuit plates
through iron and frame.
The core and coils shall be so fixed in the tank that their shifting will not occur when the
transformer is moved.
Means shall be provided for earthing the core and framework at one point only.
25.
TRANSFORMER TANK
The tank and cover of each transformer shall be of welded boilerplate with suitable
stiffeners so constructed that all joints are hot oil tight and bulging does not occur in service.
The tank shall be so designed that with the minimum dismantling necessary, the core and
winding can be lifted free of the case. External lugs or eyes for lifting the core or windings
shall be provided. Ample space shall be provided with an appropriate arrangement of things,
suitable for lifting transformer core with winding. The tank shall be fitted with a substantial
under carriage and provided with rollers.
26.
OIL
Sufficient quantity of oil shall be supplied with each transformer for filling each tank,
bushing and conservator to the proper level. The oil shall be in accordance with IS
No.335/1972 &its latest amendments. Oil test certificates shall be furnished at the time of
inspection of transformers in support of the use of new unused oil conforming to IS 335 in
the transformer.
27.
EARTHINGS
The core and tank cover shall be earthed to the tanks by means of copper connection capable
of carrying for 30 seconds without injury and over loading with earth fault current not less
than full load current of the main transformer. In no case shall the cross sectional area be
less than 0.1 sq. inch. Two earthing terminal shall be provided suitable for No 7 SGW bare
copper wire with suitable soldering lugs.
28.
TANK FITTINGS AND ACCESSORIES

The standard fittings to be provided on each transformer in line with manufacturers practice
, may be provided including the following:
a.
Oil conservator of sufficient capacity to prevent inadvertent operation of

Buchholz relay where used and shall be provided with drain plug/valve oil
gauge, with a mark to indicate oil level at a temperature of 50 C filling cap.
Silica Gel dehydrating breather to contain minimum 0.5 kg dehydrated
silicagel..
b.
Explosion Vent
A safety valve of chimney type shall be provided. The bottom of the safety
valve pipe shall project into the tank.
c.
Glass Type Thermometer

Mercury in glass type thermometer mounted on the top of the transformer to
read the temperature in the hottest part of the oil.
d.
Drain Valve
1 (15mm) drain valve cum lower filter valve suitable for connection to the
flange of the same diameter. The valve should be fitted with an adopter for 16
mm hose for filtering purposes. The valve shall be located so as to enable
with drain out of the oil from the tank. This valve shall be equipped with a
small sampling cock.
e.
f.
g.
Earthing terminal and numbers.

Air relief vent.
Rating and diagram plate
The rating plate should bear the data specified in the proper clauses of ISS2026/1977. The diagram plate should also show the internal connection and
so the voltage vector relationship of the several windings in accordance with
ISS:2026/1977 and in addition a plan view of the transformer giving accurate
physical relationship with the terminals.
h.
Oil filter valve

The oil filter valves should be fitted with adopter for 16 mm hose. These valves are
for oil filtration and for draining of oil for sample and test purpose.
i.
Joint and Gaskets

All joints in the transformer and auxiliary equipment shall be made in such a manner
as to prevent ingress of moisture of leakage of oil.
j.
k.
Arcing horn with each HT bushings.

Pad lock for tap changing switch.
l.
29.
Accessory equipment not specifically listed above but normally regarded as

standard shall be provided in accordance with relevant clauses of
ISS:2026/1977 & CBIP practice.
PACKAGE
The packing may be in accordance with the manufactures standard practice. The bushings
shall be packed and dispatched separately. Full details of packing for approval of the
purchaser should be given. The package shall be such to satisfy the conditions of transport
by rail and road to existing place where the transformer is to be erected and also be suitable
for rough handling.
30.
PAINTING
Before dispatch all steel work not under oil shall be painted with a primary coat of anticorrosive paint of durable nature and one coat of final finishing paint. The transformers shall
be painted with heat resisting dark grey paint sand blast painting will be preferred.
31.
TESTS
The transformers shall be subjected to stage inspection of core, windings, tanks and fittings before
the final inspection. Test certificates from manufacturer for core, conductors, oil, mild steel
used for tanks, insulations and etc. shall be furnished to the purchaser before calling for
stage inspection. After the successful stage inspection, final inspection will be carried out as
per the attached Appendix A& in accordance with Indian Standard Specification No.
2026/1977 at Manufacturers works before dispatch to site.
The purchaser reserves the right of having other reasonable tests carried out at his own expenses
either before dispatch or at site to ensure that transformer complies with the requirement of
the specification. The test certificates( for both stage inspection & final inspection, tests) in
triplicate shall be submitted as soon as the tests are completed for approval.
31.1
Before calling for final inspection, the supplier shall furnish the factory test results
(routine and additional routine test results) of the offered transformer along with list of
equipment used during testing with serial number, make, class of accuracy, the valid
calibration certificates of the equipments/instruments used during testing to the owner
for owners information and reference. On verification of the test results , measuring
instruments & calibration certificates, the owner may direct the contractor for use of
better equipments/meters during inspection/testing.
32.
TEST REPORT
After all tests have been completed seven certificated copies of each test report shall be furnished.
Each report shall supply the following information.
i)
Complete identification date including serial number of the transformer.

ii)
Method of application where applied, duration and interpretation of the results for
each test.
iii)
Temperature data corrected to 75 C including ambient temperature.
33.
The tenderer shall give the guaranteed technical particulars required in ANNEXURE1, failing which the tender will be rejected.
34.
The tenderer shall submit the detailed dimensional drawing ,short circuit , impulse &
temperature rise test reports conducted in a govt. approved laboratory for the
transformer offered along with the offer ,failing which the offer will not be considered.
35.
REJECTION
The transformer may be rejected at the discretion of the purchaser if the test results are not
satisfactory and tolerances are exceeded.
36.
The supplier should guarantee for after sales service for minimum period of one and half
years from the date of receipt of the equipment in complete shape or one year from the date
of commissioning of the equipment whichever is earlier.
36.1
The supplier also should guarantee after sales services beyond the free service
stipulated in 36.
period as
36.2
The supplier also should provide after sales services within 15 days of receipt of
from the field engineer in charge of the equipment .
intimation
APPENDIX A
TESTS
Routine & type tests are to be conducted at the manufacturers factory as per IS: 2026/1977 & as
indicated below, in presence of purchasers representative. Routine and type test certificates
are to be submitted in support of the tests conducted successfully, after which dispatch
clearance will only be issued. Type tests as indicated below will only be conducted on one
transformer of each rating.
1.
Routine Test
All transformers shall be subjected to routine tests at the manufacturers works. The tests shall
comprise as per the followings:a)
b)
d)
Measurement of winding resistance at normal & extreme taps.

Ratio, polarity and phase relationship & vector group test..
c)
Impedance voltage / short circuit impedance at the normal tap & extreme
taps.
Measurement of load loss and neutral unbalance current
This test shall be a carried out with three wattmeters method with low power factor
wattmeter low range Ammeters and phase sequence meters. The
e)
measurement shall be made at 100% rated current & rated frequency, but in
no case not less than 80% current of the rated current (Principal tapping) or
tapping current (in case of extreme taps). Load loss measurement to be done
on the normal tap (rated voltage tap) and extreme taps.
Measurement of no- load loss and no load current.
This test to be carried out with 3 wattmeter method by using low power factor wattmeters, 3 power factor meters, phase sequence meters, three low range
ammeters and three each average value and RMS value voltmeters. The test
voltage from 10% voltage to 121% voltage shall be applied and currents,
voltages (Average value and RMS value), wattmeter, power factor and
frequency meter readings in all the 3 phases to be recorded during the test. A
voltage (RMS) vrs. Measured current graph shall be plotted by the supplier
and handed over it to the purchaser for analysis .
During the test, suppliers own generator set shall be used for feeding the rated
voltage at rated frequency. If the applied frequency is greater than the rated
frequency, then proportionate voltage to the rated frequency will be fed
during the test and following frequency correction formula along with the
formula given in Clause 16.5 IS:2026(Part-I) shall be used.
K = 0.5/f 1 +0.5 (f/f 1)
Where f = rated frequency & f1 = applied frequency.
For example :- If measured loss = x, correction factor due to rms & Average voltage
as per ISS = k1, and frequency correction factor = k. Then corrected loss will
be calculated as = measured loss x * k1 * k.
If applied frequency is less than the rated frequency, then no frequency correction
formula will be applied. Rated voltage at that frequency will be fed during
the test.
f)
l)
Insulation resistance Test by motorized megger. Insulation resistance values

to be taken at 1 minute & at 10 minutes intervals. Ratio of insulation
resistance taken at 10 minutes and at 1 minutes should not be less than 1.5 .
g)
Induced over voltage withstand.
h)
Separate sources voltage withstand.
i)
Magnetic balance test
j)
Oil BDV Test
k)
Oil Leakage Test
Measurement of dimensions & etc.
Type test.
i. Temperature rise test
ii. Oil Leakage & Pressure Test:The transformer tanks shall be subjected
to a pressure equal to the normal pressure + 35 KN/m measured at the base
of the tank. Pressure shall be maintained for a period of 12 hours for oil
during oil leakage test and 1 hour for air during Pressure test on the Tank
where there shall not be any leakage.
i. In addition to the routine tests, the type and special test
certificates for the tests as indicated below, conducted by the
supplier on proto type of transformers of identical design at
CPRI or any Govt. approved laboratory within the last 5(five)
years from the date of opening of this tender shall be
submitted along with the tender offer, failing which the bid
will not be accepted for evaluation. CPRI/Govt. approved
laboratory test certificate along with CPRI/Govt. approved
laboratory drgs. (internal and external drgs.) must accompany
the bid.
Type & Special Tests
1. Impulse Voltage withstand test
2. Temperature rise test
3. Short Circuit Test.
The test results of CPRI tested transformer should confirm with
the technical particulars as stipulated in this specification .
37. 1) The bidder shall indicate in his offer values of resistance , stray loss, %Impedance, %
regulation, no load losses, load losses at rated out put , voltage & frequency. These values will
be guaranteed MAXIMUM VALUES.
II) losses will be capitalized at the following rates & taken in to account when tenders will be
compared as per the guaranteed losses furnished by the bidder in their guaranteed technical
particulars but within the specified losses as indicated at clause 20 of the technical
specification. Losses quoted beyond losses stipulated as at clause-20
of the technical
specification will not be accepted &offer will be
rejected :Iron losses: Rs 1,14,448/- per KW. (Rupees One Lakh Fourteen Thousand Four Hundred Forty Eighty
only))
Copper losses : Rs 68,669/- per KW
(Load Losses)
iii)The losses shall be measured during routine tests. If losses will be arrived outside the limits of the
guaranteed losses as quoted by the bidder in the Guaranteed technical particulars but will
remain within the losses stipulated as at clause-20
of the technical specification , then a
financial adjustment shall be made as follows:The successful bidder will be penalized double the above rates for any loss in excess of the values
stated in the bid considering iron & copper losses separately. No bonus shall be payable for
the losses which are less than those stated in the bid.
iv) Also on testing if any of the test results do not match with the values given in the guaranteed
technical particulars & as per technical specification, the owner reserves the right to reject the
transformer or free to take any other decision.
v) The owner also reserves the right to retain the rejected transformer & take in to service until the
supplier replaces it with a new transformer at no extra cost.
38. Following are the list of annexures enclosed with this technical specification.
1. Annexure-1 --- Schedule of technical particulars( to be furnished by the
manufacturer)
2. Annexure-II--- Format for stage Inspection

3.Annexure-III--- Quality & Delivery schedule
4. Annexure-IV--- Calibration status of testing Equipments( To be furnished by the
manufacturer)
5.Annexure-V---- Check list towards type test reports( To be furnished by the manufacturer)
ANNEXURE-II
FORMAT FOR STAGE INSPECTION
[WINDING]
Sl.No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
B.
1.
L.V. HV
Conductor Bare mm
Conductor Insulated (mm)
Type of Conductor Insulation
No. of Conductor in parallel.
Base Conductor in parallel.
Current density (A/mm2)
Rated volts per phase (volts).
Turns per phase (T)
Type of winding.
No. of discs (Nos.)
No. of turns/disc.
Inside diameter (mm)
Outside diameter ((mm)
Winding depth (mm)
Winding Length (mm)
Gap between disc (mm)
No. of spacers in one circle.
Size of the spacer (mm)
Length of mean turn in meter.
Weight of winding (Kg/each)
(Weight of winding includes the weight of
insulated conductor, spacers, runner & other
insulations as has been complete required to
make the windings).
4.
INSULATION.
Between core & L.V. Winding (Details like thickness (mm), length (mm)
type of insulation etc. to be mentioned).
Between H.V. & L.V. Winding (Details like thickness (mm), length (mm),
type of insulation etc. to be mentioned).
Between H.V. & L.V. & Stabilising (Tertiary) Winding (Details like
thickness (mm), length (mm), type of insulation etc to be mentioned.
Between windings to top yoke (Details as above to be mentioned).
5.
Between windings to top yoke (Details as above to be mentioned).
2.
3.
C
1.
2.
3.
4.
CORE
Core Diameter in mm=
Window Height in mm=
Distance between core leg center in mm=
Widths of window in mm=
5.0 OTHER PARAMETERS OF CORE:No. of steps 1

Width in
8 etc.
Stack in
Sectional
area of
6.
7.
8.
9.
10.
Total gross cross sectional area of the core in mm=

Net core iron area=gross C/S area x 0.97
Maximum flux density (Bm) in Wb/sq.mm=
Total core weight in Kg by weighment=
Thickness of core lamination in mm=
D.
E.
Condition of the Tank:Any other items/tests which have not been covered above and required & indicated in the
specification to be carried out
by the OPTCLs representative.
FOR OPTCL
FOR MANUFACTURER
Name:
Name of Manufacturer
Designation:
Designation.
Date:
Date:
Place:
Place:
ANNEXURE-IV
CALIBRATION STATUS OF TESTING EQUIPMENT AND INSTRUMENTS/ METERS
AVAILABLE IN THE FACTORY.
[FOR CONDUCTING TESTS AS PER CLAUSE 18.1 OF SECTION IV OF TECHNICAL SPECIFICATION]
Name
Of the
Test
1.
Meters &
Equipments
required for
the
corresponding
test with range
accuracy make
& Sl.No.
2.
Date of
Calibration.
3.
Due date
of
Calibration
4.
Name
of
Calibrating
Agency.
Whether
Calibrating
Agency is
Govt.
approved.
5.
6.
Whether the Whether the

Whether
meters/ Calibration
documents
relating to Equipment Agency has
fulfill the
put any
Govt.
approval of
accuracy
limitation
the
class as per towards the
Calibrating calibration
use of the
report.
particular
Agency
meter/
furnished.
equipment.
If yes state
the
limitation.
7.
8.
9.
Whether
Green
sticker or
Blue sticker
or Yellow
sticker
has been
affixed on
the body
of the
particular
equipment/
meter.
State the
colour of
the affixed
sticker.
Inspite of
imposed ,
limitations
whether the
particular
meter/
equipment can
still be used
Justify its
use for
corresponding
during test(s)
Remarks
10.
11.
12
Signature of the Tenderer with seal & date.
OPTCL-CPC-TN/41-42/08-09
TS-STN TRANS-Page 17 of 18
ANNEXURE-V
CHECK LIST TOWARDS TYPE TEST REPORTS.
Name of the
Type Test.
Date
of Test.
Name of the
Laboratory
where the
Test has
Been
conducted.
Whether the
Laboratory is
Government
approved.
Whether the
Test report
is valid
Whether the
copy of Test
report in
complete shape
along with
drawings etc
furnished
or not?
Whether the
type tested
Transformers
full fill the
technical
requirements as
per TS.
Remarks.
1.
2.
3.
4.
5.
6.
7.
8.
Signature of the Tenderer with seal & date:
OPTCL-CPC-TN/41-42/08-09
TS-STN TRANS-Page 18 of 18

FOR
390KV,216KV, 120KV & 30KV SURGE
ARRESTER
I- 390 KV
II- 216KV
III- 120KV
IV- 30KV
E15-SURGE ARRESTER- Page 1 of 21
TECHNICAL SPECIFICATION FOR SURGE ARRESTERS
FOR 400 KV,220 KV, 132KV & 33KV SYSTEMS.

CONTENTS
CLAUSE NO
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.00
10.0
APPENDIX I
ANNEXURES
A
B
C
D
APPENDIX II
TITLE
SCOPE
STANDARDS
CONSTRUCTION
TESTS
INSPECTION
DOCUMENTATION
PACKING & FORWARDING
QUANTITY & DELIVERY REQUIREMENT
TECHNICAL REQUIREMENTS
GUARANTEED TECHNICAL PARTICULARS
CHECK LIST
CALIBRATION STATUS OF TESTING
EQUIPMENTS/METERS
CHECK-LIST TOWARDS TYPE TEST
REPOR
QUANTITY AND DELIVERY SCHEDULE
TECHNICAL SPECIFICATION FOR SURGE ARRESTERS FOR400KV, 220KV,

132KV & 33KV SYSTEMS
1.0
SCOPE
1.1
This Specification provides for the design, manufacture, inspection and testing
before despatch, packing and delivery F.O.R. (destination) of metal oxide (gapless)
Surge Arresters with discharge counters, insulating base, terminal connectors and
other accessories as specified here in.
Following is the list of documents constituting this Specification. :
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Note :
Technical Specification (TS)

Technical Requirements.
Appendix-I
Quantity and delivery schedule.
Appendix-II
Guaranteed Technical Particulars.
Annexure-A
Check-List.
Annexure-B
Calibration Status of testing equipments and Annexure-C
meters/Instruments.
Check-list towards Type Test Reports.
Annexure-D
Annexure-A,B,C,& D are to be filled up by the Bidder.
1.1
All the above along with amendments thereof shall be read and interpreted together.
However, in case of a contradiction between the Technical Specification and any
other volume, the provisions of this volume will prevail.
1.2
The Surge Arrester shall conform in all respects to high standards of engineering,
design, workmanship and latest revisions of relevant standards at the time of offer
and purchaser shall have the power to reject any work or materials, which in his
judgement is not in full accordance therewith.
2.0
STANDARDS:-
2.1 Except to the extent modified in the Specification, the Surge Arrester shall conform to the
latest editions and amendments of the standards listed hereunder.
Sl. No.
2.2
Standard Ref.
No.
IEC-99-4
IS:2147
IS:2629
IS:2633
IS:3070
IS:5621
&IEC-621155
7
8
9
IEC-60-1
IEC-270
IEC-99-1
10
11.
IEC-60815
Title.
Specification for Surge Arresters
without gap for AC System.
Degree of protection, provided by
enclosures for low voltage
switchgear and control.
Recommended practice for hot dip
galvanization of iron and steel.
Method for testing uniformity of
coating on zinc coated articles.
Specification for surge arresters
for alternating current system.
Specification for large hollow
porcelain for use in electrical
installation.
High-Voltage Test technique.
Partial discharge measurements.
Non-linear resistor type gapped
arresters for a.c. systems.
Indian Electricity Rules, 1956.
Shed profile of hollow porcelain
Insulator.
Surge Arresters with the requirement of other authoritative standards, which ensure equal
or better quality than the standards, mentioned above shall also be acceptable. Where the
equipment offered by the supplier conforms to other standards, salient points of difference
between the standards adopted and the specified standards shall be clearly brought out in the
offer. 4 (Four) copies of the reference standards in English language shall be furnished along
with the offer.
3.0
GENERAL TECHNICAL REQUIREMENTS :
3.1
The Surge Arrester shall confirm the technical requirements as per Appendix-I
and this TS.
3.2
The energy handling capability of each rating of Arrester offered, supported by calculations,
shall be furnished with the offer.
3.3
The Surge Arresters shall be fitted with pressure relief devices and arc diverting paths and
shall be tested as per the requirements of IEC for minimum prospective symmetrical fault
current as specified in Appendix-I.
3.4
A grading ring shall be provided if required, (for attaining all the relevant technical
parameters) on each complete Surge Arrester.
3.5
PROTECTIVE LEVELS :
Surge Arresters shall be capable of providing protection to sub-station equipments, designed

for the withstand levels, given in the following table.
Sl.
No.
1
2
3
4
(i)
(ii)
Equipment to be
protected
Insulation
level of
420KV
Systems
L.I. Level
(KVP)
Auto Transformers/Power 1300
Transformers.
Instrument Transformers. 1425
Reactors
1300
Circuit Breakers/Isolators.
Phase to ground.
1425
Across open contacts.
1425(+
240)= 1650
Insulation
level of
245KV
Systems.
L.I. Level
(KVP)
950
Insulation
Level of
145KV
Systems
L.I. Level
(KVP)
650
Insulation
Level
of
36KV
System
L.I. Level
(KVP)
170
1050
950
650
650
170
170
1050
1200
650
170
Surge arrester shall be suitable for the following duty cycles of circuit breaker at the following
system voltages:
1.
2.
3.
4
420 KV Circuit Breaker.

245 KV Circuit Breaker.
145 KV Circuit Breaker
36 KV Circuit Breaker
3.6
DUTY REQUIREMENT :
0-0.3 sec-co-3 min-co

3.6.1 Surge Arresters shall be of heavy-duty station class and gapless type without any
series or shunt gaps.
3.6.2 Surge Arresters shall be capable of discharging over voltages occurring during
switching of un-loaded transformers, lines, capacitors and reactors.
3.6.3
The Surge Arresters shall be capable of discharging lightning and switching surges and
temporary power frequency over-voltages.
3.6.4
3.7
The Surge Arresters shall be capable of discharging the energy equivalent to class 3 of
IEC-99-4.
The reference current of the arrester shall be high enough to eliminate the influence of
grading and stray capacitance on the measured reference voltage. The supplier shall
submit values and the supporting evidence along with calculations on above.
3.8
Surge Arresters shall be fully stabilized thermally to give a life expectancy of 100 years
under site conditions.
3.9
Surge Arresters shall be able to withstand maximum wind load of 260 Kg./sq.m.
3.10
Surge Arresters shall be capable of withstanding effects of direct solar radiation
3.11
Surge arresters shall be capable of spark over on severe switching Surges and multiple
strokes.
3.12
The Surge Arrester should be adequately designed to operate satisfactorily under

temporary power frequency over-voltage as given in specific technical requirements,
after discharging two shots of respective long duration surges.
3.13
Unless otherwise brought out separately by the Bidder in the schedule of deviations,
the Surge Arresters, offered shall conform to the specification scrupulously. All
deviations from the specification shall be brought out in the schedule of deviations. The
discrepancies between the specification and the catalogues or literature, submitted as
part of the offer shall not be considered as valid deviations unless specifically brought
out in the schedule of deviations.
4.0
CONSTRUCTION :
4.1
Non linear blocks shall be sintered metal oxide material. These shall be provided in such a
way as to obtain robust construction with excellent electrical and mechanical properties even
after repeated operations.
4.1.1 All the units of arresters of same rating shall be inter-changeable without adversely affecting
the performance.
4.2
The Surge Arresters shall be suitable for pedestal type mounting.
4.3
All the necessary flanges, bolts, nuts, clamps etc. required for assembly of complete arrester
with accessories and mounting on support structure to be supplied by the purchaser, shall be
included in suppliers scope of supply.
4.4
The drilling details for mounting the Arrester on owners support shall be supplied by the
supplier.
4.5
The minimum permissible separation between the Surge Arrester and any earthed object
shall be indicated by the Bidder in his offer.
4.6
Surge Arresters shall be designed to incorporate pressure relief devices and arc diverting
paths to prevent shattering of the blocks or the porcelain housing, following prolonged
current flow or internal flash over and providing path for flow of rated fault currents in the
event of arrester failure.
4.7
Surge Arresters shall incorporate anti-contamination feature to prevent arrester failure,

caused by uneven voltage gradient across the stack, resulting from contamination of the
arrester porcelain.
4.8
Seals shall be provided in such a way that these are always effectively maintained even
when discharging rated lightning current.
4.9
The heat treatment cycle details alongwith necessary quality checks used for individual
blocks alongwith insulation layer, formed across each block are to be furnished. Metalised
coating thickness for reduced resistance between adjacent discs is to be furnished alongwith
the procedure for checking the same. Details of thermal stability test for current distribution
of current on individual disc is to be furnished.
4.10
Each individual unit of Surge Arresters shall be hermetically sealed and fully protected
against ingress of moisture. The hermetic seal shall be effective for the entire lifetime of the
arrester and under the service conditions as specified. The supplier shall furnish sectional
view of the arrester showing details of sealing employed.
4.11
The Surge Arresters shall be suitable for hot line washing.
4.12
PORCELAIN HOUSING :
4.13.1 All porcelain Housings shall be free from lamination cavities or other flaws, affecting the
maximum level of mechanical and electrical strengths.
4.13.2 The porcelain shall be well vitrified and non-porous.
4.13.3 The minimum creepage distance of the arrester housing shall be as per Appendix-I.
4.13.4 The porcelain petticoat shall be preferably of self-cleaning type (Aerofoil design). The
details of the porcelain housing such as height, angle of inclination, shape of petticoats, gap
between the petticoats, diameter (ID and OD) etc. shall be indicated by the Bidder in his
offer in the form of detailed drawing.
4.13.5
Porcelain housings shall be so co-ordinated that external flash over will not occur due to
application of impulse or switching Surge voltages up to the maximum design value for
arrester.
4.14
GALVANISATION, NICKEL PLATING ETC. :
4.14.1
All ferrous parts exposed to atmosphere shall be hot dip galvanised as per IS: 2629, as
amended from time to time. Tinned copper/brass lugs shall be used for internal wiring of
discharge counter. Screws used for electrical connections shall be either made of brass or
shall be nickel-plated.
4.14.2
Ground terminal pads and nameplate brackets shall be hot dip galvanised.
4.14.3
The material shall be galvinised only after completing all shop operations
4.15
ACCESSORIES AND FITTINGS :
4.15.1
Surge Counters;
4.15.1.1 A self- contained Surge counter, suitably enclosed for outdoor use and requiring no auxiliary
of battery supply for operation shall be provided for each unit. The surge counter shall be
operated by the discharge current, passed by the surge arrester and shall be suitable for
mounting on the support structure of the Arrester.
4.15.1.2 Surge counters shall be of the Electro-mechanical type and designed for
service.
continuous
4.15.1.3 The cyclometer counter shall be visible through an inspection window from ground level.
The counter terminals shall be robust and adequate size and shall be so located that the
incoming and outgoing connections are made with minimum possible bends.
4.15.1.4 Internal parts shall be unaffected by atmospheric conditions at site. Alternatively, a weather
proof housing to IP 55 shall be provided and this shall be designed to allow the recording
device to be read from ground level without exposing the internal parts to the atmosphere.
4.15.1.5 The Surge Counter shall be connected in the main earth lead from the arrester in such a
manner that the direction of the earth lead is not changed or its surge impedance
materially altered. A bolted link shall be provided so that the surge counter may be
short circuited and removed without taking the arrester out of service.
4.15.1.6
4.15.2
4.15.2.1.
All necessary accessories and earthing connection leads between the bottom of the
Arrester and discharge counter shall be in the suppliers scope of supply.
LEAKAGE CURRENT METERS :
Leakage current meters (suitable milli-ammeter) shall be connected in the earthing
path of the surge arresters to measure the resistor grading leakage current. Meters
shall be designed for continuous service.
4.15.2.2.
The ammeter shall be suitable for mounting on the support structure of the arrester.
The push buttons shall be mounted such that it can be operated from the ground
level.
4.15.2.3.
The internal parts shall be fully weather - proof to IP 55 or better with a transparent
cover to provide an unobstructed view of the ammeter..
4.15.3.
Arresters shall be complete with insulating base having provision for bolting to flat
surface of the structure.
4.15.4.
Grading /corona rings shall be provided on each complete Arrester unit, as required,
for proper voltage stress distribution.
4.15.5.
The grounding terminals shall be suitable for accommodating purchasers

grounding connection to steel earth mat.
4.15.6.
The Bidder has to quote unit rates of the insulting base and the surge counter
separately. The purchaser reserves its option to procure insulting base and surge
counter.
Clamp type terminal connector, suitable for 400 KV-ACSR MOOSE/AL
TUBE,220KV-ACSR MOOSE Conductor 132KV & 33KV-ACSR MOOSE
Conductor shall be provided having both horizontal and vertical take-off.
4.15.7.
4.15.8.
Two clamp type ground terminal connectors, suitable for G. I. Strip (50 x 6) or (50 x
8) should be provided.
4.15.9.
All interconnecting hard wares such as nuts, bolts, spring washers etc. with 5%
spares shall be supplied for different units
4.15.10.
Pollution Shunt (Copper braid) shall be supplied along with each surge Arrester for
by-passing the surface current..
4.15.11.
Other standard accessories, which are specifically not mentioned, but are usually,
provided with Surge Arrester of such type and rating for efficient and trouble free
operation should be supplied.
4.16
NAME PLATE :
Each single pole Arrester shall be provided with non-corrosive legible name plate, at
the base bearing thereon, voltage rating of the complete pole and the number of
demountable sections with the following data, indelibly marked
(a)
(b)
ORISSA POWER TRANSMISSION CORPORATION LIMITED.

Purchase order No. & Date.
(c)
(d)
Name of device.
Manufacturers name and trademark and identification no. Of the arrester
being supplied.
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(l)
(m)
Year of manufacture
Rated voltage
Rated Frequency
Maximum continuous operating voltage.
Type
Nominal discharge current.
Long duration discharge class.
Pressure relief current in KA(rms)
Energy discharge capability ( KJ/KV rating).
5.0
TEST :
5.1
Type Tests:
The surge Arrester offered should have been subjected to the following type tests in an
independent Government approved test laboratory. The bidder shall furnish four sets of
type test reports alonglwith the offer. These tests must not have been conducted earlier than
five years from the date of opening of technical bid. For any change in the design, type
already type tested and the design type offered against this specification, the purchaser
reserves the right to demand repetition of some or all type tests without any extra cost to
OPTCL in the presence of Purchasers representative at the cost of the supplier.
1
2
3
4
5
6
7
8
9
10
11
12
13
Insulation withstands tests :

(a)
Lightning Impulse Voltage Test.
(b)
Wet switching impulse test. (For 390KV/216KV only).
Residual voltage tests.
Long duration current impulse withstand tests.
Operating duty tests.
Pressure relief tests.
(a)
High current test.
(b)
Low current test.
Power frequency voltage vs. time curve.
(Temporary over voltage test)
Contamination test. (artificial pollution test).
IP-55 test on surge counter.
Minimum current operation tests of the surge counter.
Maximum current withstand test of the surge counter.
Mechanical terminal load test on bushing.
Partial discharge test.
N.B. :- Even if the condition i.e. the dry arcing distance or the sum of the partial dry arcing
distances is larger than the test voltage divided by 500 KV/m, the lightning impulse
voltage test must have been conducted or is to be conducted without any financial
liability to OPTCL.
Even if the type test reports are found to be valid as per this specification, the
purchaser reserves the right to demand the repetition of some or all the type tests in
the presence of purchasers representative. For this purpose, the bidder shall quote
unit rates for carrying out each type test. These prices, if necessary, will be taken into
consideration for bid evaluation.
5.2
ROUTINE TESTS :
The following routine tests shall be conducted at the suppliers cost on each surge
arrester and shall be submitted alongwith or before offering for inspection for
purchasers approval.
(a)
(b)
(c)
(d)
5.3
Measurement of reference voltage.

Residual voltage tests.
Measurement for partial discharge and contact noise.
Sealing test for units with sealed housings.
ACCEPTANCE TESTS :
The following tests, considered as acceptance tests, shall be conducted in the
presence of purchasers representative for which no charges will be payable by OPTCL.
The acceptance tests, whenever possible shall be conducted on the complete arrester
unit. The number of samples to be subjected to acceptance test shall be decided by the
purchaser at the time of actual testing.
I
II
III
IV
V
VI
VII
VIII
IX
Temperature Cycle Test on Housing.

Measurement of Power Frequency Voltage at the reference current.
Measurement of leakage current and capacitive current at M.C.O.V.
Lightning Impulse Residual Voltage Test at N.D.C., 50% of N.D.C. & 200%
of N.D.C.
Partial Discharge Tests on complete arresters/units at 1.05 times M.C.O.V.
Special Thermal stability test.
Porosity test on porcelain components.
Galvanisation test on metal parts.
The functional (operational) test on the Surge Counter by way of checking its
operation at following nominal discharge currents :
(i)
(ii)
100 Amps with 8/20 micro second wave shape.

10 KA with 8/20 micro second wave shape.
Check of calibration of leakage current meters.
INSPECTION :
I
The purchaser shall have access at all time to the works and all other places of
manufacture, where the Surge Arresters are being manufactured and the supplier
shall provide all facilities for unrestricted inspection of the suppliers works, raw
materials, manufacture of all the accessories and for conducting the necessary tests.
II
The supplier shall keep the purchaser informed in advance of the time of starting and
the progress of manufacture of equipment in its various stages so that arrangements
could be made for inspection.
III
No material shall be despatched from its point of manufacture unless the material has
been satisfactorily inspected, tested and despatch schedule attached to this
specification.
IV
The acceptance of any quantity of equipment shall in no way relieve the supplier of
his responsibility for meeting all the requirements of this specification and shall not
prevent subsequent rejection, if such equipments are later found to be defective.
7.1
The Bidder shall invariably furnish following informations alongwith his offer, failing
which the offer shall be liable for rejection.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
7.2
Statement giving list of important raw materials, names of sub-suppliers for the raw
materials, list of standards according to which the raw materials are tested, list of
tests, normally carried out on raw materials in presence of Bidders representative,
copies of test certificates.
Information and copies of test certificates as in (I) above in respect of bought-out
items.
Level of automation, achieved and list of areas where manual processing exists.
List of areas in manufacturing process where stage inspections are normally carried
out for quality control and details of such tests and inspections.
Special features provided in the equipment to make it maintenance free
List of testing equipments, meters available with Bidder for final testing of
equipment, specified and test plant limitation, if any, vis--vis the type, acceptance
and routine tests, specified in the relevant standards and this specification. These
limitations shall be very clearly brought out in the offer.
All the testing equipments, meters etc. should have been calibrated in a Government
approved laboratory. The Bidder must submit the list of testing equipments and
meters test-wise as per Annexure-C of this Technical Specification.
The suppliers, within 30 days of placement of order submit the following
informations to the purchaser.
(i)
(ii)
(iii)
List of raw materials as well as bought out accessories and the names of the materials
as well as bought-out accessories and the names of sub-suppliers, selected from
those, furnished alongwith the offer.
Quality Assurance Plan (QAP) with hold points for the purchasers inspection. The
QAP and hold points shall be discussed between the purchaser and the supplier
before the QAP is finalised.
7.3
The supplier shall submit the routine test certificates of bought out item and raw
martial at the time of acceptance testing of the fully assembled equipment.
8.0
DOCUMENTATION :
8.1
All drawings shall conform to relevant Indian Standard as per relevant IS. All
drawings shall be in ink and suitable for microfilming. All dimensions and data shall
be in S.I. Units.
8.2
The supplier shall furnish four sets of following drawings/documents along with his
offer.
(i)
(ii)
General outline drawings of the complete Arrester with technical parameters.

Drawings showing clearance from grounded and other line objects and between
adjacent poles of Surge Arresters, required at various heights of Surge Arresters.
(iii) Drawings showing details of pressure relief devices.
(iv)
Detailed drawing of discharge counters along with the wiring and schematic drawing
of discharge counter and meter.
(v)
Outline drawing of insulating base.
(vi)
Details of grading rings, if used.
(vii) Mounting details of Surge Arresters.
(viii) Details of line terminal and ground terminals.
(ix)
Volt-time characteristics of Surge Arresters.
(x)
Details of galvanization being provided on different ferrous parts.
(xi)
The detailed dimensional drawing of porcelain Housing such as ID, OD, thickness
and insulator details such as height, profile of petticoats, angle of inclination and gap
between successive petticoats, total creepage distance etc.
(xii) Cross-sectional view of the Surge Arrester Units showing all components.
8.3
TEST REPORTS :
(i)
Four copies of type test reports shall be furnished to the purchaser with the tender
specification. Copies of acceptance test reports and routine test reports shall be
furnished to the purchaser. One copy will be returned duly certified by the purchaser
and only thereafter shall the materials be despatched.
(ii)
All records of routine test reports shall be maintained by the supplier at his works for
periodic inspection by the purchaser.
(iii)
All test reports of tests, conducted during manufacture shall be maintained by the
supplier. These shall be produced for verification as and when requested for by the
purchaser.
9.0
PACKING AND FORWARDING :
9.1
The equipment shall be packed in suitable crates so as to withstand handling during

transport and outdoor storage during transit. The supplier shall be responsible for any
damage to the equipment during transit, due to improper and inadequate packing. The easily
damageable material shall be carefully packed and marked with the appropriate caution
symbols. Wherever necessary, proper arrangement of lifting such as lifting hooks etc. shall
be provided. Any material found short inside the packing cases shall be supplied by the
supplier without any extra cost.
9.2
informations :
(a)
(b)
(c)
(d)
(e)
(f)
(g)
Name of the consignee :

Details of consignment :
Destination :
Total weight of consignment :
Sign showing upper/lower side of the crate :
Handling and unpacking instructions :
Bill of materials indicating contents of each package :
9.3
The supplier shall ensure that the bill of materials is approved by the purchaser before
despatch.
10.0
QUANTITY AND DELIVERY REQUIREMENT :

(i)
The scope of supply shall include a supply of 2.5% extra quantity of bolts, nuts,
washers, split pins, cotter pins and such other small loose items free of cost.
APPENDIX I.
(TECHNICAL REQUIREMENTS)
TECHNICAL REQUIREMENTS FOR METAL OXIDE (GAPLESS) SURGE
ARRESTERS
The Surge Arrester under this Specification shall conform to the parameters given
below :390KV
216KV
120KV
30KV
Sl.
No.
1
Particulars.
3
4

(phase to phase) (KV rms).
(phase to phase) (KV rms).
System Frequency (HZ).
System Neutral earthing.
5
6
Installation.
Class.
Type of construction for 10

KA rated arrester.
8
9
No. of phases.
Maximum duration of earth
fault (Sec.)
10
Maximum prospective
symmetrical fault current at
arrester location (KA rms.)
11
Rated arrester voltage (KV
rms)
Technical
Parameters
400
Technical
Parameters.
220
420
245
50 5 %
Effectively
earthed.
Outdoor.
Station class,
10 KA, heavy
duty type.
50 5 %
Effectively
earthed.
Outdoor.
Station class,
10 KA, heavy
duty type.
Single
column,
single phase.
Single
column,
single phase.
Technical
Parameters
132
145
50 5%
Effectively
earthed
Outdoor
Station
class, 10
KA, heavy
duty type.
Single
column,
single
phase.
Three
3
Technical
Parameters
33
36
50 5%
Effectively
earthed
Outdoor
Station
class, 10
KA, heavy
duty type.
Single
column,
single phase
Three
3
Three
3
Three
3
40
40
40
40
390
216
120
30
12
13
14
15
16
17
18
19
20
21
22(a)
(b)
23
24
25
Nominal discharge current

(KAP)
10 KA of 8/20 10 KA of 8/20
micro-second micro-second
Wave.
Wave.
Disscharge current at which And 20 KA of
insulation co ordination
8/20 microsec
will be done
wave
Minimum energy discharge
As per
As per
capability (KJ/KV)
relevant
relevant
ISS/IEC
ISS/IEC
Maximum continuous
operating voltage at 50
C(KV rms)
Maximum switching surge
residual voltage (KVP)
Maximum residual voltage
at 8/20 micro second(KVP)
(i) 5 KA.
(ii) 10 KA Nominal
discharge current.
(iii) 20 KA.
Long duration discharge
class
High current short duration
test value (KAP)(4/10
Micro-second wave).
Current for pressure relief
test (KA-rms)
Minimum total creepage
distance (mm).
One minute dry and wet
power frequency withstand
voltage of Arrester housing
(KV-rms).
Impulse withstand voltage
of arrester housing with
1.2/50 micro-second wave
(KVP).
Switching Impulse Voltage
(Wet) (KVP)
Pressure relief class.
(KV-rms).
RIV at 92 KV rms.
10 KA of
8/20 microsecond
Wave.
10 KA of
8/20 microsecond
Wave.
As per
relevant
ISS/IEC
As per
relevant
ISS/IEC
102
25
272
at 1KA
72
at 500A
900 KVp
567
600
320
340
85
90
975 KVp
3
668
3
380
3
100
2
100
100
100
100
40
40
40
40
10500
6125
3625
900
630
460
275
70
+1425
+ 1050
+650
+170
A
-
A
-
303
780 at 1KA
175
496
at 1KA
+1050
700
A
320 min
A
216
Less than 500

micro volts
Less than 500

micro volts.
Less than
Less than
500 micro
500 micro
volts.
volts
26
27
28
29
Partial discharge at 1.05

times continuous overvoltage.
Seismic acceleration.
Reference ambient
temperature.
(a) IR at MCOV.
Nor more than Nor more than Nor more

50 PC.
50 PC.
than 50 PC
Nor more
than 50 PC
0.3g
horizontal
0.15g vertical
0.3g
0.3g
horizontal
horizontal
0.15g vertical. 0.15g
vertical.
50C
50C
0.3g
horizontal
0.15g
vertical
50C
Less than 500

micro
amperes.
Less than
1500 micro
amperes.
1 to 5 mA
Greater than
rated voltage.
Less than 500

micro
amperes.
Less than
1500 micro
amperes.
1 to 5 mA
Greater than
rated voltage.
Less than
400 micro
amperes
Less than
1200 micro
amperes
1 to 5 mA
Greater than
rated
voltage.
100
50C
30
a) Reference Current (mA)

b) Reference voltage at
reference current.
31
Maximum steep current

Impulse RDV (KVP). at
10
KAP
1050
654
Less than
500 micro
amperes.
Less than
1500 micro
amperes.
1 to 5 mA
Greater than
rated
voltage.
372
32
Maximum cantilever
strength of the arresters
(KGM).
TOV(KVP).
(i) 0.1 sec.
(ii) 1.0 sec.
(iii) 10.0 sec.
(iv) 100.0 sec.
1000
1000
1000
325
580
565
550
382
366
351
336
170
163
156
149
53
51
49
47
(b) IC at MCOV.
33
ANNEXURE B
CHECK LIST
Whether calculation towards energy handling capability of the Surge Arrester furnished as
per Clause No.3.2 of TS ?
Whether there is provision of Corona Grading Ring in the SA as per Clause No.3.4 and
4.15.4 of TS ? .. If not, whether justification for non-provision of the same
furnished ?
Whether calculations and supporting evidence furnished to satisfy Clause No.3.7 of TS ?
Whether the heat treatment cycle details alongwith necessary quality checks used for
individual blocks furnished as per Clause 4.10 of TS ?
Whether sectional view of arrester showing details of sealing provided as per Clause
No.4.11 of TS furnished ?
Whether S.A. is suitable for hot line washing as per Clause No.4.12 of TS ?
Whether porcelain petticoat is of Aero foil design ? Whether drawing of porcelain Housing
as per Clause No.4.13.4 of TS furnished ?
Whether information as per Clause No.7.1 (i) to (viii) of TS

furnished ?
Whether drawings and documents as per Clause No.8.2 (i) to (xii) of TS furnished ?
10
Whether special measures in the manufacture of Surge Arrester for operating at ambient
temperature of 50C (against 40C as per IEC-99-4, Clause No.4.4.1) are to be taken ?
.. State the special measures in details .
Signature of the Tenderer With Seal & Date
ANNEXURE-D

Name
of the
Type
Test.
Date
of
Test.
Name of the
Laboratory
where the
Test has been
conducted.
Whether the
Laboratory
is
Government
Approved.
Whether the
Test reports
are valid as
per Clause
No.5.1 of
T.S.
Whether the
copy of Test
Report in
complete shape
alongwith
drawings etc.
furnished or
not ?
Whether the
Type Tested
Surge
Arrester
fulfills the
technical
requirements as per
TS.
If the type tested

Surge
Arrester does not fulfill
the technical
requirements as per this
specification, whether
the bidder agrees to
conduct the particular
type test again at their
own cost without any
financial liability to
OPTCL in the presence
of OPTCLs
representative within
the specified delivery
period.
8
Remarks.
Signature of the Tenderer with seal and date.
ANNEXURE C.
CALIBRATION STATUS OF TESTING EQUIPMENTS AND INSTRUMENTS/METERS.

Name of
the test.
Meters and
equipments
required for
the
correspondi
ng test with
range
accuracy
make and
Sl. No.
Date of
Calibration.
Due
date of
Calibrat
-ion.
Name of
the
Calibrating
Agency
Whether
Calibrating
Agency
is Govt.
Approved.
Whether
documents
relating to
Govt.
Approval
of the calibrating
Agency
furnished ?
Whether
the
meters/eq
-uipment
fulfill the
accuracy
class as
per
calibratio
n report
Whether
the
calibrating agency
has put any
limitation
towards the
use of the
particular
meter/equi
pment. If
yes, state
the
limitations.
Whether
green
sticker or
blue
sticker or
yellow
sticker has
been
affixed on
the body
of the
particular
equipmet/
meter.
State the
colour of
the affixed
sticker.
10
Inspite of
imposed
limitations,
whether the
particular
meter/equip
ment can
still be
used?
Justify its
use for
correspondi
ng test(s).
Rem
arks
11
12
Signature of the tenderer with seal and date.

FOR
220,132 &33 KV IVT
&
400,220 & 132 KV CVT
E16-IVT & CVT- Page 1 of 29

JANPATH, BHUBANESWAR-751022.
TENDER SPECIFICATION
FOR
220 KV, 132KV, 33KV INDUCTIVE VOLTAGE

& 400 KV,220KV,132KV CAPACITIVE VOLTAGE
TRANSFORMERS WITH METERING WINDING OF
ACCURACY CLASS (0.2)
I- 220KV IVT
II-132KV IVT
III-33KV IVT
IV-400 KV CVT
V-220KV CVT
VI-132KV CVT
TECHNICAL SPECIFICATION FOR 220 KV, 132KV, 33KV

INDUCTIVE & 400 KV,220KV,132KV CAPACITIVE
VOLTAGE TRANSFORMER
1.0
SCOPE :
Voltage transformers shall be supplied with common marshalling box in a batch of 3 CVTs/ IVTs
along with terminal connectors and other fittings for providing necessary inter phase and control
room interconnections.
The design of capacitor/Inductive voltage transformers shall be such that its accuracy shall not be
affected by the presence of pollution on the external surface of its insulators.
The voltage transformer shall operate satisfactorily in system with high X/R ratio.(Tp=100ms)
Voltage transformer tanks along with top metallics shall be galvanised and painted to required shade
stipulated under relevant sections of the specification.
1.1
This specification provides for the design, manufacture, assembly inspection and testing at
the manufacturers works, packing and delivery FOR [Destination] of outdoor mounted type,
single phase, single unit type Inductive voltage transformers for 220 KV, 132KV & 33KV
systems, & Capacitive Voltage Transformers for 400 kv,220kv, 132KV system to be used for
voltage indication, supply of potential to tariff meters, relays for feeder protection in Grid
Sub-stations of OPTCL, Orissa.. In addition to the above functions the 400 kv,220kv, 132KV
CVT shall be suitable for carrier coupling.
1.2
The IVTs shall be complete in all respects with insulators, bimetallic connectors, fixing
details etc. as described herein.
1.3
Bidders are required to quote for 0.2 accuracy class [metering winding] for 33KV, 132KV,
220KV IVTs &220kv, 132KV CVTs in the following manner.
(a)
(b)
Technical literatures, brochures and drawings as per this specification.
(c)
Type Test reports.
(d)
List of orders, executed and Users certificates with offer, failing submission of the
above particulars with the offer, the tender may not be considered for evaluation.
2.0
Following is the list of documents constituting this Specification.
(i)
Technical Specification (TS).
(ii)
Technical requirements.
[Appendix-I]
(iii)
[Vol-III)]
(iv)
Calibration status of testing equipment

and meters/Instruments.
(vi)
Check list towards Type Test Reports.-
[Annexure-B]
[Annexure-C]
N.B.:- Annexure-A,B & ,C are to be filled up by the Bidder.

3.0
STANDARDS:-
3.1
The IVTs & CVTs shall conform in all respects to high standards of Engineering, design,
workmanship and latest revisions of relevant standards at the time of offer and the Purchaser
shall have the power to reject any work or material which in his judgement is not in full
accordance therewith.
3.2
Except to the extent modified in the specifications, the IVTS & CVTs shall conform to the
latest editions and the amendments of the standards listed hereunder:
Sl. No.
Standard Ref. No.
Title.
01
IEC-44(4)
Instrument Transformer measurement of PDS.
02
IEC-60
High voltage testing techniques.
03
IEC-171
Insulation co-ordination.
04
IEC-186
Voltage Transformers.
05
IEC-186(A)
Voltage Transformers (first supp. to IEC-186)
06
IEC-270
Partial discharge measurement.
07
IS-335
Insulating oil for transformers and switch gears.
08
IEC-8263
Method for RIV Test on high voltage insulators.
09
IS-2071
Method of high voltage testing.
10
IS-2099
High Voltage porcelain bushings.
11
IS-2147
Degree of protection provided by enclosures for

low voltage switch-gear and control.
12
IS-2165
Insulation co-ordination for equipments of

100KV and above.
13
IS-3156 (Part-I to IV).
Voltage transformers.
14
IS-3347
Dimensions of porcelain transformer bushings.
15
IS-4146
Application guide for voltage transformers.
16.
IS-5547
Application guide
Transformers.
for
Capacitor
Voltage
17.
3.3
IS-9348
Coupling Capacitor & Capacitor Devices.
All the above alongwith the amendments thereof shall be read and interpreted together.
However, in case of a contradiction between the Technical Specification and any other
volume, the provisions of this Technical Specification will prevail.
3.4
The voltage transformers with the requirements of other authoritative standards, which ensure
equal or better quality than the standards, mentioned above shall also be acceptable. Where
the equipments, offered by the supplier conforms to other standards, salient points of
difference between the standards shall be brought out in the offer. 4 (four) copies of the
reference standards in English language shall be furnished alongwith the offer.
3.5
The supplier is to furnish the standards as mentioned above from Sl. 1 to 17 at their own cost,
if required by the purchaser.
4.0
CLIMATIC AND SERVICE CONDITIONS :
4.1
The VTS are required to operate satisfactorily under the following conditions.
(a)
Maximum ambient temperature -
50C.
(b)
Maximum daily average ambient air temperature - 45C.
(c)
Maximum relative humidity 100%.
(d)
Average number of rainy days in a year 120 days.
(e)
Average annual rainfall 150 cms.
(f)
Altitude not exceeding 1000 M.
(g)
Maximum wind pressure 260kg/sq.m.
EARTHQUAKE INCIDENCE:The VTS are to be designed to withstand earthquake of an intensity, equivalent to 0.3g in the
horizontal and 0.15g in the vertical direction where, g stands for acceleration due to gravity.
5.0
PURCHASERS AUXILIARY POWER SUPPLY:-
5.1
Following power supplies shall be made available at site:

(a) AC-3 phase, 415V, 50HZ earthed.
(b) AC single phase, 240V, 50HZ earthed.
(c) 220V DC, Ungrounded.
5.2
All equipments and devices shall be capable of continuous satisfactory operation on AC and
DC supplies of nominal voltage, mentioned above with variations as given below.
(a) AC voltage variation.
10%
5.3
(b) Frequency variation.
5%.
(c) Combined voltage & frequency variation.
10%
(d) DC voltage variation.
190V to 240V DC.
The supplier shall make his own arrangements for the power supplies other than those
specified under Clause-5.1 above.
6.0
INSTALLATION:The VTS covered under this specification shall be suitable for outdoor installation without
any protection from rain, dust, mist and direct rays of the sun.
A.7.0. GENERAL TECHNICAL REQUIREMENTS FOR IVT :7.1
Each IVT shall be supplied, filled with insulating oil and shall be hermetically sealed to
prevent atmosphere coming in contact with oil, avoiding filtration and change of oil. In case
the tenderer intends to use Nitrogen or any other inert gas above the oil level, the gas must
not leak out and the same shall be stated in the tender.
1.2
However, the IVT shall have a provision for draining and filling insulating oil after drying or
preferably must have arrangement for drying the oil by continuous process with oil filters.
1.3
The IVT shall be suitable for transport in horizontal position if the transport limitations so
demand.
1.4
SECONDARY TERMINAL BOX:-
1.4.1
The secondary terminals shall be brought out in a weather proof terminal box with a rating
not less than IP-55.
1.4.2
All secondary terminals shall be brought out in a compartment on one side of each IVT for
easy access.
1.4.3
The exterior of this terminal box shall be Aluminum extruded sheets.
1.4.4
The terminal box shall be provided with removable gland plate and glands suitable for 1100
volts grade. PVC insulated, PVC sheathed multi core 4 sq.mm to 6 sq.mm stranded copper
conductor cable.
1.4.5
The terminal box shall be provided with a door in front so as to have easy access of
secondary terminals. The door shall have a sealing/locking arrangement and shall be suitable
to prevent penetration of moisture and rain water.
1.4.6
The dimensions of the terminal box and its openings shall be adequate to enable easy access
and sufficient working space for use of normal tools.
1.4.7
The terminal blocks shall be standard type and provided with ferrules indelibly marked or
numbered and their identifications shall correspond to the designation on the relevant wiring
diagram.
1.4.8
Secondary wiring terminal studs shall be provided with at least three nuts, plain and spring
washers. The studs, nuts and washers shall be of brass, duly nickel plated. The minimum
diameter of the studs shall be 6 mm. The length of at least 15 mm shall be available on the
studs for inserting the leads.
1.5
Polarity shall be indelibly marked on each primary and secondary terminals.
1.6
The IVT shall be filled with oil under vacuum after processing and thereafter hermetically
sealed to eliminate breathing and to prevent air and moisture from entering the tanks. Oil
filling and/or oil sampling cocks, if provided to facilitate factory processing should be
properly sealed before despatching the IVT. The method, adopted for hermetic sealing shall
be described in the offer.
1.7
The castings of base, collar etc. shall be diecast and tested before assembly to detect cracks
and voids, if any.
1.8
The characteristics of the IVTS shall be such as to provide satisfactory performance such as
voltage error and phase displacement at rated frequency shall not exceed the values as per
relevant standards at any voltage between 80% and 120% of rated voltage and with burdens
of between 25% and 100% of rated burden at a power factor of 0.8 lagging. The error shall be
determined at the terminals of the IVT and shall include the effects of any fuses or resistors
as an integral part of the IVT.
1.9
Inductive voltage transformers shall be designed so as to achieve the minimum risk of

explosion in service. The bidder shall bring out in his offer, measures taken to achieve this.
1.10
PRIMARY WINDING:Primary winding of the IVT will be connected phase to neutral with the neutral point solidly
earthed. The arrangement for this shall be included in the scope of supply. The primary
conductor shall be of adequate cross-section so that the maximum permissible current density
shall not be exceeded even during short-circuit conditions.
7.11
SECONDARY WINDING.
Suitably insulated copper wire of electrolytic grade shall be used for secondary windings.
The secondary conductor shall be of adequate cross section so that the maximum permissible
current density shall not be exceeded even during short- circuit conditions. Each 220KV IVT
& 132KV IVT will have two secondary windings, protection-150VA; Metering-150VA
burden at 0.8 lagging power factor and rated voltage of 110V/1.732V for protection and
110/1.732V for metering winding. Secondary windings shall be used for metering, relaying
and synchronizing. Each winding shall comply requirements of both Part-II and III of up-todate editions of IS-3156/IEC-186. 33KV IVT will have two secondary winding of 75 VA
burden at 0.8 lagging power factor and rated voltage 110/1.732 volts( one metering and one
protection winding).
7.12
CORE:- Core laminations shall be of cold rolled grain oriented silicon steel or other
equivalent alloys of low hysteresis and eddy current losses, high permeability to ensure
accuracy i.e. 0.2 accuracy class at both normal and high over voltage. The core material ,
thickness of lamination, the relevant graphs showing the characteristics of the core materials
shall be submitted along with the offer.
7.13
TANK.
7.13.1 Both expansion chambers and tanks of the IVT shall be made of high quality steel
and shall
be able to withstand full vacuum and pressure, occurring during transit and thermal and
mechanical stresses resulting from maximum short circuit current during operation. The tanks
along with all ferrous parts shall be hot- dip galvanized as per relevant standard.
7.13.2 The metal tanks shall have bare minimum number of welded joints so as to minimize possible
locations of oil leakage. Welding in horizontal plane is to be avoided as welding at this
location may give way due to vibrations during transport resulting in oil leakage. Supplier
has to obtain specific approval from the purchaser for any horizontal welding, used in the
bottom tank
7.13.3 Paint inside the metallic housing shall be of anti-condensation type.
7.14
PORCELAIN HOUSING.
7.14.1. The housing shall be made up of homogeneous, vitreous porcelain of high mechanical and
dielectric strength, Glazing of porcelain shall be of uniform brown or dark brown colour
with a smooth surface, arranged to shed away rain water or condensed water particles(
fog).The details of location and type of joint, if provided on the porcelain, shall be furnished
by the Bidder along with the offer.
7.14.2.The bushings of the IVTS shall conform to latest edition of IS-2099.The hollow porcelain
insulators shall conform to the latest edition of lS-5621
7.14.3 The insulators shall be cemented with Portland cement to the flanges resulting in high
mechanical, tensile and breaking strength
7.14.4. The bushings shall have ample insulation, mechanical strength and rigidity for the condition
under which they shall be used and shall be used and shall be designed to prevent
accumulation of explosive gases and provide adequate oil circulation to remove the internal
heat.
7.14.5 Cast metal and caps for the bushings shall be of high strength hot dip galvanized malleable
iron. They shall have smooth surface to prevent discharge taking place between the metal
parts and porcelain as a result of ionisation.
7.14.6 The insulation of bushings shall be co-ordinated with that of the IVT such that the flashover,
if any, shall occur only external to the IVT.
7.14.7 Oil level gauge and convenient means of filling, sampling and draining of oil shall be
provided.
7.14.8 End shields should be provided for distribution of stresses.
7.14.9 Corona shields for bushings, if required, should be provided.
7.15
INSULATING OIL.
The quantity of insulating oil for the filling and the complete specification of the insulating
oil shall comply in all respects with the provisions of the latest edition of IS-335. The IVTS
shall be supplied completely filled with purified oil.
7.16.
PREVENTION OF OIL LEAKAGE AND ENTRY OF MOISTURE:The supplier shall ensure that the sealing of the IVT is properly achieved. In this connection,
the arrangement provided by the supplier at various locations including the following ones
shall be described, supported by sectional drawings
(a) Locations of emergence of primary & secondary terminals..
(b) Interface between porcelain housing and metal tank(s).
(d) Cover of the secondary terminal box.
7.16.1 Nuts and bolts or screws used for fixation of the interfacing porcelain bushings for taking out
terminals shall be provided on flanges, cemented to the bushings and not on the porcelain.
7.16.2 For gasketed joints, wherever used, nitrite butyl rubber gaskets shall be used. The gasket shall
be fitted in properly machined groove with adequate space for accommodating the gasket
under compression.
7.17
FITTINGS AND ACCESSORIES:- Fittings and accessories, listed below shall be supplied
with each IVT. Any fitting, required essential other than those listed below shall also be
supplied along with each IVT.
(a) Oil level gauge.
(b) Oil filling hole and cap.
(c) Pressure relieving device.
(d) Lifting lugs for core and windings, bushings & complete transformers.
(e) Phase terminal connectors.
(f) Tank earthing pads/terminals with necessary nuts and bolts and washers for connecting to
Purchasers strip.
(g) Name/Rating plate.
(h) MCB & H.R.C. fuse.
7.18.1 OIL LEVEL GAUGE:- An oil level gauge shall be provided to indicate the oil level in the
IVT. This gauge shall be mounted in such a way that the oil level can be seen from the
ground level.
7.18.2 PRESSURE RELIEVING DEVICE:- Each IVT shall be provided with a pressure relieving
device so as to protect bushing of the IVT even under unfavourable conditions.
7.18.3 OIL DRAIN COCK:- An oil drain cock alongwith a stop cock shall be provided in the bottom
flange so as to permit taking of oil samples for testing, if required.
7.18.4 EARTHING:- Metal tank of each IVT shall be provided with two separate earthing terminals
for bolted connection to 50mm x 6mm flat to be provided by the Purchaser for connection to
station earth-mat.
7.18.5 LIFTING ARRANGEMENT:- The IVT shall be provided with suitable lifting arrangement
to lift the entire unit. The lifting arrangement shall be clearly shown in the general
arrangement drawing. Lifting arrangement [Lifting eye] shall be positioned in such a way so
as to avoid any damage to the porcelain housing or the tanks during lifting for
installation/transport. Necessary string guides shall be offered which shall be of removable
type.
7.18.6 NAME PLATE:- The IVT shall be provided with non-corrosive legible name plate with the
information specified in relevant standards, duly engraved/punched on it.
7.18.7 GASKET JOINT:- The manufacturer shall furnish the type of gasket used or setting methods.
7.18.8 TERMINAL CONNECTORS:- All the IVTS shall be provided with bimetallic solderless
clamp type, rigid type terminal connectors, suitable for ACSR Moose Conductor for 220KV
IVT & CVT
ACSR .MOOSE /MOOSE Conductor for132KV, 33KV IVT & 132KV
CVT..Each terminal connector shall be of universal type, suitable for both horizontal and
vertical connections to the transmission line conductors/station bus bar.
7.18.8.1 TERMINAL CONNECTORS shall be manufactured and tested as per IS:5561.
7.18.8.2 All castings shall be free from blow holes, surface blisters,cracks and cavities.
All sharp edges and corners shall be blurred and rounded off.
7.18.8.3 No part of a clamp shall be less than 10mm thick.
7.18.8.4 All ferrous parts shall be hot dip galvanized conforming to IS-2633.
For bimetallic connectors, copper alloy linear of minimum thickness of 2 mm shall be
cast integral with aluminium body.
7.18.8.5 All current carrying parts shall be designed and manufactured to have minimum contact
resistance.
7.18.8.6 Connectors shall be designed to be corona free in accordance with the requirements,
stipulated in IS-5561.
7.18.9 SECONDARY WIRING:The Secondary wiring shall be enclosed in conduits and shall be brought to a terminal block
ready for external connections. The wiring shall be of adequate cross-section and not less
than 4.00 sq.mm copper wire.
7.18.10The supplier shall supply necessary hardwares, required for connection of
phase side conductor to the line terminal and the grounding strip to the grounding terminal.
7..18.11 Necessary nuts and bolts for fixing the IVTS on the supporting structures shall
be in tenderers scope of supply.
B.7.0 GENERAL TECHNICAL REQQUIREMENTS FOR 400 kv,220KV & 132KV CAPACITIVE
VOLTAGE TRANSFORMER:7.1
The design of capacitor voltage transformers shall such that its accuracy shall not be affected
by the presence of pollution on the external surface of its insulators.
7.2
The CVT shall operate satisfactorily in system with high X/R ratio. (Tp=100 ms).
7,3
The CVT transformer tanks along with top metallic shall be galvanized and painted to
required shade.
7,.4
Impregnation details along with tests and checks to ensure successful completion of
impregnation cycle shall be furnished for purchasers approval.
7.5
Bellows, if used to cater for expansion of insulating oil, shall be tested in accordance with
relevant standards. The details shall be subject to the approval of the purchaser.
7.6
The CVT shall be capacitor voltage type with electromagnetic units and shall be suitable for
carrier coupling..
7.7
All windings of voltage transformer secondaries shall be protected by MCB and HRC
cartridge type fuses. In addition, fuses shall be provided for the protection and metering
windings for fuse monitoring scheme. The secondary terminals of the CVTs shall be
terminated to stud type non-disconnecting terminal blocks in the individual phase secondary
boxes via. the fuse
7.8
CVTs shall be suitable for high frequency (HF).coupling, required for power line carrier
communication. The carrier signal must be prevented from flowing into potential transformer
(EMU) circuit by meant of a RF choke/reactor, suitable for effectively blocking the carrier
signal over the entire carrier frequency range i.e. 40 to 500 KHZ. Details of the arrangement
shall be furnished along with the bid. HF terminal of the CVT shall be brought out through a
suitable bushing and shall be easily accessible for connection to the coupling devices of the
carrier communication equipment, when utilized. The bushing shall be fully protected against
rain and vermin so as to avoid the possibility of short circuits to earth. An earthing link with
fastener shall be provided for HF terminal.
7.9
The electromagnetic unit, comprising compensating reactor, intermediate transformer and

protective and damping devices should have a separate terminal box with all secondary
terminals, brought out.
7.10
Voltage transformers should be thermally and dielectrically safe when the secondary
terminals are loaded with the guaranteed thermal burdens.
7.11
The accuracy of the windings (3P/3P/0.2) shall be maintained through out the entire burden
range preferably in the frequency range of 48 HZ to 51.5 HZ on all the three windings
without any adjustment during operation. Preference will be given to such bidders who can
offer for maintaining the above accuracy class in the frequency range i.e. 48 HZ to 51.5 HZ
up to the above specified burden values.
7.12
CONSTRUCTIONAL FEATURES:-
7.12.1 The 400kv, 220KV & 132KV CVT shall be suitable for mounting on support structure of
tubular GI pipe of nominal bore of 300/200 mm. or lattice type structures.
7.12.2 Access to secondary terminals shall be possible without any danger of access to high voltage
circuit.
7.12.3 CVTs shall be hermetically sealed units.
7.12.4 A protective surge Arrester/spark gap shall be provided to prevent break down of insulation
by incoming surges and to limit abnormal rise of terminal voltage of shunt capacitor/primary
winding, turning reactor/RF choke etc. due to short circuit in transformer secondaries. In case
of an alternative arrangement, the Bidder shall bring out the details in the Bid.
7.12.5 The CVT secondary terminals shall brought out in to a weather proof terminal box for ease
of access. The terminal box shall have an IP rating of not less than IP 55. The terminal box
shall be provided with a removable gland plate at the bottom and shall be suitable for
accepting the required number of PVC insulated PVC sheathed, 10 core 2.5 mm standard
copper conductor cable.
7.12.6 All terminals shall be clearly marked to facilitate connection of secondary wiring.
7.12.7 Secondary fuses or MCBs shall be provided on or adjacent to each CVT, located such that
they are accessible while the primary is live and shall be provided with labels indicating their
function and their phase colours CVT secondary circuits shall be complete in themselves and
shall be earthed at one point only. A separate earth link shall be provided for each secondary
winding and shall be situated at the CVT.
7.12.8 Where CVTs are supplied which are, or may be connected to different sections of the bus bar,
it shall not be possible for the CVT secondary circuits, to be connected in parallel.
7.12.9 An auxiliary switch or relay shall be provided in each phase of the secondary circuit of the
synchronizing and metering voltage supply connections to break the circuits automatically as
soon as the circuit breaker is opened.
7.12.10 To prevent ferro resonance, suitable damping devices shall provided for connection to the
transformer secondaries.
7.12.11 CVTs shall meet the requirements, given in this section of the specification.
7.12.12 The creepage and flashover distances of the high voltage insulator shall be suitable for the
out door service conditions, specified in the schedules.
7.12.13 The bidder in the offer is to state the suitable precautions/methods, adopted during design
stage of the CVT to avoid the un-desirable effects due to ferro resonance phenomena. The
precautions/methods include lower level of working flux density in EMU, greater utilization
of the linear portion of the magnetization curve, providing an air gap in the magnetic circuit,
connecting a suitable damping resistance permanently across the secondary etc.
7.12.14 It should be stated in the bid offer regarding the steps taken in the design stage for
elimination/minimization of the influence of the transient response on the behavior of high
speed relays.
7.12.15 It shall be ensured by the bidder in the offer that the connection of carrier, frequency
coupling device across the CVT will not affect the designated accuracy class of the CVT
windings.
7.12.16 The capacitor divider unit shall comply to IS: 9348/1979.
7.12.17 It shall also be complied in the offer through a calculation sheet, proving that the designated
accuracy class of the CVT (both metering and protection) are not affected by extreme
temperatures, to be encountered in service conditions (Max. ambient temperature 50 C and
minimum -0 C).
7.12.18 The terminal contractors should be suitable for ACSR MOOSE,/ ZEBRA(as per
requirement) Conductor, complying to Cl.No.A.7.18.8 of this specification.
8..
8.1
TESTS:Type Tests:- The offered 220KV, 132KV & 33KV Inductive voltage transformer
&400KV,220kv, 132KV capacitive voltage transformer should have been subjected to the
following type tests in a Government approved Test Laboratory. The bidder shall furnish four
sets of type test reports along with the offer. These tests must not have been conducted earlier
than five years from the date of opening of the bid. For any change in the design/type already
type tested and to the design/type offered against this specification, the purchaser reserves the
right to demand repetition of some or all type tests/special tests without any extra cost to
OPTCL in the presence of purchasers representative at the cost of the supplier.
For 220 KV, 132KV & 33KV IVT:
(a) Temperature rise test.
(b) Short circuit withstand capability test.
(c) Lightning Impulse Test.
(d) High Voltage power frequency wet withstand voltage tests.
(e) Determination of errors.
(f) IP-55 Test on secondary Terminal Box.
N.B.:- [I] The dielectric type tests should have been carried out on the
same transformer.
(ii)
After the IVT was subjected to the dielectric tests, it should have been
subjected to all routine tests as per relevant standards.
(i)
For Temperature Rise Test, the test must have been made with the
appropriate rated burden, connected to each secondary winding.
For 400 kv,220KV & 132KV CVT.

TYPE TESTS/SPECIAL TESTS FOR 400 KV, 220KV, 132KV CVT:a)
Lightning Impulse voltage test on complete CVT unit.
b)
Power frequency over-voltage test on complete CVT unit.
c)
Partial discharge test.
d)
Radio interference voltage test.
e)
Corona extinction voltage test.
f)
Temperature rise test on complete CVT unit.
g)
Ferro resonance test on the complete C.V.T. unit.
h)
Transient response tests.
i)
Determination of Temperature Co-efficient test.
j)
High frequency capacitance and equivalent resistance measurement test (as per IEC358)
k)
Stray capacitance and stray conductance test (as per IEC-358).
l)
Accuracy tests.
m)
Thermal stability test.
n)
Thermal Co-efficient test (as per IEC-358)
o)
Fast transient test.
p)
q)
IP-55 test on secondary Terminal Box.
r)
Magnetization and internal burden tests.
s)
Effectiveness of sealing tests.
t)
Mechanical Terminal load test on Bushing.
u)
Dielectric loss angle test (Tan Delta Test).
N.B:- 1.
The dielectric type tests should have been carried out on the same CVT.
2.
After the CVT was subjected to the dielectric tests, it should have been
subjected to all routine tests as per relevant standards.
3.
The ratio errors, phase displacements before, during and after the temperature
rise test on complete CVT unit should have been determined with stipulated
burdens and the same should comply with the designated accuracy class for
each winding of the CVT.
8.2
ROUTINE TESTS:- The following routine tests shall be conducted on each VT in the presence
of Purchasers representative for which no charges will be payable by OPTCL. No sampling
is allowed.
(a) Verification of terminal markings.
(b) Power frequency withstand tests on primary windings/capacitor voltage divider for
IVT/CVT
(c) Partial discharge measurement for 400 KV,220KV, 132KV IVT & 220KV & 132KV
CVT.
(d) Power frequency withstand tests on secondary windings/Low voltage terminal of the
capaciter divider for220KV & 132KV CVT.
(e) Power frequency withstand tests between sections.
(f) Determination of errors on complete IVT./CVT.
(g) Measurement of Insulation resistance.
(h) Oil leakage test.
(i) Measurement of capacitance and dielectric dissipation factor before and after dielectric
tests (as per IEC-358)
(j) Power frequency tests on electromagnetic unit for400 KV, 220KV & 132KV CVT.
(k) Any other test as per relevant national & international standards.
N.B.:- Determination of errors shall be performed after the other tests. The standard reference
VT to be used during testing for determination of ratio error and phase angle error should of
0.05 accuracy class or better as per standard practice, presently adopted by OPTCL.
9.
INSPECTION:
9.1
The Purchaser shall have access at all times to the works and all other places of manufacture,
where the IVTs/CVTs are being manufactured and the supplier shall provide all facilities for
unrestricted inspection of the suppliers works, raw materials, manufacturer of all the
accessories and for conducting the necessary tests.
9.2
The Supplier shall keep the Purchaser informed in advance of the time of starting and of the
progress of manufacture of equipment in its various stages so that arrangement could be
made for inspection at the discretion of the Purchaser.
9.3
No material shall be despatched from its manufacture unless the material has been
satisfactorily inspected, tested and despatch clearance issued. However, the Purchaser
reserves the right to alter the despatch schedule attached to this Specification.
9.4
The acceptance of any quantity of equipment shall in no way relieve the supplier of his
responsibility for meeting all the requirements of this Specification and shall not prevent
subsequent rejection, if such equipments are found to be defective.
9.5
Clear 15 (Fifteen) days notice shall be given to this office for deputing officer(s) for
inspection. The Voltage Transformers shall be despatched only after the inspection is
conducted by a representative of OPTCL and release order, issued from this office after
approval of Routine Test Certificates. The shop routine test certificates in triplicate for all the
Voltage Transformers along with the calibration certificates of all the meters and equipments
to be used during testing (as per Annexure-B of the Specification) should be furnished along
with the Inspection Offer. The Inspecting Officer will be authorised for inspection of the
Voltage Transformers subject to the condition that the routine test certificates and calibration
certificates of the testing equipments/meters will be found to be in order.
10.
QUALITY ASSURANCE PLAN:-
10.1
The Bidder shall invariably furnish following informations along with his offer.
[i] Statement giving list of important raw materials, names of sub-suppliers for the raw
materials, list of standards, according to which the raw materials are tested, list of tests,
normally carried out on raw materials in presence of Bidders representative, copies of test
certificates.
[ii] Information and copies of test certificates as in [i] above in respect of bought out items.
[iii] List of manufacturing facilities available.
[iv] Level of automation achieved and list of areas where manual processing exists.
[v] List of areas in manufacturing process where stage inspections are normally carried out
for quality control and details of such tests and inspection.
[vi] Special features provided in the equipment to make it maintenance free.
[vii] List of testing equipments, meters and test plant limitation, if any, vis--vis the type,
acceptance and routine tests, specified in the relevant standards. These limitations shall be
very clearly brought out in the offer.
[viii] All the testing equipments, meters etc. should have been calibrated in a Government
approved laboratory. The Bidder must submit the list of testing equipments and meters testwise as per ANNEXURE-B of the Technical Specification.
10.2
The Supplier shall within 30 days of placement of order submit the following information to
the Purchaser.
[i]
List of raw materials as well as bought out accessories and the names of the materials
as well as bought out accessories and the name of Sub-suppliers selected from those,
furnished along with the offer.
[ii]
Type test certificates of the raw materials and bought out accessories.
[iii]
Quality Assurance Plan (QAP) with hold points for the Purchasers possible
inspection. The QAP and hold points shall be discussed between the Purchaser and the
Supplier before the QAP if finalised.
10.3
The Supplier shall submit the routine test certificates of bought out items and raw materials at
the time of acceptance testing of the fully assembled equipment.
11 DOCUMENT: The supplier shall furnish four sets of following drawings/documents along with
his offer.
[a]
General outline and assembly drawings of the Inductive Voltage Transformers/

Capacitive Voltage Transformers.
[b]
Sectional views showing:[i] General constructional features.

(ii) Materials/gaskets/sealing used.
iii] The insulation of the winding arrangements, method of connection of
primary/secondary winding to the primary/secondary terminals etc.
[c]
Schematic drawing.
[d]
Rating & diagram plate as per relevant IEC/ISS
[e]
Secondary Terminal Box.
[f]
Assembly Sectional view of Primary terminal./ capacitor voltage divider
[g]
Assembly drawing for secondary terminal
[h]
The detailed dimensional drawing of Porcelain Housing such as ID,OD,
thickness
and insulator details such as height, profile of petticoats, angle of inclination and gap
between successive petticoats, total creepage distance etc.
[i]
Sectional view of pressure release device.
[j]
Drawing showing details of Oil level.
[k]
All type test reports relating to the tests as specified in Clause-8.1 of the above.
[l]
Ratio and phase angle error curves for IVTS/ CVTS
[m]
Magnetization characteristic curves such as B-H curves and Sp. Loss vs. Flux density
curves for core material, used for IVT & EMU unit of CVT.
[n]
Sectional view of EMU unit of 400 KV,220KV&132KV CVT
12.
TEST REPORTS:-
[i]
Four copies of type test/special test reports shall be furnished to the Purchaser with the tender
offer.
[ii]
Copies of acceptance test reports and routine test reports shall be furnished to the Purchaser.
One copy will be returned, duly certified by the Purchaser and only thereafter shall the
materials be despatched.
[iii]
All records of routine test reports shall be maintained by the supplier at his works for periodic
inspection by the Purchaser.
[iv]
All test reports of tests, conducted during manufacture shall be maintained by the supplier.
These shall be produced for verification as and when required for by the purchaser.
13.
The necessary galvanized flanges, bolts etc. for the base of the Inductive/Capcitive Voltage
Transformers shall be supplied without any extra cost to the purchaser.
14.
PACKING AND FORWARDING:-
14.1
The equipment shall be packed in suitable crates so as to withstand handling during transport
and outdoor storage during transit. The supplier shall be responsible for any damage to the
equipment during transit, due to improper and inadequate packing. The easily damageable
material shall be carefully packed and marked with the appropriate caution symbols.
Wherever necessary, proper arrangement for lifting such as lifting hooks etc. shall be
provided. Any material found short inside the packing cases shall be supplied by supplier
without any extra cost.
14.2
informations:
[a] Name of the consignee.
[b] Details of consignment.
[c] Designation.
[d] Total weight of consignment.
[e] Sign showing upper, lower side of the crate.
[f] Handling and unpacking instructions.
[g] Bill of materials indicating contents of each package.
[h] Set of approved drawings.
14.3
The supplier shall ensure that the bill of materials is approved by the Purchaser before
despatch.
15.
Any tender without complete information as asked for in the above Specification is likely to
be rejected.
CVTs shall be suitable for high frequency (HF) coupling required for power line carrier
communication. The carrier signal must be prevented from flowing into potential transformer (EMU)
circuit by means of a RF choke/reactor suitable for effectively blocking the carrier signals over the
entire carrier frequency range i.e. 40 to 500 kHz. Details of the arrangement shall be furnished along
with the bid. HF. terminal of the CVT shall be brought out through a suitable bushing and shall be
easily accessible for connection to the coupling devices of the carrier communication equipment,
when utilised. The bushing shall be fully protected against rain and vermin so as to avoid the
possibility of short circuits to earth. An earthing link with fastener shall be provided for HF terminal.
The electromagnetic unit comprising compensating reactor, intermediate transformer and protective
and damping devices should have a separate terminal box with all secondary terminals brought out.
Voltage transformers should be thermally and dielectrically safe when the secondary terminals are
loaded with the guaranteed thermal burdens.
The accuracy of the metering winding (0.2) shall be maintained throughout the entire burden range
up to 100 VA/100 VA/1100 VA for 420kV CVTs on all the three windings without any
adjustments during operation.
420 KV CVTs shall be suitable for mounting on support structure of made out of preferably
lattice or tubular GI pipe of nominal bore of 300/200 mm.
Access to secondary terminals shall be possible without any danger of access to high voltage circuit.
Voltage transformers shall be hermetically sealed units.
A protective surge arrester/spark gap shall be provided to prevent breakdown of insulation by

incoming surges and to limit abnormal rise of terminal voltage of shunt capacitor/primary winding,
tuning reactor/RF choke etc. due to short circuit in transformer secondaries. In case of an alternate
arrangement, Bidder shall bring out the details in the Bid.
The wiring diagram for the interconnection of the three single phase CVTs shall be provided inside
the marshalling box in such a manner that it does not deteriorate with time. The wiring diagrams
shall be fixed
The primary and secondary windings of voltage transformers shall be constructed from high purity,
annealed, high conductivity copper meeting the requirements of IEC 28.
The VT secondary terminals shall be brought out into a weather proof terminal box for ease of
access. The terminal box shall have an IP rating of not less than IP 55. The terminal box shall be
provided with a removable gland plate at the bottom and shall be suitable for accepting the required
number of PVC insulated PVC sheathed 10 core 2.5 mm2 stranded copper conductor cable.
All terminals shall be clearly marked to facilitate connection of secondary wiring.
Secondary fuses or MCBs shall be provided on or adjacent to each voltage transformer, located such
that they are accessible while the primary is live and shall be provided with labels indicating their
function and their phase colours. Voltage transformer secondary circuits shall be complete in
themselves and shall be earthed at one point only. A separate earth link shall be provided for each
secondary winding and shall be situated at the voltage transformer.
Where voltage transformers are supplied which are, or may be, connected to different sections of the
busbar, it shall not be possible for the voltage transformer secondary circuits to be connected in
parallel.
An auxiliary switch or relay shall be provided in each phase of the secondary circuit of the
synchronising and metering voltage supply connections to break the circuits automatically as soon as
the circuit breaker is opened.
To prevent ferroresonance, suitable damping devices shall be provided for connection to the
transformer secondaries.
Voltage transformers shall meet the requirements given in this section of the Specification.
The creepage and flashover distances of the high voltage insulator shall be suitable for the outdoor
service conditions specified in the Schedules.
Oil Filled voltage transformers

The following facilities shall be provided for oil filled voltage transformers:
Visual oil level indicator of prismatic or other or means of determining the position of the
diaphragm or bellows seal visible from ground level.
Oil drain cock and sampling valve where applicable.
Requirement Of 420kv Capacitor Voltage Transformer
Particulars
Rated primary
Type
No. of secondaries
Rated voltage factor
Parameters
420kV
Single phase capacitor voltage transformer
3
1.2 continuous
1.5 for 30 seconds
Phase angle errors

Capacitance(pF)
kV
Voltage Ratio
V
20 minutes
4400/8800+10% ,-5%(as per applicable)
Secondary core Nos.
Core-1
Core-2
core-3
400
400
400
3
110
3
Application
Protection
3
110
3
110
Protection
Metering and
instrumentation
Accuracy
3P
3P
0.2
*
Output burden(VA) minimum
100
100
100
*The bidder shall also estimate the requirement of burden and offer the same as an alternative for the
Employers consideration.
REMARKS :
C.T., P.T. & CVT consoles. Marshalling box shall be of aluminium alloy of 3mm are to be supplied
along with the C.T., P.T. & CVT equipments. One console box is required for 3 nos. equipment.
Details of quantities required are to be engineered by the contractor. These consoles are suitable for
outdoor mounting and shall have proper slope at the top for easy discharge of water.
APPENDIX I.
TECHNICAL REQUIREMENTS FOR 400 KV,220KV, 132KV & 33KV
INDUCTIVE VOLTAGE TRANSFORMERS &400 KV,220KV, 132KV
CAPACITIVE VOLTAGE TRANSFORMER.
Sl.
No
Particulars.
Type
Nominal
system
voltage.
Highest
system
voltage.
Frequency.
System
earthing.
4
5
6
7
8
9
10
420 KV/245KV
50Hz 5%
Effectively
solidly
earthed.
of 3 [single phase]
Number
phases.
(i)Number of
secondary
windings.
(ii)Purpose of
windings.
Rated primary
voltage.
Rated
secondary
voltage.
Ratio
400 KV/220KV
CVT
Single
phase,
50Hz, oil
Filled,
self
cooled,
Hermetically
sealed,
Outdoor
porcelain type.
400 KV/220KV
3 [three]
Protection
metering.
220KV IVT
132KV IVT
33KV IVT
Single
phase,
50Hz,
oil filled, self
cooled,
Hermetically
sealed, outdoor
porcelain type.
Single
phase,50Hz,
oil filled, self
cooled,
Hermetically
sealed, outdoor
porcelain type.
220KV
Single
phase,
50Hz, oil
Filled,
self
cooled,
Hermetically
sealed,
Outdoor
porcelain type.
132KV
132KV.
33KV.
245KV
145KV
145KV.
36KV
50Hz 5%
Effectively solidly
earthed.
50Hz 5%
Effectively
solidly earthed
50Hz 5%
Effectively
solidly earthed
3 [single phase]
50Hz 5%
Effectively
solidly
earthed.
3 [single phase]
3 [single phase]
3 [single phase]
2 (two)
3 [three]
2 [two]
2
(two)
one
protection
and
one Metering)
Single
phase,
50Hz, oil filled,
self cooled,
Hermetically
sealed,
outdoor
porcelain type
& Protection &

metering
400/1.732 KV / 220/1.732 KV
220/1.732 KV
Winding-I-110V
Winding-I/1.732V
110/1.732V
(Protection)
Winding-IIWinding-II110/1.732V
110/1.732V
Winding-III(Metering)
110/1.732V
220KV/1.732/
400
KV/1.732/110V/ 110V /1.732V
1.732
&
220KV/1.732/
110V/1.732
Description.
132KV CVT
Protection
metering.
& Protection &

metering.
132/1.732 KV
132/1.732KV
33/1.732KV
Winding-I110/1.732V
Winding-II110/1.732V
Winding-III110/1.732V
Winding-I-110V/
1.732V
(Protection)
Winding-II-110/
1.732V(Metering
)
110/1.732V
(Metering)
110/1.732V
Protection
132KV/1.732/
110V/1.732
132KV/1.732/
110V/1.732V
33KV/1.732/
110/1.732
11
Rated burden.
Winding-I (P)100VA
Winding-II (P)100VA
Winding-III(M)100VA/0.2 class
& simultaneous
burden-100 VA
with accu. cl-0.2
Winding-I(P)150VA
/3P;
Winding-II(M)150VA/0.2 class &
simultaneous
burden-150VA
with accu. cl-0.2
Winding-I (P)100VA /3P;

Winding-II (P)100VA/3P;
Winding-III (M)75VA/0.2 class &
simultaneous
burden-100 VA
with accu. cl-0.2
Winding-I(P)150VA /3P;
Winding-II(M)150 VA /0.2 &
Simultaneous
Burden- 150 VA
with accu. cl-0.2
Winding-I(P)75VA /3P;
Winding-II(M)75 VA /0.2 &
Simultaneous
Burden- 75 VA
12
Accuracy class
.
Rated voltage
factor
at
rated
frequency.
Temperature
rise at 1.2
times the rated
primary
voltage, rated
frequency &
rated burdens.
Temperature
rise at 1.5
times the rated
primary
voltage for 30
seconds, rated
frequency &
rated burden.
One-minute
power
frequency dry
withstands test
voltage
for
primary
winding.
1-minute
power
frequency wet
withstands test
voltage
for
primary
winding.
3P/3P/0.2
3P/ 0.2
3P/3P/0.2
3P/ 0.2
3P/0.2
13
14
15
16
17
1.2 continuous.
1.2 continuous.
1.5
for
30 1.5 for30 seconds.
second.
1.2 continuous.
1.2 continuous.
1.2 continuous.
1.5 for 30 second. 1.5
for30 1.5
for
30
seconds.
seconds
As per IEC-186
As per IEC-186.
As per IEC-186
As per IEC-186.
As per IEC-186.
As per IEC-186.
As per IEC-186.
As per IEC-186.
As per IEC-186.
As per IEC-186
630KV
(rms)/ 460KV [rms]
460KV [rms]
275KV [rms]
275KV [rms]
70KV (rms)
630KV(rms)/460 460KV [rms]

KV [rms]
275KV [rms]
275KV [rms]
70KV (rms)
18
1.2/50 micro 1425 KV(peak) 1050KV [peak]

/1050KV [peak]
second
impulse
withstand test
voltage
for
primary
winding
19
(i)
One-minute
power
frequency
withstands test
voltage for
Secondary
winding
Between
LV(HF)
terminal
&
earth terminal
Class
of
insulation.
Material of the
conductor of
primary
and
secondary
windings.
Fault level of
the bus to
which PTs will
be connected.
Minimum
creepage
distance.
Quality of oil.
(ii)
20
21
22
23
24
25
26
27
Radio
interference
voltage at 1.1
times
maximum
rated voltage
at 1.0 MHZ.
Partial
discharge
level.
Seismic
accelerationHorizontal
Vertical.
3KV [rnms]
3KV [rms]
10KV [rms] for

exposed
terminals
&
4KV [rms] for
terminals,
enclosed in a
weatherproof
box.
A or better for A
EMU.
Copper for EMU Copper
650KV [peak]
650KV [peak]
170KV (peak)
3KV [rnms]
3KV [rms]
3 KV (rms)
10KV [rms] for exposed

terminals & 4KV
[rms]
for
terminals,
enclosed in a
weatherproof
box.
A or better for A
EMU.
Copper for EMU Copper.
A
Copper
40KA [rms].for 40KA [rms].for 1 31.5KA [rms]

1 second.
second.
31.5KA [rms].for
1second.
25KA
for
second.
10500mm /
6125mm
3625 mm
3625mm
900mm
EHV Grade
As per IS-335.
500 micro volts.
EHV Grade
As per IS-335.
500 micro volts.
EHV Grade
As per IS-335.
500 micro volts.
EHV Grade
As per IS-335.
500 micro volts.
EHV Grade
As per IS-335
-
Less than 10
piccocoulombs.
Less than 10
piccocoulombs.
Less than 10
Piccocoulombs.
Less than 10
piccocoulombs.
0.3g.
0.15g.
0.3g.
0.15g.
0.3g.
0.15g.
0.3g.
0.15g.
0.3g.
0.15g.
28
29.
Accuracy class
of standard
V.T. to be
used during
testing towards
determination
of ratio errors
and phase
angle errors
for metering
windings.
Capacitance
(Pf)
0.05 or better.
4400/8800
applicable)
10%,-5%
0.05 or better.
(as +
0.05 or better.
0.05 or better.
0.05 or better.
4400 + 10%,-5%
ANNEXURE B.
CALIBRATION STATUS OF TESTING EQUIPMENTS AND INSTRUMENTS/METERS.
Name Meters
of the and
test.
equipment
s required
for the
correspon
di-ng test
with
range,
accuracy,
make and
Sl. No.
Date of
Calibration.
Due date Name of

of Cali- the Calibration. brating
Agency.
Whether
Calibrating
Agency
is Govt.
Approved.
Whether
documents
relating to
Govt.
Approval
of the calibrating
Agency
furnished ?
Whether
the
meters/
equipment
fulfill the
accuracy
class as
per
calibration
report
Whether
the calibra
ting
agency
has put
any
limitation
towards
the use
of the
particular
meter/equi
pment. If
yes, state
the
limitations
.
9
Whether
green sticker
or blue sticker
or yellow
sticker has
been affixed
on the body of
the particular
equipment/me
ter. State the
colour of the
affixed
sticker.
Inspite of
imposed
limitations,,
whether the
particular
meter/equip
ment can
still be used
? Justify its
use for
correspondi
ng test(s).
Remarks
10
11
12
Signature of the tenderer with seal and date.
ANNEXURE-C

Name
of the
Type
Test.
Date
of
Test.
Name of
the
Laboratory
where the
Test has
been
conducted.
Whether
the
Laboratory
is
Governme
nt
Approved.
Whether
the Test
reports are
valid as per
Clause
No.8.1 of
T.S.
Whether
the copy of
Test
Report in
complete
shape
alongwith
drawings
etc.
furnished
or
not ?
Whether
the
Tested
I.V.T/CV
T fulfills
the
technical
requirements as
per TS.
If the type tested Re

I.V.T/CVT
mar
does not fulfill
k
the technical
requirements as
per this
specification,
whether the
bidder agrees to
conduct the
particular test(s)
again at their own
cost without any
financial liability
to OPTCL in the
presence of
OPTCLs
representative
within the
specified delivery
period.
8
Signature of the Tenderer with seal and date

LIMITED
JANPATH, BHUBANESWAR 751022
FOR
220 & 48 V VOLTS LEAD ACID PLANTE STORAGE
BATTERY ALONGWITH
BATTERY CHARGER
I-
a) 350AH/ 220 & 48 V BATTERY (FOR 132 and 220KV S/S)

b) 550 AH/220 & 48 V BATTERY (FOR 220 KV400 KV S/S)
II-
BATTERY CHARGER SUITABLE FOR 350 AH and 550 AH ,220V & 48 V

LEAD PLANTE ACID STORAGE BATTERY
E17-BATTERY & BATTERY CHARGER- Page 1 of 30
CONTENTS
Clause No.
Part A
TITLE
[Lead Acid Plante Storage Battery)
A1.
SCOPE.
A2.0.
Standards
A3.0.
Installations
A4.0.
Particulars of the System
A5.0.
General
Requirement
of
the
equipments.
A6.0.
Details of specifications of plante

Batteries.
A7.0.
Design & construction details.
A8.0.
Installation of battery.
A9.0.
Connectors.
A10.0.
Accessories.
A11.0.
Maximum Short circuit current.
A12.0.
Ventilation.
A13.0.
Capacity.
A14.0.
Charging.
A15.0.
Life.
A16.0.
Instruction Manuals.
A17.0.
Transport.
A18.0.
Tests.
A19.0.
Drawings/documents.
A20.0.
Guaranteed Tech. Particulars.
Part B [CHARGER]
Clause No.
TITLES
B.1
Brief description
B.2
Arrangements
B.3
Cubicle
B.4
Design and constructional details
B.4.8
Charger panel
B.5
Transport
B.6
Tests
B.7
Drawings / documents
B.8
Special tools, plants, and spares
B.9
Guaranteed Technical particulars
B.10
Deviation from specification
B.11
General
Technical
requirements
for
Battery
Charger
ANNEXURES
GTP for 220V Lead Acid Plante storage battery.
II
GTP for Battery Charger
III
Quantity and delivery schedule
IV-A
Calibration status of meters & equipments for

testing of battery.
IV-B
Calibration status of meters & equipments for

testing of battery charger.
V-A
Check list towards Type Test reports for battery.
V-B
Check list towards Type Test reports for battery

charger.
VI
Check list for delivery schedule
PART A
TECHNICAL SPECIFICATION FOR 220 & 48 VOLTS
LEAD ACID PLANTE STORAGE BATTERY.
A.1. SCOPE :
A.1.1. These specifications cover the design, manufacturer, assembly, shop testing at
manufacturers works before despatch, supply and delivery at SITE and erection
testing and commissioning of 220 volt lead Acid Plante Storage battery.
A.1.2. The scope of supply shall include all parts and accessories etc. which are usual
and necessary for erection, operation and maintenance of the battery banks and
the chargers, as specified, above though not individually and specifically stated or
enumerated.
A.2.0. STANDARDS :
2.1.
The equipments shall comply in all respects with the latest edition of relevant
Indian Standard Specifications except for the modifications specified herein. The
equipments manufactured according to any other authoritative national /
international standard which ensure an equal or better quality than the provisions
of these specifications shall also be acceptable. Where the equipment offered
conform to any other standard, salient points of differences between the proposed
standard and the provisions of these specifications shall be clearly brought out in
the tender. A Xerox copy of such standards [in English shall be enclosed with the
offer].
2.2.
A LIST OF RELEVANT STANDARDS IS GIVEN BELOW :
[i]
IS-1652-1991
Specification for stationery cells and
batteries, lead Acid type with Plante Positive Plates

[ii]
IS : 266-1993
Specification for Suphuric Acid.
[iii]
IS-6071-1986
Specification for synthetic separators for

lead acid batteries.
[iv]
IS:1069-1993
Specification for quality tolerances water for

storage batteries.
[v]
IS:1146-1981
Specification for rubber and plastic

containers for lead acid storage batteries.
[vi]
IS:8320-2000
General requirements and methods of tests

for lead-acid storage batteries.
[vii]
IS:1885-Part-8/1996
Electro technical vocabulary-stationary cells

& batteries.
[viii]
IEEE-485/1983
IEEE recommended practice for sizing large

lead storage batteries for generating stations and substations.
A3.0 INSTALLATIONS :
A3.1. Equipments covered under these specifications shall be suitable for indoor
installation.
A4.0 PARTICULARS OF THE SYSTEM:
A4.1. One set of 220 Volts, 350AH and 550 AH capacity battery alongwith equipments
such as boost charger, trickle charger shall be sufficient to cater to the DC power
requirements in the Sub-stations as proposed. The system offered should be
suitable to OPTCL system.
A.5.0 GENERAL REQUIREMENTS OF THE EQUIPMENTS :
General requirement of the different components of the Battery system are given
below.
A5.1 One set of 220V,350/550AH lead acid type plante storage battery set is required
for meeting the D.C. load requirements of indicating lamps, emergency lighting,
relays, alarms, circuits breakers etc. The battery shall be kept in healthy conditions
with the help of the existing float charging unit. The existing boost charger unit
shall supply quick charging current to bring back the battery to fully charged
conditions after it has discharged to a considerable extent while meeting the
emergency load. The battery shall meet practically all the heavy current demands,
as required for operation [closing and / or operating of circuit breakers, emergency
lighting load and field flashing load etc). It should be noted that, the 220V batteries
are to be accommodated in the Battery Room and should operate satisfactorily
over the entire range of ambient temperature of 00 C to 500 C and relative humidity
of 95%.
A.6.0. DETAILS OF SPECIFICATIONS OF PLANTE BATTERIES :

6.1.
The batteries shall be made of closed type lead acid cells with plante type plates
manufactured to conform to IS: 1652-1991.
6.2.
CAPACITY :
6.3.
The capacity of the batteries shall be as follows :

[i]
Voltage.
220V/48 V
[ii]
Output at 270 C
350AH/550AH at 10 hrs. discharge rate.
The batteries shall normally remain under floating condition with the trickle
charger supplying the continuous load. However, the batteries shall be capable of
supplying the following loads under emergency conditions without any assistance
from the chargers and without their terminal voltage falling below 200 V [90% of
rated voltage]
350AH/550AH
[I] I stage [continuous]
35A for 10 hours. ,55 A for 10 hours
[ii] Stage emergency
15A for 3 hours for lighting.
.
6.4.
The number of cells for the 220 V/48V batteries shall be so chosen that for the
nominal floating voltage of the cells, the battery voltage shall be 237.5V/51.85V
and for the minimum [discharged condition] voltage of the cells, the voltage of the
battery shall not be less than 198V/43.2V, while the assigned rating of the battery
bank can not lowered below its rated voltage of 220/48V volts.
A7.0 DESIGN AND CONSTRUCTION DETAILS :

7.1
Containers : The containers for the cells shall be of impervious, moulded

transparent, plastic/glass material having heat-resisting, high strength, nonreacting and low inflammable properties conforming to IS-1146-1981. The
containers shall be mounted on insulators blocks. The containers shall be of robust
construction and free from flaws, bubbles or foreign matter. The surface of the
containers shall have a finish substantially free from blisters, rough spots, scales,
blow holes and other imperfections or deformations. The handle bars, if provided,
shall be of such that sufficient sediment space shall be available and the batteries
will not have to be cleared out during their normal life. Battery containers shall be
subjected to type, Routine and Acceptance Tests as per the requirements of IS1146-1981. The containers of the label attached firmly to the containers shall be
marked with the information as per requirements of cl No. 2.2 of the above
standard. The suppliers manufacturers test certificates shall be submitted by the
tenderer for the scrutiny of the purchaser.
7.2
Plates : The positive plates shall be of pure lead lamelle type with plante
formation. The negative plates shall be pasted antimonial-lead Grid type so
designed as to hold the active material securely in place and in firm contact with
the grid during service. The plates shall be designed for maximum durability and
shall not buckle during all service conditions including high rate of discharge and
the fluctuation of load.
7.3
Separators : The separators shall be of synthetic material conforming to the latest

edition of IS-6071-1986. These shall permit free flow of electrolyte and would not
be affected by the chemical reaction inside the cell and shall last for indefinite time.
The internal resistance factor of the separators shall assure high discharge
characteristics under all operating conditions. Proper arrangement to keep end
plates in position shall be furnished by the bidder alongwith his offer.
7.4
Electrolyte : The electrolyte shall be prepared from the battery grade sulphuric
acid conforming to IS-266-1993 and shall have a specific gravity of 1.2 at 270C.
The sulphuric acid of battery grade shall be colourless liquid. The concentrated
sulphuric acid on dilution with an equal volume of distilled water shall be free from
suspended matter and other visible impurities. The sulphuric acid shall meet the
requirements of columns 4 and 5 Table 1 of IS-266-1993. The requisite quantity
shall be despatched in non-returnable containers suitably packed and marked as
per the requirements of the above Indian Standards. The container materials and
packing shall be subject to approval of the purchaser.
Sufficient quantity of distilled water conforming to IS-1069-1993 shall be supplied
in non-returnable containers to correct the level of electrolyte during initial testing
and commissioning. The material of containers and packing shall be subject to the
approval of the purchaser.
7.5.
Plate group bar with terminals : The plate group bar with terminals shall conform
to IS-1652-1991. The positive and negative terminals shall be clearly marked for
easy identification. The legs of the plates of like polarity shall be connected to the
load, turned to a horizontal group bar having an upstanding terminal post adopted
for connection to the external circuit. The group bars shall be sufficiently strong to
hold the plates in position.
7.6.
Buffers/spring: Suitable buffers / springs shall be provided in the cells to keep the
end plates in position. These shall have adequate length and strength.
7.7.
Cell lids : Lids used with sealed or closed type cells shall be of glass, plastic or
ebonite and shall be provided with vent plugs. Terminal post shall be suitably
sealed at the lid to prevent escape of acid spray, by means of rubber grommets,
sealing compound or other suitable device. The positive and negative terminal
posts shall be clearly and indelibly marked for easy identification.
7.8.
Water :- Water used for preparation of electrolyte and also to bring the level of
electrolyte to approximately correct height during operation / testing shall conform
to relevant standards.
7.9.
Venting device : The venting device shall be anti splash type and shall allow
gases to escape freely but shall effectively prevent acid particles or spray from
coming out. There shall be two vent holes, one serving as a guide for acid level
indicator for checking the electrolyte level and other to permit drawing of electrolyte
samples, servicing, checking of specific gravity etc.
7.10. Marking : Acid level line shall be permanently and indelibly marked around on all
the containers.
The following information shall be indelibly marked on the outside surface of each
cell :
[i]
Manufacturers name, type and trade mark.
[ii]
Nominal voltage.
[iii]
AH capacity at 10 hours rate with specified end cell voltage.
[iv]
Cell number.
[v]
Upper and lower electrolyte level in case of transparent containers.
[vi]
Type of positive plate.
[vii]
Type of container.
[viii]
Date of manufacture [ month and year] or [week and year].
A8.0. INSTALLATION OF BATTERY :
8.1.
The battery set shall be installed on wooden racks in a separate battery room non
air conditioned but ventilated. The tenderer shall offer racks and mounting
insulators etc.
8.2.
The cell shall be arranged on the racks in a two-tier arrangement with two rows of
cells on each tier or with some other suitable arrangement depending upon the
availability of space inside the battery room. The lay out shall be subject to the
approval of the purchaser. The racks shall be constructed of best quality seasoned
teakwood with at least three [3] coats of anti-acid paint of approved shade and
also flame proof coating. These racks shall be such that cells are located at
convenient height to facilitate maintenance and they may be so constructed so as
to promote free access to the floor directly beneath the rack to facilitate easy
cleaning of the floor. These shall be designed and arranged in such a way that
easy handling of the cells is possible while in operation. Numbering tags for each
cell shall be attached on to the racks.
8.3.
The tenderer shall indicate and include the proposed arrangement of the batteries
and include arrangement for fixing and mounting of inter-bank, inter-row, inter-cell
and tap-off connectors etc.
A9.0. CONNECTORS:
Bars tinned copper lead connectors shall be employed for Inter-cell and inter-row,
inter-tier connections. However, the tee-off connection from the battery unit shall
be made with acid resisting cables of suitable size. A suitable terminal box
alongwith acid-resisting cable shall be provided by the tenderer for this purpose.
The connectors shall preferably be of bolted type and the bolts and nuts shall be of
similar material as that of connectors and shall be provided with corrosion resisting
lead coating.
The connectors shall be of sufficient cross-section to withstand all the working
conditions including one minute discharge rate as well as short circuit conditions.
A.10. ACCESSORIES :The equipments and accessories, listed below shall be furnished as part of each
battery set and the price of the battery quoted shall be inclusive of these items.
[a]
Teak wood racks with three coats of anti-acid paint and flame-proof coating.
[b]
Stand insulators +5% extra.
[c]
Cell insulators +5% extra.
[d]
All Cell interconnectors and end take-offs.
[e]
Lead coated connection hardware such as bolts, nuts etc.5% extra.
[f]
Cell numbering tags with fixing arrangement.
[g]
Teakwood, cable clamps with hardware.
[h]
Diluted sulphuric acid of sufficient quantity and of specific gravity according to the
relevant ISS and 10% extra shall be supplied in non-returnable acid proof
containers, suitable packed.
[I]
Two numbers cell testing centre-zero voltmeters 3-0-3 volts range, Accuracy class
shall be 0.5 or better and resistance not less than 1000 ohms.
[j]
One number syringe type hydrometer complete with accessories and suitable for
measuring SP gravity between 1.1 to 1.320 with graduation of 0.005 Sp. Gravity
together with temperature correction charts.
[k]
One number floating hydrometer.
[l]
Two numbers thermo-meters having range 0-100 deg. C whose one division of the
graduated scale shall represent at the most 1 degree centigrade with separate
gravity correction chart.
[Accuracy of calibration shall not be less than 0.50C]
[m]
One number wall mounting teak-wood for hydrometers and thermo-meters.
[n]
Two numbers acid-resisting plastic jugs [2 litre capacity]
[o]
Two numbers plastic funnels.
[p]
Two numbers rubber syphone.
[q]
Two numbers rubber aprons.
[r]
Two pairs of rubber gloves.
[s]
Two pairs of rubber boots-knee height.
[t]
Two sets special tools or tools required for connecting the terminals of
the batteries.
[u]
The battery terminals shall be brought out in a junction box to be mounted on the
battery stands.
[v]
Ampere-hour meter[10 hour discharge rate] of 600 1250 AH range-1 no.
[w]
Any other accessories, not specified but required for installation, satisfactory
operation and maintenance of batteries for a period of 5 [five] years.
A.11.0 MAXIMUM SHORT CIRCUIT CURRENT :

The Bidder shall state the maximum short circuit current of each battery alongwith
the safe duration in seconds which it can withstand. Methods, proposed to be
adopted for protecting batteries from the short circuit conditions should also be
stated to avoid damage to the battery and loss to the associated equipment.
A.12. VENTILATION :
The bidder shall indicate in his bid the requirements of ventilation in the battery
room. The battery shall operate satisfactorily over the entire range of the
temperature and humidity indicted in this specification without affecting its normal
life. Bidder shall indicate the percentage reduction in battery capacity at the
lowest temperature of 27 deg C. If any special ventilation requirements are
necessary, the same shall be indicated.
A.13. CAPACITY :
The standard Ampere-hour capacity at ten hour rate shall be 350/550 AH with an
end cell voltage of 1.85 volts/cell.
A.14. CHARGING :
The bidders shall state whether an equalising charge is recommended for the
battery. If so, the equalising charge voltage, current, duration and the interval
between the equalising charging shall be specified in the Data sheet. Bidder shall
also indicate the requirements for boost charging.
A.15. LIFE :
The bidder shall quote in his offer the Guaranteed life of the battery when
operating under the conditions specified.
A.16. INSTRUCTION MANUALS :
Eight sets of instruction manuals for installation, commissioning, charging and
maintenance instruction shall have to be furnished.
A.17. TRANSPORT :
The batteries, accessories and racks etc. shall be suitably packed and transported
to site.
A.18. TESTS:
A.18.1 TYPE TESTS : The bidder shall submit the test reports alongwith his offer for the
following type tests, conducted on the offered samples as per relevant National
Standard[s] within five years from the date of opening of the bid and test witnessed
by any Government Department / Government undertaking, failing which the offer
is liable for rejection.
[a]
Verification of constructional requirements.
[b]
Verification of dimensions.
[c]
Test for capacity.
[d]
Test for retention of charge.
[e]
Endurance Test.
[f]
Ampere-hour and watt-hour efficiency test.
[g]
Test for voltage during discharge.
If the type test report [s] does/do not meet the requirements as per this
specification, OPTCL at its discretion may ask the supplier to conduct the above
type tests [s] at the suppliers cost in the presence of OPTCLs representative
without any financial liability to OPTCL
A.18.2 ACCEPTANCE TESTS : Following shall constitute the acceptance tests which
shall be test witnessed by the purchasers representative at the works of the
manufacturer at the cost of supplier.
[i]
Verification of marking.
[ii]
[iii]
Test for capacity for 10 hours discharge rate along with the Test
for voltage during discharge.
[iv]
A18.3.1
Ampere-hour and watt-hour efficiency test.

The Purchaser may at his discretion undertake test for capacity
and voltage during discharge after installation of the battery at site without
any extra cost.
A.18.3.2.
The supplier shall arrange for all necessary equipments including the
variable resistor, tools, tackles and instruments. If a battery fails to meet the
guaranteed requirement, OPTCL shall have the option of asking the supplier
to replace the same within 15 [fifteen] days from the date of declaring the
same to be insufficient/failed / not as per the specification [s].
A.19. DRAWINGS / DOCUMENTS :

The tenderer shall submit the following drawings / documents along with his offer
failing which the offer is liable for rejection.
[a]
General battery arrangement, proposed size of individual and

over all dimensions along with sectional views showing all connections etc.
[b]
Pamphlets and technical literature giving detailed information of

the batteries offered.
The manufacturer shall submit the following drawings / documents in 7 [seven]

copies within 15[fifteen] days from the date of issue of the purchase order for
purchasers approval. :[a]
Lay out details of the batteries.
[b]
OGA and cross-sectional details for battery cells.
[c]
Instruction manuals for initial charging and subsequent charging.
[d]
Technical data, curves etc.
A.20. GUARANTEED TECHNICAL PARTICULARS :

The Guaranteed technical particulars, as called for in the Annexure I & II shall be
furnished alongwith the tender. Any tender lacking complete information in this
respect is likely to be rejected.
A.21. All deviations from the specification shall be separately listed, in the
absence of which it will be presumed that
the provisions of these
specifications are complied with by the tenderer
PART B
CHARGER FOR PLANTE BATTERIES
B.1 BRIEF DESCRIPTION

Charging equipment comprising of a float charger and a Float cum boost
charger, is required to meet the D.C. power requirements of the sub-station under
normal conditions, i.e., when AC auxiliary power supply is available and also to
keep all the cells in the state of full charge. The float charger shall supply the
continuous DC load at the bus bars in addition to keeping, the plante batteries
floated in a healthy condition. In case of failure of A.C. mains or sudden
requirement of additional DC power, the battery shall meet the demand as the
battery shall be connected in parallel with the charger. After the battery has
discharged to a considerable extent, it shall be fully recharged by the boost charger
unit in a short period so as to prepare it for the next emergency. Even during the
boost charging of the battery, the continuous DC load at the bus shall be met by the
trickle-charging unit. The boost charging unit shall however be provided with
suitable control arrangement to function as a stand-by for float charging unit in case
of necessity.
B.2
ARRANGEMENTS :
B.2.1 Trickle (Float) Charger :

The trickle charger shall have arrangement for regulation of D.C. output voltage
by:(i)
automatic voltage regulation system.
(ii)
Shall be of thyristor control type with both auto/manual control arrangement.
B.2.2. Quick (Boost) Charger :
The quick charger shall be similar type as trickle charging equipment, but shall
have the following features.
(i)
Shall be of higher capacity to deliver D.C. output, as stipulated in this specification

for quick charging of the plante batteries.
(ii)
Shall be provided with control arrangement for auto/manual current regulation

features, necessary for quick charging
(iii)
Shall also have auto/manual voltage control arrangement for use when the
charger will be utilised as a trickle charger.
B.3.
The Trickle and Quick charger shall be self supporting cubicle type with front
panels hinged and suitable for mounting instruments, incoming A.C., circuit
breaker with thermal and instantaneous releases relays, contactors and control
switches etc. The panels shall have access from the backside also. These cubicles
shall also house transformers, rectifiers and other equipments, accessories, as
stipulated in this specification.
B.4
DESIGN AND CONSTRUCTION DETAILS:
B.4.1 The trickle charger and quick charger shall be complete with silicon controlled
rectifier units, dry type air-cooled transformers, control electronics, smoothing
filters etc. suitable for operation from 415V + 10%, 50 HZ + 5%, 3 phase A.C.
supply. The charger output shall be stabilized to + 1% of set value for + 10% input
voltage variations and 0-100% load variation.
B.4.2 The battery charger shall have full-wave, Half-controlled thyristor controlled bridge
rectifier circuit. The charger output voltage shall suit the battery offered. The float
voltage shall be adjustable from 80% to 115% of nominal voltage. The boost
voltage shall be adjustable from 80% to 135% of nominal voltage. Ripple voltage
shall be less than 3% RMS voltage.
B.4.3 Each float charger shall be capable of floating each cell of the battery bank at the
specified voltage and supplying specified float current continuously under normal
system operation.
B.4.4 Under normal operation, the float charger shall be supplying the DC load current
and at the same time trickle charge the station battery. When the battery voltage
goes down considerably, automatic transfer arrangement shall be provided such
that the battery is disconnected from the float charger and gets connected to the
boost charger. However, when battery is on boost charge, DC load shall be fed
from the float charger. In addition, means shall be provided to ensure interruption
free availability of control power from the battery whenever there is a power failure
irrespective of whether the battery is on boost charge or float charge.
B.4.5 The selection of electronic components shall be used on ambient temperature of
50 degree C. and shall be of worst-case design to ensure continuous and trouble
free service. The control electronics shall be built on plug in type glass epoxy
printed circuit boards of modular design.
B.4.6 The maximum temperature, attained by any part of trickle charger and quick
charger, when in service at site under continuous full load conditions shall not
exceed the permissible limits as fixed by relevant standards and as corrected to
site condition.
B.4.7 Charger Panel :
B.4.7.1
Charger panels shall be rigid, self supporting structures, completely
assembled and totally enclosed cubicle type construction, made out of structural
steel members with sheet steel-coverings.
B.4.7.2
The enclosure of the charger shall be made of CRCA sheet steel of
thickness not less than 2 mm for load bearing members, 1.6mm for door and nonload bearing members and 3 mm for gland plates. Panels shall be offered with
base frame of 3.0 mm thick CRCA sheet, painted black all around, suitable for
bolting/ welding/ grouting on to the foundation. Gaskets on doors and inter panel
gaskets shall be of neoprene rubber.
B.4.7.3
The panel shall have hinged front and back doors with concealed type hinged
locks and latches.
B.4.7.4
The panel shall have adequate cross ventilation arrangement to avoid any
undue rise in temperature.
B.4.7.5
All equipments and wiring used in the panel shall be tropicalised dust
proof and vermin-proof.
B.4.7.6
Power wiring for the chargers shall be done with 1.1KV grade, heavy duty,
single core, stranded copper conductor PVC insulated cables or suitable sized
PVC sleeved copper bus bars. Control wiring for the charger shall be done
with 1.1 KV grade PVC insulated copper wires of cross section 2.5 sq. mm for
all control connection. Wire of 2.5 sq. mm cross section shall be used for
control bus. All control wiring shall be ferruled.
B. 4.7.7
Necessary terminals for grounding the panel with two

separate earthings shall be arranged for bottom entry and
suitable cable glands shall be provided for the cables.
B.4.7.8
Each charger panel shall incorporate all the necessary controls, Indications,
interlocks, protective devices and timing features to ensure any operation.
Provision shall be made with necessary contact / relays for annunciation in
the event of alternating current power failures to the charger and automatic
shut down of the charger by over-voltage / current devices. Annunciation shall
however be prevented when the charger is manually shutdown or when A.C.
power supply is momentarily interrupted for adjustable period of 1 to 5
seconds.
B.4.7.9.
The float and equaliser charging rates shall both be adjustable from the front
of the charger control panel. Each charger shall be protected against any
damage from over voltage/ load currents and shall be so designed that it can
continuously deliver at least rated current output without operation of the
protective over-load device for abnormal conditions of low battery voltage
down to 175V (80%) of the rated voltage). But the chargers shall be
disconnected from A.C. input supply through an over-voltage relay, if the input
voltage exceeds 10% of the rated voltage of the equipment. Necessary
selector switches for Trickle Charging and Quick charging shall be
provided. There shall be make before break type blocking Diodes and other
equipments to be shown in the drawing or otherwise found necessary for
charging or otherwise found necessary for charging the battery without
increasing the voltage beyond safe value across the load shall also be
supplied by the tenderer.
B.4.8
The rectifier units of the chargers shall be capable of supplying an impulse

load of 6/7 times its rated capacity. The trickle charger in conjunction with
automatic voltage regulators shall have drooping characteristics, So as to
transfer the load beyond its capacity to the battery.
B.4.9
The incoming and outgoing circuits shall be provided with MCCBs with static
releases for overload, short circuit and earth fault protections. The incoming
power supply to the chargers will be from two sources with a facility of
changeover switch. The change over facility shall be provided in the charger
itself.
B.4.10
The battery circuit shall be provided with HRC fuse protection over a suitably
rated load break isolator switch and reverse protection circuits.
B.4.11
Input volt meter and ammeter shall be of moving iron type and shall be 96 x
96 mm. Square. These meters shall be of accuracy class not less than 1.0
and shall be of flush mounting type with required PTs and CTs and selector
switches. Output voltmeter and ammeter shall be moving iron type and shall
be 96 x 96 mm square. The meter shall be of accuracy class not less than 1.0
and shall be flush mounting type. The ammeter shall be centre zero type for
measurement of charging and discharging current from the battery.
B.4.12
Cluster LED lamps for indicating Input on condition and Output on

condition, float status on / off, boost status on / off etc. shall be provided.
Annunciation with audiovisual alarms shall be provided for the following.
Input mains failure.

Input phase failure.
Input fuse failure.
Rectifier fuse failure.
Filter fuse failure
DC over voltage
DC under voltage
Output fuse failure
Charger over-load
Earth leakage
Alarm supply fuse failure
Charger trip
Output MCCB tripped
AC under voltage
Battery low condition
ACCEPT, TEST AND RESET push buttons shall be provided. 20% spare
annunciation windows shall be provided.
B.4.13 :
Any other item(s), not stipulated in this specification, but required for
installation, operation and maintenance of the battery charger is / are included in

the scope of supply without any extra charge on OPTCL.
B.5
TRANSPORT : The chargers alongwith its accessories shall be suitably packed

and transported to site in ready to use condition.
B.6
TESTS
B.6.1 Type Tests : The bidder shall submit the test reports alongwith his offer for the
following type tests conducted on the offered samples (both float charger and boost
charger) as per relevant National Standard (s) within five years from the date of opening
of the bid and test-witnessed by any Government Department /Government undertaking,
(a)
Measurement of voltage regulation / AVR regulation
(b)
Efficiency and power factor measurement test
(c)
Temperature rises test so as to determine the temperature rise of SCR,

Transformer primary, Secondary and core, Diode, capacitor, choke and cabinet
etc.
(d)
Measurement of insulation resistance.

i)
AC input to earth.
ii)
AC input to DC output.
iii)
DC output to earth
(e)
Test for rectifier transformer.
(f)
DC voltage current characteristic
(g)
High Voltage Tests.
(h)
Determination of regulation
(i)
Measurement of ripple
(j)
Reverse leakage test.
B.6.2 Acceptance Tests : Followings shall constitute the acceptance tests which shall
be tested by the purchasers representative at the works of the manufacturer at the cost
of the supplier (both for FC & FCBC) for each charger. No sampling is allowed.
(a)
Measurement of voltage regulation / AVR Regulation
(b)
Efficiency and power factor measurement
(c)
Temperature rise test so as to determine the temperature rise of SCR, Transformer

primary, secondary and core, diode, capacitor, choke and cabinet etc.
(d)
Measurement of insulation resistance.

(1)
AC input to earth
(2)
AC input to DC output
(3)
DC output to earth
(e)
Test for rectifier transformer (all relevant tests as per corresponding ISS)
(f)
DC voltage current characteristic
(g)
High voltage tests.
(h)
Determination of regulation.
(i)
Measurement of ripple
(j)
Tests for indications and alarms as per this specification
(k)
Tests for indicating instruments.
(l)
Determination of system set points.
(m)
Soft start test
N.B. : The supplier shall provide arrangements for monitoring the temperature across the
elements, as stipulated above, continuously during the temperature rise test without
disconnection of any of the temperature measuring devices across the hottest spot of
each of the above elements.
All other tests, as may be necessary to ensure that all equipments are satisfactory shall
also be carried out. In addition to the above tests, manufacturers test certificates,
vendors test certificates for different equipments, accessories, instruments etc. shall be
submitted, whenever required by the purchaser.
B.7.
DRAWINGS / DOCUMENTS
The tenderer shall submit the following drawings / documents alongwith his offer

(a)
OGA of the battery chargers
(b)
General layout with overall dimensions
(c)
Electrical schematic diagram showing connections and controls.
(d)
Leaflets and technical literature giving detailed information of the panels offered.
The manufacturer shall submit the following drawings / documents in 7 (seven)

copies within 15 (fifteen) days from the date of issue of the purchase order for
purchasers approval.
(a)
OGA of the battery chargers
(b)
General layout with overall dimensions marked alongwith sectional views showing
cable entry position etc.
(c)
Rating calculations for transformer, rectifiers, diode, capacitor, inductor etc.
(d)
Detailed schematic and connection and control wiring diagram for all the
equipments.
(e)
Complete bill of materials
(f)
Technical excerpts on operation.
(g)
The circuit diagram of charger including circuit diagrams of all cards to facilitate the
maintenance of chargers
B.8
SPECIAL TOOLS, PLANTS AND SPARES
The tender shall quote for recommended special tools, plants and spares,
considered necessary for installation and maintenance of batteries and charges for a
minimum period of 5 (five years.)
The following mandatory spares are to be quoted by the bidder in the price
bid:a)
Voltage regulator cards- 1 No/Charger.
b)
protection card (if any)- l No/ Charger.
c)
Thyristor (SCR)- 2 Nos. for F.C.+ 2 Nos. for B.C./ Charger.
d)
Rectifier Diode- 2 Nos. for F.C,+ 2 Nos. for B,.C./Charger.
e)
Blocking Diode- 1 No. for F.C. + 1 No. for B.C./ Charger.
f)
Filter Capacitor- 1 Set/Charger.
g)
Auto-manual switch- 1 No. for F. C. + 1 No. for B.C./ Charger.
h)
Indicating LED- 10 Nos./Charger
i)
Indicating fuse (if any)- 10 Nos./Charger
j)
Input A.C. contactor- 1 No. for F.C,. + l No. for B.C./ Charger
k)
Rectifier H.R.C. fuses- 4 Nos. for F.C. + 4 Nos. for B.C./Charger.
B.9
GUARANTED TECHNICAL PARTICULARS

The guaranteed technical particulars of this specification shall be furnished
alongwith the tender. Any tender, lacking complete information in this respect is likely to
be rejected.
B. 10 DEVIATION FROM SPECIFICATION
All deviations from the specification shall be separately listed in the technical deviation sheet, in the absence
of which it will be presumed that the provisions of these specifications are complied with by the tenderer.
B11. GENERAL TECHNICAL REQUIREMENTS FOR BATTERY

CHARGER
SUITABLE FOR 220 V LEAD ACID PLANTE
BATTERY
1
Type
Float & Float cum boost charger, full wave, full

controlled type.
2.
RATINGS
220V/48 V -35A/60A Float cum Boost Charger

(Suitable for Plante battery) for 350 AH capacity and
220V/48V -50A/100 A float cum boost for 550 AH
capacity
3.
4.
AC INPUT
(a) Voltage
(b) Frequency
(c) Phase
D.C.OUTPUT
VOLTAGE SETTINGS
Nominal
Float
FC
220V/48V
253V/54.5V
(adj. By + 20%, - 5%
CURRENT
35A
50 A
5.
OUTPUT
LIMIT
6.
POWER
CONVERSION
7.
8.
VOLTAGE
REGULATION AT
BRIDGE OUTPUT.
RIPPLE VOLTAGE
9.
EFFICIENCY
10.
PROTECTIONS
(a) Input side
BC
220V/48V
302V/66.5V
(adj. By + 2%, - 5%)
60A (for 350AH)
100A(for 550AH)
AC to DC by means of three phase full wave, Half

controlled bridge rectifier consisting of thyristors and
diodes.
+ 1% of set value for + 10% Input Voltage Variations,
0-100% Load variation.
Less than 3% RMS without battery connected.
More than 75% at full load
(d) control circuit
AC input MCCB with input ON/OFF switch and

fuses, contactor (for source-1&2 with interlocking)
DC output MCCB with output ON/OFF switch and
fuses contactor.
Current limit protection, soft start feature, surge
suppressor. Fast semiconductor fuses for rectifier
bridge.
Fuses
(e) Capacitor circuit
Rectifier HRC fuses.
(f)
Over-voltage cut-back
(g)
Charger over load / short circuit
(h)
Blocking diode
CONTROLS AND
SWITCHES
Followings controls and switches are provided in the

system
a) AC input source MCCBs with interlocking
b) DC output MCCB
c) Auto/Manual float/boost mode selector switch.
d) Float and boost voltage variable potentiometers.
e) Manual voltage adjustment Potentiometer
f) Test push button
g) Reset push button
h) Battery current adjustment potentiometers
i) Heaters power supply switch
j) Socket power supply switch
(b) Output side

(c) Protection
11.
415VAC 10%
50Hz 5%
3-phase-4 wire
12.
FEATURES
13.
Meters
14.
Indications
The following features are provided in the systems:

a) Soft start on DC side
b) Class-F insulation for all magnetic
c) Automatic voltage regulation.
d) Automatic changeover from float to boost and vice
versa based on current, drawn by battery.
e) Filter circuit to eliminate ripple.
f) Charger current limit
g) Separate battery path current limit.
h) Built-in auto phase reversal of operation.
F.C.
B.C.
(i)Input Voltmeter
(i) Common
(ii) Input Ammeter
(ii) Input Ammeter
(iii) Output Voltmeter
(iii) Output Voltmeter
(iv) Output Ammeter
(iv) Output Ammeter.
Battery volt meter
Battery ammeter
Earth leakage ammeter
(i) R,Y,B Phase ON (i) R.Y.B.
phase
ON
lamps
lamps
(ii) Output ON lamp
(ii) Output ON lamp.
(iii) Charger ON float
LED
(iv)Charger
ON
boost
LED.
15.
Annunciation with (i) AC input mains failure

audiovisual
(ii) Input phase failure
alarms.
(iii) AC under voltage
(iv) Input phase failure
(i)
Rectifier fuse failure
v) Rectifier fuse
(ii)
Output fuse failure
failure
(iii)
Filter fuse failure
vi) Output fuse failure
(iv)
DC under voltage
vii) Filter fuse failure
(v)
DC over voltage
viii) DC under voltage
(vi)
Charger trip
ix) DC over Voltage
(vii) Capacitor fuse fail
x) Charger trip
(viii) Output MCCB tripped
xi) Capacitor fuse fail
(ix)
Charger over load
xii)
Output
MCCB
(x)
Earth leakage
tripped.
(xi)
DC earth fault
(xii) Alarm supply fuse failure
(xiii) Battery low condition.
Note : All the alarms shall be provided through electronic display cards. Audio alarm
through buzzer, visual indication through 10 mm LEDS & alarm ackn. / reset and LED
provision is through push buttons.
16.
Operating ambient
00 to 500C
temperature
surrounding the panel
17.
18.
19.
Surrounding the panel

Relative humidity.
PANEL
(a) Protective grade
(b) Cooling
(c) Paint
(a) IP 42
(b) Natural air-cooled
(c) Smoke Grey of ISS-692 shade
MAGNETICS :
As per relevant ISS.
(a) Average winding
temperature rise
over
ambient
temperature
(b) Insulation class
(c) Insulation
breakdown
voltage.
20.
0-95% non-condensing
CABLES
F
3 KV for 1 min withstand.
1100 V grade PVC insulated copper. Ferrules shall

be provided for identification of connection.
N.B. : - Besides the above general technical requirements, all other stipulations, as
enumerated in this technical specification shall be followed. Any deviation should be
clearly brought out with clear explanation.
Any extra feature/ equipment / instrument as necessary for operation and
performance of the battery charger for the 220V /48 V battery set as per this specification
shall be provided without any extra cost to OPTCL.
ANNEXURE IV-A
(For Testing of Battery)
(To be filled in by the bidder)
CALIBRATION STATUS OF TESTING EQUIPMENTS AND INSTRUMENTS/ METERS
Name of
the Test
Meters
&
Equipments
required for the
corresponding
test with range,
accuracy, make
& Sl. No.
Date of
Calibration
Due date of
Calibration
Name of
the
Calibratig
Agency
Whether
Calibrating
Agency is
Govt.
approved
Whether
documents
relating to Govt.
approval of the
calibrating
Agency
furnished
Whether the
meters/
equipments
fulfil
the
accuracy
class as per
calibration
report.
Whether the
calibrating
agency has
put any
limitation
towards the
use of the
particular
meter/
equipment. If
yes, state the
limitations
9
Whether the
calibrating
agency has put
any limitation
towards the use
of the
particular
meter/equipment/ meter.
State the colour
of the affixed
sticker
10
Inspite of
imposed
limitations.
Whether the
particular meter
/ equipment can
still be used ?
Justify its use
for
corresponding
test(s)
11
Remarks
12
ANNEXURE IV-B
(For Testing of Battery Charger)
CALIBRATION STATUS OF TESTING EQUIPMENTS AND INSTRUMENTS/ METERS
Name of
the Test
Meters &
Equipments
required for the
corresponding
test with range,
accuracy, make
& Sl. No.
Date of
Calibration
Due date of
Calibration
Name of
the
Calibratig
Agency
Whether
Calibrating
Agency is
Govt.
approved
Whether
documents
relating to Govt.
approval of the
calibrating
Agency
furnished
Whether the
meters/
equipments
fulfil the
accuracy
class as per
calibration
report.
Whether the
calibrating
agency has
put any
limitation
towards the
use of the
particular
meter/
equipment. If
yes state the
limitations
9
Whether the
calibrating
agency has put
any limitation
towards the use
of the
particular
meter/equipment/ meter.
State the colour
of the affixed
sticker
10
Inspite of
imposed
limitations.
Whether the
particular meter /
equipment can
still be used ?
Justify its use for
corresponding
test(s)
11
Remarks
12
ANNEXURE V A
CHECK LIST TOWARDS TYPE TEST REPORTS FOR BATTERY
Name of the
Type Test
Date
Test
of
Name
of
the
Laboratory where
the Test has been
conducted
Whether
Laboratory
Government
approved
the
is
Whether the
Test report is
valid as per
Spn.
Whether the
Test report in
complete
shape
alongwith
drawings etc.
furnished
or
not ?
Whether the
type
tested
Plante
lead
acid
battery
fulfills
the
technical
requirements
as per TS
If the type tested battery does not

fulfill the technical requirements as
per this specification, whether the
bidder agrees to conduct he particular
type test again at their own cost
without any financial liability to
OPTCL in the presence of OPTCLs
representative within the specified
delivery period
8
Remarks
ANNEXURE V B
CHECK LIST TOWARDS TYPE TEST REPORTS FOR BATTERY CHARGER
Name
of
the
Type
Test
Date
Test
of
Name of the
Laboratory
where the Test
has
been
conducted
Whether
the
Laboratory is
Government
approved
Whether the
Test report is
valid as per
Spn.
Whether the
Test report
in complete
shape
alongwith
drawings
etc.
furnished or
not ?
Whether the
type
tested
battery
charger
fulfills
the
technical
requirements
as per TS
If the type tested battery charger does not

fulfill the technical requirements as per this
specification, whether the bidder agrees to
conduct he particular type test again at their
own cost without any financial liability to
OPTCL in the presence of OPTCLs
representative within the specified delivery
period
Remarks
Signature of the tenderer with seal

FOR
POWER LINE CARRIER COMMUNICATION
(THE INDOOR PLCC PANELS WILL BE SUPPLIED BY
OPTCL AS A OWNER SUPPLY ITEMS BUT OTHER
MATERIALS AS REQUIRED ARE IN THE SCOPE OF
SUPPLY BY BIDDER)
E18-PLCC- Page 1 of 35
1. GENERAL
Power Line Carrier Communication equipment shall be supplied with all associated equipment
complete with all material and accessories, and installed at various substations as indicated in
relevant schedules. The Contractor shall also include all equipment and accessories including
modifications for remote end substations of the PLCC link even though the names of the
substations do not appear in the Schedule.
The Contractor shall be responsible for the provision of training engineers of the Employer
responsible for maintenance of the above equipment. The Contractor shall also be responsible
for maintenance till the equipment is handed over to the Employer.
Panels shall be supplied complete with all accessories, meters, switches, indicating lamps,
annunciation, and other devices completely wired and assembled as per approval of the Project
Manager. The contractor shall also mount and completely wire the equipment to be supplied by
others if any for installation on these panels.
2. LIST OF ABBREVIATIONS
The following abbreviations have been used in this document.
AC
AIS
BER
CCIR
CCITT
CPU
CVT
dB
DC
DTMF
EEPROM
EMI
Ghz
HF
ic
IDC
IEC
IEC
IP
kA
kb/s
kV
LED
LED
Mb/S
Alternating Current
Alarm Indication Signal
Bit Error Rate
Consultative Committee International Radio
International Telegraph and Telephone Consultative Committee
Central Processing Unit
Capacitive Voltage Transformer
Decibel
Direct Current
Dual Tone Multi-Frequency
Electrically Erasable Programmable Read Only Memory
Electromagnetic Interfaces
Gigahertz
High Frequency
Integrated Circuit
Insulation Displacement Connector
Ingress Protection
Kilo Amperes
Kilobits per second
Kilo Volts
Light Emitting Diode
Light Emitting Diode
Megabits Per Second
msec
MTBF
MTTR
nm
PAX
PCM
PLC
PSK
PSTN
PSU
QA
RF
RFI
RFI
RLDC
SDH
SLDC
SPC
sub-LDC
VF
VSWR
Millisecond
Mean Time Between Failures
Mean Time To Repair
Nanometers (meters X 109)
Private Automatic (Telephone) Exchange
Pulse Code Modulation
Power Line Carrier
Phase Shift Keying
Public Switched Telephone Network
Power Supply Unit
Quality Assurance
Radio Frequency
Radio Frequency Interference
Radio Frequency Interference
Regional Load Despatch Centre
Synchronous Digital Hierarchy
State Load Despatch Centre
Stored Programme Control
Sub-Load Despatch Centre
Voice Frequency
Voltage Standing Wave Radio
3. PLCC SYSTEM
The PLCC system shall be used to carry speech, protection and control signals, SCADA and
computer data traffic. Interface connections shall be made directly with telephone equipment and
equipment handling digital data.
The PLCC system shall be suitably designed to work over the high voltage overhead power
transmission lines and shall comply with IEC 495. The system shall operate satisfactorily under
all power system switching and weather conditions that may be encountered at any time. It shall
be capable of operating properly during its period of service.
The mean time between failures shall be stated and proof in the form of calculations or actual inservice failure rates shall be provided.
A panel or enclosure shall be provided for paralleling the HF outputs for connection to the coaxial
cable between the PLC and the Line Matching Unit. Suitable coaxial cable shall be used between
the PLC and this panel. The HF cables from the PLC shall be terminated on the panel with plugin connectors to allow each PLC to be interchanged between lines.
The PLCC system shall essentially consist of the following:
Coupling Device, phase to phase or phase to ground.
HF cable
Carrier terminal (Owner supply item)
Protection coupler(owner supply item)
Telephone instruments
Line traps
4. STANDARDS
All the PLCC equipment covered under the specification shall conform to the requirements of the
latest edition of the relevant IEC/IS Specifications or equivalent National Standards, except to the
extent modified by this specification.
The IEC/IS Specifications relevant to the equipment covered under this specification shall include
but not be limited to standards indicated in relevant schedules of this specification.
5. DRAWINGS
5.1 Reference Drawings
The drawings attached to this specification shall be the reference drawings.
The Contractor shall evolve and furnish a comprehensive protection, control, interlocking and
signalling scheme meeting all the requirements of the technical specifications based on these
reference drawings.
The Contractor while preparing the drawings for control and relay panels shall co-ordinate with
various other equipment suppliers for actual details of equipment to be directly or indirectly
associated with the control and relay panels
The current and voltage transformer parameters are given in the relevant sections of this
specification. The contractor shall ensure the supply of CVT to meet the needs of relays and
meters being supplied by him.
Attached to Specification is a schedule indicating the existing features of PLCC system at the
particular site along with details of remote end equipment.
5.2 Contractors Drawings
Contractor shall furnish the complete scheme, system, and supply drawings as called for in this
Specification.
Contractor shall provide a list of drawings and a programme for submission in accordance with
the requirements of this Specification.
All drawing submitted by the bidder including those submitted at the time of bid shall be in
sufficient detail to indicate the type, size, arrangement, material description, bill of material,
weight of each component, break-up for packing and shipment, external connection, fixing
arrangement required, dimensions required for installation, interconnection with other equipment
and components, clearance and space required for installation, interconnection between various
points of equipment and any other information as called for in this Specifications.
6. FREQUENCY PLANNING AND SURVEY

6.1 General
A frequency planning study shall be carried out by the Owner / Contractor such that the SNR for
various channels shall be as per IEC. For transposed lines the signal attenuation considered for
frequency planning shall be justified through study reports.
The frequency and output power of the PLCC system for protection shall be planned such that the
protection signal is received with full reliability even when one phase is earthed or is open circuit
on the line side causing an additional minimum loss of 6 dB.
The frequency plan will be referred to Wireless Adviser/DOP Department for clearance. In case
any changes to the Contractor's recommendations for carrier frequency and power output are
proposed by these Authorities, the Contractor shall modify his proposal accordingly. Changes of
power output shall not, however, involve repeater stations.
The frequency planning exercise shall also include the items outlined in the following sub-clause
6.2, 6.3 and 6.4.
The Contractors study report shall includes the followings
6.2 Proposed Arrangement
Facilities shall be provided for immediate opening of local breaker under direct tripping
command from remote end. The tripping of local/remote end breakers is to be achieved by
exchange of commands on PLC system between the two ends of the line in direct tripping mode.
For security reasons each transmission line shall be protected by Main-I and Main-II protections
as given below :
Main-I
Main-II
under
Distance protection type with permissive intertripping.

Distance protection of different design/ philosophy/manufacture to the relay
Main I.
6.3 Carrier requirements

6.3.1 For 400kV Lines
a)
Two protection channels for Main-I and two for Main-II distance protection schemes.
b)
Two main and two back-up protection channels for direct circuit breaker intertripping.
c)
One speech channel with facility for superimposed telex and data signals.
d)
The arrangement shall be as per plate 7.1.
6.3.2 For 220 kV Lines

a)
One protection channel for Main-I and another for Main-II distance protection
schemes.
b)
One main and one back-up protection channel for direct circuit breaker inter-tripping.
c)
One speech channel with facility for superimposed telex and data Signals.
d)
The arrangement shall be as per plate 7.2.
6.3.3 For 132 kV lines

a) One protection channel for Main-I protection scheme.
b) One speech channel with facility for superimposed telex and data signals.
c) The arrangement shall be as per plate 7.3.
6.3.4 For 33 kV lines
No PLCC Equipment is envisaged on 33 kV lines.
6.3.5 General
The equipment for protection signals shall have high degree of reliability and speed. It shall be
guaranteed to function reliably in the presence of noise impulse caused by isolator or breaker
operation. The equipment shall be suitable for direct tripping of remote end breaker for fault in
unswitched 400 kV shunt reactors. It shall also be possible to effect direct tripping of breaker at
one end when the other end breaker is opened either manually or by protection relays such as Bus
fault relay etc.
The time intervals between receipt of a trip command on the transmit side, its transmission over
the carrier link, reception at the far end and giving command to the trip relays at the distant end
shall not exceed 20 milliseconds for permissive inter-tripping and 30 milliseconds for direct intertripping. The above timings are inclusive of operating time for auxiliary relays and interposing
relays, if any, included in the PLCC equipment.
The requirement of protection signalling channel is such that security against incorrect signals
being received shall be at least two to three orders higher than reliability against a signal not
being received.
Requirement under speech and telex communication is elaborated elsewhere in this section.
The planning of frequencies for the PLCC terminals shall be done considering the existing PLCC
Network as well as full communication channel requirement detailed above so that there is no
problem of frequency allocation at a later date when the subsequent section communication
requirements come up.
For reasons of security and reliability, phase to phase/inter-circuit coupling shall be employed.
Double differential coupling shall also be considered for double circuit lines. Bidders shall
furnish details of methods of coupling and recommend suitable coupling mode for double circuit
lines along with the bids. The coupling mode shall, however, be fully confirmed by Contractor
after conducting detailed computer studies, taking into account the transpositions of 400 kV lines,
for optimum coupling mode over these line sections. The coupling arrangement shall be fully
optimised by the Contractor after conducting detailed studies of every line section individually,
taking into account temperature variations, transpositions, earth resistivity, conductor
configuration, carrier channels requirements, security and reliability criteria and other relevant
details. The line attenuation shall be calculated for complete range of frequencies. Earth
resistivity data, existing frequency networks and other relevant details of each line will be
furnished to the Contractor for carrying out computer studies and frequency planning. The
Contractor shall complete the computer studies wherever required and submit the frequency plan
and optimum coupling details within a period of one month from the date of receipt of above
data. The cost of doing the computer studies wherever required shall be included in the lump sum
bid price and details of computer study charges shall be indicated in the relevant schedule. Bidder
must indicate the links on which computer study is required.
The 400 kV transmission lines may be transposed as shown in the relevant specification drawing.
There are two transpositions in each line section at distances shown in the drawing. The third
transposition is for achieving proper phase sequence at substation.
Transmission tower configuration and conductor details shall be made available to the successful
bidder to enable the bidder to make his own computer study assessment of the carrier path based
on wave propagation over transposed lines with each transposition point acting as "Modal
Converter".
The parameters of the equipment quoted shall be such that the mode of wave propagation on 400
kV /220 kV/132 kV power lines (with transpositions indicated) shall not impose any limitation
on the efficient and reliable performance of the information link.
The Contractor shall be required to check and prove, through the results of his computer studies,
that attenuation due to transpositions in the EHV lines is within limits and the offered equipment
will perform satisfactorily.
The Contractor shall submit curves illustrating ìncorrect tripping' and "failure to trip" probability
plotted against corona noise level, in the presence of impulse noise due to switching of isolators
and circuit breakers etc. Details of field tests and laboratory tests for successful operation of his
equipment, under such adverse conditions shall be furnished by the Bidder. These are to be
related to end-to-end signalling and shall take into account the type of communication link e.g.
account shall be taken of transpositions in the phase to phase coupled HT. line. Details of field
tests and laboratory tests for successful operation of the equipment under the above circumstances
shall be submitted by the Bidder illustrating the above parameters.
7. LINE TRAP (TO BE SUPPLIED BY THE CONTRACTOR)
7.1 Technical Requirements
Line traps shall be inserted into extra high voltage transmissions line to prevent undue loss of
carrier signal for all power system conditions. Their impedance shall be negligible at power
frequency (50 Hz) so as not to disturb power transmission but shall be relatively high over the
frequency band appropriate to carrier transmission.
Line traps shall consist of a main coil designed to carry continuously the rated current without
exceeding the limit of temperature rise. It shall be supplemented with a protective device and
tuning device.
Line traps shall be broad band tuned for its entire carrier frequency range. Resistive component of
impedance of the line trap within its carrier frequency blocking range shall not be less than 450
ohms for 400kV and 570 ohms for 220kV systems.
Line traps shall be provided with a protective device in the form of a lightning arrestor. The
protective device shall be designed and arranged such that neither significant alteration in
protective function nor physical damage shall result from either temperature rise or the magnetic
field of the main coil at continuous rated current or rated short time current. The protective device
shall neither enter into operation nor remain in operation, following transient actuation by the
power frequency voltage developed across the line trap by the rated short time current. The
protective device shall be shunt connected to the main coil and tuning device.
The lightning arrestor shall be station class current limiting active gap type. Its rated discharge
current shall be 10 kA. Co-ordination, however, shall be done by taking 20 kA at 8/20 micro-sec.
discharge current into account. Bidder has to furnish full justification in case the use of gap-less
metal oxide arrestor is recommended by them.
The lightning arrestor provided with the line trap of each rating shall fully comply with the
requirements of IS 3070-Part I (1974)/IEC 99-I (1970) Part I. It shall conform to type tests as
applicable and type test certificates shall be submitted by the Bidder.
The lightning arrestor provided with the line trap shall be subject to routine and acceptance tests
as per IEC 99-1 (1970) (Part-I).
The line trap on 400kV/220kV/132KV lines shall show no visual corona discharge at a voltage of
320kV/187kV/105kV rms power frequency falling voltage. Suitable corona rings shall be
incorporated in the line trap.
Line trap shall be equipped with bird barriers.
Line trap shall be spray painted with light grey paint (shade 631 of IS 5).
7.2 Rating plates
The line trap shall be provided with a rating plate of weatherproof material, fitted so that it is
readily visible. The inscriptions shall be indelibly marked. The rating plate shall give the
following data:
Manufacturers name
Type and serial number
Rated inductance in mH
Rated continuous current in amps
Rated short time current in kA
Rated frequency in Hz
Temperature category
Insulation level
Diagram showing the terminal marking
Year of manufacture
Total mass in kg
Each tuning unit shall also be provided with a rating plate giving the following information:
Manufacturers name
Type and serial number
Frequency band in kHz
Rated impulse protective level of tuning unit
7.3 Technical parameters

Line traps shall conform to IEC 353 and the parameters given in Table. 8.3.
Parameter
400Kv
220kV
132kV
Rated power frequency (Hz)
50
50
50
Rated system voltage (kV)
400
220
132
Highest system voltage (kV)
420
245
145
Rated continuous current at 50C (A)
2000
1600
800
Rated short time current for 1 sec. (kA)
40
40
40
Nominal discharge current of protective device at 8/20 micro sec. wave

(kA)
10
10
10
Type of tuning
Broad band
Rated blocking bandwidth
To be advised by Contractor
Minimum resistive component of impedance within rated blocking

bandwidth (Ohms).
450
450
450
Rated inductance of main coil (mH)
1.0
1.0
0.5
320
187
105
Corona extinction voltage (kV)

Radio interference voltage (micro volts at 1.1. times Ur/3, where Ur =
maximum system voltage)
500
Table 8.3. Parameters for line traps

The exact quantities and rating of required line traps shall be decided by the Project Manager
based on frequency planning and recommendations of the Contractor.
The Contractor shall indicate continuous current rating of the line trap at 65C ambient.
7.4 Welding or brazing on line trap during manufacture
All the welding included in the manufacture of line traps shall be performed in accordance with
the relevant section of this Specification.
7.5 Line trap mounting (to be supplied by the contractor)
Line traps shall be suitable for outdoor pedestal mounting and shall be mechanically strong
enough to withstand the stresses due to maximum wind speed specified in the schedules. The
contractor shall recommend the mounting of line traps and prepare the lay out of the substation
for the Project Managers approval.
Where pedestal mounting is recommended, each line trap shall be mounted on a structure fitted
with insulators to provide mechanical stability and structural rigidity. The Contractor shall
submit the design calculations to establish the adequacy of his recommendations. All the
accessories and hardware, mounting stool, including bolts for fixing the line trap on insulators,
shall be of non-magnetic material.
The Bidder shall submit along with his bid, typical drawings clearly indicating the above
mentioned features of the line traps, line trap mounting arrangement and terminal connectors.
Each transmission line fitted with line traps shall be charged in the presence of the Contractor's
representatives.
8. COUPLING DEVICE (TO BE SUPPLIED BY THE CONTRACTOR)
The coupling devices shall be interposed between the capacitor voltage transformer and coaxial
line to the PLC transmitter/receiver. The coupling device, in conjunction with the capacitor
voltage transformer, shall ensure efficient transmission of carrier frequency signals between the
carrier frequency connection and the power line. In addition safety of personnel and protection of
the low voltage parts and installation, against the effects of power frequency voltage and transient
over voltages shall be ensured.
The coupling device in conjunction with the CVT shall form an electric filter of band pass type
and have the following characteristics:
1. It shall match characteristic impedance of HT line to impedance of the carrier frequency
connection. Impedance matching between power line and the carrier frequency connection
may be done by a transformer or an auto-transformer. The phase to earth characteristic
impedance of the HT line may be assumed to be 320 ohms for 400 kV lines and 400 ohms
for 220 kV lines. The design details must be submitted along with the Bids.
2. Galvanic isolation between primary and secondary terminals of the coupling device shall
be performed by the above mentioned transformer.
3. Power frequency currents derived by the CVT may be drained to the earth by a separate
inductance termed drain coil of suitable rating.
4. Voltage surges coming from the power line at the terminals of the coupling device shall be
limited by a non-linear surge arrestor of suitable rating in the primary side. Requirement of
a gas type voltage arrestor in secondary side of the coupling device shall have to be fully
justified, but in any case the input circuit of PLC equipment shall have protective devices
in the form of zener diodes and surge suppressers. The surge arrestor shall have power
frequency spark over voltage co-ordinated with the equipment ahead of it.
5. For direct and efficient earthing of its primary terminals, the coupling device shall be
equipped with an earthing switch. The coupling device shall be designed such that it shall
not be possible to remove the cover before the earthing switch is operated to the èarthed'
position. Further the earth switch shall be available for earthing of CVT-HT terminals,
when the coupling filter units are removed from circuit for maintenance and replacement.
The design shall take due regard of requirements for safety in accordance with the Indian
Electricity Rules.
Two phase to earth type coupling filters shall be used to achieve secure phase to phase intercircuit coupling in case of double circuit lines. Connection between secondaries of the two phase
to earth type coupling devices shall be through a balancing transformer/hybrid such that reliable
communication shall be ensured even when one of the coupled phase is earthed or open circuited
on the line side.
Coupling devices shall conform to IEC 481 and have the following carrier frequency
characteristics as applicable to a phase to earth type coupling device :
Nominal line side impedance
Nominal equipment side impedance

Composite loss
Return loss
Bandwidth
Nominal peak envelope
320 ohms for 400 kV line

400 ohms for 220 kV lines
75 ohms (unbalanced)
Not more than 2 dB
Not less than 12 dB
Shall suit the frequency plan between 36 and 500
kHz
Not less than 650 Watt power (for inter
modulation product 80 dB down)
The coupling device shall be suitable for outdoor mounting. Temperature of metallic equipment
mounted outdoor is expected to rise up to 65C during the maximum ambient temperature of 50C
specified. The equipment offered by the Bidder shall operate satisfactorily under these conditions.
All the elements of coupling device shall be fitted on a base plate and enclosed in a padlockable
metal box with inspection glass on front. The general arrangement and dimensional details of the
metal box shall be similar to that shown in the specification drawings. The Contractor shall
submit detailed drawing indicating a general arrangement, interconnection and all other details
for approval of the Project Manager during detail engineering.
The HT terminal of coupling device shall be connected to HF terminal of the CVT by means of
6mm2 copper wire with suitable lugs and taped with 11 kV insulation by the Contractor.
The coupling device shall have at least two terminals for carrier equipment connection. Bidder
shall confirm that such a parallel connection to coupling device directly will not result in any
additional attenuation.
9. HIGH FREQUENCY CABLE (TO BE SUPPLIED BY THE CONTRACTOR)
High frequency cable shall connect the coupling device installed in the switchyard to the PLC
terminal installed indoors. The high frequency cables supplied by the Contractor shall be suitable
for laying directly in trenches or in ducts.
The cable shall be steel armoured and its outer covering shall be protected against attack by
termites. Bidder shall offer his comments on method employed by him for earthing of screen and
submit full justification for the same with due regard to safety requirements.
Bidder shall enclose in his bid a detailed construction drawing of the cable being offered, with
mechanical and electrical parameters.
Impedance of the cable shall be such as to match the impedance of the PLC terminal on one side
and the coupling device on the other side, over the entire carrier frequency range of 40-500 kHz.
Loop resistance of cable shall not exceed 30 ohm per km at 20C.
The cable shall be designed to withstand a test voltage of 4 kV between conductor and outer
sheath for one minute.
Bidder shall specify attenuation per km of cable at various carrier frequencies in the range of 40
to 500 kHz. The typical attenuation figures for HF cable shall be in the range of 1 to 5 dB/km in
the frequency range of 40-500 kHz.
The HF cable shall conform to type tests and be subjected to routine tests as per IEC 96-2/ BS
2316/ IS 5802.
The Bidder shall submit along with the bid, copies of type tests and performance reports of the
cable being offered.
All HF cables within the scope of this specification shall be supplied, laid and terminated by the
Contractor.
Cables shall be supplied wound on drums containing lengths not less than 500 metres each.
10. POWER LINE CARRIER TERMINAL (OWNER SUPPLY ITEMS -OPTCL )
10.1 General
As already indicated the information link shall be provided for speech, protection, fax and data
services. PLC terminals shall be fully co-ordinated to match with the specific requirements.
Because of strict requirement of high speed of operation, security, reliability and efficient
operation of protection channel along with the carrier terminals, Bidder shall ensure the complete
and fool-proof co-ordination of the PLC and protection equipment. It shall therefore be necessary
to have these combinations as one unit without any mismatch or necessity of any intermediate coordination unit.
PLC terminal shall use amplitude modulation and shall have single side band transmission mode.
These shall be equipped for fixed frequency duplex working and shall be fully solid state.
Characteristic input and output parameters of the PLC terminals shall be as per IEC 495 unless
otherwise specified.
10.2 Features of PLC terminals
Each PLCC channel shall be capable of carrying any of the following:
1. One speech channel plus telephone signalling channel, nominally 300 Hz to 3.4 kHz for
speech. This is also required to carry facsimile transmission and computer data.
2. One restricted speech channel 300 Hz - 2 kHz plus a band of 2 kHz - 4 kHz for the
transmission of data and a telephone signalling channel. Data signalling rates of 50,
200,300, 600 baud shall be possible.
3. Two 600 baud channels or one 1200 baud channel. It shall be stated if higher data rates up
to 9600 bit/s can be transmitted.
4. One channel for the transmission of speech and teleprotection signals.
5. One channel for the transmission of speech, teleprotection signals and data.
The equipment shall preferably be capable of operation in all the above modes without the
provision of additional modules and components. The telephone signalling channel shall be
nominally 3.8 kHz out-of-band.
Subject to frequency allocation considerations, PLC equipment may be required to be expanded
by the addition of channels to a link (i.e. upgrade to 2 or 4 channels as appropriate). The PLC
equipment shall be modular in construction and shall permit such upgrading to be carried out.
The equipment shall be suitable for use with E and M signalling between telephone exchanges at
both ends of the lines. Signalling shall be on the pilot tone using a 50 baud channel. If DTMF
signalling is available as an alternative this should be stated.
10.3 Transmitter/receiver
The equipment shall use single channel amplitude modulated single sideband suppressed carrier
transmission. The Bidder shall quote for terminals which have an output power of 20, 40 and 80
watts.
PLC equipment shall be designed to operate over a frequency band of 50 kHz to 500 kHz.
For each PLC link, the Bidder shall indicate the required frequency spacing between the
transmitters and receivers. Spaced band and contiguous band operation should be possible. In
twin channel versions, it shall be possible to operate both transmitters and both receivers in
adjacent bands. The Bidder shall state the full range of carrier frequencies over which the
equipment may be operated.
The carrier frequency output impedance shall be 75 or 125 unbalanced. Any alternative shall
be stated in the tender. The return loss within the nominal carrier frequency band in the transmit
direction shall be not less than 12 dB.
The maximum permitted level of spurious emissions shall meet the requirements of IEC 495
Section 8.3.2. Spurious emissions shall be measured as described in Clause 6.2.3 of the
recommendations.
The receiver shall have high selectivity and the attenuation of out of band signals shall be as
follows:
Frequency out of
band (kHz)
Attenuation(dB)
0.3
70
0.3 - 4.0
70 - 90
4.0
90
The generation of carrier frequencies shall be fully synthesised. It shall be possible to select any
carrier frequency within the whole carrier frequency range in discreet steps of 4kHz. The
frequency synthesis shall be highly accurate such that the actual carrier frequency shall not differ
from the nominal by more than 20 Hz.
10.4 Speech and signal levels
The voice frequency input impedance shall be 600 balanced. The return loss within the
effectively transmitted frequency bands shall be not less than 14 dB.
The minimum send level shall be not more than -14 dBm. The maximum receive level shall be at
least +4 dBm. Attenuators to facilitate interfacing and matching should be provided.
The absolute input and output levels for signal channels shall be chosen in accordance with the
relevant ITU-T Recommendations.
In a pair of PLC terminals, the frequency difference between a voice frequency signal applied to
the transmit end and that received at the receive end shall not exceed 2 Hz.
The linearity as a function of the voice frequency input level, shall be such that the overall loss of
the speech circuit, of a pair of PLC terminals without compandors and limiters, does not differ by
more than 0.8 dB from the overall loss at 0 dBm for any input level between -10 dBm and 0
dBm. The measurements shall be made at 800 Hz.
Automatic Gain Control: In the case of a 30 dB change in carrier frequency signal level within
the regulation range, the change in voice frequency receive levels of both speech and signals shall
be less than 1 dB.
Graphs showing frequency/attenuation response of the line filters shall be included with the
tender.
The use of companders shall be optional and the final arrangement shall be agreed with the
Project Manager.
10.5 Maintenance facilities
Set up and maintenance facilities shall be provided, preferably through the use of a portable PC.
The facility shall enable the variable parameters of the equipment to be modifiable.
Details of test equipment required for the set-up and maintenance of the equipment shall be given.
Provision shall be made on each point to point PLC link for emergency and maintenance
telephone communications together with audible and visible calling annunciators.
10.6 Alarm facilities
The failure of a module, fuses or loss of power or any other condition affecting the correct
operation of individual components of the PLC system shall be automatically detected. Provision
shall be made for the indication of these alarms on the affected equipment, and on the substation
alarm annunciator panels or alarm monitoring system via potential free contacts.
10.7 Technical parameters
10.7.1 General
1. Carrier frequency range,
programmable.
40 - 500 kHz
2. Mode of transmission
Amplitude modulation single side band with suppressed

carrier or reduced carrier.
3. Frequency difference
Between VF signal at the PLC terminal transmitting and

receiving ends will not exceed 2 Hz with suppressed
carrier. With reduced carrier frequency difference shall be
zero. This shall include permissible ambient temperature
variation and supply frequency and voltage variation of
(+) 15% and (-) 10%.
4. RF output power (PEP) at

coaxial cable
20W, 40W, 80W as required.
5. Nominal RF impedances
75-125ohm unbalanced 150ohm balanced, optional.
6. Life expectancy
15 Years
7. Carrier frequency output return

loss
12 dB minimum
8. Out of band selectivity
90 at 4 kHz
9. Method of generating carrier
Synthesised
10. Accuracy of carrier frequency

generation
+/- 20 Hz
11. Minimum VF send level
-14 dBm
12. Maximum VF receive level
+4 dBm
13. VF linearity
+/- 0.8 dBm
14. Module/Card type
Plug In
15. Operating Temperature Range
0-50C
16. Number of AF channels
1-4
17. Effective AF bandwidth
300 - 3600 Hz
18. Alarms for
loss of transmit signal

loss of receive signal
inadequate S/N ratio
19. Power supply, mains
230VAC, +15%, - 15%
20. Power supply, battery
48VDC, +20%,-15% + ve earthed
21. Ambient conditions according to
IEC 495 (revised )
22. Automatic gain
For 40 dB change in control carrier frequency signal level

within the regulation range, change in VF receive levels of
both speech and other signals shall be less than 1 dB.
10.7.2 User interfaces

1. Telephone interface, 4-wire
600 ohm
10.7.3
1. Number of separate audio 1/0 per
channel
2. Number of commands with

plugged-in Protection Coupler
10.7.4 Other system components

1. plug-in protection signalling
module
plug-in AF modem programmable
10.8 General requirement for PLC terminal

All the PLC terminals shall be of multipurpose type. The Bidder shall confirm that the total
transmission time for teleprotection shall not exceed 20 ms for permissive and 30 ms for direct
tripping signals. Speech and teleprotection channels shall independently fulfil the SNR
requirements out of the power allocated to its channel from the total power of the PLC terminals.
Detailed calculation for SNR requirement and power allocation over different channels should be
furnished along with the bid.
Multiplexing equipment, VFTs and measurand and converters etc. for data are not included in
the scope of present specification and shall be procured separately. The successful Bidder shall,
however, be required to co-ordinate his carrier equipment with these equipments for successful
operation of the system.
The final selection of the output power shall be based on the frequency planning and computer
studies conducted by the Contractor. The evaluation of bids shall, however, be done on the basis
of prices for carrier sets with power output as stated in this Specification.
In the input circuit of the PLC terminal protective devices shall be provided in the form of zener
diodes or surge suppressers in order to eliminate any surge transfer through the coupling device
or induced in the connecting path of HF cable.
To improve voice transmission characteristics for the system, compressors and expanders
(companders) shall be provided. The companders shall have at least 2:1 compression ratio with a
corresponding expansion ratio of 1:2. The operating range of compander shall be compatible with
the audio power levels specified for four wire operation. The improvement gained by companders
shall however not be taken into account for power allocation and shall be in-hand reserve.
Sudden changes in input level to the receiver shall not cause false tripping. The Bidder shall
clearly indicate in his offer the methods adopted to ensure above phenomenon. The receiver
design shall also provide protection against false tripping from random noise.
Fail safe devices shall be provided, so that a malfunction in one unit or sub-assembly cannot
cause damage elsewhere in the system. All plug in equipment shall be fitted with features to
prevent improper insertion. The electrical cables shall not be routed across sharp edges or near
sources of high temperature. The adjustments, which are susceptible to misadjustment from
accidental contact/vibration, shall be equipped with suitable locking devices.
The PLC set shall be designed to give guaranteed performance from 0C to 50C ambient temperature. The thermal capability of the equipment shall be so designed that the equipment remains
operational successfully up to 60C ambient temperature. Any ventilation fans provided for
circulation of air inside the cabinets shall conform to relevant Standards.
Terminals shall be provided with a built-in indicating instrument to facilitate checking of
important voltage and current values and signal levels in different parts of the PLC Terminals.
Protection fuses shall be provided in all important circuits, and fuses shall be so mounted as allow
their easy inspection and replacement. All test points shall be easily accessible.
The carrier set shall be provided with suitable supervision and alarm facilities. Individual parts of
the carrier set should be accessible from front, making it possible to place the carrier cabinets
side-by-side. All components and parts of the carrier set shall be suitably tropicalised.
PLC terminals shall be housed in floor mounting sheet metal cabinets, suitable for mounting on
concrete plinth as well as channel frame by means of nuts and bolts or welding. The cabinets shall
be properly cleaned and spray painted with two coats of synthetic enamel paint. Exterior of the
cabinets shall be painted with smoke-glossy finish. Interior of the cabinets shall be painted with
white enamel paint with glossy finish. All the panels shall be properly earthed to the Employers
earthing grid by the Contractor. Contractor shall submit detailed drawings for earthing connections.
All panels shall be protected against moisture ingress and corrosion during storage. Panels shall
be properly dried before they are installed and energised. Bidder shall indicate measures adopted
to prevent ingress of moisture during operation.
All cabinets having PLC terminals shall be provided with lamps of sufficient wattage for interior
illumination with switch.
A name plate shall be provided on the front door of each cabinet indicating channel function,
transmitter frequency and direction etc.
10.9 PLC Terminal Speech Communication
PLC equipment offered shall provide telephone communication between the stations where the
transmission lines specified in the schedules are terminating.
It shall be possible for a subscriber at any of the stations to contact the subscriber at all other stations connected in the system by dialling his call number. To achieve this an EPAX with four
wire interface and remote subscriber units shall be provided at different stations.
The equipment shall contain all normal facilities such as ring back tone, dial tone, engage tone
and priority tone, and suitable pulses to establish and disconnect communication between
subscribers.
The equipment shall be provided with necessary alarm circuits and fuses etc.
The equipment shall be of 4 kHz bandwidth on either direction and be suitable for providing
superimposed data and teleprinter facilities at a later date without major modifications and high
cost. The Bidder shall clearly indicate in his bid the provision made in his proposal for future
development and the extent to which such additional facilities can be added at a later date.
The system shall be completely automatic with a definite number allocated for each telephone.
The numbering scheme for telephones, exchange and tie lines shall be developed by the Bidder
and indicated in the bid. Final numbering scheme shall be fully co-ordinated with the existing and
proposed future systems by the Contractor.
Arrangement for over-riding facilities shall be provided by means of priority keys wherever
specified. The over-riding facility shall enable cutting-in on ongoing calls with the priority key to
ask the concerned parties to finish their conversation. The wanted number should then be
automatically connected without having to redial the number.
All carrier telephone conversations shall be secret and it should not be possible for anybody to
over hear a conversation going on between any two parties excepting those provided with overriding facilities.
The necessary cables for connecting all the telephone instruments ordered for each substation
(including wiring and terminations) shall be provided by the Contractor. These telephone
instruments shall be located within the control room building at the respective substation.
All relays etc. used in the equipment shall be of sufficiently robust design to cope with the duty
imposed on them. Electronic components used in the equipment shall be of long life type and as
few types as possible shall be used.
The cabinets housing the equipment for EPAX, four wire E/M interface and remote subscriber
units (four wire) shall have mounting arrangements similar to those for PLC terminals as
elsewhere in this section of this Specification.
All the terminals for speech shall be supplied fully wired for addition of VFTs and transit filters
in future.
Equipment for speech communication must be fully compatible with Employer's existing
equipment. Any interfaces required for proper matching and connection with the Employers
existing equipment shall be provided by the Contractor.
Terminals for protection shall be suitable for operation between the two ends of each
transmission line or on tandem operation basis with back to back connection at the intermediate
stations.
Each PLC terminal for speech as well as protection purposes shall be provided with a plug-in type
service telephone and buzzer. Further, four wire remote telephone instruments (parallel to service
telephone) shall also be provided on one PLC terminal for protection for each link. These
instruments shall be located in the respective switchyard control rooms to enable the operator to
make emergency calls on point-to-point basis. Each such instrument shall be equipped with a
buzzer and `press-to-call' key and shall not require any additional power supply units.
There is also a requirement for express telephone links between substations and Area and State
Load Dispatch Centres. A call from the substation shall be initiated by lifting the handset. This
would cause a lamp to light on the communications console (to be provided under another
contract) at the control centre.
11. ELECTRONIC PRIVATE AUTOMATIC EXCHANGE (EPAX) (TO BE SUPPLIED
BY THE CONTRACTOR)
11.1 General requirements
Private automatic telephone exchanges (PAX) are required at substations as stated in the detailed
description of work and Bill of Quantities.
The equipment shall be capable of providing proper performance throughout its fifteen year life
expectancy.
All equipment shall be designed for ease of maintenance and shall include a variety of built-in
alarms associated with vital operating parameters.
All equipment supplied under this specification shall conform with the latest IEC Specifications
and CCITT Recommendations.
The topographical, meteorological and system operating conditions shall be as stated elsewhere in
this Specification
Each interface shall be protected so that neither a short circuit nor open circuit on the telephone
line shall cause permanent damage to the exchange equipment. The application of a 500 volt, 50
Hz, signal to either or both legs of the line, shall not cause permanent damage to, or
malfunctioning of the exchange equipment.
The exchange equipment shall be protected from electrostatic discharges transmitted to, or
occurring at the line interface units.
Each interface shall have an insulation resistance of greater than 10 Mohms at 500V DC
between line terminals and earth.
Each interface shall be capable of withstanding longitudinal 2kV, 10/1000 microsecond voltage
surges.
The equipment shall operate from a 48 V DC positive earthed battery supply.
Switching equipment shall provide for the following:
Interconnection of calling and called extension.
Interconnection of PAXs via circuits conforming to CCITT Rec. G703 and G705 and
PLC channels conforming, to IEC 495.
Interconnection with a central PAX telephone console at the State Load Dispatch Office
and Area Load Dispatch Office.
A traffic monitoring and reporting system.
11.2 PAX interfaces
11.2.1 General
The PAX requires both analogue and digital interfaces. It shall be capable of interfacing to
existing and future GRIDCO telecommunications equipment, and to the public telephone system
at selected sites. It shall be capable of interfacing with power line carrier, pilot cable, digital
multiplexer, and the PSTN.
The PAX shall be capable of handling analogue and digital trunks, tie lines and extensions, and
shall be able to provide the following interfaces:
2 wire loop extensions
2 wire loop tie lines
2 wire E and M tie lines
4 wire E and M tie lines
2 wire loop PSTN lines
The analogue interfaces shall be two and four wire interfaces, with and without E and M
signalling and busy/test signalling, to suit telephone, PLC and pilot cable equipment.
The digital interfaces shall be 64 kbit/sec and 2048 kbits/sec with and without common channel
signalling, to suit digital data links and inter-exchange trunks.
11.2.2 Two wire analogue telephone interface requirements
The interface shall be suitable for both standard telephone instruments and telephone consoles for
control centre, generating station and substation operators, using DTMF signalling. The interfaces
shall provide BORSCHT functions, i.e. Battery supply, Overvoltage protection, Ring current
supply, Supervision, Code, Hybrid and Testing functions, for each line connection.
The line feed shall be sufficient to ensure the satisfactory performance of two telephones in
parallel on a balanced line of between 0 and 1500 metres in length. The range of loop resistance
over which the interface will operate will be 0 to 500 ohms, with a similar limit for the
Transmission Equivalent Resistance (TER).
The two wire port impedance shall be 600 ohms, nominal, balanced and suited to the telephone
instruments during ringing, signalling and voice transmission conditions.
11.2.3 Analogue power line carrier (PLC) interfaces
The interfaces shall operate as four wire plus E and M interconnections, with the facility for
equipment busy signalling wire and test signalling wire, for use with existing transmission
equipment interfaces, i.e. PLC and pilot cable interfaces.
The electrical interface requirements are as follows:
Transmit and receive pairs
than
impedance 600 ohms balanced; return loss better

20 dB; levels - 3.5 dBm;
E wire
50 volt battery and relay coil;
M wire
voltage free relay contact to earth;
Test/busy wires
voltage free relay contact to earth;
11.2.4 PAX to PAX interfaces operating over digital trunk circuits

The interfaces shall operate as analogue and digital trunk/tie line interfaces to enable existing
changes to be interconnected with the digital PAX and multiplex equipment.
64 kbit/sec interfaces shall be in accordance with requirements of CCIIT Recommendation G 70J,
and shall be complete with channel associated signalling.
The Contractor shall be responsible for ensuring that these 64 kbit/sec interfaces enable the full
range of network facilities to be available for the PAX extensions.
11.2.5 Pilot cable interface
The interface shall provide facilities to interconnect telephone and other terminals to multiplex
and exchanges sites via existing pilot cable systems. These interfaces generally conform to those
of the PLC system, and are suitable for extending four wire analogue telephone interfaces beyond
the 500 ohm limit.
64 kbit/s interfaces shall be in accordance with CCITT recommendation G703, and shall be
complete with channel associated signalling,
The PAX shall have facilities for handling DTMF, decadic, feature and digital phones. It shall be
possible to connect remote extensions directly to the PAX over four wire E and M circuits.
11.3 Exchange equipment
The PAX shall be a full digital stored programme controlled type, suitable for the transmission of
64 kbit/s and 2 Mbit/s digital signals and for interfacing with PSTN and other public ISDN
exchanges.
The PAX shall be capable of being connected via analogue PLC and pilot cable voice circuits
utilising MF and E and M signalling to other PAXs installed in the GRIDCO PAX network.
The PAX shall be capable of automatically searching for alternative routes if the first choice
route is unavailable.
The equipment shall be expandable to at least the specified maximum switching capacity without
impairment of reliability or performance, and without the need for replacement of installed major
software and equipment.
11.4 Extension features
The PAX shall provide for the interconnection of any two extensions connected to the exchange
without the participation of a telephone operator, on the basis of keyed or dialled numbers.
The PAX shall provide for:
Normal inter extension communication.
Automatic call-back on "Busy" or "No Reply". The calling extension shall have to
enter a prefixed code for this facility to be operable
Conference call, both three way established by an extension, or a multiple conference

up to 20 extensions .
Call transfer to transfer a calling party to another extension.
Call transfer/follow me to reroute all incoming calls to another extension.
Call transfer to allow a called extension to be answered at another extension by

dialling a code at the other extension.
Last number redial to allow a redial by using a code.
Abbreviated dialling to allow codes or a telephone button to dial previously stored

numbers.
Call waiting indication.
Extension group hunting to allow a number of extensions to be grouped on a common

extension number, with incoming calls being assigned in cyclic order to free
extensions.
The facility to hold a call while making a second call.
The features shall be available on an assigned basis.

The exchange transmission performance shall conform with CCITT Recommendations G712,
Q507 and Q517 for combined transit/local exchanges and related recommendations in regard to
measurement techniques, interface characteristics, and definitions.
11.5 Software
The preferred programming language is CHILL, as described in CCITT Recommendation Z200,
Red Book. However other high level languages may be offered which can provide the reliability
and maintainability required, and which conform to the basic structural requirements.
The software used on the system shall be of' tried and tested modular construction. The Bidder
shall state if software upgrades have been implemented and which version of software is being
offered. The procedure for upgrading the system software shall be stated. Details of software
licensing arrangements shall be provided.
11.6 Maintenance
The exchange shall provide automatic monitoring and reporting functions to verify the proper
execution of call handling and exchange software or hardware malfunctions, and report on the
condition of interfaces and exchange resources, e.g. memory occupation, call queue levels, CPU
utilisation, traffic levels.
Printed and visual display reports shall be date and time stamped and shall identify exchange and
software version codes.
The exchange shall be equipped with the following alarm facilities:
Urgent alarms indicating a major malfunction
Non-urgent alarms resulting from transient conditions or self clearing (automatic partial
restart) conditions
Local urgent and non-urgent alarm indications shall also be provided.
11.7 Hardware
To meet functionality, reliability and performance requirements, the hardware for the exchange
shall use:
Duplicated call handling processors
Duplicated memory and memory control
Duplicated buses for common data, memory and control
High speed RAM backed by non-volatile, e.g. EPROM, memory and duplicated hard
disk storage (storage to have 50% spare capacity)
Duplicated ringing/tone signalling
Bulk software loading facilities, preferably of the floppy disc or hard cassette disc
type
System control and display panel
11.8 Numbering plan

The PAX shall have facilities to transpose telephone numbers for routing to and from extensions
on remote exchanges.
A closed numbering plan is being used for all extensions on new and existing SPC exchanges.
There will be four numbering zones. It shall be possible to restrict interconnection between each
numbering zone. However it shall be possible to give any extension interzone access.
11.9 Cables and cabling
Supply, storage, and laying of all necessary telephone cables, special cables and other associated
cables in order to render the exchanges fully functional and connected with the requisite number
of telephones as detailed in the relevant sections of this Specification shall be within the scope of
the Bidder.
11.10 Telephone operators console

An operators console may be required for some PAXs. It shall be equipped with visual display
unit, keyboard, handset, headset and exchange function controls, and be designed for stress free
operation. Bidders shall include a cost for this optional item.
11.10.1 Voice message recording system
The exchange shall be capable of incorporating a facility for recording of voice messages on a
store and forward basis. Telephones connected to the system shall be able to send a voice
message to the PAX, together with the called extension number. A message waiting indication
shall be available to telephone stations to advise that a message has been stored when a prefix
code is keyed. The system shall be capable of 30 hours message storage, with an indefinite
retention period, message repeat and message erase codes.
11.10.2 Telephone signalling
Line, information, tone and ring signalling shall be provided to suit analogue and digital
telephone extension equipment.
Analogue telephone extension signalling, shall provide the line, information, tone and ringing
facilities as follows:
The extension line control signalling shall use line loop signalling to initiate and terminate
extension calling and answer activities, in accordance with BORSCHT exchange and
multiplex interface requirements.
Information signalling will be DTMF in accordance with CCITT Recommendations Q23,
Q16 and associated recommendations.
Tone signalling will conform to the suppliers standard equipment and appropriate CCITT
Recommendations.
Ringing current shall be to manufacturers standard.
11.11 Remote end four wire E/M interface and subscriber unit
The Remote end four wire E/M interface unit, wherever specified, shall be electronic type and be
suitable for working on fixed frequency power line carrier systems with E/M signalling. This
equipment shall be housed in the carrier set and be fully wired to the carrier terminal equipment.
This unit shall receive and register various signals on PLCC channels from remote end exchanges
or other remote end subscriber units and associated four wire interface units.
The unit shall be equipped for routing transit calls and shall be supplied prewired to handle calls
from a minimum of eight directions, in a form suitable for transmission over PLCC. The bidder
shall indicate the total trunk line capacity for the unit.
The unit shall be suitable for connecting to two wire telephone sets. The associated telephone
cables for connecting to the telephones within the control room shall be within the scope of
supply.
12. NETWORK PROTECTION EQUIPMENT (PROTECTION COUPLER)(OWNER

SUPPLY ITEM OPTCL)
12.1 General
The Bidder shall offer voice frequency transmission equipment which shall work on frequency
shift or coded signal principle for transmission/reception of protection signals as single purpose
channel. The equipment shall be suitable for connection to the power line carrier terminal
mentioned in Clause above.
The voice frequency transmission equipment shall not only be insensitive to corona noise but
shall also remain unaffected by impulse type noise which is generated by electrical discharge and
by the opening and closing of circuit breakers, isolators, earthing switches etc. The equipment
shall also be made immune to a field strength of 10V/m expected to be caused by portable radio
transmitters in the range of 20-1000 MHz. In his offer, the Bidder shall clearly explain what
measures have been taken to make the equipment insensitive to corona noise, white noise and to
impulse noise of an amplitude larger than the wanted signal, and submit full field test and
laboratory test reports. The guarantee on design data shall not be acceptable.
The equipment shall be unaffected by spurious tripping signals. The Bidder shall submit evidence
to show how this is achieved satisfactorily.
The equipment shall be designed in accordance with IEC 834-1. All works shall conform with
the Indian Electricity Rule, 1956, unless modified by this specification. All materials and
equipment offered shall comply with the relevant Standards. These standards shall be stated by
the Bidder.
Voice frequency transmission equipment is required for line protection signalling. The
equipment shall be used in conjunction with distance protection systems and power line carrier.
It shall operate in a duplex mode. It shall be housed in the power line carrier cabinet.
When a line fault occurs, the carrier channel to which the equipment is connected shall be
switched over to the teleprotection unit. This shall simultaneously disconnect speech and other
signals. This interruption will continue for the short period of the teleprotection command, after
which the normal operation of the carrier equipment will be restored. During the transmission of
teleprotection signals or when a fault has been detected by the protective relays, the entire output
power of the carrier will be made available for transmission of the teleprotection signals. The
transmission time of the teleprotection signal, from receipt of command from the transmit end of
the channel to the output of the trip command at the receive end of the channel, shall not be more
than 20 milliseconds.
The equipment shall allow speech and superimposed data to be transmitted by the carrier along
with the teleprotection guard signal. The tripping signal shall be a tone in the speech band which
shall be capable of boosting above the guard signal level. Its frequency shall be stable within 4
Hz.
The operating frequencies of the teleprotection shall be so chosen that under no circumstances
shall a spurious tripping signal be transmitted. The equipment shall not issue false commands
due to transient phenomena. It shall be insensitive to corona noise and noise generated by the
operation of circuit breakers, disconnects and switches, and to electrical surges. It shall be
insensitive to harmonics of speech signals.
The teleprotection equipment is to be used together with the PLC equipment. It shall comprise
modules, which are directly plugged into reserved slots of the PLC equipment.
The Protection Coupler shall use microprocessor techniques with digital signal processing, to
meet the stringent requirements for command transmission over PLC links even under adverse
channel conditions.
Full duplex transmission of up to two non-coded permissive or blocking commands plus two
coded prioritised direct tripping commands shall be possible for the protection of single and
double lines including breaker failure protection.
12.2 Test Facilities
The equipment shall be constructed such that in permissive line protection system, operational
reliability of the protection channels may be checked over the carrier link by means of a Local
and End To End loop test. It shall be possible to carry out the above test from either end of the
carrier link. During healthy condition of the transmission line, the loop test shall not initiate a
tripping command. In the event of a system fault, while loop test is in progress, protection signal
shall over-ride the test signal.
It shall be possible to test the protection link from either end. This test procedure must not
initiate a tripping command.
Facilities shall be provided for displaying and extending alarms (including the tone generator),
trip and test conditions and for monitoring and measuring levels. The following operating
conditions shall be visually indicated:
Protection in service
Protection out of service
Equipment under test
A cyclic and a manual loop test procedure shall allow in-service testing of the teleprotection
channel. Internal self-tests shall continuously supervise the equipments operating ability.
A hand-held terminal shall be supplied and shall be connectable to a diagnosis interface to
display service and operating information.
12.3 Channel Requirements
The equipment shall be suitable for transmission of direct and permissive trip signal as well as
blocking signals for protective gear of power system. The equipment shall be operated in the
audio frequency range in speech band or above speech band as superimposed channel in 4 kHz
band of SSB carrier. The equipment shall operate with full duplex frequency shift mode of operation. The protection signalling equipment shall be of solid state design, modular in construction
and have a proven operating record in similar application over EHV systems. Details regarding
application of the equipment over 400kV/220kV systems shall be submitted along with the bid.
In its minimum configuration, the Protection Coupler shall convey four independent commands.
The four commands are grouped into two non-coded permissive and two coded direct tripping
commands, the latter having priority. The first and second main protection schemes with
redundancy features are shown in the relevant drawings in the schedules.
The arrangement shown in the drawings is for guidance only and actual arrangement shall be
developed by the Contractor in co-ordination with protective relay supplier. The parallel wiring
should however retain the concept of two protection channels of each type of protection with each
backing up the other 100% during normal operation and also permit testing without affecting the
other. The Contractor shall submit drawings showing inter-connection between PLCC and
protection panels for approval by the Owner.
The protection coupler shall be designed for transferring commands in blocking, permissive and
direct transfer tripping schemes. An unblocking output to be used in deblocking schemes with
overreaching first zones and without starters shall be available on the unit.
The command interfaces to the protection relays and alarms shall be free and d.c. isolated from
ground and all other circuits. Each of the tripping outputs shall have associated auxiliary signal
output. The standard relay interface modules are to be fitted with tripping signal counters.
The protection coupler shall use the pilot signal of the PLC as a guard signal. The guard signal is
to be continuously evaluated on the receive side. In case of insufficient signal quality (signal-tonoise ratio or signal level) the protection coupler shall initiate an alarm.
In the command state, the protection coupler shall cut the guard signal (pilot) and transmit the
command signal within the PLC speech frequency band. It shall be possible to boost the
command signal to the maximum available transmitter power. The speech and data signals on the
same channel are to be interrupted during the short time of command transmission.
As soon as the receiver recognises the missing guard signal and simultaneously detects a valid
command signal, the corresponding command output relay is to be operated. Simultaneous loss
of a command signal and the guard tone shall lead to an alarm.
A number of frequencies corresponding to the individual commands or command combinations
are to be provided in the PLC speech frequency band. Depending on the application (permissive
or direct tripping) these frequencies are to be assigned to the actual command. Setting up of the
equipment and adapting to field requirements is to be done by means of programming switches
on the modules.
It shall be ensured that under no circumstances should the protection channel share the power.
Each protection channel shall be able to transmit the power for which the system is designed. For
example, a 40 W PLC terminal shall transmit 40 Watt (max) for protection channel alone in the
event of fault. Speech and super-imposed data channels, in the same protection terminal must be
disconnected momentarily during the operation of protection channels.
The equipment shall be complete with built in counters for counting the number of trip
commands sent and number of trip commands received.
The Contractor shall develop drawings showing interconnection between protection panels and
PLCC panels and submit the drawings for Project Managers approval. Supply, laying and
terminating of control cables for interconnection between protection panels and PLCC panels at
each substation, for the transmission lines covered under this specification, shall be included in
the Contractors scope of work.
12.4 Operating time
The equipment shall be designed for remote tripping/ blocking on permissive basis and direct
tripping for reactor fault and others. The overall time of PLC, VFT and transmission path for
permissive trip/blocking shall be 20 milliseconds or less.
Operating time lower than that specified above may be offered provided the equipment meets the
following requirements of security and reliability:
False - trip probability (noise burst of any amplitude):
10-5
Fail to trip probability (for S/N 6dB in 3.1kHz band - white noise measurement):
10-2
The specified time mentioned above comprises the following :

a)
Back-to-back signal delay in frequency shift or coded signals protection equipment.
b)
Back-to-back delay in PLC terminal.
c)
Delay in transmission line.
d)
Operation time of interposing relay, if any, in frequency shift or coding equipment.
Reference is invited in this regard to the guide lines expressed in CIGRE Publication
Teleprotection" report by Committee 34 and 35.
12.5 Input/Output criteria
12.5.1 Transmit side
One potential free NO (normally open) contact of protective relays shall be provided for each of
the following functions:
Each Permissive trip command
Direct trip command
Contact Rating:
Maximum voltage:
660V
Maximum current rating:
5A
Maximum power rating:
1250 W / VA
12.5.2 Receive Side

Voice frequency transmission equipment for network protection shall be provided with one
potential free NO (normally open) contact for each of the following functions:
Permissive trip command
Direct trip command
Contact Rating:
Rated voltage:
250 Volts DC
Rated current:
0.1 A DC
Other parameters:
As per IEC-255-0-20
12.5.3 Alarm
In addition, the voice frequency protection terminal shall provide at least one potential free
changeover contact for alarm purposes.
Rated voltage:
250V DC
Rated current:
0.1A DC
Other parameters:
As per IEC 255-0-20
13. MODEMS (OWNER SUPPLY ITEMS OPTCL)

13.1 General
The PLCC System shall be equipped with modems for data communication to the LDC SCADA
over the bearer circuits.
The signalling data rate of the modems shall be adjustable between 200 - 2400 Baud. The
modulation method shall be Frequency Shift Keying (FSK) and modem frequencies and audio
bandwidth shall be in accordance with ITU recommendations.
Where necessary, modem audio connections to the site cables shall be protected by barrier
transformers and surge arresters, and shall provide 15 kV of isolation.
The modems shall have front panel indications for Carrier Detection and Rx /Tx Data.
The transmit output level should be adjustable between 0dbm and -25dbm with the typical output
level being set at 13dbm.
13.2 Channel parameters
Channel parameters are given in Table. 14.3. below.
CCITT
channel
Transmission
rate (Baud)
Frequency
deviation
(Hz)
Channel spacing
bandwidth (Hz)
Channel mean frequency

adjustable in steps of 120
Hz
Lowest
Highest
R35
50/75
30
120
420
3900
R37
100/150
60
240
480
3840
R38B
200/225
90
360
540
3780
R38A
200/200
120
480
600
3840
R38A
300/300
120
480
600
3840
600
240
960
840
3600
1200
400
2400
1700
1200 + speech
400
1640
2860
2400
800
3200
1800/2000
V23
Table. 14.3.
Channel parameters
13.3 Fax equipment (To be supplied by the contractor)

The FAX equipment to be supplied shall be compatible to CCITT Group 3 and shall be of plain
paper type . The equipment shall be suitable for operation with PLCC equipment as well as with
PSTN telephone network. The equipment shall be suitable for operation with 230V single phase
supply.
13.4 AC/DC distribution board (To be supplied by the contractor)

13.4.1 General
The Contractor shall provide and install power distribution boards for the PLCC equipment
defined in the previous sections. The distribution boards shall distribute power to the equipment
and protect against failures on feeder circuits supplying the equipment. The scope of supply shall
include distribution boards, installation, cabling, conduit and all associated hardware and
accessories required to provide power from the station auxiliary power supplies to the PLC
equipment loads.
13.4.2 AC distribution boards
One AC distribution board shall he supplied at each control room/PLCC room for power
distribution to the PLC loads. Each panel shall include a minimum of twenty (20) load
distribution moulded case circuit breakers. Contractor shall co-ordinate breaker sizing and
protection with the PLCC equipment.
13.4.3 DC distribution boards
Separate DC distribution boards shall be provided at each control Room/PLCC room. The DC
distribution boards shall provide 48 volt DC power supplies to communication equipment.
DC distribution board shall be fitted with a main MCCB of bi polar type rated for 3,000A at 48V
DC and a minimum of 20 manually operated, single pole, feeder circuit. The Contractor shall
co-ordinate feeder breaker sizing and protection with the communication equipment. All breakers
shall he fitted with magneto thermal tripping and shall comply with IEC 157-1.
14. TESTING AND MAINTENANCE EQUIPMENT (OWNER SUPPLY ITEMS
OPTCL)
Besides the stipulations made elsewhere in this Specification the testing and maintenance
equipment shall conform to following technical particulars. Each set of these equipment shall
consist of one of the following items.
1. 200HZ to 620kHz Selective Level Meter (SLM) including impedance and return loss
measuring attachments compatible with level generator (item 2 below).
2. Level Generator with a range of 50Hz
synchronisation with SLM.
to 620kHz including facility for
3. Eight digit time interval and frequency counter with a frequency range of 1Hz to 10MHz
and timer range of one microsecond to one second in decade steps.
4. Dual trace 15MHz oscilloscope with a display screen 8 x 10 cm and input impedance of 1
Mohm/25 pF with a deflection co-efficient of 5mV/div to 20V/div.
5. Four and a half digit LCD Multimeter with an input impedance of 10 Mohm and a range
of 0.1 mV to 1000V DC, 0.1 mV to 600V AC, 0-10A DC and 0-10A AC (40Hz to 10kHz)
and 0 - 20 Mohm with built-in power-supply.
6. Print test kits for PLC terminal, E/M interface, and subscriber unit, protection coupler,
EPAX etc..
15.
15.1 General
15.2 Factory tests to be performed on line traps
The following type tests in accordance with IEC 353 shall be performed on each type of line trap
in presence of the Project Manager. Test reports shall be subject to the approval of the Project
Manager before shipment of the equipment. The cost of doing each of these tests shall be indicated in the relevant Schedule of the Bidding Document.
a) Measurement of inductance of the main coil
b) Measurement of temperature rise
c) Insulation tests
d) Short time current tests
The following additional type tests shall be conducted on line traps along with other type tests
mentioned in IEC 353.
a) Corona extinction voltage test
b) Radio interference voltage measurement
Procedure for these tests shall be mutually agreed. Prices for these type tests shall be quoted in
relevant Schedule of the Bidding Document.
The line traps shall be subject to routine tests as per IEC 353.
The Bidder shall furnish along with his Bid the reports of type and routine tests conducted on
similar equipment earlier as per IEC 353.
15.3 Factory test requirements for coupling device
The coupling device including the drainage coil, surge arrester and earthing switch shall conform
to type tests and shall be subject to routine tests as per IEC 481/IS 8998.
Routine tests shall include but not be limited to the following :
Composite loss and return loss tests on coupling device.
Turns ratio test and insulation tests on the balancing transformer.
Milli volt drop test, power frequency voltage test and mechanical operation test on earthing
switch.
Power frequency spark over test for lightning arrester as per relevant IS/IEC.
Bidder shall furnish along with his Bid copies of all type and routine test conducted earlier on
similar coupling devices in accordance with relevant standards.
15.4 Factory test requirements for HF coaxial cables
The HF cable shall conform to type tests and be subjected to routine tests in accordance with IEC
96-2/BS 2316/IS 5802.
15.5 Factory tests on EPAX

The PAX shall be tested in accordance with the relevant CCITT Recommendations and IEC
specifications. In addition, all the functions and features specified shall be tested.
15.6 List of commissioning tests on complete system

The following tests shall be carried out on complete system/subsystem during commissioning:
1. Composite loss and return loss on coupling device using dummy load.
2. Composite loss (attenuation) for HF cable coupling device.
3. End to end attenuation measurement for verification of optimum coupling mode. Test shall
be done for all combinations.
4. End to end return loss for optimum coupling mode with.
open behind line trap.
grounded behind line trap.
5. If end to end return loss for optimum coupling mode is not satisfactory, same shall be
measured for other coupling modes also.
6. Adjustment of Tx/Rx levels on PLC equipment as per test schedule.
7. AF frequency response (end to end) for the entire 4kHz bandwidth for speech and
operation channels.
8. Measurement of noise in 2kHZ bandwidth with and without line energised.
9. SNR (test-one) with line energised noting down weather conditions.
10.Transmission time for teleprotection and other data channels.
11.Observation of Tx/Rx levels (test-tone) for each channel at both ends by sequential
switching on/off parallel channels using dummy load and also with the transmission line.
12.Observation of end to end and trunk dialling performance.
13.Observation of end-to-end protection signalling (command sent and received) in
conjunction with protective relays, noting down transmission/receipt of unwanted
commands under switching operations in the switchyard during protective relay testing.
15.7 Notes on testing
All measurements for link attenuation, composite loss and return loss shall be carried out for the
entire range of carrier frequencies with specific attention to the frequencies as follows:
Frequencies within coupling device bandwidth.
Frequencies within line trap bandwidth
Operating frequencies.
The following tests shall be carried out independently at each end:
Composite loss and return loss for coupling device.
Attenuation test for HF cable + coupling device.

Levels and other local adjustments (on dummy load). Final adjustment shall be on end to
end basis.
Test for loading by parallel channels with dummy line load. This test can be done
with tests for coupling device.
along
Protection signalling under local loop-test (dummy load).

All end to end tests shall require availability of healthy complete line for a duration of
approximately 5 days.
Necessary test instruments required for all the above tests shall be brought by commissioning
engineers of the contractor.
16. NOTES ON COMMUNICATIONS RELATED ASPECTS
16.1 General
The OPTCL have proposed a unified telecommunications and control scheme. Under this
scheme the State Load Despatch Centre at Bhubaneswar will be improved and four Sub-Load
Despatch Centres will be established. An Interim Augmented Scheme has already been
implemented to provide a limited capacity master station and a relatively small number of RTU
outstations. A further interim development phase known as the Enhanced Interim Augmented
Scheme (EIAS) is currently under examination.
Overall telecommunications planning has to be considered in relation to the complete
transmission network. Services required between locations have to be decided as does the
bandwidth they require. Transmission media and routing are then to be planned. Services at
some stations require links not alone to the adjacent station but also tandem through other stations
in the network, for instance SCADA or express speech to the SLDC. Some of the projects under
PMUs scope are included in the EIAS project. The EIAS project has already specified services
required to specific locations in respect of :
Conduction of condition survey in respect of existing PLC equipment, both outdoor and
indoor removal of old equipment and addition of new equipment including reallocation of
equipment wherever necessary/possible.
Administrative telephone and fax network requirement and advanced PAX systems
Express telephone requirement to SLDC/Sub-LDC
Requisite SCADA data channel network (main/standby)
Provision of settlement metering data channels only
Provision of high capacity communication network
EIAS project however does not cover the following :
Provision of protection couplers for lines under this package for 220 KV and 400 KV
lines.
Provision of EPAX for the sub-station:
Lapanga (220 KV)
Udala (132 kV)

Gopinathpur(220kV)
Kuanrmunda(220 KV)
The scope of work under this contract and the facilities required in the network shall be broadly
classified under the following heads.
1) Supply,erection,testing and commissioning of the equipments and materials at remote and
new end of the sub-station(except indoor PLC panels, which is owner supply items).
2) The erection, testing,commissioning works at both new sub-station and remote end are to
be taken care.
16.2 The administrative telephone network
The purpose of this network is to provide a means of non-urgent operational and/or administrative
telephone speech or fax communication throughout the whole OPTCL. This scope includes
supply and installation of equipment to sites which require the same.
This will comprise of a mesh of mainly PLC based telephone circuits between adjacent
substations, each of which will require a EPAX to cater for telephones at that site, and the
switching of incoming and outgoing calls.
It is required that these switches are configured so as to provide a "closed" numbering system, i.e.
one in which each station and each telephone has a unique telephone number which can be
accessed from anywhere else on the network by simply dialling its unique number, routing then
being carried out automatically by the system. This numbering system is to be compatible with
the national numbering scheme being developed by POWERGRID.
In order to support FAX traffic it is necessary that the full available bandwidth of the
communications circuits is usable and therefore the Administrative telephone network cannot also
support data, teleprinter or protection over its constituent circuits. It is planned that the teleprinter
system wherever existing be allowed to run down, and that FAX facilities be used instead.
The administrative telephone network, being composed of short lines between adjacent
substations, is to be completely supported on PLC circuits and has to be configured with a certain
degree of interconnection so as to allow simultaneous calls to be set up over parallel routes in
some cases, and to give some resilience against outages. Whenever possible existing PLCs using
modern equipment already in place shall be specified for this network. It shall be possible to
extend the network detailed by the addition of extra lines and EPAXs as necessary. Where
optical fibre trunk routes have been specified for administrative speech channels, two or more
such channels have been allowed.
At the outer edges of this network there are some less important substations which already have
PLC circuits from an adjacent more important site. In these cases a single telephone is to be
installed, configured as a 'long-line' extension from the EPAX at the larger site.
Where the remote site is also defined as providing metering data and only has a single channel
existing PLC circuit then, rather than installing a separate PLC simply for infrequent use of
metering data transfer, the ability to relay FAX traffic has been sacrificed and the data channel
superimposed on the existing PLC with consequently reduced bandwidth for only speech.
The plan of the proposed administrative speech and fax network is shown in the sketches with
this Specification. The existing /proposed PAX installation list is given in the relevant schedule.
16.3 The express speech to SLDC network(Owners supply)

In order to impose effective control, the SLDC will require rapid call set-up to its constituent
substations and power stations. For this reason direct speech lines have been planned from the
SLDC to each such site, but instead of each terminating on a separate telephone in the SLDC (as
in the present SLDC) they will be presented on a communications console with key and lamp
control.
The bandwidth of these circuits need not be as wide as that for the administrative network and
hence the use of cut-off filters will allow the upper frequencies to be used for data transmission
and/or teleprotection as necessary.
16.4 Data to the SLDC (owners supply)
The upper bandwidth of the express speech to the SLDC circuits will be used to carry the
associated data from the RTUs. By cutting off the speech band at 2.0 kHz a 200 baud data path
can also be carried, as well as up to two 50 baud metering data channels and teleprotection as
needed.
Where required for critical substations, it shall have two such 200 baud data channels to the
SLDC and the all other substations have only one data channel. Whenever possible the routes of
the main and standby data channels shall be different in order to maximise reliability and
resilience.
The plan of the main and standby RTU data networks are shown in the schedules as is a list of the
RTUs giving their facilities and recommended sizes.
16.5 Settlement metering data (owners supply)
The OPTCL distribution system is to be divided into ten distribution 'circles' formed into four
distribution 'groups'.
Settlement metering data will be required from the power stations, 400 kV supply points and the
inter-state connectors as well as the distribution bulk supply points.
The groups, and the bulk supply points (BSPs) in each group have been decided but the
geographic boundaries between the groups are not consistent with the boundaries between the
future generation and transmission sub-LDC areas.
Settlement metering data comprising half hourly data on MW, MWhr, MVAR and MVArh is
required, initially to be gathered at the SLDC but with facilities to allow the derived data to be
available to the future distribution companies.
A metering data network operating at 50 baud will therefore be required. This is shown in the
schedules.
This network is to be provided under this Contract. This will allow all distribution metering data
to be available at the SLDC, and in due course when the distribution companies are in existence,
data links from their respective offices to the SLDC will allow selected distribution metering data
to be supplied to them as required.
16.6 Teleprotection (owners supply)
Teleprotection equipment already exists in OPTCL for the protection of most 400 KV AND 220
kV lines and some 132 kV lines.
The protection coupler requirements for 400kV , 220kV, and 132 kV levels have been shown in
the schedules.
It is proposed that the same philosophy be adopted. Therefore all 400 KV and 220 kV lines will
have teleprotection as well as the important 132 kV links.
16.7 Trunk networks (owners supply)
The requirements of the Load Despatch Communications network in the scope of EIAS cannot be
met by PLC equipment alone. Therefore there will be an additional trunk network which will
interconnect the proposed sub-LDCs and the SLDC. In addition a number of key power stations
and substations have been included.
Scope of EIAS already covers the required communications between the SLDC and the future
sub-LDCs. There will be a full network of high capacity optical fibre links/microwave between
these sites. These are shown in schedules. While designing the PLC network under the present
scope of work these high capacity communication networks shall be kept in view and shall be
utilised wherever possible.

FOR
DISTRUBUTION BOARDS
1) ACDB
2) DCDB
3) OTHER CONSOLES INCLUDING BMK
E19-DISTRIBUTION BOARD- Page 1 of 25
1)
TECHNICAL SPECIFICATION FOR DISTRIBUTION BOARDS
General
Requirements of AC and DC systems
The electrical auxiliary systems shall be of a quality commensurate with the performance,
reliability and availability requirements of the substation.
The electrical station services shall be in accordance with all the relevant standards, shall satisfy the
requirements specified herein and shall be designed to operate in the environmental conditions
specified in the relevant sections of this Specification.
The electrical station systems shall be required to provide the voltage classes indicated in Table 1.1.
for operation of various plant equipment operating mechanisms, plants, control and communication
systems
Nominal
Voltage V
Tolerance
Frequency
Hz or DC
Phases
Wires
430
240
220
50
10%
10%
187V to 242V
10%
505%
505%
DC
DC
3
1
DC
DC
4
2
2
2
Table 1.1.
Neutral
Connection
Solidly earthed
Solidly earthed
Isolated 2 wires
+ve earthed
Voltage classes
The auxiliaries shall be capable of withstanding all over frequency and undervoltage conditions
without loss of supply to the power circuits or shutdown of any auxiliary system meeting the
essential loads of the substation plant and equipment.
Configuration
The basic design of the substation electrical auxiliary services shall be as shown in the schematic
drawing. This drawing is for guidance only and the Contractor may propose an alternative keeping
in view the design philosophy stipulated in this section of the Specification. The design philosophy
for auxiliary supply systems shall be as follows:
a) The AC supply for station auxiliary systems shall generally be obtained from a single source from the
local distribution network having a track record of good power availability. For 400/220kV
substations two separate sources shall be used.
b) Where 11kV or 33kV busbars are available at the substation site station auxiliary transformers shall
be installed to provide reliable auxiliary power supplies. At least two auxiliary transformers of a
rating sufficient to feed the substation load shall be installed. Where specified, in order to meet the
station essential loads a back-up supply from a standby diesel generator set shall be provided. The
requirement of diesel generator sets have been indicated in the bill of quantity of relevant schedules.
c) The Contractor shall estimate loads of the substation and determine the required capacity of station
auxiliary transformers and diesel generator set and submit same for the approval of the Project
Manager. The contractor shall classify the loads based on the principles defined in the following
clauses.
Load Classes
Essential loads
These are loads whose failure will affect the capability of the station and station plant and
equipment. These loads shall include cooling and other auxiliaries of transformers and reactors,
non-interruptible power units, auxiliaries of reactive power compensators, and station services of
the relays in the substation.
Emergency loads
These are loads that must remain in service during complete loss of the ac power supply. These
loads shall include the station battery chargers, disconnecting switch and circuit breaker operating
mechanisms, control room air-conditioning and the emergency lighting of the switchyard and
control building. Some emergency loads operate on ac voltage and the others on dc voltage.
Normal loads
These loads, whose failure does not affect capability, shall include but not be limited to control
building and switchyard lighting, control building air-conditioning except in control room, air
compressors, normal and fire-fighting water pumps, oil treatment loads, etc.
Basic design criteria
The failure or the disconnection for maintenance of any motor, feeder, motor control centre, or
415V power centre or auxiliary transformer shall not affect the power transmission capability of
the substation.
To achieve the above criteria, the following facilities shall be incorporated, by the Contractor, in
the design of the auxiliary systems :
1. Highly reliable duplicate primary supply sources, with automatic change-over facilities.
2. Duplicate essential loads (e.g. cooling pumps, fans, heat exchangers, etc.). Duplicated loads
shall be supplied from two different 430VAC distribution boards (ACDB). Essential loads
which are not duplicated shall have duplicated supply circuits with the source having auto
change over facility.
3. Provision of a diesel generator set for the essential loads. The generator shall start up
automatically, in case of loss of all normal and stand by supplies, to feed the essential loads
and emergency loads.
4. In order to limit fault currents, to prevent back feed into the AC bus, and to ensure
independence of supply sources, parallel operation between station service transformers
shall not be permitted at any voltage level. Also parallel operation shall not be permitted
between transformers and diesel generator.
5. System shall be clear and simple to operate to minimise the risk of loss of supply due to
human error.
6. The Contractor shall design the LV distribution system to ensure that the voltage supply
limits are maintained at all times and that the switchboards and cabling are never overloaded.
On larger stations it may be necessary to supply more than one main LVAC switchboard.
415V AC distribution system
General
The 430V secondary distribution system shall comprise 430V power centres serving the different
classes of loads either directly or through motor control centres.
Each power centre shall consist of two sections, supplied through two station service transformers
of adequate capacity. Each transformer and each section of the 430V power centre shall be
designed to carry the total load of both sections. The two sections shall be interconnected through
normally open bus tie breakers and normally closed fuse disconnects. An automatic transfer
scheme shall be incorporated within each power centre. This transfer scheme shall automatically
disconnect the voltage deficient bus and then re-energise it from the healthy bus.
Restoration of normal supply conditions shall automatically return the power centre to the normal
operating mode. The 430V power centres shall be of the metal enclosed switchgear type according
to the relevant IEC or Indian Standards.
AC distribution board.
The ACDBs shall be in accordance with the relevant IEC or Indian Standards and shall also
comply with the following requirements:
The MCC shall be located near the supplied loads or inside the control room at a suitable
place.
The circuit breakers of the MCC shall be individually interlocked to prevent paralleling of
two different power centre buses.
The 240V loads shall be supplied by 240V panels located in the MCC or outside the MCC
where it is required.
Supply of essential loads

Essential loads shall be fed from ACDB-1 and ACDB-2 respectively. A diesel generator set shall
be connected as indicated in schematic drawing so as to meet the complete requirement of the
essential loads of the substations. ACDBs shall be independently fed from two different sections of
the main distribution board.
Supply of emergency loads

The emergency loads shall also be supplied from essential bus ACDB-1, ACDB-2, 220V DCDB-1
and 220V DCDB-2, and 50V DCDB-1 and DCDB-2 as shown in the schematic drawing.. These
loads shall be supplied from the two different buses under duplicate supply philosophy. Switchyard
bay kiosks shall be fed from the two different buses alternatively and interconnected locally with
auto changeover switches. Power supply to equipment operating Mechanisms shall be fed from the
respective bay kiosks.
Supply of normal loads

Normal loads shall be fed through motor control centres connected with two cables to two different
sections of the 415V power distribution centres. A manual change-over switch shall be installed in
each MCC, so that the supply is not lost in case of maintenance of one section of the 415V power
centre or for a fault. These MCC shall also supply the lighting and small single-phase loads
through 240V lighting or distribution panels, located in the MCC and all over the substation.
Some loads, such as switchyard lighting and air-conditioning of the control buildings, normal and
fire-fighting water pumps, shall be supplied by duplicate feeders so as not to interrupt working in
case of maintenance of one of the sections of the power centre.
For oil treatment and welding, special service outlets shall be provided in local 415V motor control
or distribution centres.
2.0 LVAC supplies and equipment

General
Switchboards shall be of the free standing design, suitable for mounting directly above the cable
trenches laid inside the control room. Cable trench walls shall be flush with the control room floor.
Switchboards shall be suitable for terminating all incoming and outgoing cables and will normally
be of the bottom rear entry type, generally in accordance with IEC 947 and 439 and of metal clad
design arranged for drawout isolation. Switchboards shall be equipped with circuit breakers and
moulded case or miniature circuit breakers. The use of fuse switches will not be permitted.
LVAC scheme
General requirement
The 415V incoming supplies shall be derived from the station auxiliary transformers or in the case
of a loss of supplies, from the standby diesel generator where ever applicable. The two incoming
supplies shall be interlocked to ensure that only one of the two circuit breakers can be closed at any
one time. Where a bus section circuit breaker is provided it shall also be suitably interlocked to
prevent the station auxiliary transformer from being backfed.
Main distribution board

The two sections of the main distribution board shall be supplied from separate station auxiliary
transformers. The two sections shall have automatic change over facilities in the event of failure of
supply from one source. Each section of the board shall feed the following panels:
Main lighting distribution board
Fire fighting pump house.
AC and ventilation plant
Maintenance equipment and oil treatment plant supplies.
AC distribution board
This shall comprise two sections each of which shall be supplied through different cables from both
sections of the main distribution board. Each sections shall be equipped with a back up feed from
the standby diesel generator set with automatic change-over facility to generator in the event of loss
of supply from the main distribution board.
The AC distribution board shall supply the following loads:
Control room supply for panels, computers, etc..
One section of the 220V battery charger / rectifier.
One section of the 50V battery charger / rectifier .
50% of switchyard bay marshalling kiosks.
Emergency AC lighting system.
Transformers and reactors (cooling devices and OLTC panels)
Fire water and civic water pumps
Spare feeders for future use.
Main lighting distribution board

The main lighting distribution board shall receive incoming supplies from the two sections of the
main distribution board as well as a supply from the diesel generator set. This board shall be
further connected to lighting panels through a lighting sub-distribution panel. The panel supplying
emergency lighting load and the income from the diesel generator shall be equipped to switch on in
the event of failure of supply from the primary source.
3.0 Construction
Panels
For indoor applications the switchboards shall be of the cubicle pattern, each circuit being self
contained within its own cubicle (compartmentalised type). An access door shall be provided for
each cubicle such that access can only be obtained to individual circuits. Circuits shall be
segregated one from the other by earthed metal. For outdoor installation they shall be of multi-box
construction.
Sheet steel for fabrication of the panels shall be a minimum of 2 mm thick cold rolled grain
oriented sheet steel or 2.5 mm hot rolled sheet steel.
All panel edges and cover/door edges shall be reinforced against distortion by rolling, bending or
by the addition of welded reinforcement members.
Switchboard
Switchboards shall be vermin proof and suitable for use in a tropical climate. All ventilating
louvers shall be covered with a fine mesh from inside.
All switchboards shall be provided with a degree of protection of IP 52 as per IEC 947 or
equivalent Indian standard. Provision shall be made in all compartments for providing IP 52 degree
of protection, when circuit breaker or module trolley, has been removed.
Switchboards shall be of uniform height and shall not exceeding 2450 mm.
Switchboards shall be easily extendible on both sides, by the addition of the vertical sections after
removing the end covers.
All switchboards shall be divided into distinct vertical sections, each comprising:
1. A completely enclosed busbar compartment for horizontal and vertical busbars. Busbar
chamber shall be completely enclosed with metallic partitions. Bolted covers shall be
provided for access to horizontal and vertical busbars and all joints for repair and
maintenance. Access shall be possible without disturbing feeder compartment.
2. Completely enclosed switchgear compartment(s), one for each circuit for housing circuit
breaker or motor starter.
3. A compartment or alley for power and control cables. Cable alley door shall preferably be
hinged. Cable alley shall have no exposed live parts, and shall have no communication with
busbar chamber.
4. A compartment for relays and other control devices associated with a circuit breaker.
All access doors shall be provided with facilities for locking in the closed position. It shall be
possible to move each circuit breaker or MCCB to the disconnected position without the need to
open the cubicle access door. Attempted disconnection of a circuit breaker or MCCB when in the
closed position shall not result in tripping of the particular equipment.
4.0 Cubicle
Cubicles may be arranged vertically in tiers, the number being limited only by the need to ensure
that circuits are thermally independent.
It shall be possible to work within each cubicle with the equipment withdrawn whilst the incoming
contacts are energised. The minimum requirements for protection shall be:
Insulating barriers installed between phases within the cubicle.
An insulating cover to be affixed over the protruding feeder and busbar connections when the
equipment is withdrawn.
Where this is not available, protection shall be provided by automatically operated shutters. It shall
be possible to open the shutters intentionally, against spring pressure for testing purpose.
Each phase of the down dropper connections from the busbars to the equipment isolating contacts
shall be separated from the incoming or outgoing connections and from the other phases by
barriers.
Cubicles shall be suitable for terminating all necessary cabling whether of copper or aluminium
conductor design. It shall be possible to terminate any cable whilst adjacent circuits are energised.
5.0 Busbar and other equipment housing
All incoming connections, busbars and feeder connections up to the particular MCCB shall be
capable of the short time current rating specified, but connections beyond the MCCB need only be
matched to the MCCB characteristic.
The overall height of each tier of cubicles shall be such that the operating handles of all equipment
are within the reach of a person standing at ground level. Control switches as specified shall be
fitted and suitably labelled to indicate their function.
The equipment shall be complete with cable boxes and glands suitable for XLPE or PVC insulated
cables.
The switchboard shall be provided with 240V single phase ac illumination and anti-condensation
space heaters and each heater shall be provided with an ON/OFF switch.
Sheet steel barriers shall be provided between two adjacent vertical panels running to the full height
of the switchboard, except for the horizontal busbar compartment. Each shipping section shall have
full metal sheets at both ends for transport and storage.
All equipment associated with a single circuit shall be housed in a separate compartment of the
vertical section. The compartment shall be sheet steel enclosed on all sides with the withdrawable
units in position or removed. The front of the compartment shall be provided with a hinged single
leaf door complete with locking facilities. The main switch shall be operable from outside and will
be interlocked with the compartment door such that the latter can be opened only when the switch
is off. However, it shall be possible to defeat this interlock and open and close the door with the
switch ON. The main switch shall have the facility of being pad-locked in both ON and OFF
positions. The switch handle shall clearly indicate the position of main switch.
After isolation of power and control circuit connections it shall be possible to 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 termination located in cable alley.
The temperature rise of horizontal and vertical busbars when carrying rated current along its full
run shall in no case exceed 55C, with silver plated joints and 40C with all other type of joints over
an outside ambient temperature of 50C.
All single front switchboards shall be provided with removable bolted covers at the rear. The
covers shall be provided with danger labels.
All identical circuit breakers and module chassis of same test size shall be fully interchangeable
without having to carry out modifications.
All 415V switchgear cubicles shall be of single front type, with fully withdrawable circuit breakers,
which can be drawn out without having to unscrew any connections. The circuit breakers shall be
mounted on rollers and guides for smooth movement between SERVICE, TEST and ISOLATED
positions and for withdrawal from the switchboard. Testing of the breaker shall be possible in the
TEST position.
Wherever two breaker compartments are provided in the same vertical section, insulating barriers
and shrouds shall be provided in the rear cable compartment to prevent accidental contact with the
live parts of one circuit when working on the other circuit.
All disconnecting contacts for power circuits shall be of robust design and fully self aligning.
Fixed and moving contacts of the power drawout contact system shall be silver plated. Both fixed
and moving contacts shall be replaceable.
All modules shall be fixed type except circuit breaker and motor feeder modules, which shall be
drawout type.
The connections from busbars to the main switch shall be fully insulated/shrouded, and securely
bolted. The partition between the feeder compartment and cable alley may be non-metallic and
shall be of such construction as to allow cable cores with lugs to be easily inserted in the feeder
compartment for termination.
All equipment and components shall be neatly arranged and shall be easily accessible for operation
and maintenance. The internal layout of all modules shall be subject to approval of the Project
Manager.
All sheet metalwork shall be painted in accordance with the painting clause specified elsewhere in
this Specification. The shade of the paint shall be 692 as per IS 5 (smoke grey).
Earthing
It shall be possible to earth all incoming supplies to the switchboard by means of a fully rated
earthing device, either by using the circuit breaker with earthing attachments, a separate earthing
truck, or a fixed fully rated earth switch.
Busbars and dead end feeders may be earthed by means of a voltage checking device and hand
applied portable earth switches. These shall normally be applied from the front of the switchboard.
Earthing of current free metallic parts on the body of the switchboard shall be done with soft drawn
bare copper bus. Tail connections shall have a minimum cross sectional area of 16 mm2 and the
main earth bar for the switchboard shall be brought out to two terminals for connection to the
station earth grid.
Earthing connections shall be carried out with green wire and the earthing studs shall be identified
as such by an earthing symbol.
Clearances and insulation level
Clearances and creepage distances in air shall be those stated in IEC 158 and 947 and be such that
the equipment can withstand the dielectric tests specified.
Thermal performance of switchboard and equipment
The complete switchboard shall be capable of carrying rated load current without the temperature
rise of any portion exceeding a level of 65C. Parts that may be touched by operating personnel
shall not exceed a level of 35C. In determining the load current performance of tiered cubicles it
shall be assumed that all circuits are carrying rated current.
The cross sectional area of the busbars may be graded according to the current rating, but shall
remain capable of the short time current rating stated in the Schedules.
Protection co-ordination
It shall be the responsibility of the Contractor to fully co-ordinate the overload and short circuit
tripping of the circuit breakers with the upstream and down stream circuit breakers/fuses/motor
starters, to provide satisfactory discrimination.
6.0 EQUIPMENT TO BE FURNISHED

General
The Contractor shall supply all equipment in accordance with this Specification in each of the
modules as specified in the following sub clauses.
Type Designation /Description of Modules
Each 415V switchgear and distribution board shall comprise of a number of different type of
modules as detailed in the following clauses. The Contractor shall obtain the approval of the Project
Manager for the details of the modules to be provided in each of the Boards. The Employer has
classified and type designated the modules to be used in the various Boards.
Module type
AE
M1
M2
E
G1
G2
H and H(BC)
S
X
DC
DG1
H1
EL
K2
AN
Application
Electrically controlled circuit breaker for incomer and bus coupler
Circuit breaker controlled motor feeder
MCCB controlled motor feeder
VT module with undervoltage relay
Isolating switch controlled incoming circuit
DC metering and protection module
Incomer from battery and charger
Electrically controlled circuit breaker for incomer from DG set
Non reversible motors having star stop control at MCC

Annunciator module
Table 4.2. 430V switchgear modules and applications

Composition of the Modules
The following are the preferred composition of various modules along with their Bill of Materials.
However the Contractor may suggest alternatives keeping in view the requirement of the
specification. Such changes shall be subject to approval of the Project Manager. In addition to the
items listed all other items required to provide the necessary functionality as specified in this
Specification, shall be deemed to be included in the scope of supply for the module.
7.0 (A) Module type AE

1.
4.
Triple pole air circuit breaker (Device No. 52)

complete with
all accessories and power operated mechanism as specified.
Neutral link.
Circuit breaker control switch with spring return to normal.
Current transformer for metering.
2
1
3
5.
Ammeter
6.
Ammeter selector switch.
7.
Current transformer for relaying.
8.
9.
Triple pole instantaneous over-current relay having the setting

range of 200-800% or 500-2000% of CT secondary and adjustable
definite minimum time. Alternatively suitable overcurrent releases
capable of proper discrimination with all down-stream protection
are also acceptable.
HRC control fuse.
10.
Auxiliary relays
11.
Indicating lamps with series resistors and selector lenses (e.g. red,
blue, green, white and amber
Instantaneous earth fault relay
having an adjustable setting
range of 10-40% or 20 - 88% of CT secondary current. The earth
fault relay shall be provided with a stabilising resistor.
2.
3.
12.
7.0 (B) Module type M1

1.
Triple pole air circuit breaker complete with accessories, and power
1
operated mechanism as specified.
2.
Circuit breaker control switch with spring return to normal.
1
3.
Three position 6 pole selector switch SWITCHGEAR / NORMAL /
1
TRIAL.
4.
3
5.
Ammeter
1
6.
1
7.
3
8.
Triple pole instantaneous over-current relay for providing positive
1
sequence current protection in all the three phases. The relay setting
range shall be continuously adjustable between 200-800% or
400-1600% of CT secondary rated current as require
1
9.
Double pole inverse definite minimum time overcurrent relays
connected in R and B phases for over current protection of motor
rated 110 kW - 200 kW. The relay shall have an adjustable setting
range of 50% - 200% of CT secondary current and time setting
range of 0-30 seconds. The relay shall be CDGM-22 (GEC
Alsthom) or equivalent.
10. Single pole adjustable definite time delay relay for motor overload
1
alarm connected in Y-phase only. The relay shall have resetting
ratio of not less than 90%. The relay shall have continuously
adjustable time delay range of 2.5 to 25 seconds.
11. Instantaneous earth fault relay having an adjustable setting range of
1
10-40% or 20-80% of CT secondary current. The earth fault relay
shall be provided with a stabilising resistor.
12. Auxiliary relays
4
13.
14.
Indicating lamps with resistors and coloured lenses suitable for

220V DC.
HRC control fuses.
5
8
7.0 (C) Module type M2

1.
2.
3.
415V, 250A, P2 duty 20 kA, 50 Hz MCCB having 4 NO and 4 NC

Aux. contacts.
Auxiliary relays
Indicating lamps with resistors and coloured lenses suitable for
240V AC.
1
1
3
7.1 Module type E

1.
2.
3.
Triple pole load break isolating switch

Neutral link
HRC fuses
1
1
3
7.2 Module type G1

1.
2.
3.
4.
5.
6.
7.
8.
(415/3)/ (110/3) volts single phase voltage transformer star/star

connected with star point solidly earthed mounted on common
draw out chassis. Accuracy Class 0.5 for protection and metering
with 50VA burden.
HRC Fuses mounted on the above chassis.
Four position voltmeter selector switch.
Voltmeter (0-500V)
Double pole instantaneous undervoltage relays with continuous
variable setting range of 40-80% of 110 Volts.
Time delay pick up relay having a time setting range of 0.5 to 3
seconds. With 3 NO self reset contacts, suitable for 220V DC.
Auxiliary relay 220V DC with 2 NO. self reset contacts.
Indicating lamps with series resistor and colour lenses (Red, blue
and yellow).
6
1
1
1
1
1
3
7.3 Module type G2

1.
2.
3.
4.
HRC Fuse
Voltmeter (0-500V)
Voltmeter selector switch four position (R-Y, Y-B, B-R OFF).
Indication lamps (Red, blue and yellow)
3
1
1
3
7.4 Module type H and H (BC)

1.
2.
3.
Triple pole load break isolating switch with padlocking facility in

OFF position and arrangement to defeat door interlocking
Neutral link.
Red indicating lamp to indicate isolating switch closed position.
1
1
1
7.5 Module type S

1.
2.
3.
4.
Voltmeter 0-300V DC for 220V DC DB

1
Voltmeter 0-75V DC for 50V DCDB.
1
Three (3) position voltmeter selector switch
1
Instantaneous under voltage relay with 95% of 220V DC. The
1
resetting ratio of relay of relay should not be more than 1.25. The
relay shall be provided with a series resistor and a push button
5.
6.
7.
8.
across if for resetting (pick up) the relay at about 105% of the
drop out voltage.
Instantaneous over voltage relay with setting range of 110% of
220V DC. The resetting ratio of relay should not be less than 0.8.
The relay shall have a push button in series capable of resetting
the relay at about 95% of the operating voltage.
Earth leakage relay only for 220V DC system having adjustable
pick up range between 3 to 7 milliamps the relay shall be suitable
for 220V DC/240V AC Auxiliary supply.
Indicating lamp each for fault annunciation and for 220V DC with
earth leakage relay mentioned above.
HRC control fuses.
2
2
7.6 Module type X

1.
2.
Double pole single throw 250V DC air break isolating switch.

HRC fuses
1
2
7.7 Module type DC (Incomer from battery and chargers)

1.
2.
3.
4.
5.
HRC fuses for incomer from battery.

DC ammeter with shunt and range of 40-0-50 Amps. For 220V
DC DB and 60-0-150 Amp for 50V DC DB.
Double pole single throw 250V DC air break switch.
HRC fuses for incomer from charger.
Double pole single throw 250V DC air break switch connecting
battery and charger sections to DCDB
2
1
2
2
1
7.8 Module type DG1
2.
Triple pole circuit breaker complete with all accessories and

power operated mechanism as per the relevant sections of this
Specification.
Frequency meter.
3.
Voltmeter with selector switch.
4.
Remote/Local selector switch.
5.
Circuit breaker control switch
6.
7.
8.
Current transformers for differential protection (out of this 3 Nos.

will be supplied loose for mounting in DG set panel).
9.
HRC Control fuses
10.
11.
Ammeter
12.
Wattmeter of range 0-300 kW.
13.
Three pole voltage controlled definite time delay relay having

current setting range of 50-200% of CT secondary current and
adjustable time delay 0.3 to 3 seconds.
Watt hour meter with six (6) digits and minimum count of one (1)
kWh.
Single pole definite time over current relay having a continuous
setting range of 50-200% of CT secondary current and a time
1.
14.
15.
with spring return to normal.
1
1
16.
17.
18.
delay of 2.5-25 seconds connected in CT of Y phase for overload

alarm. The relay shall have a setting ratio of not less than 90%.
Three pole differential protection relay having an operating
current setting range of 10-40% of generator full load current. The
relay shall be of high impedance type, with necessary stabilising
resistors.
Indicating lamps with resistors
and enclosed lenses.
Push buttons for remote starting and stopping of diesel generator
set (Red and green).
5
2
7.9 Module type H1

1.
Double pole DC switch with pad locking facility in off position.
7.10 Module type EL

1.
Triple pole and neutral switch
2.
HRC fuses
3.
Contactor
4.
Electronic timer suitable for continuous operation.
5.
Control Switch.
7.11 Module type K1

Triple pole load break isolating switch (device identifier - SW)
with neutral link.
HRC fuses (device FU) and one control fuse.
7.
Triple pole contactor 240V AC rated (device No. 42) with hand
reset thermal overload relay (device No. 49) for thermal overload
relay for more than 30 kW feeder, connection through suitable
current transformers may be taken.
Auxiliary relay (device No. 42 X) 240V AC rated with 3 NO and
3 NC self reset contacts.
Indicating lamp 240V AC rated red coloured to give motor ON
indication.
Indication lamp 240V AC rated, green coloured to give motor
OFF indication
Push button labelled (STOP).
8.
Push button labelled `START'
9.
Switch fuse unit for space heater supply for motors rated 30 kW
and above.
Current transformer and an ammeter for all motors rated 50 kW
and above.
1.
2.
3.
4.
5.
6.
10.
1
1
1
7.12 Module type K2 (mounted at motor)

1.
Triple pole load break isolating switch with neutral link.
2.
HRC fuses and one (1) Control fuse
3.
Triple pole contactor rated for 240V AC
4.
Indicating lamp 240V AC rated red/green coloured to give

ON/OFF indication.
5.
Push button labelled STOP
6.
Push button labelled START
7.13 Module type DG- ( mounted at generator)

1.
Indicating lamps
2.
Push buttons
3.
DC Ammeter (0-40A)
4.
DC Voltmeter (0-30V)
5.
Voltmeter selector switch
6.
AC ammeter
7.
AC voltmeter
8.
Timers (24V DC)
9.
Auto/Manual selector switch
10.
Auto/test/Manual selector switch
11.
CT's for metering
12.
PS class CT's for differential protection of diesel generator set
13.
Auxiliary contactors suitable for 24V DC
11
14.
Motorised potentiometer for voltage adjustment
15.
16.
Battery charger as per clause no Error! Reference source not

found. of this section
HRC control fuses
12
17.
Set of phase and neutral busbars.
Module type AN (Annunciation module)

Where an integrated PC based system is not provided at the substation a central alarm annunciator
shall be provided for the auxiliary power systems. The annunciation system shall consist of 30
annunciator units each having an engraved translucent plastic window of 35 mm x 50 mm
(minimum) size. Engraving shall be black letters and indicate the alarm function. Annunciators
shall be suitable for operation on 220V DC and shall have a single common audible alarm.
Push buttons with appropriate nameplates shall be provided for audible alarm acknowledge, alarm
reset and lamp test. The push buttons shall be common to all alarm points. Annunciators shall be
suitable for operation with both normally open and normally closed alarm contacts. Annunciation
system shall be solid state type of reputed make.
On receiving any alarm pulse, including fleeting pulses, the appropriate alarm relay shall pick up
energising the corresponding visible and audible alarm units. It shall be possible for the operator to
reset the audible alarm even if the alarm condition persists. However, visible alarm shall not reset
unless the alarm condition has disappeared and the reset push button is operated. Annunciator shall
provide sealed in lamp indication and audible alarm shall be ready to operate for any new alarm
condition immediately after the alarm is reset push button. Annunciator shall operate satisfactorily
between 80% and 110% of rated supply voltage.
Module equipment and instrumentation.

Circuit breakers, MCCBs, MCBs, selector switches, instrumentation, relays and protection
equipment for LV supplies etc. shall generally conform to the requirement of the stipulated under
relevant sections of this Specification.
7.14
TECHNICAL SPECIFICATION FOR INDOOR TYPE 415/240 V.A.C POWER

DISTRIBUTION SWITCH BOARDS.
7.14.1 SCOPE
The specification covers manufacture, assembly and testing at manufacturers Works,
supply and delivery at site of Indoor and out door type 415/240 volts A.C. power distribution
switch-boards, A.C consoles, Bay Marshalling Kiosk ,Receptacle panels complete in all respects as
per system requirement for S/S and switchyards 20% spare feeders shall be provided in each
Distribution Boards.
7.14.2 STANDARDS
The equipment covered by this specification shall unless otherwise specified be built to conform
to Indian Electricity Rule 2956 wherever applicable and shall satisfy the requirements of the latest
Indian Standard. Permissible temperature rise shall be as per relevant ISS.
7.14.3 SWITCH BOARD DESIGN
The switch board shall be self supporting, steel cubicle, compartmentalized, fully enclosed with
doors for access to the interior. The switch boards shall comprise a non/draw out type panels
placed side by side to form a continuous unit with access door for each panel at the rear 3 mm
sheet shall be used for fabrication of the panels. Modular type construction for inter-changeability
will be preferred.
The complete panels shall not be more than 2450 mm. high with the channel base and 500 mm.
depth measured form rear to front faces and of suitable with. The working height shall be limited
to maximum 2200 mm. The design shall be such as to permit extension at site on either end. The
bottom of the switch board frame shall be suitable for erecting flush on concrete floor by securing
it by means of evenly spaced grouting bolts projecting through the base channels. The panels
shall be designed to facilitate cable entry from the bottom and removable plates shall be supplied
along with the panels for this purpose which will be drilled at site to fit the cable glands.
The switchboard shall be vermin proof and suitable for use in tropical climate. All ventilating
louvers and holes shall be covered with fine wire mesh from inside (for indoor use). All control
and power cables will be laid in open distribution trenches running under the A.C. switchboards.
The cable will enter the cubicles through entry holes of removable plates provided at the bottom
of the cubicles. The cable entry holes required and the position of the foundation bolts.
The switchboards shall be supplied complete with channel base, removable bottom plates
grouting bolts, lock nuts, washer, etc. and cable glands as specified hereafter. All unfinished
surfaces of the steel panels and frame work shall be free from adhesive matter or greases. A
suitable rust resisting primer paint shall be applied on the interior and exterior surface of the steel
housing allowed by application of an undercoat to serve as base and binder for the finishing coat.
The finishing coat on the exterior of the switchboards shall be polished cellulose enamel or dark
batter ship grey, evenly sprayed to present a fine appearance while the interior faces shall be
sprayed with a finishing coat of light grey paint to provide contrasting background for the wiring
inside the cubicle.The internal illumination for working should be of adequate intensity CFL
lamps.
A small quantity of finishing paint shall be supplied with the consignment of the Switchboards to
enable the employer to restore at site any surface finish which may get damaged during transit.
7.14.4 BUS BARS
The bus bars shall be of E.G. copper/aluminum alloy, liberally sized for the specific current
ratings (both short circuit and continuous currents). The size of the bus bars shall be such that the
current density is not more than 1A/1.75 A per sq.mm. for aluminum alloy and copper
respectively at rated capacity. Necessary precaution shall be taken to avoid bimetallic action
where copper conductors shall be connected to the aluminum bus. Means shall be provided for
identifying various phases of bus bars. Bus support shall be of arc resistant, non-tracking, low
absorption type insulators of high impact strength and high creepage surface. Buses shall be
spaced with adequate clearance between phases and phases to ground.
The bus and connections shall be so supported as to be capable of safety withstanding stresses
due to maximum short circuit current and also take care of any thermal expansion.
The droppers/riser from or to the bus bars should not be twisted but reasonable bend or joint may
be allowed. The bidder shall sbsrish necessary calculations about the adequacy of sleeted bus
suyyrot insulator cantilever sireugth w.r to short cicess forces.
7.14.5 AIR CIRCUIT BREAKER FOR INCOMER
A.C. air circuit breaker shall be triple pole, non-draw out type, suitable for 1100 volts grade/650
volts grade service, having continuous current carrying capacity of 400 Amps with breaking
capacity of 20 KA at 415 volts. The breaker shall be provided with trip free manually operated
mechanism and a push butter to trip the breaker electrically.
The breaker shall be provided with mechanical OFF/ON indicators.
The breaker shall be provided with sets of auxiliary contacts for OFF/On indicating lamps, trip
circuit and inter-locking circuit along with two sets of spare contacts. The door of the circuit
breaker compartment shall be so interlocked that :
i)
ii)
The door cannot be opened whist the breaker is in closed opposition (i.e. ON)
When the door is opened, the breaker shall be locked so that it can not be closed (i.e.
it cannot be made ON). The circuit breaker shall comply with the relevant I.S.S.
The breaker shall be complete with cable glands suitable for entry of 3 x 400 sq.mm. 1100
V/650 V grade aluminum cables.
One number 195 sq.mm. aluminum cable of same voltage grade as above shall be
used for neutral, and cable gland suitable for entry of this cable shall also be provided in the
switchboard. Thermal overload relay range shall be 100 Amps to 200 Amps calibrated at 55%,
75%, 100% of the height setting and suitable time settings.
Drop out and pick up voltage of the under-voltage release shall be 60% and
80% respectively of the rated voltage.
For incoming circuit 1 no. ACB( as per requirement, it differs from substation to sub-station) of suitable capacity according to the system should be design
and furnished provided in the panel.The details of main ACDB is as below.
1) Station Transformer capacity: 33/0.433 KV, 250 KVA . Each substation there will
be two nos station transformer, hence in Main ACDB there will be two incomer i.e.,
as source I and source II. There will be a bus coupler in main ACDB for extending
the supply as and when required.
All outgoing feeders shall be provided with MCCB & SFU of
suitable capacity according to the systems are to be provided.
7.14.6 INDICATING LAMPS
Indicating lamps shall be LED type provided with suitable safety resistor, and coloured
dust-tight lens. Lamps shall be of very low wattage consumption and heat generated due to
continuous burning shall not deteriorate lamp cover. The lamp holders shall preferably be
screwed type.
7.14.7 SPACE HEATERS
The A.C. switchboards shall be provided with space heaters rated for 240 volts single phase A.C.
Each heater shall be provided with ON/OFF switch. The wattage of the heater shall be such as to
keep 10 deg. C. above the ambient temperature during rainy season but the temperature shall not
damage the wiring.
7.14.8 CABLE TERMINATION
Switchboards shall be designed to facilitate PVC cable entry from the bottom of the
switchboards. Removal plates shall be supplied for this purpose which will be drilled at site to fit
the cable glands.
Sufficient space shall be provided to avoid sharp bending and for easy connection.
Cables shall be PVC insulated, armored and PVC sheathed with 7/0.029 copper conductor
for control and Aluminum for cables feeder up to 15 Amp. Rating. Rest of the power
cable shall be of aluminum conductor of suitable size as per feeder rating.
Multiway terminal blocks of sturdy construction complete with terminating the internal
wiring and outgoing cables.
Power terminals shall be complete with lugs and control terminals shall be clamp type.
Screw type terminals with screw directly impinging on conductor shall not be
supplied.
Each terminal for 15 Amps. Feeders shall be capable for connection of 2 Nos. 7/0.029
copper wires at one end without any damage to the connector or any looseness of
connection.
The terminal shall be properly tagged and ferruled in compliance with approved drawings.
The terminal blocks shall be readily accessible and those shall be rust proof and of
best quality. Terminal block connector built from cells of moulded dielectric and
brass-stud inserts shall be provided. The connection stud shall project at least 6 mm.
from the lock nut surface. All blocks shall be shrouded of easily removable shrouds
moulded of transparent dielectric material of non-breakable type.
7.14.9 WIRING
The wiring shall be complete in all respect so as to ensure proper functioning of control,
protection and inter-locking schemes.
All wiring shall be complete up to the terminal blocks at the factory.
Control wiring shall be carried out with flexible, heat resistant, switchboard wires. PVC
insulated with 2.5 sq.mm. stranded copper conductors. Each wire shall be identified
at both ends with wire destinations numbered ferrules in accordance with bidders
wiring diagram. Wires shall not be spliced or tapped between terminal points. Each
wire shall be continuous and there shall not be any joint within itself. Individual wire
shall be connected only at the connection terminal, blocks, meters, relays,
instruments, and other devices used in the switchboards. Red, Yellow, Blue and
Black ferrules shall be used for Red. Yellow, Blue phases and Neutral respectively.
Wires shall be neatly bunched and adequately supported so as to prevent sagging and strain
on termination.
All spare contacts of the equipment shall be wired up to the terminal block. The wiring shall
be cf 1.1 KV grade. At least 20% spare terminals shall be provided.
7.14.91
Terminal connection shall be such that the conductors. LM10 may be connected by
means of screw or other equivalent means so as to ensure that the necessary contact
pressure is maintained permanently.
7.14.9.2
7.14.9.3
Terminal shall be such that they cannot turn or be LM10 displaced when the
connecting screws are tightened and such that the conductor can also not become
displaced.
Terminals should be so mounted that the appropriate wire may be connected
without impairing the normal performance of the unit.
7.14.10
SAFETY EARTHING
Earthing of current free metallic parts of metallic bodies of the equipment on the
switchboard shall be done with soft drawn bare copper bus. Tail connections shall
have minimum area of 16 sq. mm. and the main earth connection for earth
switchboard shall be brought out of two terminals for connection with the station
earthing system.
7.14.10.1
Earthing terminals should be identified by means of the sign marked on a legible and
indelible manner on or adjacent to the terminals.
Earthing lugs shall be provided an all earthing connections shall be carried out with
green wires.
7.14.10 SWITCHBOARD LIGHTING
The switchboard illumination by providing CFL lamps and space heating arrangement to
be provided.
7.14.11 INDICATING INSTRUMENT & ENERGY METERS
All instruments shall be switchboard type, back-connected, suitable for flush
mounting. The construction shall conform to appropriate Indian Standard Specifications.
The instruments shall be capable of indicating freely without error when operated
continuously at any ambient temperature from 0 deg. to 50 deg. C. They shall withstand
the effects of shock, vibration and humidity. All circuits of instruments shall be capable
of withstanding 20% overload for a period of at least 8 hours. All instruments shall be
provided with suitable means of adjusting the accuracy in a laboratory. KWH meters
specified shall be of commercial grade accuracy. Ammeter and voltmeter shall be with
accuracy of +/- 1% of full scale value.
7.14.12
7.14.13
RELAYS
The relays shall be suitable for operation within a temperature range of 0 deg. c to 50
deg. C. The contacts of the relays shall be silvered. When open, the contacts shall
withstand a voltage of 110% of the normal circuit voltage of the contacts. The relays
shall not deteriorate in performance due to ageing of any constituent material.
The relays shall generally comply with the requirements of I.S.S. 3842.
A.C. DISTRIBUTION BOARD SCHEME

Power will be fed to A.C. distribution board through 2 Nos. incoming breakers
separately from one no. 250 KVA station service transformer. Normally two feeders
will feed power to two sections of A.C.D.B. coupled through a bus coupler breaker.
Normally this coupler breaker will be kept upon when both the incomers are kept on. In
case of failure of any one of the incomer, this bus-coupler will be made ON. These two
incomers breakers and the bus coupler will be interlocked through castle interlock so
that any two of the three breakers can be kept on at a time, Suitable scheme for electrical
interlock and automatic switching on of the bus-coupler in the event of tripping of any
of the healthy incomer is to be taken up by the bidder. Suitable annunciation for failure
of A.C supply and for any of the incomer is to be provided.
A 415 V single line diagram accommodating the above facilities and to suit the system is
to be design and submitted to the Employer for approval. However, exact requirement
layout is to be taken up by the contractor depending on the layout, rating and type of
equipment for preparation of drawing.
7.14.14 PROTECTION SCHEME FOR INCOMING CIRCUIT BREAKER
Each incoming circuit to the L.T. switchboard shall be preceded by thermal overload
relays, short circuit release and over current and earth fault relays.
The breaker shall also be provided with under-voltage release of tripping out in case of
supply failure.
220/240 volts D.C. operated audible as well as visible alarm with cancellation device
shall be provided for the auto trip of the breakers.
7.14.15 CURRENT TRANSFORMERS
The current transformer to be provided with the incoming/outgoing circuit for metering
shall be air-cooled of class CM accuracy. The VA burden should be such as to suit the
requirements. C.Ts shall be bar primary type moulded/cast resin type. The current
transformer shall be manufactured and tested according to relevant I.S.S.
7.14.16 INSULATION LEVEL
The insulation at any point of the wiring in switchboards shall be suitable for 1100/660
volts grade service.
TEST TYPE TEST REPORT shall be furnished.
7.15 DC supply equipment

General scheme
At 400kV and 220kV substations, each DC supply system (50V and 220V dc) shall comprise
duplicate batteries and battery chargers, a dc distribution board and control gear. The system shall
be arranged such that only one of the station batteries and one of the battery chargers shall be in
service at any one time, but should either item of equipment fail or need to be taken out of service
for maintenance, then the duplicate item of equipment can be brought into service without
disruption of supplies. Battery chargers shall be provided with an automatic change-over facility
that will operate should one of the charger units fail.
At 132kV substations, each DC supply system shall be provided with one battery and one battery
charger, dc distribution board and control gear for 220V DC. However the 50V DC system shall be
duplicated as in case of 400/220kV substation.
Each battery shall be either of the lead acid or alkaline type and comprise a sufficient number of
cells to provide the required rating. The battery charger shall be capable of float charging the
battery, from the AC supply voltage specified. A facility shall be provided for boost charging
individual battery cells in situ, by means of wander leads.
The batteries shall be located in a battery room and connected to the distribution boards and battery
charger located in an adjacent room via a fuse box located in the battery room.
Where the battery size is less than 200 Ah, and the cells are of the totally enclosed type,
consideration will be given to housing the battery in a sheet steel cubicle mounted alongside the
charger and distribution board so as to form a complete suite of panels.
The 220V DC power supplies system will operate with both battery terminals free of earth whilst
that for communications equipment ( the 50V DC power supply ) will operate with the positive
pole permanently earthed. A suitable earth fault detection scheme shall be provided.
The battery rated output shall be that available at the outgoing terminals, after making due
allowance for the resistance of inter cell connections.
The battery size selected by the Contractor shall be proved by calculation which shall be subject to
the approval of the Project Manager. Allowance shall be made for ageing of the battery during its
service life.
Earthing of current free metallic parts on the body of the distribution boards shall be done with soft
drawn bare copper bus. Tail connections shall have a minimum cross sectional area of 16 mm2 and
the main earth bar for the distribution shall be brought out to two terminals for connection to the
station earth grid.
Earthing connections shall be carried out with green wire and the earthing studs shall be identified
as such by an earthing symbol.
The distribution board shall be provided with 240V single phase ac illumination and anticondensation space heaters and each heater shall be provided with an ON/OFF switch.
7.15.1 TECHNICAL SPECIFICATION FOR INDOOR TYPE 220 VOLT D.C. SYSTEM
POWER DISTRIBUTION SWITCH BOARDS
7.15.2 SCOPE
This specification covers manufacture, assembly and testing at manufacturers
works, supply and delivery of Indoor Type 230 volts D.C. Power Distribution on
Switchboards complete in all respects as per system requirement for 220/132/33 KV
substation and switchyards. 20% spare feeders shall be provided in each DCDB.
7.15.3 STANDARDS
The equipment covered by this specification shall unless otherwise specified, be built
to conform to Indian Electricity Rules 1956 wherever applicable. Permissible
temperature rise shall be as per relevant ISS.
Switchboard Design
The switchboards shall be self supporting steel cubicle compartmentalized fully
enclosed with doors for access to the interior. The switchboards shall comprise of
non/draw out type panels placed side by side to form a continuous unit with access
door for each panel at the rear. 12 SWG sheet shall be used for fabrication of the
panels. Modular type construction for interchangeability will be preferred.
The complete panels shall not be more than 2250 mm. high with me channel base
and 600 mm. depth measured from rear to front faces and of suitable width.
The working height shall be limited to maximum of 2000 mm. The design shall be
such as to permit extension at site on either end. The bottom of the switchboard
frame shall be suitable for erecting flush on concrete floor by securing it by means
of evenly spaced grouting bolts projecting through the base channels. The panels
shall be designed to facilitate cable entry from the bottom and removable plants shall
be supplied along with the panels for this purpose which will be drilled at site to fit
the cable glands.
The switchboards shall be vermin proof and suitable for use in tropical climate. All
ventilating louvers and oleos shall be covered with fine wire-mesh from inside or
inbuilt type. All control and power cables will be paid in open distribution trenches
running under the D.C. Switchboards. The cable will enter the cubicles through
entry holes of removable plates provided at the bottom of the cubicles. The
successful bidder shall furnish foundation drawings for the switchboards showing
the cable entry holes required and the position of the foundation bolts.
The switchboards shall be supplied complete with channel base, removable bottom
plates, grounding bolts, lock nuts, washers, etc. and cable glands as specified
hereafter. All unfinished surfaces of the steel panels and frame work shall be free
from adhering matter or grease. A suitable rust resisting primer paint shall be
applied on the interior and exterior surface of the steel housing followed by
application of an undercoat to serve as base and binder. The finishing coat on the
exterior of the switchboards shall be polished cellulose enamel, or dark battleship
grey, evenly sparyed to present a fine appearance, while the interior faces shall be
approved with a finishing coat of light grey paint to provide a contrasting
background for the wiring inside the cubicle.
A small quantity of finishing paint shall be supplied with each consignment or the
switchboards to enable the Employer to restore at site any surface finish which may
get damaged during transit.
7.15.4 BUS BARS
The bus bar shall be of E.G. copper/aluminum alloy, liberally sized for the
specified current rating (both short circuit and continuous currents). The size of bus
bars shall be such that the current density is not more than (1A/1.75A) per sq. mm.
for aluminum alloy and copper respectively at rated capacity. Necessary precaution
shall be taken to avoid bimetallic action where copper conductors shall be connected
to the aluminum bus. Means shall be provided for identifying the positive and
negative bus bars. Bus supports shall be of arc resistant, non-tracking, low
absorption type insulators of high impact strength and high creep age surface.
The bus and connections shall be so supported as to be capable of safety
withstanding stresses due to maximum short circuit current and also take care of any
thermal expansion.
The droppers/risers from or to the bus bars should not be twisted but reasonable bend
or joint may be allowed.
7.15.5 MCCB/MCB
All incomer feeders will be provided with DC MCCB and all outgoing feeders with
DC MCB conforming to latest IS : standards as per system requirements.
7.15.6 FUSE
Fuses shall be HRC link type of renowned make conforming to latest issue
of ISS 2208. Rewirable fuses shall not be supplied.
Fuse shall be complete with fuse bases and fittings of such design as to
permit easy replacement of the fuse elements.
Link shall also be easily replaceable. Visible indication shall be provides on
blowing of the fuse.
7.15.7 INDICATING LAMPS
Indicating lamps shall be LED type provided with suitable safety resistor and
coloured dust-tight lens. Lamps shall be of very low wattage consumption and heat
generated due to continuous burning shall not deteriorate lamp cover.
7.15.8 CABLE TERMINATION
Switch boards shall be designed to facilitate PVC cable entry from the bottom of the
switchboard. Removable places shall be supplied for this purpose which will be
drilled at site to fit the cable glands.
Sufficient space shall be provided to avoid sharp bending and for easy connection
Cables shall be PVC insulated, armored and PVC sheathed with 7/0.029 copper
conductor for control and for feeders up to 15 Amps. Rating. Rest of the power cable
shall be of aluminum conductor of suitable size as per feeder rating.
Multiway terminal blocks of sturdy construction complete with screws, nuts.
Washers and marking strips shall be furnished for terminating the internal wiring
and outgoing cables.
Power terminal shall be complete with lugs and control terminals shall be clamp
type. Scew type terminals with screw directly impinging on conductor shall not be
supplied. Connectors built from cells of moulded dielectric and brass stud inserts
shall be provided for terminating the internal wiring and outgoing cables.
Each terminal for 25 Amps. Feeders shall be capable for connection of 2 Nos.
7/0.029 copper wires at one end without any damage to the connector or any
looseness of connection. The terminals shall be properly tagged and ferruled in
compliance with approved drawings. The terminal blocks shall be readily accessible
and those shall be rust proof and of best quality.
7.15.9 WIRING
The wiring shall be complete in all respect so as to ensure proper functioning of
control, protection and interlocking scheme.
All wiring shall be complete up to the terminal blocks at the factory. The insulation
grade of wire to be used for internal wiring if the switch board shall be 1100 volts
grade. Wiring shall be carried out with flexible heat resistant, switchboard wires
PVC insulated with 2.5 sq.mm. stranded copper conductors.
7.15.10
7.15.11
7.14.17
7.15.13
7.15.14
7.15.15
Earth wire shall be identified at both ends with ferrules showing wire designations in
accordance with bidders wiring diagram. Wires shall not be spliced or tapped
between terminal points.
Each wire shall be continuous and there shall not be any joint within itself. Individual
wire shall be connected only at the connection terminals, blocks, meters, relays,
instruments and other devices used in the switchboards. Red ferrules with positive
marking shall be used for positive terminals and white ferrule with negative marking
shall be used for negative terminals for D.C. wiring.
Wires shall be beatly bunched and adequately supported so as to prevent sagging and
strain on termination. All spare contacts of the equipment shall be wired up to the
terminal block.
SAFETY EARTHING
Earthing of current free metallic parts of metallic bodies of the equipment on the
switchboards shall be done with soft drawn bare copper bus Tail connections shall
have minimum area of 26 sq. mm. and the main earth connection for each
switchboards shall be brought out to two terminals for connection with the station
earthing system.
Earth terminals should be identified by means of the sign marked in a legible and
indelible manner on or adjacent to the terminals. Earth lugs shall be provided and all
earthing connections shall be carried out with green wires.
SWITCH BOARD LIGHTING
The interior of each panel switchboard shall be illuminated by CFL lamps
connected to 230 volts. Single phase A.C. supply and shall be controlled by a dooroperated swich. All A.C. wiring shall be carried out with black wires. The incoming
A.C. supply to the D.C. boards shall be provided with H.R.C. fuse and link of proper
rating.
INDICATING INSTRUMENTS
All instruments shall be of switchboard type, back-connected suitable for
flush mounting. The construction shall conform to the appropriate Indian Standard
Specifications. The instruments shall be capable of indicating freely without error
when operated continuously at any ambient temperature from 0 deg. C to 50 deg. C.
Those shall withstand the effects of shock, vibration and humidity. All circuits of
instruments shall be capable of withstanding 20% overload for a period of at least 8
hours.
COMPLETENESS OF SUPPLY
The switchboards offered by the bidder shall be complete in all respects. Any
materials necessary which may not have been specifically mentioned but which is
usual or necessary for satisfactory and trouble-free operation and maintenance of the
switchboards shall be supplied without any extra charge to the employer.
SPARES
The item wise price for the spares recommended for three years operation
and maintenance of each switchboard shall be quoted.
INTER CHANGEABILITY
All similar materials and removable parts shall be interchangeable with each other.
All switches, contactors, etc. shall be easily removable as a complete unit from the
switchboards and shall be capable of being put in similar position in other switchboards
for performing identical functions.
The spares called for in respective sections shall be identical with like parts provided
in the main equipments in all respects and shall be capable of replacing the main
equipments wherever required to carry out identical functions.
7.15.16 ACCEPTABILITY OF DIFFERENT EQUIPMENTS & AUXILIARIES
7.15.17
7.15.18
7.15.19
7.15.20
All equipments, cables, wires and accessories offered shall be of best quality and of
renowned make for successful and trouble free operation of the switchboards.
Equipments/accessories of substandard quality shall not be accepted by the
Employer.
TESTS
The following tests are to be carried out.
i)
Checking continuity of the wiring.
ii)
Insulation resistance of all wiring circuit with all equipments mounted on the
board, before and after application of H.V.
iii)
One minute power frequency voltage withstand test. All equipments and wiring
shall withstand a power frequency voltage of 2 KV applied between any circuit
and earth.
iv)
Routine test of all equipments, switches and devices according to relevant I.S.S.
v)
Type test reports shall be furnished.
CLEARANCE
The apparatus forming part of the panel shall have requisite clearances and these
shall be maintained during normal service conditions. When arranging the apparatus
within the panels, the clearances for them shall be complied with taking into account the
relevant service condition. In addition, abnormal conditions such as in short circuit shall
not permanently reduce the distances between bus bars.
NAME PLATE OF D.C. SWITCHBOARDS
Each panel shall be provided with name plates, marked in a durable manner and
located in a place such that they are visible and legible when the panel is installed. The
following information should be given on the name plate.
a)
The manufacturers name and /or trade mark & identification number.
b)
Rated operational voltage.
c)
Purchase order number and date.
d)
Weight.
D.C. SYSTEM
The 220 volts .D.C. supply will be available from the lead acid station storage
battery banks associated with battery charging equipment.
In the 220 KV system the D.C. supply will be available from two sources. So the
system should be designed with provision for a bus coupler.
The battery shall normally float under trickle charge conditions with the charger
which continuously supplies the D.C. load to the load bus in D.C. switchboard and
trickle charging current to the battery. The charger will be connected to the bus through
double pole switch fuse unit. These two double pole switch unit should be mechanically
interlocked so that only one switch can be closed at a time. An emergency D.C. lighting
system would be provided in each sub-station to operate a separate lighting system with
D.C. power in case of total failure of A.C. supply. The D.C. lighting system would be
completely independent from the normal A.C. lighting system. For this purpose,
provision shall be made in the panel for main failure contactors with contacts rated for
32 Amps. And a switch on emergency lighting circuit across the D.C. but in the vent of
main failure. The two switch fuse units required for D.C. lighting feeders shall be taken
from the D.C. panel Board. D.C. fail alarm both audible and visual shall be provided in
case of total failure of D.C. supply at the load bus as per drawing. 220 volts D.C. system
single line diagram (No.SWG/570) is enclosed in Section-8 for guidance and
understanding of D.C. system. As the entire D.C. system is to be designed by the
contractor depending on the rating and type of equipment being supplied, the necessary
modification in the schematic diagram has to be taken up by the contractor and got
approved from the Engineer.
8. BAY MARSHALLING KIOSK:

8.1: Same as ACDB but out door type. The purposes of these boards are to be
installed in the switch yard at different locations. There shall be two incomer as source I
and source II. There shall be adequate AC out lets both 3 phase with neutral and single
phase, which will be taken to all the equipments and equipment marshalling boxes. At
lest 20% extra outlets are to be provided besides the requirement to meet during
exigencies. All the inlet and out lets shall be provided with MCBs. The board shall
have two doors one at front and the other at the rear end. Since these boards are to be
installed out side in the switch yard sufficient care as per the relevant standards are to be
taken care fomr weathering effect. At the front end all AC inlets and out lets are to be
provided and at the rear end terminal blocks are to be provided in column wise for DC
control /AC control purpose. The minimum quantity of terminal blocks of rating 20
Amps shall be 300 nos with duly marked the number of terminals. At the front side also
adequate capacity (current rating) as per the rating of MCB terminal blocks to be
provided for inlet and out let points of AC supply.
8.2 Proper engineering to be made and to be submitted for approval to OPTCL before
manufacturing and supply. The components and wirings to be used shall be of as per IS
standard and of reputed make.
9. AC CONSOLES:
9.1: Same as ACDB but out door type suitable for use in switchyard illumination control.
Adequate nos of MCB,s for incoming and outlets are to be provided in the console to take
care of the switch yard illumination system. No of such boards will be as per
requirement. Care should be taken as these boards are of outdoor type. 20 % extra outlets
should be provided to meet the exigencies.
10. RECEPTACLE AC SUPPLY PANEL:
10.1: Receptacle panels both indoor and out door types are to be provided to meet the
emergency requirement of AC supply. For example welding purpose, testing purpose
etc. Both three phase and single phase out lets should be provided. One no receptacle
panels outdoor type shall be provided near the transformer for oil filtration purpose. The
rating of the inlet and out let MCCB, s shall be 250 Amp.
DETAILS OF DISTRIBUTION BOARDS.

1) MAIN ACDB:
a) Incomer - 1: 800 Amp, 50KA, drawout type, Microprocessor Control, ACB. It
shall contain 3 O/C & E/F relays with high setting provision, UV relay, Electrical
Close/Open facility for ACB,ON/OFF lamp indication, Auto trip indication, TC healthy
indication with P.B, Spring charge indication, R,Y,B healthy indication, Ammeter &
voltmeter with selector switch, Annunciation facia with Acc, Reset and Test P.B.
b) One Bus-coupler: Same as Incomer 1 above.
c) Incomer 2: Same as Incomer 1 above.
d) Out going Feeders: (For Incomer 1) ,1)250 Amp MCCB: 4 Nos,
2) 100 Amp MCCB: 4 Nos, 3) Spare compartment: 2 Nos.
e) Out going Feeders: (For Incomer 2) , 1)250 Amp MCCB: 4 Nos,
2) 100 Amp MCCB: 4 Nos,3) Spare compartment:2 Nos
2) ACDB: R,Y,B Healthy Indication, Ammeter and voltmeter with selector switch.
a) Incomer -1: 250 Amp MCCB and 250 Amp MCCB for DG incomer.(with
interlocking facility.
b) Out going feeder(for inc 1): 1) 63 Amp MCCB : 16 Nos 2) 32 A MCCB: 8 Nos
c) Bus coupler: 250 Amp MCCB
d) Incomer -2: 250 Amp MCCB and 250 Amp MCCB for DG incomer. (With
interlocking facility.
e) Out going feeder (for Inc 2): 1) 63 Amp MCCB: 16 Nos 2) 32 A MCCB: 8 Nos
3) MAIN LIGHTING DB: R, Y, B Healthy Indication, Ammeter and voltmeter with
selector switch.
a) Incomer -1: 250 Amp MCCB.
b) Out going feeder (for inc 1): 1) 63 Amp MCCB: 4 Nos 2) 32 A MCCB: 2 Nos
c) Bus coupler: 250 Amp MCCB
d) Incomer -2: 250 Amp MCCB
e) Out going feeder (for Inc 2): 1) 63 Amp MCCB: 4 Nos 2) 32 A MCCB: 2 Nos
4) INDOOR RECEPTACLE DB: R,Y,B Healthy indication.
a) Incomer: 63 Amp MCB
b) Out going: 32 Amp ,3 Phase,MCB: 2
c) Out going: 32 Amp ,1 Phase,MCB: 4
5) 220 V DC Indoor Ltg. DB:
a) Incomer : 32 Amp DC MCB from DCDB with auto changeover facility
having delay timer with auto/manual selection switch.
b) Outgoing feeder: 16 Amp DC MCB: 5 Nos
6) 220 V DC DB:1: Having Earth fault relay (Earth leakage), Under and over voltage,
DC Ammeter and Voltmeter. Annunciation scheme.
a) Incomer: 100 Amp DC MCCB:
b) Out going: 100 Amp DC MCCB : To couple the other DCDB
c) Out going feeder: 32 Amp DC MCB: 20 Nos.
7) 220 V DC DB:2: Having Earth fault relay (Earth leakage), Under and over voltage,
DC Ammeter and Voltmeter. Annunciation scheme.
a) Incomer: 100 Amp DC MCCB:
b) Out going: 100 Amp DC MCCB : To couple the other DCDB

8) 50 V DC DB:1: Having Earth fault relay (Earth leakage), Under and over voltage, DC
Ammeter and Voltmeter. Annunciation scheme.
a) Incomer: 100 Amp/250 Amp DC MCCB:
b) Out going: 100 Amp/250 Amp DC MCCB: To couple the other DCDB
9) 50 V DC DB:2: Having Earth fault relay (Earth leakage), Under and over voltage, DC
Ammeter and Voltmeter. Annunciation scheme.
a) Incomer: 100 Amp/250 Amp DC MCCB:
b) Out going: 100 Amp/ 250 Amp DC MCCB: To couple the other DCDB
10) BMK (Suitable for Outdoor type) (Provision of telephone jack points)
a) Incomer : 63 Amp TP MCB : 1 for source - 1 and 1 for source -2 ( with
timer,for auto changeover, contactors (two nos each rated 70 Amp) suitable to
take care of changeover automatically.)
b) Out going feeder: 16 Amp TP MCB : 10 Nos , 10 Amp DP MCB: 8 Nos (at
Front side)
c) 300 Nos of Terminal Block of Elmex/ any renowned make suitable for 35 Amp
rated.
11) OUTDOOR RECEPTACLE DB:
a) Near Transformer: Incomer 250 Amp MCCB: 1 No., Outgoing: 250 Amp
MCCB : 1 No., Having provision of R,Y,B indication. (For transformer oil
filteration)
b) Inside switch yard at Different location: Incomer: 63 Amp TPN MCB, Out
going feeder: 2 Nos 32 Amp TP MCB and 2 Nos 16 Amp DP MCB.
All outdoor kiosk top cover shall be of Aluminum alloy having 3mm thickness & proper
sloping shall be maintained for easy drainage of water.

LIMITED

FOR
CONDUCTOR, AL TUBE G.I GROUND WIRE,
INSULATORS, HARDWARE, CLAMPS & CONNECTORS
E20-COND, E/W, INSULATORS- Page 1 of 78
SECTION-I
S.NO.
DESCRIPTION
PAGE NO.
1.
SCOPE
2.
STANDARDS
3.
MATERIALS
4.
SIZES
5.
TOLERANCES
6.
MECHANICAL PROPERTIES
7.
SURFACE CONDITIONS
8.
JOINTS IN WIRES
9.
STRANDING
10.
PACKING AND MARKING
11.
LENGTHS
12.
TESTS AND CERTIFICATES
13.
RETEST AND REJECTION
11
14.
GUARANTEED TECHNICAL PARTICULARS 11
15.
SAG TENSION CHARTS AND SAG
11
TEMPLATES
CONDUCTORS
SECTION-I
TECHNICAL SPECIFICATION OF ACSR MOOSE,ZEBRA,
AND PANTHER CONDUCTORS
1.
SCOPE :-
1.1. This specification provides for the manufacture, testing, supply and
delivery at destination of the steel cored aluminum conductors as per
Appendix-I attached.
2.
STANDARDS :-
2.1
The conductors shall comply in all respects to the clauses of this
specification as indicated below & with the Indian Standard Specification,
International standards with latest amendments. Some of the standards are :i)
IS 398 - Specification for Aluminium Conductors for

overhead transmission purposes,
IS 398, Part-II-Aluminium conductors for overhead
Transmission purpose - Specification
3.
ii)
IS 1521, 1972 - Method of tensile testing of steel
iii)
IS 1778 -1989 Reel & drums for bare conductors.
iv)
IEC - 1098
MATERIALS :-
3.1
The material offered shall be of best quality and workmanship.
The steel Cored Aluminum conductor strands will consist of hard-drawn
aluminum wire manufactured from 99.5% pure electrolytic aluminum rods of
E.C. Grade. The steel wire shall be made from materials produced either by
the acid or basic open hearth process or by electric process. No steel wire
drawn from pressmen process shall be used. The steel wire shall not contain
sulphur or phosphorus exceeding 0.05 percent, and the total of sulphur and
phosphorus shall not exceed 0.085 percent.
3.2
The steel wires shall be evenly and uniformly coated with zinc
complying with Indian Standard 4826-1979 specification for galvanized
coatings on round steel wires. The uniformity of zinc coating and the weight of
coating shall be in accordance with Appendix-II. The coating on the
galvanized steel wires may be applied by the hot process or the electrolytic
process.
4.
SIZES :-
4.1
The size of steel-cored Aluminum Conductors shall be as given in
Appendix-I. The resistance and weights shall be in accordance with the
values given in the same appendix.
5.
TOLERANCES :5.1
The following tolerances shall be permitted on standard diameter of
aluminum wires.
Tolerance on standard diameter of aluminum wire + 1 percent.
wires.
Note : -
5.2
6.
The cross-section of any wire shall not

depart from circularity by more than an
amount corresponding to a tolerance of
2 percent on the standard diameter.
A tolerance of + 2 percent shall be permitted on the
standard diameter of the galvanized steel wires. The
variation from the approximate weights shall not be more
than plus or minus 5 percent.
MECHANICAL PROPERTIES : -
6.1
The value of the final modules of elasticity for steel cored aluminum
conductor in the average of values obtained from actual stress strain tests.
The co-efficient of linear expansion for steel Cored Aluminum Conductors has
been calculated on the basis of co-efficient of linear expansion of 23.0 x 10-6
per degree centigrade of aluminum and 11.5 x 10-6 per degree centigrade for
steel and represent only the average values. These values shall however, be
given by the bidder under the guaranteed technical particulars.
7.
SURFACE CONDITIONS :-
7.1
The wires shall be smooth and free from inequalities, spills and splits.
The surface conductor shall be free from points, sharp-edges, abrasions or
other departures from smoothness or uniformity of surface contour that would
increase radio interference and corona losses. When subjected to tension up
to 50% of the ultimate strength of the conductor, the surface shall not depart
from its cylindrical form nor any part of the component, parts or strands, move
relative to each other in such a way as to get out of place and disturb the
longitudinal smoothness of the conductor.
8.
JOINTS IN WIRES : -
8.1
Aluminium wires : No joints shall be permitted in the aluminium wires in
the outermost layer of the ACSR conductor. Joints in the inner layers are
permitted, in addition to those made in the base rod or wire before final
drawing, but no two such joints shall be less than 15 meter. apart in the
complete stranded conductor. Such joints shall be made by cold pressure
butt-welding.
Joints are not permitted in the outermost layer of the conductor in order
to ensure a smooth conductor finish and reduce radio interference levels and
corona losses on the extra high voltage lines.
8.2
Galvanized steel wires : - There shall be no joints except those in the
base rod or wire before final drawing, in steel wires forming the core of the
steel-reinforced aluminum conductor.
Joints have not been permitted in the steel wires after final drawing in
order to avoid reduction in the breaking strength of the conductor that may
occur as a result of failure of the joints.
9.
STRANDING :-
9.1
The wires used in construction of a stranded conductor shall before
stranding, satisfy all requirements of IS-398/ (part-II)1976 with latest
amendments. For steel-cored aluminum conductors the lay ratio of the
different layers shall be within the limits given under Appendix-I.
9.2
For all, constructions, each alternate layer shall be stranded in opposite
directions. The wires in each layer shall be evenly and closely stranded round
the under laying wire or wires. The final layer of wires shall have a right hand
lay.
10.
PACKING AND MARKING : -
10.1 The conductor shall be wound in non-returnable reels or drums

conforming to Indian Standard 1978-1961 specification for Reels and Drums
for Bare Wire, or any other authoritative standard and marked with the
following : a)
c)
e)
g)
i)
Trade name, if any

b)
Contract/Award letter Number
d)
Name & Address of Consignee
Drum Number
f)
Length of conductor
Size of conductor
h)
Gross Weight of drum with conductor
Weight of empty drum
j)
Net and gross of conductor.
with lagging.
k)
Arrow marking of un-winding
10.2
The reel shall be of such construction as to assure delivery of
conductor in the field from displacement and damage and should be able to
withstand all stresses due to handling and the stringing operations so that
conductor surface is not dented, scratched or damaged in any way during
manufacture, transport and erection. The conductor shall be properly lagged on
the drums and the method of lagging to be employed may be clearly stated in the
tender. It should be stocked to suit the reel and held in place by steel strapping.
Lagging shall not be nailed or bolted in place.
10.3
The conductor drum should be suitable for wheel mounting.
Before reeling, the card-board or other suitable material shall be secured to
the drum and inside flanges of the drums. After reeling the conductor, the
exposed surfaces should be wrapped with suitable soft material to prevent the
conductor from dirt and grit. Any space between the drum lagging and
conductor should be suitably filled with soft filler material compactly packed.
The conductor drum shall be made as per the relevant IS.
11.
LENGTHS : -
11.1
The conductor shall be supplied in the standard lengths as
below with a permitted variation of 5%. Not less than 90% of the total quantity
of the conductor shall be supplied in the standard lengths. Thus the quantity of
the conductor in lengths shorter than standard ones shall not exceed 10% of
the total quantity to be supplied. Further no single conductor lengths in
respect of such 10% (Maximum supply) in random lengths, shall be shorter
than 50% of the standard lengths.
Type of conductor
Length per drum.
MOOSE ACSR
ZEBRA ACSR
PANTHOR ACSR
1.1 K.M
1.1 K.M.
2.2 K.M.
12. TESTS AND TEST CERTIFICATES :The following type tests ,(& any other tests if purchaser decides to do), shall
be conducted on the conductor at any Govt. approved laboratory or CPRI, in
presence of the representatives of OPTCL, on the samples collected and
sealed by the representative of OPTCL from the manufactured & offered
drums of conductor at random at free of cost to OPTCL or firm may quote
their test charges which will be taken in to account during bid price evaluation.
If test charges will not be quoted by the firm, it will be treated as nil during bid
price evaluation & firm have to do the type tests at free of cost to OPTCL.
Also the tenderer shall furnish valid type test reports, the tests are as
per the IS 398 (part-2) conducted in any govt. approved laboratory or
CPRI within last 5 years, from the date of opening of the bid (Technocommercial) document, without which their bids will not be considered
for evaluation.
12.1 Individual wire and finished steel cored Aluminum Conductor shall be
subjected to before dispatch from the works, to the tests as per the provision
of the Indian standard Specification 398 (Part-II-1976) with the latest
amendments & as per the tests indicated in this specification below.
12.2 Samples for individual wires for test shall be taken before stranding
form not less than 10 percent of the spiels in the case of aluminum wire and
ten percent of the wire coils in the case of steel wires. If samples are taken
after stranding, they shall be obtained by cutting 5 meters from the outer end
of the finished conductor from not more than 10 percent of the finished reels.
12.3
The mechanical tests shall be carried out on single wires only.
12.4 The Tensile test shall apply to wires of all diameters forming part of
steel cored aluminum conductors. If it is not possible to test the component
wires before stranding the test may be made on wires taken from stranded
conductors. The tensile strength of any of the wires shall not be less than the
minimum values given in Appendix-II.
12.5 A suitable tensile testing machine shall be used the accuracy of which
can easily be checked and the machine adjusted if necessary. The test
sample before being placed in the machine, shall be straightened, if
necessary in such a way as to cause the minimum alteration in its physical
properties.
The load shall be applied gradually and rate of separation of the Jaws
of the testing machine shall not be greater than 10cm/min. and less than
2.5cm/min.
TYPE TESTS
12.6
Wrapping Test : -
12.6.1
Samples of aluminium wires shall be wrapped round a wire of its
own diameter to form a close helix of eight turns. Six turns shall then be
unwrapped and again clearly wrapped in the same direction as before. The
wire shall not break.
12.6.2
Samples of steel wires shall be closely wrapped eight times
round a mandrel of diameter equal to four times the wire diameter. Six turns
shall then be unwrapped and again closely wrapped in the same direction as
before. The wire shall not break.
12.7
Galvanizing Test : -
12.7.1 The uniformity of zinc coating and the weight of coating shall be as
given in Appendix-II and shall be determined according to Indian Standard
Specification 4826-1979. with latest amendments.
12.7.2 This test shall be made whenever practicable, on wires before stranding
and before the specimen has been bent, straightened or tested in any other way.
12.8
Ductility Test : -
This test shall be made on galvanized steel wires only by any of the
proceedings given in 12.8.1 and 12.8.2.
12.8.1 Torsion Test : - One specimen cut from each of the sample shall be
gripped at its ends in two vices, one of which shall be free to move
longitudinally during the test. A small tensile bond not exceeding 2% of the
breaking load of the wire, shall be applied to the sample during testing. The
specimen shall be twisted by consisting one of the vices to revolve until
fracture occurs and the number of twists shall be indicated by a counter or
other suitable device. The rate of twisting shall not exceed 60 rev/min.
When tested before stranding, the number of complete twists before
fracture occurs shall not be less than 18 on a length equal to 100 times the
diameter of the wire. The fracture shall show a smooth surface at right angles,
to the axis of the wire.
When tested after stranding, the number of complete twists
before fracture occurs shall be not less than 16 on a length equal to 100 times
the diameter of the wire. The fracture shall show a smooth surface at right
angles to the axis of the wire.
12.8.2 Elongation Test : - The elongation of one specimen cut from each of
the samples shall be determined. The specimen shall be straightened by hand
and on original gauge length of 200 mm shall be marked on the wire. A tensile
load shall be applied as described in 12.5 and the elongation shall be
measured after the fractured ends fitted together. If the fracture occurs outside
the gauge marks, or within 25mm of either mark and the required elogation is
not obtained, the test shall be disregarded and another test made. When
tested before stranding, the elongation shall be not less than 4 percent. When
tested after stranding, the elongation shall be not less than 3.5 percent.
12.9
Surface Condition Test
A sample of the finished conductor having a minimum recommended

length of 5 meters with compression type dead end clamps compressed on
both ends in such a manner as to permit the conductor to take its normal
straight line shape, shall be subject to a tension of 50% of the UTS of the
conductor. The surface shall not depart from its cylindrical shape nor shall the
strands move relative to each other so as to get out of place of disturb the
longitudinal smoothness of conductor. The measured diameter at any place
shall be not less than the sum of the minimum specified diameters of the
individual aluminum and steel strands.
12.10 Ultimate Strength (UTS) Test on Stranded Conductor
Circles perpendicular to the axis of the conductor shall be
marked at two places on a sample of conductor of minimum 5 m length
suitably compressed with dead end clamps at either end. The load shall be
increased at a steady rate up to specified 50% of UTS and held for one
minute. The circles drawn shall not be distorted due to Relative movement of
strands. Thereafter the load shall be increased at a steady rate to the
minimum UTS specified in Appendix-I and held for one minute. The applied
load shall then be increased until the failing load is reached and the value
recorded.
12.11 Corona Extinction Voltage Test
One sample of conductor of 5m length shall be strung. In case
of twin conductor, two samples shall be arranged with the actual subconductor spacing between them. This sample assembly when subjected to
power frequency voltage shall have a corona extinction voltage of not less
than 320 KV (rms) for 400 KV and 176 KV (rms) for 220 KV system line to
ground under dry condition. There shall be no evidence of corona on any part
of sample when all possible sources of corona are photographed in a
darkened room. The test shall be conducted without corona control rings. The
voltage shall be corrected for standard atmospheric conditions.
12.12 Radio Interference Voltage Test
Under the conditions as specified in 12.11 above, the conductor
samples shall have a radio interference voltage level below 1500 microvolts
at one MHZ when subjected to 50HZ AC voltage of 1.1 times maximum line to
ground voltage under dry condition. This test may be carried out with corona
control rings and arcing horns.
12.13 D.C. Resistance Test on Stranded Conductor
On a conductor sample of minimum 5 m length two contact clamps
shall be fixed with a pre-determined bolt torque. The resistance shall be
measured by a Kelvin double bridge by placing the clamps initially zero meter
and subsequently one meter apart. The test shall be repeated at least five
times and the average value recorded. The value obtained shall be corrected
to the value at 20 degree centigrade as per clause No.12.8 of IS : 398 (part
V). The resistance corrected at 20 degree centigrade shall conform to the
requirements of this specification.
12.14 Stress-Strain Test
12.14 (i)This test is contemplated only to collect the creep data of the
conductor from the supplier. A sample of conductor of minimum 10 metres
length shall be suitably compressed with dead end clamps.
12.14 (ii)Test Set-up
12.14 (ii) (a) The test sample shall be supported in a trough over its full length
and the trough adjusted so that the conductor will not be lifted by more than
10 mm under tension. This shall be ascertained by actual measurement.
12.14 (ii) (b) The distance between the clamp and the sleeve mouth shall be
monitored with callipers during the test to ensure that, after the test, it does
not change by more than 1 mm +/-0.1mm from the value before the test.
12.14 (iii) (c) The conductor strain shall be evaluated from the measured
displacements at the two ends of the gauge length of the sample. The gauge
reference targets shall be attached to the clamps which lock the steel and
aluminum wires together. Target plates may be used with dial gauges or
displacement transducers and care shall be taken to position the plates
perpendicular to the conductor. Twisting the conductor, lifting it and moving it
from side-to-side by the maximum amounts expected during the test should
introduce no more than 0.3mm error in the reading.
12.14 (iii)Test Loads for Complete Conductor
The loading conditions for repeated stress-strain tests for complete
conductor shall be as follows :
12.14 (iii) (a) 1 KN load shall be applied initially to straighten the conductor.
The load shall be removed after straightening and then the strain gauges are
to be set at zero at zero tension.
12.14 (iii) (b) For non-continuous stress-strain data, the strain reading at 1 KN
intervals at lower tensions and 5KN intervals above 30% of UTS shall be
recorded.
12.14 (iii) (c) The sample shall be reloaded to 50% of UTS and held for 1
hour. Readings are to be noted after 5, 10, 15, 30, 45 and 60 minutes during
the hold period. The load shall be released after the hold period.
12.14 (iii) (d) Reloading up to 70% of UTS shall be done and held for 1 hour.
Readings are to be noted after 5, 10, 15, 30, 45, and 60 minutes and then the
load shall be released.
12.14 (iii) (e) Reloading up to 85% of UTS shall be done and hold for 1 hour.
Readings are to be noted after 5, 10, 15, 30, 45 and 60 minutes and then the
load shall be released.
12.14 (iii) (f) Tension shall be applied again and shall be increased uniformly
until the actual breaking strength is reached. Simultaneous readings of
tension and elongation shall be recorded up to 90 % of UTS at the intervals
described under Clause 12.14 (iii) (e).
12.14 (iv)Test Loads for Steel core Only.
The loading conditions for repeated stress-strain tests for the steel core
of ACSR shall be as follows :
12.14 (iv) (a) The test shall consist of successive application of load applied in
a manner similar to that for the complete conductor at 30%, 50%, 70% and
85% of UTS.
12.14 (iv) (b) The steel core shall be loaded until the elongation at the
beginning of each hold period corresponds to that obtained on the complete
conductor at 30%, 50%, 70% and 85% of UTS respectively.
12.14 (v)Stress Strain Curves
The design stress-strain curve shall be obtained by drawing a smooth
curve through the 0.5 and 1 hour points at 30%, 50%, and 70% of UTS loadings.
The presence of any aluminum slack that can be related to any observed
extrusion entering the span from the compression dead ends shall be removed
from the lower ends of the design curves. Both the laboratory and design stressstrain curves shall be submitted to the purchaser along with test results. The
stress-strain data obtained during the test shall be corrected to the standard
temperature i.e. 20 degree centigrade.
12.15
Chemical Analysis of Zinc

Samples taken from the Zinc ingots shall be chemically/
spectrographically analyzed.
The same shall be in conformity to the
requirements stated in this specification.
12.16 Chemical Analysis of Aluminum and Steel
Samples taken from the Aluminum ingots/ coils/ strands shall be chemically/
spectrographically analyzed. The same shall be in conformity to the requirements
stated in this specification.
ROUTINE/ACCEPTANCE TESTS
12.17 Visual and Dimensional Check on Drums
The drums shall be visually and dimensionally checked to ensure that they conform to
the requirements of this specification. Drum dimensions should confirm to IS:
1778.The flange diameter, traverse width, barrel diameter and flange thickness are to
be as per relevant standard.
12.18 Visual Check for Joints, Scratches etc.
Conductor drums shall be rewound in the presence of the inspector. The inspector
shall visually check for scratches, joints, etc. and that the conductor generally
conforms to the requirements of this specification.
12.19 Dimensional Check of Steel and Aluminum Strands
The individual strands shall be dimensionally checked to ensure that they
conform to the requirements of this specification.
12.20 Check for Lay-ratios of various Layers
The lay-ratios of various layers shall be checked to ensure that they conform to
the requirements of this specification.
12.21 Breaking load test on welded Aluminum strand & Individual wires
Two Aluminum wires shall be welded as per the approved quality plan
and shall be subjected to tensile load. The welded point of the wire shall be able
to withstand the minimum breaking load of the individual strand guaranteed by
the supplier.
12.22 Ductility Test
12.23 wrapping test

12.24 Resistance test
12.25 Galvanising Test
13.
RETEST AND REJECTION : 13.1 Each coil or spool selected for testing shall be tested for compliance with the
requirements of Indian Standard Specification 398 (part-II) 1976 with latest
amendment if any selected coil or spool not fulfill any of the test requirements, that
particular coil or spool shall be withdrawn. In respect of each failure, two test pieces
shall be selected from two different coils in the lot and subjected to the test under
which the failure occurred. If either of the two retest pieces fails to pass that test, the
lot concerned shall be rejected.
If samples are taken for test after stranding and if any selected reel fails
in the retest, the manufacturer may test each and every reel and submit them for
further inspection. All rejected materials shall be suitably marked and
segregated.
14.
GUARANTEED TECHNICAL PARTICULARS : -
The bidder shall fill in the guaranteed technical particulars in the

Performa at Appendix-IV and submit the same with his tender, without which
bid will not be considered.
15.
SAG TENSION CHARTS AND SAG TEMPLATES : -
The contractor shall supply each six copies of sag tension charts
and sag templates in respect of each type of the steel core aluminum
conductor. The Contractor shall also supply sag template in celluloid which
shall be subject to the approval by the purchaser and without involving any
extra charges. The design data of the lines on which these conductors will be
used are given in Appendix-III.
APPENDIX-I
ACSR CONDUCTOR:
MOOSE
ZEBRA
1.
Size of conductor:
54/7/3.53 mm
2.
Stranding and wire diameter
54/7/3.18 mm
Aluminum
54/3.53 mm
54/3.18 mm
Steel
7/3.53 mm
7/3.18 mm
3.
Sectional area of Aluminum (in mm2)
4.
Approximate total mass (in Kgs/KM)
2004
5.
Calculated resistance at 20C Max.:
0.05552
528.50
428.90
1622
0.06868
( in Ohms/Km.)
6.
Calculated breaking load of:
161.20 KN
130.32 KN.
composite conductor (in KN)

(U.T.S.) (Min)
7.
Lay Rating :Steel core
Max 18
Max- 28
Min - 16
Min-13
Aluminium Layers
8.
12 Wire Layer
Max 14
Max-17
(Innermost Layer)
Min 12
Min - 10
18 Wire Layer
Max -13
Max - 16
(Lay immediately beneath outside Layer)
Min 11
Min - 10
24 wire layer (outside layer)
Max -12
Max - 14
Min -10
Min - 10
Modulus of elasticity (in Kg / mm2 ):
6860
8158
0.7036 x 106 Kg x CM2

( 69 GN per Sq. meter )
9.
Co-efficient of linear expansion
-------------19.3 x 10-6 -------------------
of conductor per degree centigrade.
10.
Standard area of Cross Section in
597.0 mm2
484.5 mm2
31.77 mm
28.62 mm
Sq. mm of conductor.
11.
Diameter of complete conductor in
A P P E N D I X - II
Solid Steel and Aluminum Wires used in Steel cored
Aluminum Conductors
ZEBRA
1.
2.
MOOSE
Diameter
Steel Aluminum
Steel Aluminium
Standard (in mm)
3.18
3.53
3.53
Maximum (in mm)
3.24
3.60
3.55
Minimum (in mm)
3.12
3.15
3.46
3.51
7.942
9.791 9.791
Cross Sectional Area
3.18
3.21
7.942
of nominal Diameter
Wire (in mm2)
3.
Weight (in Kg/KM)
61.95
21.47
4.
Minimum tensile strength:As per relevant ISS
5.
Minimum breaking load 10.43
1.29
12.86 1.57
1.23
12.22 1.49
before stranding (in KN)

6.
Minimum breaking load: 9.91

after stranding (in KN)
7.
Zinc coating of steel

strands
Number and duration:
3 (1 Min. dip)
3 dips of 1min
of dips
Minimum Weight of :
260
260
Coating (in gm/ m2)

(A s per IS-4826 1979)
8.
Maximum resistance at:
3.626
2.974
2.921
20C of Aluminum strands

( in Ohms / KM)
9.
Minim Purity of aluminum rod:
------------------------99.5 %-------------------
A P P E N D I X III
ACSR CONDUCTOR:
1.
2.
ZEBRA
Conductor
MOOSE
---------Steel cored Aluminum-----
(a)
Copper equivalent: mm2
(b)
Stranding (in mm)
54/7/3.18
54/7/3.53
Normal Span.
320 Meters
Wind Span.
320 Meters
Weight Span.
3.
(a)
Max.
500 Meters
(b)
Min.
50 Meters
52 Kgf per M2
Wind Pressure on full

project area.
4.
5.
Temperature
(a) Minimum
5C
(b) Maximum
67 C
(c) Every day
32C
Factors of safety : Minimum

(i)
Every day temperature

and no wind.
(ii)
4.00
Minimum temperature
and 2/3 maximum wind :
(iii)
2.00
Every day Temperature and

full wind
2.00
This is as per Indian Electricity Rules, 1956.
6.
Relative Humidity.
Maximum.
100 Percent
Minimum.
60 Percent
7.
Isoceramic level.
100/Years
8.
Number of rainy days per year.
100 days
9.
Average rainfall per year
1150 mm. approx.
10.
Altitude.
Less than 350 Metres
Sl. No.
1
Description
Number of Strands
Steel centre
1st Steel Layer
1st Aluminium Layer
2nd Aluminium Layer
3rd Aluminium Layer
Sectional area of aluminium
Total sectional area
Overall diameter
Approximate weight
Calculated DC resistance at 2O oC
Minimum UTS
The details of aluminium strand are as follows:
Minimum breaking load of strand before
stranding
Minimum breaking load of strand after stranding
Maximum DC resistance of strand at 2O oC
The details of steel strand are as follows
Minimum breaking load of strand before
stranding
Minimum breaking load of strand after stranding
Minimum number of twist to be with stood in
torsion test when tested on a gauge length of
100 times diameter of wire
Tolerances
Diameter of aluminium strands
Standard
Maximum
3
4
5
6
7
8
9
10
11
12
12a
ACSR MOOSE
54Al /3.53 mm+7
Steel/3.53 mm
1
6
12
18
24
528.5 mm2
597.00 mm2
31.77 mm
2004 kg/km
0.05596 /km
161.2 kN
1.57 kN
1.49 kN
2.921/km
12.86 kN
12.22 kN
18 - before stranding
16 - after stranding
3.53 mm
3.55 mm
Minimum
Diameter of steel strands
Standard
Maximum
Minimum
13
13a
Steel - 6 wire layer

Maximum
Minimum
Aluminium - 12 wire layer
Maximum
Minimum
Aluminium - 18 wire layer
Maximum
Minimum
Aluminium - 24 wire layer 12
Maximum
Minimum 11
13c
13d
Materials composition
Aluminium
18
16
14
12
13
11
99.5% with copper content less than

0.4%
Steel
0.50 to 0.85 %
Carbon
Manganese
0.50 to 1.10 %
Phosphorous
not more than 0.035 %
Sulphur
not more than 0.045 %
Silicon
0.10 to 0.35 %
electrolytic high grade zinc of 99.95%
purity conforming to IS 209-1979.
14b
14c
3.60 mm
3.46 mm
Lay ratio of Conductor
13b
14
14a
3.51 mm
3.53 mm
Zinc for galvanising
APPENDIXI
PANTHER
1.
Size of conductor
30/7/3.00 mm
2.

Aluminum
30/3.00 mm
Steel
7/3.00 mm
3.
Sectional Area of Aluminum
212.10 mm2
4.
Approximate total mass
974 Kgs/KM
5.
Calculated resistance at
0.139 Ohm/KM
20 C Max.
6.
Calculated breaking load
89.67 KN
of composite conductor
(U.T.S) (Min)
7.
Lay Ratio :Steel Core
Max - 28
Min - 13
Aluminum Layers
12 Wire layer (Layer below
Max - 16
outside layer)
Min - 10
18 Wire layer (Outside Layer)
Max - 14
Min - 10
8.
Modulus of elasticity
0.815 x 106Kg/CM2 (80GN/M2)
9.
Co-efficient of Linear
17.8 x 10-6 / C
expansion of conductor.
10.
Standard area of cross
261.50 Sq. mm
Section in sq. mm of
conductor
11.
Diameter of complete
21 mm
conductor in mm
A P P E N D I X - II
PANTHER
Solid Steel and Aluminium Wires used in Steel cored
Aluminium Conductors
1.
Diameter
Steel
Aluminum
Standard
3.00 mm
3.00 mm
Maximum
3.06 mm
3.03 mm
Minimum
2.94 mm
2.97 mm
of nominal Diameter Wire
7.069 mm2
7.069 mm2
3.
Weight
55.13 Kg/KM
19.11Kg/Km
4.
Minimum tensile strength
134Kg/mm2
16.87Kg/mm2
5.
Minimum breaking load
9.29 KN
1.17 KN
8.83 KN
1.11 KN
2.
Cross Sectional Area
before stranding
6.

after stranding
7.
Zinc coating of steel strands

No and duration of dips
3 (1 Min. dip)
Minimum Weight of
As per IS 4826-1979
coating
8.
Maximum resistance at
4.079 Ohms/KM
20C of Aluminum strands

9.
Purity of aluminum rod
99.5%
A P P E N D I X - III
PANTHER
1.
2.
Conductor
Steel cored Aluminum
(a)
Copper equivalent
130 mm2
(b)
Stranding
30/7/3.00 mm
Normal Span.
320 Meters
Wind Span.
320 Meters
Weight Span.
3.
(a)
Max.
500 Meters
(b)
Min.
50 Meters
52 Kgf per M2
Wind Pressure on full

projected area.
4.
5.
Temperature
(a) Minimum
5 C
(b) Maximum
67C
(c) Every day
32C
Factors of safety : Minimum

(i)
Every day temperature

and no wind.
(ii)
4.00
Minimum temperature
and 2/3 maximum wind :
(iii)
2.00
Every day Temperature and

full wind
2.00
This is as per Indian Electricity Rules, 1956.

6.
Relative Humidity.
Maximum.
100 Percent
Minimum.
60 Percent
7.
Isoceramic level
100/years
8.
Number of rainy days per year.
100 days
9.
Average rainfall per year
1150 mm. approx.
10.
Altitude.
Less than 350 Meters
SECTION II
S.NO.
DESCRIPTION
PAGE NO.
1.
SCOPE
22
2.
STANDARDS
22
3.
MATERIALS
22
4.
SIZE AND CONSTRUCTION
22
5.
LENGTH OF JOINING
22
6.
TESTS AND TEST CERTIFICATES
22
7.
PACKING AND MARKING
23
8.
SAG AND TENSION CHARTS AND SAG TEMPLATE 23
9.
OVERHEAD EARTH CONDUCTORS
25
FOR
G.I. GROUND WIRE.
( 7/3.15 mm and 7/3.66mm )
TECHNICAL SPECIFICATION OF 7/3.15 mm and

7/3.66mm G.I. EARTH WIRE
1.
1.1
2.
2.1
3.
3.1
3.2
3.3
4.
4.1
5.
5.1
5.2
5.3
6.
6.1
SCOPE :
This specification provides for the manufacture, testing before despatch, supply and
delivery of Ground wire for the purpose of earthing and protection of power
transmission line, as per the particulars given in Appendix-I attached. The ground wire
shall consist of standard galvanized steel wire.
STANDARDS :
The ground wire shall comply in all respect with the Indian Standard (IS) 2141-1979
MATERIALS :
The material offered shall be of best quality and workmanship. The steel wires
(Strands) shall be manufactured from steel produced by any suitable process. The steel
wire shall not contain sulphur and phosphorous exceeding 0.040 percent each as per IS
: 2141-1971.
The steel wires shall be evenly and uniformity quoted with zinc complying with IS:
209-1965 specification for zinc (Retired). Only virgin zinc shall be used and reclaimed
zinc is not permitted. The virgin zinc shall be of zn 99.95 percent quality.
The content of carbon shall not be more than 0.55 percent, manganese and silicon
contents shall be 0.40 to 0.90 and 0.15 to 0.35 respectively.
SIZE AND CONSTRUCTION :
The size of ground wire shall be as given in Appendix-I. The physical properties have
been given in the same Appendix. The lay of the strands shall be of lengths as given in
the Appendices. The wires shall be so stranded together that when any evenly
distributed pulls applied at the end of the completed strands each wire will take on
equal share of the pull.
LENGTH OF JOINING:
The ground wire may be supplied in the standard length as per manufacturers standard
practice and such length will be specifically indicated in the tender. However random
length of ground wire upto a maximum of 10 (Ten) percent may be allowed.
The length of strand which may be supplied without joints in the individual wires
comprising it depends on the length of wire which may be carried by the bobbin in a
normal stranding machine. The normal lengths of strand which shall be supplied
without joints in individual wires, excluding welds made in the rod before drawing
shall be as given in Appendix I.
Each coil shall be warranted to contain no weld joints or splice ether than in the rod
before it is drawn and those permitted in 5.3 above. The wire shall be circular and shall
be free from scale or irregularities, imperfections, flow spite and other defects. The zinc
coating shall be smooth even and bright.
TESTS AND TEST CERTIFICATES:
Ground wire shall be subjected to the tests as specified in the IS:2141-1979 before
despatch.
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
7.
7.1
8.
8.1
Al the coils of the galvanized strand shall be of the same grade, diameter and
construction manufactured under similar condition shall be grounded to constitute one
lot.
Samples from each lot shall be tested for ascertaining the conformity to the
requirements of the ground wire specified herein. The coils selected shall be tested for
length of the lay and joints. The lot shall be declared conforming to the requirements of
these characteristics if all the coils are found satisfactory. One test specimen from each
wire of the strand shall be drawn, from every selected coil and subjected to tensil tests,
ductility test and coating test. One specimen of the completed strand from each coil
shall be subjected to tensil strength. The lot shall be declared conforming to the
requirements of these characteristics if the entire best specimen satisfy the relevant
requirements.
Chemical Analysis : One sample shall be drawn from the lot for chemical analysis.
Unless otherwise agreed to between the purchase and supplier the chemical analysis
shall be carried out.
Tensile Test : The wire when tested in accordance with IS : 1521-1960 shall have
minimum tensile strength specified in the Appendix I. The tensile strength of the
finished strand shall not be less than 95% of the aggregate of the single wires.
Ductility test : The wire shall be subjected to wrapping test in accordance with IS :
1755-1961. When wrapped eight times round its own diameter and on being
subsequently straightened the wire shall not break or split.
Coating test : The uniformity of zinc coating shall be tested as per IS: 2633-1964. The
wire shall withstand the number of dips specified in Appendix I.
Three copies of manufacturers test certificate shall be submitted by the contractor to the
purchaser for approval immediately after such tests have been conducted on the strands
and the wire.
The purchaser reserves the right to inspect the material at Manufacturers works before
despatch.
PACKING AND MARKING :
The ground wire shall be supplied in non-returnable reals or drums of non-perishable or
treated wood conforming to IS: 1778-1991 specification for Reals and Drums for Bare
wire. Each coil shall be provided with a level fixed firmly on the inner part of the coil,
bearing the following information.
(a)
Trade name, if any.
(b)
(c)
Type of wire, size and length of wire.
(d)
Not weight of the wire.
(e)
Total weight, and
(f)
Number of lengths on the real or drum unless otherwise agreed to between the
purchaser and the supplier, the stranded wire shall be supplied in 50 Kg. coil.
SAG AND TENSION CHARTS AND SAG TEMPLATE :
The successful tenderer shall be required to submit six copies of sag templates and
strings charts for different temperatures and spans, One set of charts shall be ink on
tracing cloth. The design date of the lines on which the ground wire will be used are
given in Appendix II
APPENDIXI
TECHNICAL SPECIFICATION OF GROUND WIRE
(i)
(ii)
Material
Purity of material
:
:
(iii)
(iv)
(v)
Standing and wire diameter

Weight
Single wire before stranding
Diameter of wire
Tolerance
:
:
Steel
Sulphur and phosphorous contents not
exceeding 0.040 percent each. Carbon
content not exceeding 0.55 percent. Total
silicon contents shall be 0.15 to 0.35 and
Manganese contents shall be 0.40 to 0.90
respectively.
7/3.15 mm
428 Kg / Km.
:
:
3.15 mm
+ 0.060 mm
- 0.030 mm
4 mm.
Minimum elongation in 100 :

mm.
Minimum breaking strength
:
Minimum tensile strength
:
(vi)
857 kg.
85.7 kgf / mm2
Stranded wire length of lay
Maximum
Minimum
Over all diameter
Modulus of elasticity
:
:
:
:
:
175 mm
145 mm
5810 kg
9.45 mm
1.938
x
106
Kg/Cm2
11.50 x 106 per
deg. C.
3.375 Ohms/Km.
Co-efficient
of
linear :
expansion
:
D.C. resistance at 200C
(vii)
Zinc coating :
Number of one minute dips
Number of half-minute dips
Quality of zinc
Weight of coating on wire
process of galvanising
Process of galvanising
(viii) Joints
(ix)
Lengths Standard length

Tolerance on standard length
Random lengths
:
:
:
:
Three
One
Zn 98 IS:209/1966
275 g/m2
:
:
Hot-dip.
There shall be no joint in any of the wires
constituting the ground wire.
:
:
:
1500 metres.
+ 5 percent
Not more than 5 percent of the lengths
ordered.
(x)
(xi)
Tests : :
Type tests Ultimate tensile
strength test.
Electrical Tests
Routine Tests
:
:
Test Reports
9.
A sample of the finished ground wire

when tested in tensile testing machine
shall not fail at a stress less than 100% of
UTS value of the ground wire. The length
of the test sample shall be not less than 5
meters.
As per BS : 182/1972 and BS : 3229/1960
As per clause No. 6 of IS: 2141 1968. In
addition to these tests, the weight and
adherence of Zinc coating tests shall be
conducted as per clause 4 and 5 of IS :
4826/1968.
Three copies of manufacturer test
certificates shall be submitted by the
Contracts to the purchaser for approve
immediately after such test have been
conducted on the galvanised steel strand
and the wire.
Overhead earth conductors
General(7/3.66mm)
Where earth conductors are erected to provide the specified degree of lightning protection, they
shall consist of stranded galvanised steel and shall comply with IEC 888 and IEC 1089 in so
far as it applies to steel wires.
Galvanising shall comply with the requirements of IS 2141.
The arrangement of earth conductors shall be such that failure of a single conductor cannot
predictably result in a fall across both bus bars in a duplicate bus bar substation.
SI No.
1
2
3
4
5
6
7
8
9
9a
9b
Parameter
Number of strands
Total sectional area
Overall diameter
Approximate weight
Calculated DC resistance at 20C
Minimum ultimate tensile strength
Direction of outer lay
Tolerances
Diameter
standard
maximum
minimum
Lay length
standard
maximum
Value
7/3.66mm
1/6
73.65 mm2
10.98mm
583 kg/km
2.5 ohms/m
68.4kN
Right hand
3.66mm
3.75mm
3.57mm
181mm
198mm
10
11
minimum
Steel composition Carbon
Manganese
Phosphorous
Sulphur
Silicon
Zinc for galvanising
165mm
0.55%
0.4 to 0.9%
0.04%
0.04%
0.1 to 0.35%
Electrolytic high grade zinc
of 99.95% purity to 209 1979
Table for Technical parameters for earth wires
SECTION-III
S.NO.
DESCRIPTION
PAGE NO.
1.
SCOPE
28
2.
STANDARDS
28
3.
30
4.
31
5.
DETAILS OF SOLID CORE ROD INSULATORS
37
6.
SPECIFICATION DRAWINGS
37
7.
37
8.
MATERIAL DESIGN AND WORKMANSHIP
38
9.
TESTS (FOR DISC INSULATORS)
40
10
INSPECTION
44
11.
45
12.
TEST DETAILS
46
INSULATORS
TECHNICAL SPECIFICATION FOR DISC INSULATORS FOR

SUBSTATION AND TRANSMISSION LINE WORK
1.0 SCOPE.
1.1
This specification provides for design, manufacture, engineering, inspection and

testing before despatch packing and delivery FOR (destination) for Indian
manufacturers of disc. Insulators as per technical requirements furnished in this
specification.
These insulators are to be used in suspension and tension insulators strings for
the suspension and anchoring of the conductors on EHV transmission line
towers.
1.2
Following is the list of documents constituting this package.
(i)
(ii)
(iii)
(ii)
1.3
Technical specification.
Technical data sheet.
Drawings of insulators
1.4
The insulators shall conform in all respects to high standards of engineering,

design workmanship and latest revisions of relevant standards at the time of
offer and purchaser shall have the power to reject any work or material which in
his judgment, is not in full accordance therewith.
2.0
2.1
STANDARDS:
Except as modified in this specification, the disc insulators shall conform to the
following Indian Standards, which shall mean latest revisions and amendments.
Equivalent International and Internally recognized standards to which some of
these standards generally correspond are also listed below.
All the above volumes along with amendments there of shall be read and
interpreted together. However, in case of a contradiction between the
Technical Specification and any other volume, the provisions of this volume
will prevail.
Sl.
No.
1.
2.
3.
Indian
Stand
ard
IS:
206
IS:
209
IS:
731
Title.
International
Standard.
Method for Chemical Analysis

of Slab Zinc.
Specification for Zinc.
BS: 3436
Porcelain insulators for

overhead power lines with a
BS: 137(I&II);
IEC 274 IEC
4.
5.
6.
7.
IS:
2071
Part(I)
Part(II)
Part(III)
IS:
2121
(PartI)
IS:
2486
Part
I
Part
II
Part
III
IS:
2629
8.
IS:
2633
9.
IS:
3138
IS:
3188
IS:
4218
10.
11.
normal voltage greater than

1000V
Method of High Voltage
Testing.
Specification of Conductors
and Earth wire Accessories for
Overhead Power lines.
Armour Rods, Binding wires
and tapes for conductor.
Specification for Insulator
fittings for overhead power
lines with a nominal voltage
greater than 1000V.
General Requirement and
Tests.
Dimensional Requirements.
IEC: 120
Locking devices.
IEC: 372
Recommended practice for

Hot Dip Galvanisation for iron
and steel.
Testing for Uniformity of
Coating of Zinc coated
articles.
Hexagonal Bolts & Nuts.
Dimensions for Disc
Insulators.
Metric Screw Threads
12.
IS:
6745
13.
IS:
8263
Determination of weight of
zinc coating on zinc coated
iron and steel articles.
Methods of RIV Test of HV
insulators.
14.
IS:
Methods for switching impulse
383
BS: 3288
ISO/R 947 &

ISO/R 272
IEC: 305
ISO/R 681969
R 26-1963,
R 262-1969
&
R965-1969
IEC 437
NEMA
Publication
No.107/1964
CISPR
IEC: 506
8269
15.
16
2.2
IEC
test on HV insulators.
Thermal mechanical
performance test and
mechanical performance test
on string insulator units.
Long Rod Insulators
IEC: 575
IEC-433
The standards mentioned above are available from:

Reference.
BS
IEC
CISPR
Abbreviation.
IS
ISO
NEMA
3.0
Name & Address:

British Standards, British Standards
Institution, 101, Pentonvile Road, N19 ND,U
International
Electro
technical
commission
Electro
Technique
International. 1, Rue de verembe
Geneva SWITZERLAND.
Bureau of Indian Standards, Manak
Bhavan, 9 Bahadurshah Zafar Marg,
New Delhi-110001, ORISSA
International
Organisation
for
Standardization. Danish Board of
Standardization Dansk Standardizing
Sraat
Aurehoegvej-12
DK-2900
Helleprup DENMARK.
National
Electric
Manufacturers
Association 1`55, East 44th. Street
New York, NY 10017 USA
PRINCIPAL PARAMETERS.
3.1
DETAILS OF DISC INSULATORS:
3.1.1 The Insulator strings shall consist of standard discs for use in three phases. 50
Hz effectively earthed 33/132/220 KV transmission system of OPTCL in a
moderately polluted atmosphere. The discs shall be cap and pin, ball and
socket type, radio interference and have characteristics as shown in Table-I
and all ferrous parts shall be hot dip galvanized as per the latest edition of IS
2629. The zinc to be used for making sleeves shall be 99.95 % pure.
3.1.2 The size of disc insulator, minimum creepage distance the number to be used
in different type of strings, their electromechanical strength and mechanical
strength
3.1.3 of insulator string along with hardware shall be as follows:

3.1.4
No. of
Sl.
Type of String. Size of disc.
Minimum
standard
No.
Insulator
creepage
discs
(mm)
distance of
33/132/220
each
disc(mm)
KV
1X3/1x9/1x14
1.
Single
255 x 145
430
suspension
2X3/2x9/2x14
2.
Double
-do-dosuspension.
1X4/1x10/1x1
3.
Single
280x170
-do5
Tension
2X4/2x10/2x1
4.
Double
-do-do5
Tension
Electromechanical
strength of
insulator string
fittings (KN)
90 KN
2x70/2x90
120/160
2X120/2x160
3.2
SPECIFICATION DRAWINGS:
3.2.1 A list of specification drawings in respect of the disc insulators indicated above
given at Annexure-I. These specification drawings are attached herewith for
information and guidance of the Bidder only. The drawings to be furnished by
the supplier shall be as per his own design and manufacture and shall be
distinct and separate from these specification drawings.
4.0
GENERAL TECHNICAL REQUIREMENTS:

4.1
Porcelain:
The porcelain used in the manufacture of the shells shall be ivory white
nonporous of high dielectric, mechanical and thermal strength, free from
internal stresses blisters, laminations, voids, forgone matter imperfections or
other defects which might render it in any way unusable for insulator shells.
Porcelain shall remain unaffected by climatic conditions ozone, acid, alkalis,
zinc or dust. The manufacturing shall be by the wet process and impervious
character obtained by through vetrification.
The insulator shall be made of highest grade, dense, homogeneous, wetprocess porcelain, completely and uniformly vitrified throughout to produce
uniform mechanical and electrical strength and long life service. The porcelain
shall be free from warping, roughness, cracks, blisters, laminations, projecting
points foreign particles and other defects, except those within the limits of
standard accepted practice. Surfaces and grooves shall be shaped for easy
cleaning. Shells shall be substantially symmetrical.
4.1.1 Porcelain glaze:
Surface to come in contact with cement shall be made rough by stand glazing.
All other exposed surfaces shall be glazed with ceramic materials having the
same temperature coefficient of expansion as that of the insulator shell. The
thickness of the glaze shall be uniform throughout and the colour of the glaze
shall be down. The Glaze shall have a visible luster and smooth on surface and
be capable of satisfactory performance under extreme tropical climatic weather
conditions and prevent ageing of the porcelain. The glaze shall remain under
compression on the porcelain body through out the working temperature range.
4.2
METAL PARTS:
4.2.1 Cap and Ball Pins:
Ball pins shall be made with drop forged steel caps with malleable cast iron.
They shall be in one single piece and duly hot dip galvanized. They shall not
contain parts or pieces joined together welded, shrink fitted or by any other
process from more than one piece of materials. The pins shall be of high tensile
steel, drop forged and heat-treated. The caps shall be cast with good quality
black heart malleable cast iron and annealed. Galvanizing shall be by the hot
dip process with a heavy coating of zinc of very high purity. The bidder shall
specify the grade composition and mechanical properties of steel used for caps
and pins. The cap and pin shall be of such design that it will not yield or distort
under the specified mechanical load in such a manner as to change the relative
spacing of the insulators or add other stresses to the shells. The insulator caps
shall be of the socket type provided with nonferrous metal or stainless steel
cotter pins and shall provide positive locking of the coupling.
4.2.2 Security Clips:
The security cops shall be made of phosphor bronze or of stainless steel.
4.3
FILTER MATERIAL:
Cement to be used, as a filler material be quick setting, fast curing Portland
cement. It shall not cause fracture by expansion or loosening by contraction.
Cement shall not react chemically with metal parts in contact with it and its
thickness shall be as small and as uniform as possible.
4.4
MATERIALS DESIGN AND WORKMANSHIP:
4.4.1 GENERAL:
(II)
All raw materials to be used in the manufacture of these insulators
shall be subject to strict raw material quality control and to stage
testing/ quality control during manufacturing stage to ensure the
quality of the final end product. Manufacturing shall conform to the
best engineering practices adopted in the field of extra high voltage
transmission. Bidders shall therefore offer insulators as are
guaranteed by them for satisfactory performance on Transmission
lines.
(III)
The design, manufacturing process and material control at various
stages be such as to give maximum working load, highest mobility,
best resistance to corrosion, good finish elimination of sharp edges
and corners to limit corona and radio interference voltages.
4.4.2 INSULATOR SHELL:
The design of the insulator shells shall be such that stresses due to expansion
and contraction in any part of the insulator shall not lead to deterioration. Shells
with cracks shall be eliminated by temperature cycle test followed by mallet
test. Shells shall be dried under controlled conditions of humidity and
temperature.
4.4.3 METAL PARTS:
The pin and cap shall be designed to transmit the mechanical stress to the
shell by compression and develop uniform mechanical strength in the
insulator. The cap shall be circular with the inner and outer surfaces
concentric and of such design that it will not yield or distort under loaded
conditions. The head portion of the pinball shall be suitably designed so that
when the insulator is under tension the stresses are uniformly distributed
over the pinhole portion of the shell. The pinball shall move freely in the cap
socket either during assembly of a string or during erection of a string or
when a string is placed in position.
ii)
Metal caps shall be free from cracks, seams, shrinks, air holes, blowholes
and rough edges. All metal surfaces shall be perfectly smooth with no
projecting part or irregularities, which may cause corona. All load bearing
surfaces shall be smooth and uniform so as to distribute the loading stress
uniformly. Pins shall not show any microscopically visible cracks, inclusions
and voids.
i)
4.4.4 GALVANIZING:
All ferrous parts, shall be hot dip galvanized in accordance with IS: 2629. The
zinc to be used for galvanizing shall conform to grade Zn 99.5 as per IS: 209.
The zinc coating shall be uniform, smoothly adherent, reasonably light,
continuous and free from impurities such as flux, ash, rust stains, bulky white
deposits and blisters. Before ball fittings are galvanized, all die flashing on the
shank and on the bearing surface of the ball shall be carefully removed without
reducing the designed dimensional requirements.
4.4.5 CEMENTING:
The insulator design shall. Be such that the insulating medium shall not directly
engaged with hard metal. The surface of porcelain and coated with resilient
paint to offset the effect of difference in thermal expansions of these materials.
High quality Portland cement shall be used for cementing the porcelain to the
cap & pin.
4.4.6 SECURITY CLIPS (LOCKING DEVICES)
The security clips to be used as locking device for ball and socket coupling
shall be R shaped hump type to provide for positive locking of the coupling as
per IS: 2486 (Part-IV). The legs of the security clips shall allow for spreading
after installation to prevent complete withdrawal from the socket. The locking
device shall resilient corrosion resistant and of sufficient mechanical strength.
There shall be no possibility of the locking device to be displaced or be capable
of rotation, which placed in position, and under no circumstances shall it allow

separation of insulator units and fittings. W type security clips are also
acceptable. The hole for the security clip shall be counter sunk and the clip
shall be of such design that the eye of the clip may be engaged by a hot line
clip puller to provide for disengagement under energized conditions. The force
required for pulling the clip into its unlocked positions shall not be less than 50
N (5 kg.) or more than 500 N (50 kgs.).
4.4.7 MARKING:
Each insulator shall have the rated combined mechanical and electrical
strength marked clearly on the porcelain surface. Each insulator shall also bear
symbols identifying the manufacturer, month, and year of manufacture. Marking
on porcelain shall be printed, not impressed, and shall be applied before firing.
4.5 BALL AND SOCKET DESIGNATION:
The dimensions of the ball and sockets for 70 and 90 KN discs shall be of
16 mm and for 120 KN and 160 KN discs shall be of 20 mm designation in
accordance with the standard dimensions stated in IS: 2486 (Part-II).
4.6 DIMENSIONAL TOLERANCE OF INSULATOR DISCS:
It shall be ensured that the dimensions of the disc insulators are within the limits
specified below:
a)
Diameter of Disc (mm)

Standard.
70/90 KN Disc/ 120 KN
255/280
160 KN Disc
280
b)
Maximum
266/293
293
Minimum
244/267
267
Ball to Ball spacing

Between Discs (mm)
70/90 KN Disc/ 120 KN

160 KN Disc
Standard.
145
170
Maximum
149
175
Minimum
141
165
4.7
INTERCHANGEABILITY:
The insulators inclusive of the ball and socket fittings shall be of standard
design suitable for use with hardware fittings of any make conforming to
relevant Indian Standards.
4.8
CORONA AND RIV PERFORMANCE:
All surfaces shall be even, smooth, without cuts, abrasions or projections. No
part shall be subject to excessive localized pressure. The metal parts and
porcelain shall not produce any noise-generating corona under all operating
conditions.
4.9
SUITABILITY FOR LIVE LINE MAINTENANCE:
The insulator shall be compatible for use with hot line or live line maintenance
techniques so that usual hot line operation can be carried out with easy speed
and safety.
4.10
FREEDOM FROM DEFECTS:

Insulators shall have none of the following defects:
1)
Ball pin shake.
2)
Cementing defects near the pin like small blow holes, small hair
cracks lumps etc.
3)
Sand fall defects on the surface of the insulator.
4.11 INSULATOR STRINGS:

4.11.1 TYPE AND RATING:
The insulator strings shall be formed with standard discs described in this
specification for use on 3 phases 132/22 KV 50 Hz effectively earthed systems
in an atmosphere with pollution level as indicated in project synopsis.
Suspension insulator strings for use with suspension/tangent towers are to be
fitted with discs 70/90 KN EMS rating while tension insulator strings for use with
Anchor/ Tension towers are to be fitted with discs of 120 KN / 160 KN EMS
level rating.
4.11.2 STRING SIZE:
The sizes of the disc insulator, the number to be used in different types of
strings, their electro-mechanical strength and minimum nominal creep age
distance shall be as given in clause 3.12
4.12 STRING CHARACTERISTICS:
4.12.1 The characteristics of the complete string shall be as follows:
Description.
Suspension.
132KV
220kV
Switching surge withstand

voltage (dry & wet) KV
peak.
Lighting impulse withstand 650
voltage (dry) KV Peak.
Power frequency without 275
voltage (wet) KV r.m.s.
Tension.
132KV 220KV
1050
650
1050
460
275
460

level KV rms
176
176
Max. RIV for comp. Etc.

strong including corona
rings at 156 KV (rms).
hours clamps etc. at 1.1.
times maximum knee to
ground
voltage
(micro
volts).
Mechanical failing load for 6500
each sting (kgf)
500
500
No deformation load for

each string (kgf)
7705
Max. voltage across any 13%

disc.
11500
11500
15500
13%
13%
10385
13%
4.12.2 Insulator units after assembly shall be concentric and coaxial within limits as
permitted by Indian Standards.
4.12.3 The strings design shall be such that when units are coupled together there
shall be contact between the shell of one unit and metal of the adjacent unit.
5.0
5.1
DETAILS OF SOLID CORE LONG ROD INSULATORS:

The insulator shall consist of standard-discs for a three-phase 50 Hz effectively
earthed 132 KV transmission system heavily polluted atmosphere. The
insulator shall be ball and socket type.
5.2
The size of long rod insulator, minimum creepage distance, the number to be
used in different type of strings, their electromechanically strength and
mechanical strength of insulator string alongwith hardware shall be as follows:
1.
Singlesuspension
of Minimumcreepage No.ofunit132/ Electromechanical

220KV)
strength of
distance
longrodi
insulator
(mm)
nsulator
(KN)
132/220
(mm)/(U
KV
nit)
180x1305
3625/6125
1
80 KN
2.
Doublesuspension
-do-
Sl. Type of string.

No.
Size
-do-
2x80 KN
3.
Single tension.
190x1450
4020/6125
120 KN
4.
Double Tension.
-do-
-do-
2x120 KN
6.0
6.1
SPECIFICATION DRAWINGS:
A list of specification drawings in respect of the long rod insulators indicated
above is given at Annexure-II. These specification drawings are attached
herewith for information and guidance of the bidder only. The drawings to be
furnished by the supplier shall be as per his own design and manufacture and
shall be distinct and separate from these specification drawings.
7.0
GENERAL TECHNICAL REQUIREMENT:

7.1
PORCELAIN:
The porcelain used in the manufacture of the shell shall be ivory white,
nonporous of high dielectric, mechanical and thermal strength free from internal
stress blisters and thermal strength from internal stresses blisters, laminations,
voids, foreign matter. Imperfections or other defects, which might render it in
any way unsuitable for insulator shells. Porcelain shall remain unaffected by
climatic conditions, ozone, acid alkalis, and zinc of dust. The manufacturing
shall be by the wet process and impervious character obtained by through
vetrification.
7.2
PORCELAIN GLAZE:
Surfaces to come in contact with cement shall be made rough by stand glazing.
All other exposed surfaces shall be glazed with ceramic materials having the
same temperature coefficient of expansion as that of the insulator shell. The
thickness of the glaze shall be uniform throughout and the colour of the glaze
shall be brown. The glaze shall have a visible luster and smooth on surface and
be capable of satisfactory performance under extreme tropical climatic weather
conditions and prevent ageing of the porcelain. The glaze shall remain under
compression on the porcelain body throughout the working temperature range.
7.3
METAL PARTS:
7.3.1 Cap and Ball pins:
Twin Ball pins shall be made with drop forged steel and caps with malleable
cast iron. They shall be in one single piece and duly hot dip g galvanized. They
shall not contain parts or pieces joined together, welded, shrink fitted or by any
other process from more than one piece of material. The pins shall be of high
tensile steel, drop forged and heat malleable cast iron and annealed.
Galvanizing shall be by the hot dip process with a heavy coating of zinc of very
high purity with minimum of 6 dips. The bidder shall specify the grade,
composition and mechanical properties of steel used for caps and pins.
7.3.2 SECURITY CLIPS:
The security clips shall be made of phosphor bronze or of stainless steel.
7.4
FILLER MATERIAL:
Cement to be used as a filler material shall be quick setting, for curing
Portland cement. It shall not cause fracture by expansion or loosening by
contraction. Cement shall not react chemically with metal parts in contract with
it and its thickness shall be as small and as uniform as possible.
8.0
MATERIAL DESIGN AND WORKMANSHIP:

8.1
GENERAL:
i)
All raw materials to be used in the manufacture of these insulators shall
be subject to strict raw materials quality control and to stage testing
quality control during manufacturing stage to ensure the quality of the
final end product. Manufacturing shall conform to the best engineering
practices adopted in the field of extra high voltage transmission. Bidders
shall therefore offer insulators as are guaranteed by them for satisfactory
performance on Transmission lines.
ii)
The design, manufacturing process and material control at various
stages be such as to give maximum working load, highest mobility, best
resistance to corrosion good finish, elimination of sharp edges and
corners to limit corona and radio interference voltage
8.2
INSULATOR SHELL:
The design of the insulator shell shall be such that stresses due to expansion
and contraction in any part of the insulator shall not lead to deterioration. Shells
with cracks shall be eliminated by temperature cycle test followed by
temperature cycle test followed by mallet test. Shells shall be dried under
controlled conditions of humidity and temperature.
8.3
METAL PARTS:
i)
The twin ball pin and cap shall be designed to transmit the mechanical
stresses to the shell by compression and develop uniform mechanical
strength in the insulator. The cap shall be circular with the inner and
outer surfaces concentric and of such design that it will not yield or
distort under loaded conditions. The head portion of the insulator or is
under tension the stresses are uniformly distributed over the pinhole
portion of the shell. The pinball shall move freely in the cap socket either
during assembly of a string or during erection of a string or when a string
is placed in position.
ii)
Metal caps shall be free from cracks, seams, shrinks, air holes,
blowholes and rough edges. All metal surfaces shall be perfectly smooth
with no projecting parts or irregularities which may cause corona. All
load bearing surfaces shall be smooth and uniform so as to distribute the
loading stresses uniformly. Pins shall not show any macroscopically
visible cracks, insulations and voids.
8.4
GALVANIZING:
All ferrous parts shall be hot dip galvanized six times in accordance with IS:
2629. The zinc to be used for galvanizing shall conform to grade Zn 99.5 as per
IS: 209. The zinc coating shall be uniform, smoothly adherent, reasonably light,
continuous and free from impurities such as flux ash, rust stains, bulky white
deposits and blisters. Before ball fittings are galvanized, all die flashing on the
shank and on the bearing surface of the ball shall be carefully removed without
reducing the designed dimensional requirements.
8.4.1 CEMENTING:
The insulator design shall be such that the insulating medium shall not directly
engage with hard metal. The surfaces of porcelain and coated with resilient
paint to offset the effect of difference in thermal expansions of these materials.
8.5
SECURITY CLIPS (LOCKING DEVICES

The security clips to be used as locking device for ball and socket coupling
shall be R shaped hump type to provide for positive locking of the coupling as
per IS: 2486 (Part-IV). The legs of the security clips shall allow for sore adding
after installation to prevent complete withdrawal from the socket. The locking
device shall be resilient corrosion resistant and of sufficient mechanical
strength. There shall be no possibility of the locking device to be displaced or
be capable of rotation when placed in position and under no circumstances
shall it allow separation of insulator units and fitting W type security clips are
also acceptable. The hole for the security clip shall be countersunk and the clip
shall be of such design that the eye of the clip may be engaged by a hot line
clip puller to provide for disengagement under energized conditions. The force
required for pulling the clip into its unlocked position shall not be less than 50 N
(5 Kgs.) or more than 500N (50 Kgs.)
8.6
BALL AND SOCKET DESIGNATION:

The dimensions of the balls and sockets for 80 KN long rod insulators shall be
of 16mm and for 120 KN shall be of 20mm designation in accordance with the
standard dimensions stated in IS: 2486 (Part-III).
8.7
DIMENSIONAL TOLERANCE OF INSULATORS DISCS

It shall be ensured that the dimensions of the long rod insulators are within the
limits as per relevant IEC/ISS.
9.0
9,1
TESTS (FOR DISC INSULATORS) :

The following tests shall be carried out on the insulator string and disc
insulators.
9.2
TYPE TEST:
This shall mean those tests, which are to be carried out to prove the design,
process of manufacture and general conformity of the material and product with
the intents of this specification. These tests shall be conducted on a
representative number of samples prior to commencement of commercial

production. The Bidder shall indicate his schedule for carrying out these tests.
9.3
ACCEPTANCE:
This shall mean these tests, which are to be carried out on samples taken from
each lot offered for pre-despatch inspection for the purpose of acceptance of
the lot.
9.4
ROUTINE TESTS:
This shall mean those tests, which are to be carried out on each insulator to
check the requirements, which are likely to vary during production.
9.5
TESTS DURING MANUFACTURE:

Stage tests during manufacture shall mean those tests, which are to be carried
out during the process of manufacture to ensure quality control such that the
end product is of the designed quality conforming to the intent of this
specification.
9.6
TEST VALUE:
For all type and acceptance tests the acceptance values shall be the value
guaranteed by the bidder in the guaranteed technical particulars of the
acceptance value specified in this specification of the relevant standard
whichever is more stringent for that particular test.
9.7
TEST PROCEDURE AND SAMPLING NORMS:

The norms and procedure of sampling for the above tests shall be as per the
relevant Indian Standard or the Internationally accepted standards. This will be
discussed and mutually agreed to between the supplier and purchaser before
placement of order. The standards and normal according to which these tests
are to be carried out are listed against each test. Where a particular test is a
specific requirement of this specification, the norms land procedure for the
same shall be as specified in Annexure-IV attached hereto as mutually agreed
to between the supplier and the purchaser in the quality assurance programme.
9.8
TYPE TESTS:
The following type test shall be conducted on a suitable number of individual
unit components, materials or complete strings.
9.8.1 On the complete insulator string with hardware fittings.

a)
Power frequency voltage withstand test with

corona control rings and under wet condition.
b)
Switching surge voltage withstand test under

wet condition (400 only)
Impulse voltage withstand test under dry
c)
:
BS:137(P
art-I)
:
: IEC: 383
d)
e)
f)
g)
h)
9.8.2
a)
b)
c)
d)
e)
f)
9.8.3
9.9
9.9.1
condition.
Impulse voltage flashover test under dry
condition.
Voltage distribution test.
Corona & RIV test under dry condition.
Mechanical strength test.
Vibration.
On Insulators:
Thermal mechanical performance test:
Power frequency voltage withstand and
flashover
(I) dry (ii) wet.
Impulse voltage withstand flashover test
(dry)
Visible discharge test (dry)
RIV test (dry)
All the type tests given under clause
No.6.8.1 above shall be conducted on single
suspension and Double Tension insulator
string alongwith hardware fittings.
ACCEPTANCE TESTS:
For insulator:
a) Visual examination
b) Verification of dimensions.
c) Temperature cycle test.
d) Galvanizing test.
e) Mechanical performance test.
f) Test on locking device for ball and socket
coupling.
g) Eccentricity test.
h) Electro-mechanical strength test.

i) Puncture test.
j) Porosity test.
:
:
: As per
this
specificati
on.
: As per
this
specificati
on.
:
: IS: 731
: IEC:575
: BS: 173
: IEC: 383
: IS:731
: IS:8263
: IS:731
: IS:731
: IS:731
: IS:731
: IEC:575
: IEC:372
: As per
this
specificati
on.
:
: IS:731
: IS:731
9.10
9.10.1
9.11
ROUTINE TESTS:
For insulators:
a) Visual inspection.
b) Mechanical routine test.
c) Electrical routine test.
TEST DURING MANUFACTURE:
On all components as applicable.
a) Chemical analysis of zinc used for
galvanizing.
b) Chemical analysis, mechanical and
metallographic
test and magnetic particle
inspection for malleable castings.
c) Chemical analysis, hardness test and
magnetic particle inspection for forgings.
d) Hydraulic Internal Pressure tests on shell.

e) Crack detection test for metal parts.
: IS:731
:
: IEC:383
:
:
: As per
this
specificati
on.
:
:
9.12
ADDITIONAL TEST:
The purchaser reserves the right for carrying out any other tests of a
reasonable nature at the works of the supplier/ laboratory or at any other
recognized laboratory/ research institute in addition to the above mentioned
type, acceptance and routine tests at the cost of the purchaser to satisfy that
the material complies with the intent of this specification.
9.13
CO-ORDINATION FOR TESTING:

For insulator strings, the supplier shall arrange to conduct testing of their disc
insulators with the hardware fittings to be supplied to the purchaser by other
suppliers. The supplier is also required to guarantee overall satisfactory
performance of the disc insulator with the hardware fittings.
NOTE:
In respect of electrical tests on a complete string consisting of insulators
and hardware guarantee of values of responsibility of testing shall be with
hardware manufacturer of RIV corona and voltage distribution test and with
insulator manufacturer for all other tests.
9.14 TEST CHARGES AND TEST SCHEDULE:

9.14.1 TYPE TEST:
The insulator offered shall be fully type tested as per this specification. In case
the equipment of the type and design offered, has already been type tested in
an independent test laboratory. The bidder shall furnish four sets of type test
reports alongwith the offer. These tests must not have been conducted earlier
than five years. The purchaser reserves the right to demand repetition of some
or all type tests in the presence of purchasers carrying representative. For this
purpose the bidder may quote unit rates for carrying out each type test. These
prices shall be taken into consideration for bid evaluation. For any change in
the design/type already type tested and the design/type offered against this
specification, purchaser reserves the right to demand repetition of tests without
any extra cost.
9.14.2 ACCEPTANCE AND ROUTINE TEST:
All acceptance and routine tests as stipulated herein shall be carried out by the
supplier in the presence of purchasers representative.
9.14.3 Immediately after finalisation of the programme of type/ acceptance/ routine
testing, the supplier shall give sufficient advance intimation to the purchaser to
enable him to depute his representative for witnessing the tests.
9.14.4 For type tests involving tests on a complete insulator string with hardware
fittings, the purchaser will advice the supplier of the hardware fittings to provide
the necessary fittings to the place of the test.
9.14.5 In case of failure of the complete string in any type tests, the supplier whose
product has failed in the tests, shall get the tests repeated at his cost. In case of
any dispute, assessment of the purchaser as to the items that has caused the
failure in any of the type tests shall be final and binding.
10.1
10.
i.
ii.
iii.
iv.
10.2
INSPECTION:
Purchaser and its representative shall at all times be entitled to have
access to the works and to all places of manufacturer where insulators
are manufactured and the supplier shall afford all facilities to them for
unrestricted inspection of the works, inspection of materials, inspection
of manufacturing process of insulators and for conducting necessary
tests as specified herein.
The supplier shall keep the purchaser informed in advance of the time of
starting and of progress of manufacture of insulators in its various stages
so that arrangements could be made for inspection.
No material shall be dispatched from its point of manufacture unless the
materials has been satisfactorily inspected and tested.
The acceptance of any quantity of insulators shall in no way relieve the
supplier of his responsibility for meeting all the requirement of this
specification and shall not prevent subsequent rejection, if such
insulators are later found to be defective.
IDENTIFICATION MARKING:
10.2.1 Each unit of insulator shall be legibly and indelibly marked with the trade mark
of the supplier, the year of manufacture, the guaranteed combined mechanical
and electrical strength in kilo-newtons abbreviated by KN to facilitate easy

identification and proper use.
10.2.2 The marking shall be on porcelain for porcelain insulators. The marking shall be
printed and not impressed and the same shall be applied before firing.
11.1
11.
QUALITY ASSURANCE PLAN:
The bidder hereunder shall invariably furnish following information alongwith his
offer, failing which the offer shall be liable for rejection.
i.
ii.
iii.
iv.
v.
vi.
vii.
Statement giving list of important raw materials, names of subsuppliers for the raw materials, list of standards according to
which the raw material are tested, list of tests normally carried out
on raw materials in presence of bidders representative, copies of
test certificates.
Informations and copies of test certificates as in (i) above in
respect of bought out materials.
Level of automation achieved and lists of area where manual
processing exists.
List of areas in manufacturing process, where stage inspections
are normally carried out in quality control and details of such tests
and inspection.
Special features provided in the equipment to make it
maintenance free.
List of testing equipping available with the bidder for final testing
of equipment specified and test plant limitation, if any, vis--vis
the type, special, acceptance and routine tests specified in the
relevant standards. These limitations shall be very clearly brought
out in schedule of deviations from specified test requirements.
11.2
The supplier shall within 30 days of placement of order submit the following
information to the owner.
i)
List of raw material and the names of sub-suppliers selected from those
furnished alongwith the offer.
POST INSULATORS.
Post insulator shall conform in general to IS 2544, IEC 168 and IEC 815.
3.1
constructional features
Post type insulators shall consist of a porcelain part permanently
secured in a metal base to be mounted on the supporting structures. They shall
be capable of being mounted upright and be designed to with stand any shocks
to which they may bed subjected to by the operation of the associated
equipment. Only solid core insulators will be acceptable.
Porcelain used shall be homogeneous, free from lamination, cavities and other
flaws or imperfections that might after the mechanical or dielectric quality and
shall be thoroughly vitrified, tough and impervious to moisture.
Glazing of the porcelain shall be of uniform brown in colour, free from blisters,
burrs and other similar defects.
The insulator shall have alternate long and short sheds with aerodynamic
profile. The shed profile shall also meet the requirements of IEC 815 for the
specified pollution level.
When operated at normal rated voltage there shall be no electric discharge
between conductor and insulators which would cause corrosion or injury to
conductors or insulators by the formation of substance produced by chemical
action.
The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
All ferrous parts shall be hot dip galvanized in accordance with the latest edition
of IS 2633, and IS 4579. The zinc used for galvanizing shall be grade Zn 99.95
as per IS 209. The zinc coating shall be uniform, adherent, smooth, reasonably
bright, continuous and free from imperfections such as flux ash, rust stains,
bulky while deposits and blisters. The metal parts shall not produce any noise
generating corona under the operating conditions. Flat washer shall be circular
of a diameter 2.5 times that of bolt and of suitable thickness. Where bolt
heads/nuts bear upon the beveled surfaces they shall be provided with square
tapered washers of suitable thickness to afford a seating square with the axis of
the bolt.
Bidder shall make available data on all the essential features of design
including the method of assembly of shells and metals parts, number of shells
per insulator, the manner in which mechanical stresses are transmitted through
shells to adjacent parts, provision for meeting expansion stresses, results of
corona and thermal shock tests, recommended working strength and any
special design or arrangement employed to increase life under service
conditions.
12. TEST DETAILS.

1.
VOLTAGE DISTRIBUTION TEST:
The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted into percentage and
proportionate correction be applied as to give a total of 100% distribution. The
voltage across any disc. Not exceed the values given in clause 4-12.1
2.
CORONA EXTINCTION VOLTAGE TEST (DRY):
The sample assembly when subjected to power frequency voltage shall have a
corona extinction voltage of not less than the value specified at clause 4.12.1
(iv) under dry condition. There shall be no evidence of corona on any part of the
sample when all possible sources of corona are photographed in a darkened
room.
3.
RIV TEST (DRY):
Under the conditions as specified in (2) above, the insulator string along with
complete hardware fittings shall have a radio interference voltage level below
500 micro volts at one MHz when subjected to 50 Hz AC voltage of 1.1 times
maximum time to ground voltage under dry condition. The test procedure shall
be in accordance with IS: 8263.
4.
The complete insulator string along with its hardware fitting excluding arcing
horn corona controlling/grading ring and suspension assembly/dead end
assembly shall be subject to a load equal to 50% of the specified minimum
ultimate tensile strength (UTS) which shall be increased already rate to 68% of
the minimum UTS specified. The load shall be held for five minutes and then
removed. After removal of the load, the string components shall not show any
visual deformation and it shall be possible to disassemble them by hand,. Hand
tools may be used to remove cotter pins and loosen the nuts initially. The string
shall then be reassembled and loaded to 50% of UTS and the load shall be
further increased at a steady rate till the specified minimum UTS and held for
one minute. No fracture should occur during this period. The applied load shall
then be increased until the failing loads reached and the value recorded.
5.
VIBRATION TEST:
The suspension string shall be tested in suspension mode, and tension string in
tension mode itself in laboratory span of minimum 30 meters. In the case of
suspensions string a load equal to 600 Kg. shall be applied along with the axis
of the suspensions string by means of turn buckle. The insulators string along
with hardware fittings and two sub conductors throughout the duration of the
test vibration dampers shall not be used on the test span. Both the subconductors shall be vertically vibrated simultaneously at one of the resonance
frequencies of the insulator string (more than 10Hz) by means of vibration
inducing equipment. The amplitude of vibration at the antipode point nearest to
the string shall be measured and the same shall not be less than 120.4 being
the frequency of vibration. The insulator strings shall be vibrated for five million
cycles then rotated by 90 deg and again vibrated for 5 million cycles without
any failure, after the test, the disc insulators shall be examined for looseness of
pins and cap or any crack in the cement. The hardware fittings shall be
examined to fatigue fatter and mechanical strength test. There shall be no
deterioration of properties of hardware components and disc insulators after the
vibration test. The disc insulators shall be subjected to the following tests as per
relevant standards.
Test.
Percentage
disc
a)
Temperature cycle test followed by

Mechanical performance test.
To be tested.
60
40
of
b)
Puncture test (for porcelain insulator only)
6.
CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING.
Samples taken from the zinc ingot shall be chemically analysed as per IS: 209.
The purity of zinc shall not be less than 99.95%.
7.
TEST FOR FORGINGS:

The chemical analysis hardness tests and magnetic particle inspection for
forgings will be as per the internationally recognized procedures for these tests.
The sampling will be based on heat number and heat treatment batch. The
details regarding test will be as discussed and mutually agreed to by the
supplier and purchaser in quality assurance programme.
1.
TEST ON CASTING:
The chemical analysis mechanical and metallographic tests and magnetic
particle inspection for castings will be as per the internationally recognized
procedures for these tests. The samplings will be based on heat number and
heat treatment batch. The details regarding test will be as discussed and
mutually agreed to by the supplier and purchaser in quality assurance
programme.
2.
HYDRAULIC INTERNAL PRESSURE TEST ON SHELLS:

The test shall be earned out on 100% shells before assembly. The details
regarding test will be as discussed and mutually agreed to by the suppliers and
purchaser in Quality Assurance Programme.
3.
THERMAL MECHANICAL PERFORMANCE TEST:

The thermal mechanical performance test shall be carried out on minimum 15
number of disc insulators units as per the procedure given in IEC 575. The
performance of the insulator unit shall be determined by the same standard.
4.
ECCENTRICITY TEST:
The insulator shall be vertically mounted on a future using dummy pin and
socket. A vertical scale with horizontal slider shall be used for the axial run out.
The pointer shall be positioned in contact with the bottom of the outermost
petticoat of the disc. The disc insulators shall be rotated with reference to the
fixture and the slider shall be allowed to move up and down on the scale but
always maintaining contact with the bottom of the outer most petticoats. After
one full rotation of the disc the maximum and minimum position the slider has
reached on the scale can be found out. Difference between the above two
readings shall satisfy the guaranteed value for axial run out.
Similarly using a horizontal scale with veridical slider the radial run out shall be
measured. The slider shall be positioned on the scale to establish contact with
the circumstance of the disc insulator and disc insulator rotated on its future
always maintaining the contact. After one full rotation of the disc the maximum
and minimum position the slider has reached on the scale can be found out.
Difference between the above two readings shall satisfy the guaranteed value
for axial run out.
5.
CRACK DETECTION TEST:

Crack detection test shall be carried out on each ball and pin before assembly
of disc unit. The supplier shall maintain complete record of having conducted
such tests on each and every piece of ball pin The bidder shall furnish full
details of the equipment available with him for crack test and also indicate the
test procedure in detail.
6. Tubular bus conductors:
General
Aluminium used shall be grade 63401 WP conforming to IS 5082. The tube shall be seamless
and shall be manufactured by either of the following processes:
Hot extrusion process through die and mandrel (Hollow billet process). Heat treatment
shall be carried out after hot extrusion of tube.
Bridge extrusion process and then cold drawn. Heat treatment shall be carried out after
cold drawing of tube.
For outside diameter (OD) and thickness of the tube there shall be no minus tolerance, other
requirements being as per IS 2678 and IS 2673.
The aluminium tube shall be supplied in suitable cut length to minimise wastage.
Size
Outer diameter (mm)
Thickness (mm) :
Cross-sectional area (sq.mm) :
Weight (kg/m) :
Chemical composition
i)
Cu
ii)
Mg
iii)
Si
iv)
Fe
v)
Mn
vi)
Al
Minimum ultimate Tensile
strength Kg/Sq mm
Temp co-eff of resistance
Minimum electrical conductivity
at 20 deg C
Modulus of Elasticity
4" IPS
(EH type)
3IPS
(EH type)
114.20
8.51
2825.61
7.7
88..9
7.62
2373.63
6.44
0.05 max
0.4 to 0.9
0.3 to 0.7
0.5 max
0.03 max
Remainder
20.5
0.05 max
0.4 to 0.9
0.3 to 0.7
0.5 max
0.03 max
Remainder
20.5
4.5IPS
(EH type)
120.0
12.0
4071.5
10.993
0.05 max
0.4 to 0.9
0.3 to 0.7
0.5 max
0.03 max
Remainder
20.5
0.00364 per Deg C

55% of IACS
6700 Kg/sq mm
7. Post insulators:
Post insulators shall conform in general to IS 2544, IEC 168 and IEC 815.
Post type insulators shall consist of a porcelain part permanently secured in a metal base to be
mounted on the supporting structures. They shall be capable of being mounted upright and be
designed to withstand any shocks to which they may be subjected to by the operation of the
associated equipment. Only solid core insulators will be acceptable.
Porcelain used shall be homogeneous, free from lamination, cavities and other flaws or
imperfections that might affect the mechanical or dielectric quality and shall be thoroughly
vitrified, tough and impervious to moisture.
Glazing of the porcelain shall be of uniform brown in colour, free from blisters, burrs and other
similar defects.
The insulator shall have alternate long and short sheds with aerodynamic profile. The shed
profile shall also meet the requirements of IEC 815 for the specified pollution level.
When operating at normal rated voltage there shall be no electric discharge between conductor
and insulators, which would cause corrosion or injury to conductors, or insulators by the
formation of substance produced by chemical action.
The design of the insulators shall be such that stresses due to expansion and contraction in any
part of the insulator shall not lead to deterioration.
All ferrous parts shall be hot dip galvanised in accordance with the latest edition of IS 2633,
and IS 4579. The zinc used for galvanising shall be grade Zn 99.95 as per IS 209. The zinc
coating shall be uniform, adherent, smooth, reasonably bright, continuous and free from
imperfections such as flux ash, rust stains, bulky white deposits and blisters. The metal parts
shall not produce any noise generating corona under the operating conditions.
Flat washer shall be circular of a diameter 2.5 times that of bolt and of suitable thickness.
Where bolt heads/nuts bear upon the bevelled surfaces they shall be provided with square
tapered washers of suitable thickness to afford a seating square with the axis of the bolt.
Bidder shall make available data on all the essential features of design including the method of
assembly of shells and metals parts, number of shells per insulator, the manner in which
mechanical stresses are transmitted through shells to adjacent parts, provision for meeting
expansion stresses, results of corona and thermal shock tests, recommended working strength
and any special design or arrangement employed to increase life under service conditions.
Services to be performed by the equipment being furnished

The equipment shall be able to withstand forces due to wind load on the equipment and
approach conductor and due to short circuit, all forces considered together.
The Contractor shall submit detailed calculations proving the satisfactory performance of the
equipment under short circuit conditions to meet the layout requirements.
Technical Parameters
SI No.
1
2
3
4
5
6
7
9
10
11
12
13
14
15
16
Parameter
Type
Voltage class (kV)
Dry and wet one minute withstand
voltage (kVrms)
Dry lightning impulse withstand
voltage (kVp)
Wet switching surge withstand
voltage (kVp)
Max. RIV at corona extinction
voltage (microvolts)
Corona extinction voltage (kVrms)
Total minimum cantilever strength
(kg)
Minimum torsional moment
Total height of insulator (mm)
PCD (mm)
top/bottom
No. of bolts
top/bottom
Diameter of bolt holes (mm)
top/bottom
Pollution level as per IEC 815
Minimum total creepage

distance (mm)
400kV
245kV
132kV
Confirming to IEC 273 (solid core )
420
245
145
630
460
235
33klV
36
70
1550
1050
650
250
1175
NA
NA
NA
500
500
500
NA
320 (min)
not< 800
156 (min)
not< 800
105
not< 600
not< 300
As per IEC 273

3650
2300
127/300
127/254
1100
127/254
325
127/254
4/8
4/8
4/8
4/8
M16/18
M16/18
M16/18
M16/18
Heavy
Heavy
Heavy
Heavy
10500
6125
3625
900
If corona extinction voltage is to be achieved with the help of corona ring or any other similar
device, the same shall be deemed to be included in the scope of the Supplier.
8. Spacers
General
Spacers shall conform to IS 10162. Spacers are to be located at a suitable spacing to limit the
short circuit forces and also to avoid snapping of sub conductors during short circuit
conditions.
No magnetic material shall be used in the fabrication of spacers except for GI bolts and nuts.
Spacer design shall be made to take care of fixing and removing during installation and
maintenance.
The design of the spacers shall be such that the conductor does not come in contact
with any sharp edge.
SECTION-IV
S.NO.
DESCRIPTION
PAGE NO.
1.
2.
3.
4.
5.
SCOPE
STANDARDS
MATERIALS AND DESIGN
GALVANISING
ACCESSORIES FOR CONDUCTOR AND GROUND WIRE
52
52
53
53
54
6.
VIBRATION DAMPER FOR ACSR PANTHER, ZEBRA, MOOSE

AND GROUND WIRE
54
7.
REPAIR SLEEVE FOR ACSR PANTHR, ZEBRA, MOOSE AND

GROUND WIRE
54
8.
9.
10.
11.
12.
13.
SUSPENSION CLAMPS : FOR GROUND WIRE

55
TENSION CLAMPS (DEAD AND ASSEMBLY) FOR GROUND WIRE 56
BONDING PIECES
56
INSULATORS HARDWARE
56
CLAMP
57
TESTS, TEST CERTIFICATE AND PERFORMANCE REPORTS
58
HARDWARES
TECHNICAL SPECIFICATION FOR HARDWARE

FITTINGS.
SUITABLE FOR GALVANISED STEEL STRANDED GROUNDWIRE
(7/3.15mm and 7/3.66 mm) ACCESSORIES AND POWER
CONDUCTOR ACSR PANTHER ,ACSR ZEBRA AND MOOSE.
1.0 SCOPE
This Specification covers design (if required), manufacture, testing at manufacturers
Works, supply and delivery of GSS), power conductor and ground wire accessories,
insulator and hardware fittings for string insulators suitable for use in 220 and 132 KV
Over-head transmission lines and sub-stations of OPTCL. The hard wares to be
supplied shall be as per approved drawings of OPTCL. Any change there of shall be
with due permission of Sr. G.M (CPC).The firm shall submit his drawings for approval
of OPTCL and only after which the manufacturing shall be started.
The materials/equipment offered, shall be complete with all components, which are
necessary or usual for the efficient performance and satisfactory maintenance. Such
part shall be deemed to be within the scope of contract.
2.0 STANDARDS
i)
The materials covered under this Specification shall comply with the requirement of the
latest version of the following standards as amended upto date, except where specified
otherwise.
IS;2486 Part-II & III
: Insulator fitting for overhead power lines with a
nominal voltage greater than 1,000 volts.
ii)
IS:2121 Part I & II
Conductor & earth wire accessories for overhead

power lines.
iii)
IS:9708
Stock Bridge Vibration Dampers on overhead

power lines.
iv)
IS:2633
Method of testing of uniformity of coating on zinc

coated articles
v)
IS:209
Specification for Zinc.
vi)
BS:916
Specification for Hexagonal bolts and nuts.
3.0 MATERIALS AND DESIGN

Aluminium and aluminium alloys, malleable iron and forget steel, having required
mechanical strength, corrosion resistance and mach inability depending on the types of
application for which accessories / fittings are needed, shall be employed.
In manufacturer of the accessories / fittings, the composition of the aluminium alloys
used shall be made available to Employer if required for verification.
The materials offered shall be of first class quality, workmanship, well finished and approved
design. All castings shall be free from blow-holes, flaws, cracks of other defects and shall be
smooth, close grained and true forms and dimensions. All machined surfaces should be free,
smooth and well finished.
Metal fittings of specified material for conductor and earth wire accessories and string insulator
fittings are required to have excellent mechanical properties such as strength, toughness and
high resistance against corrosion. All current carrying parts shall be so designed and
manufactured that contact resistance is reduced to the minimum.
All bolts, nuts, bolt-heads shall be the white worths standard thread. Bolt heads and nuts shall
be hexagonal. Nuts shall be locked in an approved manner. The treads in nuts and tapped holes
shall be cut after galvanising an shall be well fabricated and greased. All other treads shall be
cut before galvanising. The bolt treads shall be undercut to take care of increase in diameter
due to galvanising.
All nuts shall be made of materials to Clause 4.8 of IS:1367 (latest edition) with regard to its
mechanical properties.
The general design conductor and earthe wire accessories and insulator fittings shall be such
as to ensure uniformity, high strength, free from corona formation and high resistance against
corrosion even in case of high level of atmosphere pollution.
All hooks, eyes, pins, bolts, suspension clamps and other fittings for attaching to the tower or
to the line conductor or to the earthwire shall be so designed that the effects of vibration, both
on the conductor and the fittings itself, are minimized.
Special attention must be given to ensure smooth finished surface throughout. Adequate
bearing area between fittings shall be provided and point or line contacts shall be avoided.
All accessories and hardwares shall be free from cracks, shrinks, slender air holes, burrs or
rough edges.
The design of he accessories and hardwares shall be such as to avoid local corona formation or
discharge likely to cause interference to tele-transmission signals of any kind.
4.0 GALVANISING :
All ferrous parts of conductor and ground wire accessories and insulator
hardwares shall be galvanised in accordance with IS:2629-Recommended Practice for
hot dip galvanising of iron and steel or any other equivalent authoritive standards. The
weight of zinc coating shall be determined as per method stipulated in IS:2633 for
testing weights, thickness and uniformity of coating of hot dip galvanished articles or as
per any other equivalent authoritative standards. The zinc used or galvanisation shall
conform to grade zn 98 of IS:209. The galvanised parts shall withstand four (4) dips of
1 minute each time while testing uniformity of zinc coating as per IS:2633.
Spring washers shall be elctro galvanised.
5.0 ACCESSORIES FOR CONDUCTOR AND GROUND WIRE,
MID SPAN COMPRESSION JOINTS:FOR ACSR- PANTHER ,ZEBRA,

MOOSE AND GROUNDWIRE OF 7/3.15 and 7/3.66 mm.
The Mid-Span Joints for conductor and earthwire shall be of compression type. The
conductor mid-span joints shall comprise of outer aluminium sleeve of extruded
aluminium (99.5% purity) and inner sleeve HDG Steel. All filler plug shall also be
provided. The ground wire mid-span joints shall be of HDG steel. The sleeves shall
be of circular shape suitable for compression into hexagonal shape.
The compression type mid-span straight joints shall be suitable for making
joints in the ACSR PANTHER,ZEBRA & MOOSE conductor or in the
galvanised steel stranded ground wire.
The joints shall be so designed that when installed no air space is left within the
finished joints. The joints shall have the conductivity as specified in relevant
Clause.
The joints shall conform to IS:2121 (latest edition) unless specified otherwise.
The details of the joints both suitable for ACSR- Panther,Zebra & Moose and
ground wire are given in the technical particulars.
The inner and outer diameters and lengths of the offered joints before and after
compression shall be clearly shown in the drawings.
6.0 VIBRATION DAMPER FOR ACSR PANTHER,ZEBRA

MOOSE AND GROUND WIRE(7/3.15 and 7/3.66 mm)
Vibration Damper having 4 resonance frequency characteristic commonly
called 4R Damper shall be offered. The Damper shall eliminate fatigue on the
conductor due to vibration and damp out the vibration effectively so that no damage
due to vibration is caused to conductor / ground wire / string.
The dampers are proposed to be used at all tension locations and also at
suspension locations. One or more dampers are proposed to be used on
tension/suspension locations depending upon the span.
Bidder shall also recommend the number of damper required to effectively
damp out conductor or ground wire vibration for different values of span lengths
and the distance of fixation.
Vibration dampers shall be of approved design. The clamps of the vibration
dampers shall be made of aluminium alloy, so designed as to prevent any damage
while fixing on the conductor during erection or in continued operation. The
fastening bolts should be approved by the Employer. The spring washers should be
elctro galvanised and of minimum 2 mm thickness.
The messenger cable shall be made from high tensile strength steel strands in order
to prevent subsequent drop of weight in service.
Clamping bolts shall be provided with self locking nuts as designed to prevent
corrosion of the threads. All ferrous parts including the messenger cable shalal be
bot dip galvanised. The end of the messenger cable shall be effectively sealed to
prevent corrosion.
The vibration dampers and its attachment shall have smooth surface so that no
corona occurs on them.
The clamps of the stock bridge vibration dampers shall be so designed that in
case of loosening of the bolt or changing free parts of the clamp, it does not allow
the damper to disengage from the conductor.
7.0
REPAIR SLEEVE FOR ACSR PANTHER,ZEBRA,MOOSE AND

GROUNDWIRE :
Compression type repair sleeves shall be offered to provide reinforcement for
conductor with broken or damaged aluminium strands/galvanished steel ground wire
broken in damaged steel strands. The repair sleeve shall be designed to make good a
conductor of which not more than one-sixth (1/6th) of the strands in the outermost layer
and damaged or severed. The repair sleeves after compression should present a smooth
surface.
8.0 SUSPENSION CLAMPS : FOR GROUND WIRE

Suspension clamps of suitable size are require for holding the galvanised steel
stranded ground wire at suspension points. The suspension clamps shall be
suspended from the lower hanger or D belt of 16 mm. dia. And should, therefore,
be supplied with a suitable attached that would allow the clamps to swing freely
both in the transverse and longitudinal direction. The clamps shall be so designed
that the effect of vibration both on the groundwire and the fittings itself is
minimum.
The clamps shall be manufactured and finished so as to avoid sharp radia of
curvature, ridges which might lead to localized pressure and damage the ground
wire in service.
The clamps shall be made of heat treat malleable iron one Eye hook made of
forced steel. The entire assembly shall be hot dip galvanised.
The clamping surface shall be smooth and formed to support the groundwire on
long easy curves to take care or required steel vertical and horizontal angles.
The clamps shall permit the groundwire to slip before the failure of the latter
occurs. The leg of U-bolt holding the keeper piece of the clamps shall be kept
sufficient long and shall be provided with threads, nuts and locking nuts for fixing
the flexible earthing hond between the suspension clamps and tower structures.
9.0 TENSION CLAMPS (DEAD AND ASSEMBLY) FOR

GROUND WIRE.
Compression type dead end assembly of G.S.S. ground wire shall be required
for use on the tension towers. The dead end assembly shall be supplied with
complete jumper terminals, nuts and bolts suitable link pieces between the steel
clevis and tower strain plates so as to provide sufficient flexibility not less than that
of G.S.S. ground wire and the tensile strength not less than 90% that of the G.S.S.
ground wire.
The assemblies shall comprise of compression type dead end clamps and one
anchor shackle made of forget steel. The entire assembly shall be hot dip
galvanised.
One of bolt holding joint per terminal of dead end assemblies shall be kept
sufficiently long and threaded and shall be provided with nuts, washers and locking
nuts for fixing the flexible earthing bond between the dead-end clamp and tower
structures.
10.0 BONDING PIECES (FLEXIBLE COPPER EARTHING

BOND FOR EARTHWIRE 7/3.15 and 7/3.66 mm)
The tenderer shall offer flexible copper earthing bonding pieces for connecting
the ground wire suspension and tension clamps and tower legs suitable for earthing.
Each bond piece shall have suitable compression type galvanises steel lug or
thimble on either and for making connections to clamp and tower legs. The size,
strength, etc. of the bonding piece is given in this Specification.
11.0 INSULATOR HARDWARES

The insulator disc hardwares and string assemblies to be offered by the tenderer
shall be suitable to meet the requirement given in the specific technical particulars as
detailed hereinafter.
Hardwares for suspension and tension insulator shall be suitable for insulator with
normal pin shank diameter of 20 mm. in case of tension string unit and 16mm. for
suspension string unit.
Each insulator string shall generally include the following hardware components.
Single Suspension Set.
Double Suspension Set.
a) Ball Hook
a) Ball Hook.
b) tower side arcing horn
b) Socket clevis with R-Type security

clip-3 Nos.
c) Socket Eye with R-Type security c) Yoke Plate-2 Nos.

clip.
d) Line side arcing horn.
d) Tower side arcing horns-2Nos.
e) Armour grip suspension clamps
e) Ball clevis 2 Nos.

f) Line side arcing homs-2 Nos.
g) Clevis Eye.
h) Armour Grip Suspension Clamp.
Single Tension Set :

a) Anchor Shackle.
Double Tension Set :

a) Anchor Shackle.
b) Ball Eye.
b) Chain Link.
c) Tower side arcing horn.
c) Yoke Plate 2 Nos.
d) Socket Clevis with R-Type d) Tower side arching horn.

security clip.
e) Line side arcing horn
e) Ball Clevis 2 Nos.
f) Compression type dead end f) Socket Clevis with

clamp.
security clip 2 Nos.
R-Type
g) Line side arcing horns.

h) Compression
clamps.
type
dead
end
12.0 CLAMP
12.1 ARMOUR GRIP SUSPENSION CLAMPS
Armour Grip Suspension Clamp shall consist of 2 neoprene insert, one set of armour
rods made of aluminium alloy, two aluminium housing having inner profile matching with the
profile of the armour rods page and supporting strap made of aluminium alloy. The A.G. type
suspension clamp shall be designed, manufactured and finished as to have a suitable shape
without sharp edges at the end and to hold the respective conductor properly. It should,
however, have sufficient contact surface to minimise damagedue to fault current. The clamp
shall be or Armour Grip Type.
The A.G. type suspension clamp shall permit the conductor to slip before the
occurrence of failure of the conductor and shall have sufficient slip strength to resist the
conductor tension under broken wire conditions. The clamp shall have slip strength of not less
than 15 % of respective conductors.
12.2 TENSION CLAMPS
The Tension Clamps shall be made out of aluminium alloy and of compression type
suitable for PANTHER,ZEBRA & MOOSE conductor. The tension clamps shall not permit
slipping or damage to failure of the complete conductor or any part thereof at a load less than
90% of the ultimate strength of conductor. The mechanical efficiency of tension / clamps shall
not be affected by method of erection involving come / along or similar clamps or tension
stringing operation during or after assembly and erection of tension clamp itself. The tension
clamp shall be of a design that will ensure unrestricted flow of current without use of parallel
groove clamps.
The clamps shall be as light as possible.
12.3 ARCING HORNS
Each hardware assembly shall have provision for attaching arcing horns of both
adjustable and non/adjustable type across the suspension and tension strings or tower side.
However each hardware assembly shall be provided with arching horn of fixed type on line
side only.
12.4 UNIVERSAL JOINTING COMPOUND
BENDEX-HV Universal jointing compound which is a chemically inert compound to be
used as filler for the compression joints and dead end clamps to be supplied.
13.0 TESTS,
REPORTS
TEST
CERTIFICATE
AND
PERFORMANCE
The fittings and accessories for the power conductor and G.S.S. ground wire, insulator and
hardwares shall be tested in accordance with IS:2121, IS:2486, IS:9708 (For V Dampers),
BS:916 for hexagonal bolts and nuts or any other authoritative equivalent standards. Six sets of
type and routine test certificates and performance reports are to be submitted by the bidder.
The Employer however, reserves the right to get all the tests performed in accordance with the
relevant I.S. Specification as Acceptance Test in presence of Employer-s representatives.
The tenderer shall clearly state the testing facilities available in the laboratory at his Works and
his ability to carry out the tests in accordance with this Specification. All the specified tests
shall be carried out without any extra cost.
Acceptance Test for power conductor and G.S.S. ground wire accessories.
a)
Visual examination
b)
Dimensional verification
c)
Failing load test
d)
Slip strength test (for clamps)
e)
Electrical resistance test
f)
Resonance frequency test (for vibration dampers)
g)
Fatigue test (for vibration dampers)
h)
Mass pull off test (for vibration dampers)
i)
Galvanising test.
13.1 ACCEPTANCE TEST FOR HARDWARES

a)
b)
c)
d)
Dimensional verification.
Ultimate tensile test.
Slip strength test.
Electrical resistance test.
e)
f)
g)
Heating cycle test

Breaking strength of full string assembly.
Galvanising test.
13.2 SPECIFIC TECHNICAL REQUIREMENTS FOR CONDUCTOR

ACCESSORIES AND INSULATOR HARDWARES
Conductor
a) Type
Panther/zebra/Moose
ACSR Panther/zebra/Moose
b) Material
Aluminium
reinforced.
c) Strand &
diameter.
conductor
steel Galvanised
steel wire.
Wire Panther/Zebra/Moose
Aluminium 30/3mm
Steel 7/3mm,/all.54/3.18mm
steel-7/3.18mm,/
all.54/3.53mm
steel-7/3.53mm
resp.
d) Weight per Km.
974/1622 /2004Kg/Km.
e) Overall diameter
21/28.62/31.7 mm
f) D.C. Resistance at 0.13750/0.06915/0.05552

20 deg. C when Ohms/KM.
corrected
to
standard weight.
g) Minimum
Breaking
load/Ultimate
tensile strength.
stranded
7/3.15 mm. and 7/3.66

mm
426
Kg/Km.and
583Kg/Km
9.4mm. and 10.98 mm
3.375 Ohms/KM
144/13289/16120 Kg
5710 Kg.and 10580 Kg
3806/4325 Kg.
h) Maximum
working tension at
minimum
temperature & 2/3
full wind.
i) Maximum Sag at 6120/9240 mm.
maximum
temperature & no
wind.
GSS ground wire

Ground wire.
1393 Kg.
5150mm.
DISC Insulator (for suspension & tension Insulator strings) (132 ,220 and 400 KV)
Disc Insulators
a) Type
b) Ball size
c) Diameter
d) Spacing
e) E.M. strength
Suspension
Ball & Socket
16mm. Alt. B
(IS:2486 Pt.II)
254/255 mm.
146/145 mm.
90/120 KN,.
Single
Suspension
132 KV / 220 KV /400 KV
String Arrangements :
a) No. of insulator discs. 10/14/25
b) Length
of
string
assembly (mm)
1672/2340
Single
Tension
10/14/25
1851/3003
Tension
Ball & Socket.
20mm. Alt. B/20mm
(IS:2486 Pt.II)
255/280 mm
145/170mm.
120/160 KN.
Double
Suspension
Double
Tension
2x10/2X14
/2X25
1837/2243
2x10/2X14/
2X25
2132/3082
GENERAL REQUIREMENT FOR POWER

CONDUCTOR & GROUND WIRE:
I) ACCESSORIES.
GENERAL REQUIREMENTS
POWER CONDUCTOR AND GROUND WIRE ACCESSORIES
A)
MID-SPAN COMPRESSION JOINTS

Suitable
for
ACSR Suitable
for
G.S.S.
Panther/zebra/Moose
i) Type
Compression
groundwire 7/3.15
7/3.66 mm.
Compression
ii) Material
a) Outer sleeve
Extruded
Aluminium
Extruded
aluminium.
b) Inner sleeve
Steel (galvanised)
Steel (Galvanised)
Before
Compression
After
Compression
iii) Dimension
of
Compression
joint
for
Aluminium
part.
Outer
dia:38mm
Inner
Dia:23mm.
Minimum
length
:
610mm.
Minimum
weight
1.2
kg.
(approx)
Adjacent
Size 32
mm.
Diagonal
Size
:
37nn.
iv) Dimension
of
compression
joint for Steel
Part
Outer
dia:18mm
Inner dia. 9.3
mm Adjacent
Size
:
15.1mm
Minimum
Length
:
203mm.
Minimum
weight
:
0.28Kg (app.)
Adjacent
size
:
15.1mm.
10mm.
Minimu
m
v)
Minimum 95%
of
failing load.
ultimate
tensile
strength of
conductor
Before
Compression
and
After
Compressi
on
Adjacent
Outer
Size
:
dia.18mm.
Inner dia : Diagonal
size : 17.4mm
Length
203mm.
95%
of
ultimate
tensile
strength of
groundwir
e
vi)
Electrical 75%
of
resistance
20 measured
Deg. C
resistance
of
the
equivalent
length
of
conductor.
vii) Galvanising
:
Hot-dip
galvanised
(HDG)
a) Ferrous
Parts.
b) No.of dips 4 4 dips

dips
for
1
minute
withstand.
viii)
Minimum
Corona
formation
voltage
Hot
dip
galvanised
.
4 dips
110% of maximum
line to ground
voltage
B) VIBRATION DAMPERS:
(SUITABLE FOR ACSR CONDUCTOR: PANTHER/ZEBRA /MOOSE
AND G.S.S. GROUND WIRE 7/3.15 and 7/3.66 mm.
i)
ii)
iii)
Type : 4R Stock Bridge Type

Distance between conductor : 74.5 mm. & axis of the Vibration Damper.
Messenger Cable : 130 Kg/mm sq. quality (19 strands)
iv)
v)
vi)
Bolt size : 16 mm. (dia.)

Slip strength of messenger Cable : 500 Kgs.
Mass pull-of : As per I.S.S.
C) REPAIR SLEEVES:
SUITABLE FOR ACSR PANTHER/ZEBRA/MOOSE CONDUCTOR
AND G.S.S. GROUND WIRE.
Suitable
for
ACSR Suitable
for
panther/Zebra/Moose.
Ground wire.
i)
Type
Compression
Compression.
ii)
Material
Extruded aluminium.
Steel
iii)
Min. failing load
95%
of
conductor.
iv)
Length
241/279 mm.
v)
Dimension :
UTS
21mm
a) After compression
(i) Adjacent side
G.S.S.
of 95% of UTS of ground

wire.
200 mm (150 mm. min.)
11.5 mm
(b) Before Compression :

(i)
Outer
diameter 21mm.
38/48mm.
11.5mm.
(ii)
Inner
diameter
23/40mm
vii) Electrical
Resistance at
20 deg. C
Not more than

75% of the resistance of equivalent
length of conductor.
vii) Galvanising :
Hot dip galvanized
a) Ferrous parts
b) No. of dips for
one-minute stand.
4 dips
D) SUSPENSION CLAMP:
FOR GROUND WIRE 7/3.15 and 7/3.66 mm

i)
Type
Envelop type
ii)
Material
Forged Steel / NCL.
iii)
Minimum slip strength : 25% of UTS of ground wire.
iv)
Dimension :
(a)
Overall length
: 230mm
(b) Inner dia. (before

compression).
: 10mm.
(c)
Outer diameter
(before compression).
: 18mm.
(d) After Compression :

Adjacent
Diagonal side
: 15.1 mm.
: 17.4mm.
(e) Galvanising :
(i) Fwerrous parts.
: Hot-dip galvanised.
(ii) No. of dips for oneminute withstand.
: 4 dips
E) BONDING PIECES:
a) material
flexible copper bond (37/7/

0.417 mm. tinned copper flexible stranded cable).
b) Length
Not less than 750 mm.
c) Bolt size
16mm x 40 mm.
d) Copper area.
34 sq.mm.
e) Thickness of long
6 mm.
f) Material for connect ing socket.
Tinned Brass
F) INSULATOR HARDWARES
A)
String hardwares :
Material and strength
Description of item. Material
UTS
i)
Bolt hook
Forged Steel 11,500 Kgs (90 KN)
ii)
Anchor Shackle
-do-
15,500 Kgs (120 KN)
iii)
Socket Eye Horn

Holder.
- do-
11,500 Kgs (90 KN)
iv)
Socket Clevis. -do-
v)
Ball Clevis
-do-
15,500 Kgs.
vi)
Clevis Eye
-do-
15,500 Kgs.
vii)
Socket Eye.
-do-
15,500 Kgs.
vii)
Bottom / Top Yoke plate :
15,500 Kgs.
Double suspension Mild Steel
11,500 Kgs.
Double Tension
-do-
15,500 Kgs.
ix)
Arcing Horn
-do-
x)
Suspension Clamp. Aluminium

Alloy and
Neoprene.
xi)
Tension Clamp.
___
___
All.Alloy & 11,500 Kgs.
Steel.
xii)
Ball Pin
High tensile
forged steel
(hot-dip
galvanised)
90% of UTS of
conductor.
xiii)
Security Clip
Brass (R-Type)
Mininum failing load
Single Suspension : 11,500
String (KN)
Single Tension
: 11,500/15,500
Double Suspension : 11,500
Double Tension
: 11,500/15,500
II) CLAMPS.
i) Type
Single
suspension
string
AGS Type
Single tension Double

string
suspension
string
Compression
AGS Type
Type
Double
tension string.
Compression
Type
ii) Material
Aluminium
Alloy and
neoprene
Aluminium
Alloy and
Steel
Aluminium
Ally and
Neoprene
Aluminium
Alloy and
Steel
ii) Minimum
slip strength
Not less than

15%
90% of UTS of Not less than

90% of UTS of
conductor
15% of UTS of conductor
conductor
iv) Minimum
failing load
(kg)
11,500
90% of UTS of 11,500 90%

conductor
Of UTS of
conductor
III).
Suspension assembly: armour grip clamp.
1.
The armour grip suspension clamp shall comprise of retaining strap, support
housing, elastomer inserts with aluminum reinforcements and AGS preformed rod
set.
2.
Elastomer insert shall be resistant to the effects of temperature up to 85 deg. C,

ozone, Ultraviolet radiation and other atmospheric contaminants likely to be
encountered in service. The physical properties of the elastomer shall be of
approved standard. It shall be electrically shielded by a cage of AGS preformed rod
set. The elastomer insert shall be so designed that the curvature of the AGS rod
shall follow the contour of the neoprene insert.
3.
The AGS preformed rod set shall be as detailed above in general except that the
length of the AGS preformed rods shall be such that it shall ensure sufficient
slipping strength and shall not introduce unfavourable stress on the conductor
under all operating conditions.
IV)
Fasteners: bolts, nuts & washers.
1.
All bolts and nuts shall conform to IS-6639 1972. All bolts and nuts shall be
galvanized. All bolts and nuts shall have hexagonal heads, the heads being truly
concentric, and square with the shank, which must be perfectly straight.
2.
Bolts upto M16 and having length upto ten times the diameter of the bolt should be
manufactured by cold forging and thread rolling process to obtain good and
reliable mechanical properties and effective dimensional control. The shear

strength of bolt for 5.6 grade should be 310 Mpa minimum as per IS-12427. Bolts
should be provided with washer face in accordance with IS-1363 Part-I to ensure
proper bearing.
3.
Fully threaded bolts shall not be used. The length of the bolt shall be such that the
threaded portion shall not extend into the place of contact of the component parts.
4.
All bolts shall be threaded to take the full depth of the nuts and threaded enough to
permit the firm gripping of the component parts but not further. It shall be ensured
that the threaded portion of the bolt protrudes not less than 3 mm and not more
than 8 mm when fully tightened. All nuts shall fit and be tight to the point where
shank of the bolt connects to the head.
5.
Flat washers and spring washers shall be provided wherever necessary and shall be
of positive lock type. Spring washers shall be electro-galvanized. The thickness of
washers shall conform to IS-2016-1967.
6.
The bidder shall furnish bolt schedules giving thickness of components connected,
the nut and the washer and the length of shank and the threaded portion of the bolts
and size of holes and any other special details of this nature.
7.
To obviate bending stress in bolt, it shall not connect aggregate thickness more
than three time its diameter.
8.
Bolts at the joints shall be so staggered that nuts may be tightened with spanners
without fouling.
9.
Fasteners of grade higher than 8.8 are not to be used and minimum grade for bolts
shall be 5.6.
GENERAL:
1.
All ferrous parts including fasteners shall be hot dip galvanized, after all machining
has been completed. Nuts may however be tapped (threaded) after galvanizing and
the threads oiled. Spring washers shall be electro-galvanized. The bolt threads shall
be undercut to take care of the increase in diameter due to galvanizing. Galvanizing
shall be done in accordance with IS-2629-1985 and shall satisfy the tests
mentioned in IS 2633-1986. Fasteners shall withstand four dips while spring
washers shall withstand three dips of one-minute duration in the standard Preece
test. Other galvanized materials shall be guaranteed to withstand at least six
successive dips each lasting one minute under the Standard Preece test for
galvanizing.
2.
The zinc coating shall be perfectly adherent of uniform thickness, smooth,

reasonably bright, continuous and free from imperfections such as flux, ash, rust
stains, bulky white deposits and blisters. The zinc used for galvanizing shall be of
grade Zn 99.95 as per IS 209-1979.
3.
Pin balls shall be checked with the applicable G) gauges in at least two
directions, one of which shall be across the line of die flashing and the other 90
deg. to this line. NO GO gauges shall not pass in any direction.
4.
Socket ends, before galvanizing shall be of uniform contour. The bearing surface
of socket ends shall be uniform about the entire circumference without depressions
or high spots. The internal contours of socket ends shall be concentric with the axis
of the fittings as per IS 2486/IEC-120. The axis of the bearing surfaces of socket
ends shall be coaxial with the axis of the fittings. There shall be no noticeable
tilting of the bearing surfaces with the axis of the fittings.
5.
All current carrying parts shall be so designed end manufactured that contact
resistance is reduced to minimum.
6.
Welding of aluminum shall be by inert gas shielded tungsten are or inert gas,
shielded metal arc process. Welds shall be clean, sound, smooth, and uniform
without overlaps, properly fused and completely sealed. There shall be no cracks,
voids incomplete penetration, incomplete fusion, under-cutting or inclusions
Porosity shall be minimized so that mechanical properties of the aluminum alloys
are not affected. All welds shall be properly finished as per good engineering
practices.
Electrical Design:
The normal duty and heavy duty suspension, light duty, normal duty and heavy
duty tension insulator sets shall all comply with the technical requirements of
schedule C and satisfy the test requirements stated in Section-7.
Mechanical design:
The mechanical strength of the insulators and insulator fittings shall be as stated in
Schedule-C
The design shall be such that stresses due to expansion and contraction in any part
of the insulator shall not lead to the development of defects.
Insulating material shall not engage directly with hard metal. All fixing materials shall
be of approved quality, shall be applied in an approved manner and shall not enter into
chemical action with the metal parts or cause fracture by expansion in service. Where
cement is used as a fixing medium, cement thickness shall be as small and even as
possible and proper care shall be taken to correctly centre and locate the individual
parts during cementing.
Technical Specification for Design, Supply and Testing of Hard ware fittings.
Type tests:
The following type tests shall be conducted on hardware fittings.
A. On suspension hardware fittings only.
(a)
(b)
(c )
(d)
B.
Magnetic power loss test.

Clamp slip strength Vs torque
Mechanical strength test.
On one test on elastomer.
On Tension hard ware fittings only.

Electrical resistance test for
Dead end assembly.
IS 2486 (Part-I) 1971
(a) Heating cycle test for

dead end assembly.
-do-
(b) Slip strength test for

dead end assembly.
IS 2486 (Part-I)
(c ) Mechanical strength test.

C. On both suspension and tension hardware fittings.
(a) Visual examination.
IS-2486 (Part-I) 1971
(b) Verification of dimension.
-do-
(c ) Galvanizing / electroplating test.
-do-
(d) Mechanical strength test of each component

(including corona control ring/grading ring and arcing horn)
(e) Mechanical strength test of welded joint.
(f) Mechanical strength test for corona control ring/
grading ring and arcing horn.
BS-3288 (Part-I)
(g) Test on locking device for ball and socket coupling.
IEC 3721984
(h) Chemical analysis, hardness tests, grain size,

inclusion rating and magnetic particle inspection for forging/casting.
D. On suspension hardware fittings only.
(a) Clamp slip strength ver as torque test for suspension clamp.
(b) Shore hardness test of elastomer cushion for AG suspension clamp.
(c) Bend test for armour rod set.
IS-2121 (Part-I)
(d) Resilience test for armour rod set.
-do-
(e) Conductivity test for armour rod set.
-do-
E. On tension hardware fittings only
MID SPAN COMPRESSION JOINTS

FOR CONDUCTORS.
Weight of the joint.
Slipping strength.
Resistance of the completed joint.
Materials of the joints specify alloy type and
its aluminum contents.
Before compression dia of sleeve.
(a) Inner diameter.
(b) Outer diameter.
Dimensions after compression.
(a) Corner to corner.
(b) Surface to surface.
Length of the sleeve.
(a) Before compression.
(b) After compression.
Compression pressure.
Whether designed for intermittent or
continuous compression.
Minimum corona extinction voltage under
dry condition.
Radio interference voltage under conditions.
Unit.
37/4.00
mm2
Kg.
KN
Ohms.
1.27
129.6
0.000027
6201
mm
31+/-0,5
48+/-1.0
mm
46+/-0.5
40+/-0.5
mm
Kv
500+/-5.0
540+/-5.0
100
Continuous
compressio
n.
154
Micro
Below 1000
Tone
volt.
REPAIR SLEEVE FOR CONDUCTOR
Weight of the sleeve.
Before compression dia of sleeve.
(a) Inner diameter.
(b) Outer diameter.
Dimensions after compression.
(a) Corner to corner.
(b) Surface to surface.
Length of sleeve.
(a) Before compression.
(b) After compression.
Compression pressure.
dry condition.
Radio interference voltage under condition.
(a) Slip strength test for dead end assembly.
Kgs.
0.63
mm
mm
31.05
48.10
mm
mm
48.05
40.05
mm
mm
Tone.
Kv.
279.50
300.50
100
154
Microvolt.
IS-2121 (Part-I)
Below 1000
All the acceptance tests stated at clause shall also be carried out on composite insulator
unit, except the eccentricity test at clause. In addition to these, all the acceptance tests
indicated in IEC 1109 shall also be carried out without any extra cost to the employer.
F. For hardware fittings.
(a) Visual examination.
IS-2121 (Part-I)
(b) Proof & test.

G. Tests on conductor accessories.
H. Type tests.
I.
Mid span compression joint for conductor and earthwire.
(a) Chemical analysis of materials.

(b) Electrical resistance tests.
& 6.6
IS-2121 (Part-II) 1981 clause 6.5
(c) Heating cycle test.
-do-
(d) Slip strength test.
-do-
(e) Corona extinction voltage test (dry)
(f) Radio interference voltage test (dry)

J. Repair sleeve for conductor.
(a) Chemical analysis of materials.
VIBRATION DAMPER FOR CONDUCTOR.

Vibration Damper for AAC
37/4.00 mm
Total weight of the damper.
Unit.
Weight of each damper mass.

Resonance frequencies.
1. First frequency.
2. Second frequency.
Kgs.
Hz
Hz
12+/- 1
28+/- 2
Dimension of each damper mass.

Material of:
1. Damper miss.
2. Messenger cable.
Mm
55 Ox165
Ox195
No. of strands in messenger

cable strands.
Lay ratio of messenger cable
strands.
Min
tensile
strength
of
messenger cable.
Miss pull-off strength.
Clamping forque.
Slipping strength of the damper
clamp.
1. Before fatigue test.
2. After fatigue test.
Magnetic power loss per
vibration damper.
Min. corona extinction voltage
under dry conditions.
Radio interference voltage under
dry condition 1MHz, at 154 KV.
Percentage variation in reactance
after fatigue test in compassion
with that before the fatigue test.
Kgs.
4.5
Left.
1.6
Right.
2.2
18+/- 2
36+/- 2
60
Cast iron hot dip

galvanized.
High tensile galvanized
steel wire.
19
9-11
Kg./
Sq.mm
KN
Kg.m
KN
135
5
7
2.5
2.0
Watts.
1 watt at 500 amps.
Kv.
154
Microvolt.
Below 1000
20
SECTION V
S.NO.
DESCRIPTION
PAGE NO.
(A)TECHNICAL SPECIFICATION FOR CLAMPS & CONNECTORS

1.
2
3.
4.
5.
6.
7.
8.
SCOPE
STANDARDS
MATERIAL AND WORKMANSHIP
RATING
EQUIPMENT CONNECTORS
TEMPRATURE RISE
WEIGHTS
INTERCHANGE ABILITY
75
75
75
76
76
77
77
77
(B)TECHNICAL SPECIFICATION FOR ACSR BUS-BAR

1.
2.
3.
4.
5.
6.
SCOPE
MATERIALS
MECHANICAL CHARACTERISTICS
DIMENSIONAL TOLERANCE
CHEMICAL COMPOSITION
ELECTRICAL & MECHANICAL CHARACTERISTICS
AND CURRENT RATINGS
77
77
77
78
78
78
CLAMPS AND CONNECTORS

(A)
TECHNICAL SPECIFICATION FOR CLAMPS & CONNECTORS
1.
SCOPE
This specification covers design, manufacture, assembly, testing at manufacturers
works, supply and delivery at site of all terminal connectors of 220,132 & 33KV
equipments (mainly breaker, isolator, CT,PT,CVT,BPI and LA) and all other clamps
and dropper connectors required for the switch yard as per approved lay out and system
design.
2.
STANDARDS
The terminal connectors under this specification shall conform strictly to the
requirements of the latest version of the following standards as amended up-to-date,
except where specified otherwise.
i)
ii)
IS: 5561
Power Connectors.
IS:617 Aluminium & Aluminium Alloy
iii)
IS: 2629
Recommended Practice for hot dip galvanizing of
iron and steel.
iv)
IS: 2633
Method of testing uniformity of coating of zinc
coated articles.
The materials conforming to any other authoritative standards which ensure equal or
better performance shall also be acceptable. The salient point of these specifications
and points of difference between these and the above specifications, shall be clearly
brought out in the bid.
3.
MATERIAL & WORKMANSHIP

The terminal connectors shall be manufactured from Aluminium Silicon Alloy and
conform to designation A6 of IS: 617 (latest edition)
The connectors shall be of best quality and workmanship, well finished and of
approved design. Specific materials for clamps and connectors should have high current
carrying capacity, high corrosion resistance and be free from corona formation.
All connectors or its components to be connected with ACSR conductor shall be of
compression type having aluminium purity not less than 99.5%.
All bus bar clamps shall be made preferably from forged aluminium of purity not
less than 99.5%. The thickness and contact surface should be maintained in such a way
that the clamp should conform to IS:5561/1970 or any latest revision thereof.
4.
RATING
The connector rating shall match with the rating of the respective equipments for the
terminal connectors and the connectors for bus bar and dropper should be of the
following rating. Minimum thickness at any part of connector shall be 10(ten)mm.
Indicative ratings are given below:
Rating
220 / 132 KV
1. Main bus bar connectors high level and

low level (Amps)
2.
High level bus sectionalisation
isolator(Amps)
3.
Connectors along the bay (Amps)
4.
Terminal connectors for CB(Amp.)
5.
-do- for Isolator(Amps)
6.
-do- for CT
7.
-do- for PI
8.
-do- for LA
9.
-do- for PT
10.
-do- for CVT
11.
-do- for WT
5.
2000
2000
800
2000
2000
As per CT rating
As per PI rating
As per LA rating
As per PT rating
As per CVT rating
As per WT rating.
EQUIPMENT CONNECTORS
Bimetallic connectors shall be used to connect conductors of dissimilar metal. The
following bimetallic arrangement shall be preferred.
i)
ii)
copper clodding of minimum 4 mm. thickness on the aluminium portion of

connector coming in contact with the copper palm or stud of the equipment.
alternatively, to provide cold rolled aluminium copper strip between the
aluminium portion of the connection, the sheet thickness shall not be less than 2
mm.
Sufficient contact pressure should be maintained at the joint by the provision of the
required number of bolts or other fixing arrangements, but the contact pressure should
not be so great as to clause relaxation of the joint by cold flow, the joint should be such
that the pressure is maintained within this range under all conditions of service, to avoid
excessive local pressure, the contact pressure should be evenly distributed by use of
pressure plates, washers or suitable saddles of adequate area of thickness should be less
than that of an equal length of conductor where measured individually test results
showing the milli drop test and resistance should be enclosed with the bid.
All connectors shall be so designed and manufactured as to offer ease of

installation as these are to be used in overhead installations, design shall be such that
full tightening of nuts and bolts should be possible with the use of double wrench.
The connectors shall be such as to avoid local corona, sound or visible discharge.
6.
TEMPRATURE RISE
The temperature rise of connectors when carrying rated current shall not exceed
45 C above reference design temperature of 50 C.
i)
Acceptance Tests
(a) Tensile Test
(b) Temperature rise test
Temperature rise test

ii)
Routine Test
(a) Visual Inspection
(b) Dimensional Check
Type test reports from a recognized laboratory shall have to be submitted.
7.
WEIGHTS
Weights of different materials uses in manufacture, such as aluminium, silicon,
copper etc. should be clearly indicated in the bid.
8.
INTERCHANGE ABILITY
Corresponding parts of similar clamps and connectors shall be made to gauge or
jig and shall be interchangeable in every respect.
(B)
TECHNICAL SPECIFICATION FOR ACSR BUS-BAR
1.
SCOPE
The specification covers design, engineering, manufacture, testing at manufacturers works,

supply and delivery of heavy duty ACSR bus-bar for use in 220 KV and 132 kV substation.
2.
MATERIALS
The ACSR bus bar shall be drawn by using MOOSE/ZEBRA as per system requirement.
The strung ACSR bus-bar shall be of heavy duty type and design to operate within set
temperature limits and to withstand thermal and electromechanical forces developed
due to short circuits.
3.
MECHANICAL CHARACTERISTICS
The mechanical strength of the strung ACSR bus-bar shall be limited to be maximum
allowable tension for specific size of conductor as per ISS.
4.
DIMENSIONAL TOLERANCE
Dimensional tolerances shall be as per relevant ISS.

5.
CHEMICAL COMPOSITION
The chemical composition for ACSR conductors (MOOSE/ZEBRA) shall be holding good
under all operating condition.
6.
ELECTRICAL & MECHANICAL CHARACTERISTICS AND CURRENT

RATINGS
Electrical and mechanical characteristics and current ratings for ACSR bus-bar shall be same
as stipulated for MOOSE/ZEBRA ACSR conductors, the details of which has been
specified.

CONTROL AND RELAY PANEL
E21-CONTROL & RELAY PANEL- Page 1 of 67
CONTROL AND RELAY PANELS

protection and control panels
1.0 Panels
General
Simplex and/or duplex panels shall be provided to suite the substations site. Bidder shall be fully
responsible for his bids to match the dimensions, colour and fittings with those in the existing
control rooms where the extensions are required. In no case any proposal for increase in price at a
later date shall be entertained by the Employer. However panels not matching those already
installed may be acceptable to the Project Manager. Specific approvals will be required on a case
by case basis.
Panels shall be free standing mounted on floors fitted with embedded channels, insert plates or
foundation bolts. The panels shall be made vibration and shock proof by providing anti vibration
strips.
The base frame of all panels shall have a smooth bearing surface such that when fixed on the
embedded foundation channels/insert plates it shall be free standing and provide a level surface.
The panels shall be completely metal enclosed, dust, moisture and vermin proof. The enclosure
shall provide a degree of protection not less than IP-31 in accordance with IS 13947
The design, materials selection and workmanship shall be such that it provides a neat appearance
both inside and outside without signs of welds, rivets or bolt heads from outside. The exterior
surfaces shall be smooth and sleek.
Relay panels of modern modular construction in 19 inch hinged racks would also be acceptable.
Cable entry to the panels shall be from the bottom. The provision of all cable glands and shrouds
of the panel shall be part of the scope of supply. Cable gland plate fitted on the bottom of the panel
shall be connected to earthing of the panel/station through a flexible braided copper conductor.
1.1 Simplex Panel

Simplex panels shall be provided with equipment mounted on front panel vertically. The wiring
access shall be from rear for control panels and either from front or rear for relay panels. Where
panel width is more than 800 mm, double leafed doors shall be provided. Doors shall be fitted
with either built-in locking facility or with padlock.
1.2 Duplex Panel

Duplex panels shall be walk-in, tunnel type comprising of two vertical front and rear panels
connected back to back by formed sheet steel roof as tie members and a central corridor in between.
The corridor shall facilitate access to internal wiring and external cable connections. Where a
number of duplex panels are located in a row side by side, the central corridor shall be aligned to
form a continuous passage. Both ends of the corridor shall be provided with double leaf doors with
lift off hinges. Doors shall be fitted with either built-in locking facility or with padlock. Separate
bottom cable entries shall be provided for the front and rear panels. The inter-connections between
front and back panels shall be established by providing wiring at the top of the panel.
1.3 Constructional Features

It is the responsibility of the Contractor to ensure that the equipment specified and such
unspecified complementary equipment required for completeness of the protective/control schemes
can be properly accommodated in the panels without congestion.
Panels shall be free standing, floor mounting type and shall comprise of structural frames
completely enclosed with smooth finished, cold rolled sheet steel of thickness not less than 3 mm
for all weight bearing members such as base frame, front panel, door frames. All other parts may be
provided with 3.0 mm thick steel sheet. There shall be sufficient reinforcement to provide level
surfaces, resistance to vibration and rigidity during transportation and installation.
All doors, removable covers and panels shall be
gasketted all around with neoprene or superior
material. Ventilating louvres, where provided shall have screens and filters. The screens shall be
made of either brass or GI wire mesh.
1.4 Mounting
All equipment on and in panels shall be mounted and completely wired to the terminal blocks
ready for external connections. The equipment on front of panel shall be mounted flush.
Equipment shall be mounted such that removal and replacement can be accomplished individually
without interruption of service to adjacent devices. Equipment shall be readily accessible without
use of special tools. Terminal marking on the equipment shall be clearly visible.
The Contractor shall carry out cut-out, mounting and wiring of all equipment and items which are
to be mounted in his panel. Cut-outs if any, provided for future mounting of equipment shall be
properly blanked off with blanking plates.
The centre lines of switches, push buttons and indicating lamps shall be not less than 750 mm from
the bottom of the panel. The centre lines of relays, meters and recorders shall be not less than 450
mm from the bottom of the panel.
The centre lines of switches, push buttons and indicating lamps shall be matched to give a neat and
uniform appearance. The top lines of all meters, relays and recorders etc. shall be matched.
No equipment shall be mounted on the doors.
All the equipment connections and cabling shall be designed and arranged to minimise the risk of
fire and damage which may be caused by fire.
1.5 Terminal Blocks

Terminal blocks and boards shall conform to the requirements of the relevant sections of this
Specification. De-link type terminal blocks shall be provided in all the circuits and Terminals.
1.6 Supporting steel

All necessary embedded levelling steel, sills, anchor bolts, channels and other parts for supporting
and fastenings the panels and vibration damping shall be supplied by the Contractor.
Instruments, Meters, Recorders and Transducers
2.0 General
All instruments, meters, recorders and transducers shall be enclosed in dust proof, moisture
resistant, black finished cases and shall be suitable for tropical use. All indicating instruments and
recorders shall be digital type and provided with individual transducers and shall be calibrated
along with the transducers to read directly the primary quantities. They shall be accurately adjusted
and calibrated at works and shall have a means of calibrations check and adjustment at site. The
Contractor shall confirm that the indicating instruments, recorders along with transducers and
energy meters offered by him are suitable for connecting to the instrument transformers having the
technical particulars given in reference drawing.
Synchronising Instruments shall also meet the requirements of the relevant clause of this section of
the Specification.
Digital bus voltage and frequency meters shall be of class 0.5 and shall have digital readouts of five
and four digits respectively, with display size, not less than 50 mm (height)
2.1 Metering Instruments

Energy-meters
Energy meters shall be provided on all line feeders, transformer feeders, buscoupler and bus
transfer bays as per the requirements stated in the schedule of requirement of this specification.
On 400/220/132 kV feeders emanating from various substations, where commercial

metering is required redundant energy metering in form of MAIN shall be employed.
All 33 kV feeders emanating from various substations shall be treated as feeders with commercial
metering requirements. Only single energy meters shall be employed.
Energy meters shall be solid state trivector type. The energy meters are intended to measure,
record and display active energy (kWh/MWh), reactive energy (kVARh/MVARh), apparent energy
(kVAh/MVAh), Maximum Demand (MVA/kVA/MW/kW/ etc. They should be of three phase two
element type or three element type suitable for measurement of unbalanced loads in three phase,
three wire circuits. The meters shall be provided with at least six registers for TOD metering
purposes. The meters shall have LCD or cyclometer type registers.
Energy meters shall be of draw out or non-drawout type and suitable for flush mounting
with back connected terminals.
Energy meters shall be suitable for operation from the secondary of CTs and VTs. Separate test
blocks for the testing of the meters (without disturbing the CT and VT secondary connections)
shall be provided.
Energy Meters shall have reverse running stops. Meters shall conform to IEC 687 /IS
13779. All watt-hour meters shall have accuracy class of 0.2. All VARh-hour meters shall have
accuracy class of 3.0. The energy meters shall also conform the requirements stipulated in
Technical Report of Central Board of Irrigation and Power, India.
Energy Meters shall be compensated for temperature errors and factory calibrated to read
the secondary quantities. The number of digits provided shall be adequate to cover at least 1500
hours of operation.
Current coils of the meters shall have continuous overload capacity of at least 200% for
both accuracy and thermal limits, and shall withstand at least 20 times of rated current for 0.5
seconds without loss of accuracy.
Energy meters should have facilities for data transfers remote metering with proper
security via an optically isolated communication port using serial communication. Where
required, output ports shall be provided for summation and time synchronisation.
Energy meters shall be provided with features for monitoring tamper and fraud. The
possible cases of tamper and fraud shall be proposed by the Project Manager to Contractor for
incorporation in to the metering software.
Energy meters should be provided with adequate software and hardware to store the load
survey data from the last reset time. Energy meters shall also be provided with self diagnostic
features.
Technical requirement for energy meters

Description
Operating voltage
Operating current
Measurement
Display
Communication
Table 9.3.2.
Requirement
110V Phase to phase, 65.3V Phase to neutral
15 A
Real and reactive energy
Maximum demand
Bi-directional power flow
Digital type (electronic type). In case of electronic
type of display the minimum retention time for
non volatile memory shall not be less than 5
years
Optical Port / E Port
Technical requirements for energy meters
2.2 Recording instruments

Recording instruments shall have the following characteristics features :
Static/Digital type voltage and frequency recorders in individual units for the sub-station with
time tagged information shall be acceptable. It shall meet the accuracy of +/-:1.0% span and
full span response time of less tha 2 seconds. It shall also meet the high voltage susceptibility
test,impulse voltage withstand test,high frequency disturbance test class III and fast
transient disturbance test leve III as per IEC 602555.
2.3 Transducers
General
The transducers used for recording/indicating instruments and telemetry/data
communication applications shall in general conform to IEC 688-1.
Transducers shall be suitable for measurement of active power, reactive power, voltage,
current and frequency in three phase, four wire system. These could be separate or combined type.
Serial port on combined type is also acceptable.
The input to the transducers will be from substation current and potential transformers. The
output shall be in milli ampere DC proportional to the input. It shall be possible to feed the output
current directly to the telemetry terminals, indicating instruments or recording instruments.
The transducer characteristic shall be linear throughout the measuring range.
The transducer output shall be load independent.
The input and output of the transducers shall be galvanically isolated.
The transducer shall derive its auxiliary supply from the quantity to be measured without
need for any external supply.
Each transducer shall be housed in a separate compact case and have suitable terminals for
inputs and outputs. Input side terminal connectors (from CTs and PTs) to be suitable for three
phase, four wire connection.
The transducers shall be suitably protected against transient high peaks of voltage and
current.
The transducer shall withstand indefinitely without damage and work satisfactorily at 120%
of the rated voltage and 200% of the rated input current as applicable.
Voltage, frequency and current transducers associated with the ISCS shall have an output to
0-10 mA and the active and reactive power transducers shall have an output of 10-0-10 mA.
Voltage, frequency and current transducers associated with conventional systems shall have an
output to 4-20 mA and the active and reactive power transducers shall have an output of 10-0-10
mA.
The response time of the transducers associated with ISCS shall be less than 500
milliseconds. Response time for transducers associated with conventional systems shall be less than
one second.
The transducers shall have a working temperature range of 0-50C.
The accuracy class of transducers shall be 0.5 or better except for frequency transducer
which shall be 0.2.
The transducers shall have an AC ripple on output of less than 1%
The transducers shall be suitable for load resistance of 1000-1500 ohms
The CT and PT ratios and scale ranges for the voltage, current and frequency transducers
shall be suitable for the various CT and PT ratios (as applicable) furnished with the specification
and compatible with the feeder/transformer voltage levels and ratings.
The transducer shall be provided with terminal connectors for wire of maximum cross
section of 4 mm., with dual screws, for rigid connections.
The transducer shall have dual output.
Transducers (recording/indicating instruments and telemetry/data

communication application)
The transducers shall in general conform to IEC 688-1 and have the following features:
Each transducer shall be housed in a separate compact case and have suitable terminals for
inputs and outputs.
The transducers shall have an output of 4-20 mA.

The response time of the transducers shall be less than one second.
The accuracy class of transducers shall be 0.5 or better except for frequency transducer which
shall be 0.2.
The PT ratios and scale ranges for the voltage and frequency transducers shall be as follows:
PT Ratio
Scale range
Voltage transducer :
400kV/110V
0-500kV
220kV/110V
0-300kV
132kV/110V
0-200kV
33kV/110
0-50kV
Frequency transducers : as above
45-55 Hertz.
All the transducers shall be suitable for CT and PT parameters specified.
The transducer shall have dual output.
2.4 Annunciation System:
General
The annunciation shall be of visual and audible type. The visual annunciation shall be provided by
annunciation facia, mounted flush on the top of the control panels. The audible alarm shall be
provided by alarm buzzer or bell.
The annunciation facia shall be provided with translucent plastic windows for alarm points with
minimum size of 35 mm x 50 mm. The facia plates shall be engraved in black lettering with
inscriptions. The list of such inscriptions shall be furnished by the Contractor for the Project
Managers approval. The inscriptions shall be engraved on each window in not more than three
lines with letter sizing not less than 5 mm. Where annunciation systems are already provided, the
annunciation scheme shall be engineered as an extension to the existing scheme.
Each annunciation window shall be provided with two white lamps in parallel to provide safety
against lamp failure. Long life lamps shall be used. The lamp circuit shall include series resistor of
adequate rating. The cover plate of the facia windows shall be flush with the control panel and
shall be capable of easy removal to facilitate replacement of lamps. The cover plate transparency
and the lamps wattage in the facia windows shall be designed to ensure clear visibility of the
inscriptions in the control rooms ( having an illumination level of 350 lux) from the location of the
Operators desk.
TRIP and NONTRIP facia shall be differentiated. All TRIP facia shall have red colour and all
NONTRIP facia shall have green colour.
Sequence of operation of the annunciator shall be as given in Table 10.1.
Alarm Condition
Normal
Abnormal
Accept push button is
pressed
Reset push
Lamp test push button
pressed
Table 10.1.
Fault Contact
Status
Visual
Annunciation
Audible
Annunciation
Open
Close
(a) Close
(b) Open
(a) Close
(b) Open
Open
OFF
Flashing
Steady on
Steady on
ON
ON
Steady on
OFF
ON
OFF
OFF
OFF
OFF
OFF
Sequence of annunciator operation
Visual and audible annunciation for the failure of DC supply to the annunciation system shall also
be provided and this annunciation shall operate on 240 Volts AC supply with separate fuses. On
failure of the power supply to the annunciation system for more than two or three seconds
(adjustable setting) a facia shall light up and an audible alarm shall sound. A separate push button
shall be provided for the cancellation of this audible alarm alone, however the facia window shall
remain steadily lit till the supply to the annunciation system is restored. The sound of the audible
alarm (bell) provided for this annunciation shall be different from the audible alarm provided for
the annunciation system.
A separate voltage check shall be provided to monitor the failure of supply (240V AC) to the
scheme mention above. If the failure of supply exists for more than two to three seconds this relay
shall initiate visual and audible annunciation.
The annunciation system shall be capable of catering to at least 20 simultaneous signals at time.
One self resetting push button shall be provided on each panel for testing the facia window lamps.
Push buttons for testing flasher and audible alarm circuits of the annunciation system and for
testing the annunciation supply failure monitoring circuit shall be provided. These testing circuits
shall be so connected that while testing is being done it shall not prevent the registering of any new
annunciation that may occur during the test.
One set of the following push buttons shall be provided on each panel as shown in the sample front
view drawing attached to this Specification.
Reset push button for annunciation system.
Accept push button for annunciation system.
The annunciation shall be repetitive type and shall be capable of registering fleeting signals.
Minimum duration of the fleeting signal registered by the system shall be 15 milliseconds.
Auxiliary relays for the annunciation system shall have adequate auxiliary potential free contacts
for use in event logger.
The annunciation shall be suitable for operation with normally open contacts which close on a fault
or contacts which open on a fault. It shall be possible at site to change annunciators from close to
fault to open to fault and vice-versa.
In case of a static annunciator scheme, special precautions shall be taken by Contractor to ensure
that spurious alarm conditions do not appear due to the influence of external electro magnetic or
electrostatic interference on the annunciator wiring, and switching disturbances from the
neighbouring circuits within the panels.
Annunciation systems to be supplied for existing substations should be matched with the existing
scheme in co-ordination with the Project Manager during detail engineering stage.
2.5 PANEL INTERNAL WIRING
1. Panels shall be supplied complete with interconnecting wiring provided between all electrical
devices mounted and wired in the panels and between the devices and terminal blocks for the
devices to be connected to equipment outside the panels. When panels are arranged to be located
adjacent to each other all inter panel wiring and connections between the panels shall be furnished
and the wiring shall be carried out internally
2. All wiring shall be carried out with 1100V grade, single core, stranded copper conductor wires
with PVC insulation. The m minimum size of the multi-stranded copper conductor used for
internal wiring shall be as follows.
3. All circuits except current transformer circuits and voltage transfer circuits meant for energy
metering one 2. sq. per lead.
4.1 All current transformer circuits one 4.0 sq. mm lead.
4.2 Voltage transformer circuit (for energy meters): Two 2.5 mm sq per lead.
4.3.
All internal wiring shall be securely supported, neatly arranged, readily accessible
and connected to equipment terminals and terminal blocks. Wiring gutters & troughs
shall be used for this purpose.
4.4.
4.5.
4.6.
4.7.
4.8.
Circuit
Auxiliary bus wiring for AC and DC supplies, voltage transformer circuits,

annunciation circuits and other common services shall be provided near the top of
the panels running throughout the entire length of the panels.
Wire germination shall be made with solder less crimping type and tinned copper
lugs, which firmly grip the conductor. Insulated sleeves shall be provided at all the
wire terminations. Engraved core identification plastic ferrules marked to
correspond with panel wiring diagram shall be fitted at both ends of each wire.
Ferrules shall fit tightly on the wire and shall not fall off when the wire is
disconnected from terminal blocks. All wires directly connected to trip circuit
breaker or device shall be distinguished by the addition of red coloured unlettered
ferrule.
Longitudinal troughs extending throughout the full length of the panel shall be
preferred for inter panel wiring. Inter-connections to adjacent panel shall be brought
out to a separate set of terminal blocks located near the slots of holes meant for
taking the inter-connecting wires.
Contractor shall be solely responsible for the completeness and correctness of the
internal wiring and for the proper functioning of the connected equipments.
All wiring shall be switch board type single conductor tinned annealed copper wire
insulated with varnished cambric, faulted asbestos, single braided cotton cover
painted overall with flame proof moisture resistant paint and suitable for 660 volt
service or equivalent polyncychloride insulation which has proved its utility in
tropical regions against hot and moist climate and vermin (Misc. white ants and
cockroaches etc) Rubber insulated wiring will not be accepted.
The sizes of wiring in different circuits shall not be less than those specified below
:
Table I
Minimum permissible
Size of wire.
Metering and relaying circuits connected

to Current Transformers.
4.0 mm sq.
Potential circuits for metering and

Relaying,
Other control, visual and audible
alarm signaling circuits etc.
4.0 mm sq.
2.5 mm sq
The following colour scheme shall be used for the wiring.

Table II
Circuit where use.
Red phase of instrument transformer circuit

Yellow phase of instrument transformer
Blue phase of instrument transformer circuits
Neutral connections earthed or not earthed
in the instrument transformer circuit
Colour of wire and

ferrule.
Red.
Yellow.
Blue.
Green.
A.C. Control wiring circuits using D.C.

upply
Grey
All wiring inter-connecting the front cubicles with the rear cubicles of the
panel board over the access corridor shall be wired in gutters held against the ceiling of the corridor
by means of screws. All potential bus wiring, audible alarm bus wiring, AC and DC control supply
bus wiring, wiring for cubicles lighting and such other wiring which funs from cubicle to cubicle
within the switch board shall be laid out in gutters and shall be carefully screened. As the front and
rear cubicles with be detachable, the inter-connection shall be made through suitable terminal
connectors securely fixed on the panel.
Wiring connected to the space heaters in the cubicles shall have porcelain braided
insulation over a safe length from the heater terminals.
Each wire shall be continuous from end to end without having any joint within itself.
Individual wires shall be connected only at the connection terminals or studs of the terminal blocks,
meters, relays, instruments and other switchboard devices.
Terminal ends of all wires shall be provided with numbered ferrules suitable
coloured (Ref : Table-II) for phase identification. At point of inter/connection where a change of
number is necessary, duplicate ferrules shall be provided with the appropriate numbers on the
changing end.
At the terminal connection, washers shall be interposed between terminals, wire
terminals and the holding nuts. All holding nuts shall be secured by locking nuts. The connection
stud shall project at least 6 mm. from the lock nut surface.
Wire ends shall be so connected at the terminal studs that no wire terminal number ferruled
gets masked due to succeeding connections. All wires shall be suitable for bending to meet the
terminal stud at rectangles with the stud axis, and they shall not be skewed.
All studs, nuts, bolts, scores, etc. shall be threaded according to the British Standard practice
unless Employers prior approval to any other practice of threading is obtained. Spare quantities
of nuts, lock nuts and washers of all varieties used on the panel board shall be supplied to the
extent of 10% of the used quantities.
2.6
TERMINAL BLOCKS
(i)
(ii)
(iii)
(iv)
(v)
(vi)
All internal wiring to be connected to external equipment shall terminate on terminal

blocks. Disconnecting typeTerminal blocks shall be 1100 V grade and have 20
Amps. Continuous rating, molded piece, complete with insulated barriers, stud type
terminals, washers, nuts and lock nuts,. Markings on the terminal blocks shall
correspond to wire number and terminal numbers on the wiring diagrams. All
terminal blocks shall have shrouding with transparent unbreakable material.
Disconnecting type terminal blocks for current transformer and voltage transformer
secondary leads shall be provided. Also current transformer secondary leads shall be
provided with short-circuiting and earthling facilities.
At least 20% spare terminals shall be provided on each panel and these spare
terminals shall be uniformly distributed on all terminal blocks.
Unless otherwise specified, terminal blocks shall be suitable for connecting the
following conductors of external cable on each side.
There shall be a minimum clearance of 250mm between the first row of terminal
blocks and the associated cable gland plate or panel sidewall. Also the clearance
between two rows of terminal blocks edges shall be minimum of 150mm
Arrangement of the terminal block assemblies and the wiring channel within the
enclosure shall be such that a row of terminal blocks is run in parallels and close
proximity along each side of the wiring duct to provide for convenient attachment of
internal panel wiring. The side of the terminal block opposite the wiring duct shall
be reserved for the owners external cable connections. All adjacent terminal blocks
shall also share this field-wiring corridor. All wiring shall be provided withadequate
(vii)
support inside the panels to hold them firmly and to enable free and flexible
termination without causing strain on terminals.
The number and sizes of the Owners multi core incoming external cables will be
furnished to the contractor after placement of the order. All necessary cableterminating accessories such as gland plates, supporting clamps & brackets, wiring
troughs and gutters etc. (except glands & lugs) for external cables shall be included
the scope of suppl
2.7 PAINTING:Powder coating type is preferable.

All sheet steel work shall be phosphated in accordance with the IS:6005 Code of
practice for phosphating iron and steel.
(1)All unfinished surface of the steel panels and frame work shall be sand blasted to
remove rust, scale, foreign, adhering matter of grease.
(2) A suitable rust resisting primer shall be applied on the interior and exterior
surfaces of the steel, which shall be followed by application of an under coat suitable
to serve as base and binder for the finishing coat. The finishing coat on the exterior
of the panels shall be deep gray powder coated. Polished cellulose appearance while
on the interior faces the finishing coat shall be of light gray shaded paint sprayed to
give a contrasting effect with the cubicle wiring.
A small quantity of finishing paint shall be supplied with each consignment of
the panels to enable the Employers store at site any finish which may get
damaged curing the transshipment. The panel boards may alternatively be
given a plastic durable covering coat for protection of the finish during the
transshipment, which shall be capable of being peeled off after installation.
2.8
TERMINAL BLOCK CONNECTION

Terminal Block connectors built from cells of moulded dielectric and brass stud
inserts shall be provided for terminating the outgoing ends of the cubicle wiring and
the corresponding incoming tail ends of the control cables.All the terminal
connectors shall have de-link(disconnecting) facilities.
Provision shall be made on each pillar for holding 20% extra connection (10%
incoming + 10% outgoing). All blocks shall be shrouded by easily removable shroud
molded of transparent dielectric materials. The terminal blocks shall be suitable for
660 volts service and connection with both aluminum and copper cable.
2.9
SPACE FOR CONTROL CABLES AND CABLE GLANDS

Sufficient space for receiving the control cables inside the board at the bottom of
the cubicles and mounting arrangement for the terminal cable glands shall be
provided. The specification does not cover supply of control cables and cable glands
for which the employer will make separate arrangement.
2.10
SPACE HEATERS
60 W. 240 V. 50 HZ tubular space heaters with thermostat auto suitable for
connection to the single phase AC supply complete with on-off switches located at
convenient positions shall be provided at the bottom of the switch board cubicle to
prevent condensation of moisture. The watt loss per unit surface of heater shall be
low enough to keep surface temperature well below sensible heat.
2.11
DISTRIBUTION AND CONTROL OF AUXILIARY POWER CIRCUIT
2.11.1 D.C. CIRCUIT
There shall be separate D.C. incomers for the each control and relay board panel
fed from D.C. distribution boards through a suitable fuse switch unit, provided there.
M.C.B,s. of required Amps rating shall be provided in the panel as D.C. incomer
2.11.2
2.12
2.13
2.14
(source I one number and source II one number). A continuous D.C. bus shall be
provided in the control and relay board panel and D.C. supply for control,
protection, supervision and indication of circuit breaker and other equipments shall
be teed off in each panel from D.C. bus through a set of HRC Fuse (both on +ve and
ve side) D.C. supply to individual panel thus teed off shall be distributed within the
panel as below.
SWITCHES & FUSES:
Each panel shall be provided with necessary arrangement for receiving, distributing
and isolating of DC and AC supplies for various control, signaling, lighting and
space heater circuits. The incoming and sub-circuits shall be separately provided
with fuses. The selection of the main and sub circuit fuses rating shall be such as to
ensure selective clearance of sub-circuit faults.
Voltage transformer circuits for
relaying and metering shall be protected by fuses. All fuses shall be HRC catridge
type confirming to IS: 3703 mounted on plug in type fuse bases. The short time fuse
rating of fuses shall be not less than 9 KA. Fuse carrier base shall have imprints of
the fuse rating and voltage.
A D.C. operated no-volt, auxiliary relay provided with hand reset reverse
flag and two set of self reset N/C contracts with test push button shall be provided in
the operating circuit of each control and relay panel to supervise the breaker control
supply. One N/C contact shall be used for visual alarm and the other N/C contact
shall be used for audible alarm and shall be connected to the alarm bus of the
annunciation scheme.
A.D.C. operated no-voltage auxiliary relay provided with hand reset
reserve flag indicator and two sets of self reset N/C contacts with test push button
shall be provided in the main alarm bus to supervise the alarm but supply. One N/C
contact shall be used for visual alarm and the other for audible alarm. The visual and
audible alarm of alarm bus fail and those of incoming D.C. bus fail shall be common
and shall be operated by 240 V single phase A.C. auxiliary supply as described in
the Specification.
(** DC sources supervision relays are to be mounted in the panel)
A.C. CIRCUIT
240 volts, single phase, A.C. auxiliary supply to the control and relay board will be
fed from A.C. distribution board through a suitable fuse switch provided thereof. A
continuous A.C. bus shall be provided at the control and relay board where from
A.C. supply to each panel shall be teed off through a set of links. One 16 Amp rated
M.C.B. shall be provided at the control and relay board for the incoming A.C.
supply. A set of fuse and link rated for 6 amps for 3 pin plug circuit, 6 amps for 2
pin ply circuit and 6 amps for heater and illuminating lamp circuits shall also be
provided. A hand reset type no-volt auxiliary relay rated for 240 volts A.C. and
provided for monitoring the auxiliary A.C. supply from D.C. operated facial
annunciation scheme.
MCBs
The incoming DC supply sources (source I and source II )circuits in the control and
relay panels shall be controlled by required Two pole DC MCBs. In each control
and relay panel there shall be separate DC MCB as incoming to the panels and the
sub circuits shall be controlled by HRC fuses of different circuits having both + ve
and - ve control.The incoming MCBs also followed by HRC fuses for better
protection. The ratings of the MCBs are to be designed to take care of the
continuous rating and also during short ckt or in the event of faults. For AC
incoming circuits and other distributed circuits circuits also to be provided with
MCB of proper ratings.
MIMIC DIAGRAMS
10 mm. wide, 2mm thick colour mimic diagrams and symbols showing the exact
representation of the system shall be provided in the front of control panel. The
mimic strips shall be made with anodized aluminum materials, which shall be
screwed on to the panel and can be easily cleaned. The colour code of such
aluminium strips are as given in the following table. Upper bus and lower bus of the
mimic shall represent the main bus and transfer bus of the station respectively.
Central line of the upper bus mimic shall be at a distance of 695 mm from the top of
the panel and center to center distance between the bus mimic shall be 610 mm.
When semaphore indicators are used for equipment position they shall be so
mounted in the mimic that the equipment close position shall complete the
continuity of the mimic.
Indicating lamp , one for each phase, for each bus shall be provided on the mimic to
indicate bus charged condition.
TABLE
COLOUR SCHEME FOR MIMIC DIAGRAMS
Equipment
Colour
I.S. Code
No.(IS.5)
400 KV
220KV/. 132KV
Orange
Signal Red
537
33 KV
Brilliant Green
414
415/250V
Black
221
Earth
White
309
110 V
Canary Yellow
Automatic semaphore indicators shall be provided for isolators and earth switch position
indication and incorporated in the mimic diagram.
2.15 DISCREPANCY TYPE CONTROL SWITCHES.

Control switches for circuit breakers shall be incorporated in the mimic diagram
to represent the relevant circuit breakers as also the sequence of the mimic
diagram. The switches shall be provided with a built-in two lamp. The switches
shall have maintained contact positions for ON and OFF positions respectively
and two momentary contact positions for ON and OFF impulse.
2.15.1 The switches shall be provided with a notching mechanism which should
accurately limit the angles of actuation. A strong restoring spring is to be provided
to return the switch mechanism automatically from the momentary contact
position to the maintained contact position. Such control springs shall be strong
enough to prevent any inadvertent operation due to light touch or some other
different arrangement should be provided to prevent any inadvertent operation.
Such springs shall not be used as current carrying parts in these switches. The
rating of the switch contacts shall be suitable for the duty imposed by the circuit
breaker closing mechanism and shall conform to the recommendations to be given
by the circuit breakers manufacturers. The built-in-pilot lamp of the control
switch shall give a steady light when the position of the control switch
corresponds to the position of the associated circuit breaker. A flickering light
shall be given by the same lamp when due to hand operation or due to automatic
tripping of the breaker, the position of the control switch does not coincide with
that of the corresponding circuit breaker. The arrangement to provide the
flickering voltage for the above purpose shall be made. In order to avoid
continuous burning of the aforesaid built-in lamps associated with the control
switches under steady state condition, the said lamps shall be connected through a
switch. The circuit should be such that irrespective of the position of the
aforesaid switch, winking of the lamp shall not be affected by change in
respective control switch position. The winking of the control switch pilot lamp
shall be followed by an alarm annunciation after a preset time adjustable between
0-10 secs. Switches complete with accessories for the above function shall be
supplied.
2.16
INDICATING LAMPS
5/7 Watt Indicating cluster LED type Lamps shall be provided on the control
panel mounting with rear terminal connections. Lamps shall be provided with
series connected resister preferably built in the lamp assembly. Lamps shall have
translucent lamp covers to difuse lights coloured red,green,amber,clear white or
blue as specified as per the following:
Function
1.
Quantity
Circuit Breaker spring
1 No.
Colour of lens
Blue
2.
3.
4.
5.
6.
2.17
2.18
charged/normal pressure
indication.
Circuit Breaker trip circuit
healthy indication.
Circuit Breaker Low Air
Pressure indication
Incoming D.C. fail
indication.
A. C. fail indication.
P. T. supply indication.
2 Nos.
White
1 No.(where
necessary
2 Nos.
White
White
1 No.
White
3 Nos.(where
Red/Yellow/
necessary)
Blue.
7. Indication lamps for CB closing ,opening
Red and Green
Isolator closing and opening
8. Auto trip
1 No.
Amber
All the indicating lamps under (1) and (2) shall be provided with push
button control. All the lamps shall be connected to the auxiliary D.C. supply
of the sub-station except Sl.No 4 and Sl. No.6 which should be connected to
the auxiliary A.C. supply and P.T. secondary supply. The lamps shall be
suitable for switch board purpose and shall be of low watt consumption. Lamp
and lenses shall be interchangeable and easily replaceable from the front of
the panel.Tools if required for replacing the bulbs and lenses shall aalso be
included in the scope of supply. The indicating lamps with resistors shall
withstand 120% of rated voltage on a continuous basis. In initial supply, 20%
of the lamps actually used on the switch boards and 10% of the lamp covers
used shall be supplied in excess to serve as spares.
TEST BLOCKS
Switchboard type, back connected, test blocks with contacts shall be
provided with links or other devices for shorting terminals of C.T. leads
before interrupting testing instruments in the circuit without causing open
circuit of the C.T. The potential testing studs shall preferably be housed in
narrow recesses of the, block molding insulation to prevent accidental shortcircuit across the studs. All Test Blocks for meters, relays, etc. shall be placed
as close to the respective equipment as possible.
NAME PLATES & MARKING OF IDENTITY
All equipments,instruments, relays and such other similar electrical
devices mounted on the front and rear side as well as mounted inside control
and relay panels shall be provided with name plates bearing the
manufacturers name, serial number and the electrical rating data.
All front mounted equipment shall also be provided at the rear with
individual name plates engraved with tag numbers corresponding to the one
shown in the panel internal wiring to facilitate easy tracing of the wiring.
Each equipment and meter shall be prominently marked with the quantity
measured e.g. KV,A,MW,MVAR, etc. All relays and other devices shall be
clearly marked with manufacturers name,type,sl No & electrical rating.
Name plates shall be made out of non-rusting metal or 3 ply lamicoid. Name
plate shall be black with white engraving lettering.
Each switch shall bear clear inscription identifying its function e.g.
BREAKER 52A,SYNCHRONISING etc.Similar inscription shall also
beprovided on each device whose function is not otherwise identified.
Switches also have clear inscription for each position indicating e.g. TRIPNEUTRAL-CLOSE,ON-OFF,R-Y-B-OFF etc.
All panel shall be provided with name plate mounted inside the panel bearing
LOA NO. & Date,Name of the sub-station & Feeder and reference drawing
number.
2.19
SAFETY EARTHING FOR THE PANEL

All panels shall be equipped with an earth bus securely fixed.Location of
earth bus shall ensure no radiation interference for earth system under
various switching conditions of isolators and breakers. The materials and
size of the bus shall be atleast 25X6 sq.mm perforated copper threaded
holes at gap of 50mm with a provision of bolts and nuts for connection
with cable armours and mounted equipment etc for effective earthing.
When several panels are mounted aadjoining each other,the earth bus shall
be made continuous and necessary connectors and clamps for this purpose
shall be included in the scope of supply. Provision shall be made for
extending the earth bus bars to future adjoining panels on either side.
Provision shall be made on each bus bar of the end panels for connecting
substation earth grid. Necessary clamps and connectors shall be included
in the scope of contract.
All metallic case of the relays,instruments and other panel mounted
equipment including gland plate shall be connected to the earth bus by
copper wires of size not less than 2.5 sq mm.The colour code of earthing
shall be green.
Looping of earth connections which would result in loss of earth
connections to other devices when loop is broken shall not be
permitted.However looping of earth connections between equipment to
provide alternative path to earth bus shall be provided.
VT and CT secondary neutral or common lead shall be earthed at one
place only at the terminal blocks where they enter the panel. Such earthing
shall be made through links so that earthing may be removed from one
group without disturbing the continuity of earthing syatem for other
groups.
2.20
PANEL BOARD LIGHTING

The panel interior (both control panel and relay panel) shall be illuminated
by 20W, CFL tube light connected to 240 V. single phase A.C. The
illumination of the interior shall be free from hand shadows and shall be
planned to avoid any strain or fatigue to the fireman likely to be caused
due to subnormal or non-uniform illumination. One emergency D.C. light
(CFL type) shall also be provided for each relay panel with individual
switch, with proper identification mark.
2.21
A door operated button switch shall be provided for control of the A.C.
lighting for all the control and relay panel interiors.
One 5 amps. two pin socket and one 15 amps. 3 pin power socket outlets
together with plugs shall be provided at convenient points in the panel
board for A.C. supply.
ANNUNCIATOR
Each control and relay panel shall be provided with an anunciator facial
on the front of the control panel for projecting mal-operation in the system
equipment due to fault. The annunciation board shall be of the switch
board type, back connected suitable for semi-flush mounting provided
with dust tight cases. The single relays shall be suitable for tropical use.
The alarm concealing visual signal resetting and annunciation testing
buttons shall be mounted on the front of each control panel at convenient
height, preferably under the annunciation board.
a) One part of the annunciation shall comprise of one electrical D.C.
operated bell and one D.C. operated hooter for trip and non-trip alarm
mounted inside or on top of the switch board cubicle on vibration
absorbent mountings. A suitable hand reset relay device shall be
employed in the suitable hand reset relay device shall be employed in
the suitable alarm circuit to permit manual cancellation of the audible
alarm in token of its acceptance by an operator before rectification of
the abnormality. The wiring shall be such that a single set of bell and
alarm cancellation relay will be sufficient and serve in commons with
all the alarm actuating devices.
b) The other part of the anunciator shall discriminate and sort out the
cause of alarm and project visual alarm signals by tokens of telephone
type flush lamps illumined windows on facial plate. There shall be an
independent token for each abnormal condition announced and the
wiring of all the tokens shall be so done that each token will operate
independently of the other without causing any maloperation on the
enunciator. A reset device, manually operated by an operator, shall be
provided for each column of the visual alarms to enable the operator to
cancel each visual alarm at will after removal of the discrepancy or
abnormal condition. Suitable testing device shall be provided on each
enunciator to be assembled for routine checking of enunciator alarm
and indication.
The enunciator shall be suitable for operation across the D.C. supply
voltage of the sub-station.
Momentary closing of fault contacts shall also cause operation of
enunciator system as above and shall require canceling and resetting
operations by the operator to silence the bell and reset the enunciator
window.
c) 2 Nos spare windows each for trip and non trip are to be provided in
each annunciator
2.22
2.23
INCOMING D.C. FAIL ALARM SCHEME

Control and Relay Board shall have a common Incoming D.C. Fail
alarm scheme operated by 240 V single phase A.C. auxiliary supply for
audible as well as visual alarm in case of failure of D.C. incoming supply
to the board.
All auxiliary relays, test relays, canceling, resetting and testing
push buttons, alarm bells etc. required to render the annunciation system
operative as above shall be considered to be within the scope of the tender.
Separate scheme for each source of DC supply shall be considered.
INCOMING A.C FAIL ALARM SCHEME
Control and Relay Board shall have a common Incoming A.C. Fail
alarm scheme operated by 240 V D.C. auxiliary supply for audible as well
as visual alarm in case of failure of A.C. incoming supply to the board.
3.0
INDICATING INSTRUMENTS AND METERS

3.1 All electrical indicating instruments shall be of digital Type suitable for flush
mounting
3.2 Instruments shall have 4- digit display, display height being not less than25 mm.
3.3 Instrument shall confirm to relevant IS and shall have an accuracy class of 1.0 or
better. For energy meters it should be of minimum 0.2. watt and VAR meters
shall have an indication of (+) and (-) to indicate EXPORT and INPORT
respectively
3.4 Digital voltage and frequency meters shall be of class 0.5 and shall have digital
display of 5 and 4 digits respectively, with display size, not less than 25 mm
height.
3.5 All instrument shall be switchboard type, back connected suitable for flush
mounting and provided with dust tight cases for tropical use with dull black
enamel finish.
3.6 All fixing screws, nuts and treated parts shall be designed to Indian Standards.
3.7 All instruments shall have a practicable laboratory means of adjustment of
accuracy. The limits of error shall be those permissible for industrial grade
instruments of switch board type. The calibration of the instruments shall function
satisfactorily when mounted on steel panels or alternatively magnetically
shielded instruments shall be used.
3.8 Instruments shall be capable of indicating freely when operated continuously at
any temperature from 0 to 50 deg. C.
3.9 All circuits of instruments shall be capable of withstanding the effect of shock
vibration and humidity and a dielectric test of 2500 volts r.m.s to ground for one
minute as per relevant BSS/ISS
4.0
NON-TARIFF ENERGY METERS
a)
Export/Import KWH and KVARH meters for 33KV , 132 KV and 220
KV. Line shall be supplied by the Bidder. Necessary cut-out, wiring and 3
element Test Terminal Block are to be supplied by the bidder as specified
4.1
in the Schedule of requirement of control panel. Export/Import meters for

non-tariff use shall be of the commercial grade accuracy i.e 0.2 Class, and
shall be of 3 element type and suitable for 3-phase, 3wire connection.
b)
One 3 element type KWH meter with M.D.I. for each 33 KV. 132 KV,220
KV. Transformer panel shall also be provided and shall be connected
preferably on H.V. side.
c)
One Trivector metre of solid state type with KWH, KVAH, KVARH with
MDI is to be provided both for 33 KV. 132 KV,220 KV control panel.
MW INDICATOR
In all the 33KV, 132 KV,220,400 KV lines and transformer feeders,
indicating MW meters with M.D.I. (three) element type shall be mounted
on the front side of the control panels to indicate the instantaneous MW
flowing. The MW meters shall be connected to the measuring C.T. core.
Scale range for line feeders shall be 200-0-200 MW and for transformer
feeders 0-150 MW or as suitable for the proposed system.
4.2
MVAR INDICATOR
In all the 400 KV,220KV. 132 KV line feeders indicating MVAR meters
shall be mounted on the front side of the control panel to indicate the
instaneous MVAR following through the feeder in either direction. The
scale should be center zero. The MVAR meters shall be connected to the
measuring C.T. core. The scale shall be 200-0-200 MVAR or as suitable
for the proposed system
5.0 Relays
General Requirements
5.1
5.2
5.3
5.4
All electro mechanical relays (auxiliary and tripping relays shall conform to the
requirements of IS:3231/ICE-60255 and all Main numerical relays shall confirm
to ICE-61850 and other applicable standards for future SCADA purpose. Relays
shall be suitable for flush or semi-flush mounting on the front with connections
from the rear.
All protective relays shall be in draw out or plug-in type/modular cases with
proper testing facilities. Necessary test plugs/test handles shall be supplied loose
and shall be included in contractors scope of supply.
All AC operated relays shall be suitable for operation at 50 Hz AC Voltage
operated relays shall be suitable for 110 Volts VT secondary and current operated
relays for 1 Amp CT secondary. All DC operated relays and timers shall be
designed for the DC voltage specified, and shall operate satisfactorily between
80% and 110% of rated voltage. Voltage operated relays shall have adequate
thermal capacity for continuous operation.
The protective relays shall be suitable for efficient and reliable operation of the
protection scheme described in the specification. Necessary auxiliary relays and
timers required for interlocking schemes for multiplying of contacts suiting
contact duties of; protective relays and monitoring of control supplies and circuits,
lockout relay monitoring circuits etc. also required for the complete protection
schemes described in the specification shall be provided. All protective relays
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
shall be provided with at least two pairs of potential free isolated output contacts.
Auxiliary relays and timers shall have pairs of contacts as required to complete
the scheme, contacts shall be silver faced with spring action. Relays case shall
have adequate number of terminals for making potential free external connections
to the relays coils and contacts, including spare contacts.
All protective relays, auxiliary relays and timers except the lock out relays and
interlocking relays specified shall be provided with self-rest type4 contacts. All
protective relays and timers shall be provided with externally hand reset positive
action operation indicators with inscription. All protective relays which do not
have built-in-hand-reset operation indicators shall have additional auxiliary relays
with operating indicators (Flag relays) for this purpose. Similarly, separate
operating indicator (auxiliary relays) shall also be provided in the trip circuits of
protections located outside the board such as Buchholtz relays, oil and winding
temperature protection, sudden pressure devices,Oil surge relay and fire
protection etc.
Timers shall be of the electromagnetic or solid state type. Pneumatic timers are
not acceptable. Short time delays in terms of milliseconds may be obtained by
using copper slugs on auxiliary relays. In such case it shall be ensured that the
continuous rating of the relay is not affected. Time delays in terms of milliseconds
obtained by the external capacitor resistor combination is not preferred and shall
be avoided to the extend possible.
No control relays which shall trip the power circuit breaker when the relays is deenergised shall be employed in the circuits.
Provision shall be made for easy isolation of trip circuits of each relay for the
purpose of testing and maintenance.
Auxiliary seal-in-units provided on the protective relays shall preferably be of
shunt reinforcement type. If series relays are used the following shall be strictly
ensured.
a.
The operating time of the series seal-in-unit shall be
sufficiently shorter than that of the trip coil or trip relay in
series with which it operates to ensure definite operation of the
flag indicator of the relay.
b.
Seal-in-unit shall obtain adequate current for operation when
one or more relays operate simultaneously.
c.
Impedance of the seal-in-unit shall be small enough to permit
satisfactory operation of the trip coil on trip relays when the
D.C. Supply Voltage is minimum.
All protective relays and alarm relays shall be provided with one extra isolated
pair of contacts wired to terminals exclusively for future use.
The setting ranges of the relays offered, if different from the ones specified shall
also be acceptable if they meet the functional requirements.
Any alternative/additional protections or relays considered necessary for
providing complete effective and reliable protection shall also be; offered
separately. The acceptance of this alternative/additional equipment shall lie with
the OPTCL.
5.13
The bidder shall include in his bid a list of installations where the relays quoted
have been in satisfactory operation.
5.14
All relays and their drawings shall have phase indications as R-Red, Y-yellow, Bblue.
5.15
Wherever numerical relays are used, the scope shall include the following:a)
b)
Necessary software and hardware to up/down load the data to/from

the relay from/to the personal computer installed in the substation.
However, the supply of PC is also covered under this clause.
The relay shall have suitable communication facility for future
connectivity to SCADA. The relay shall be capable of supporting
IEC 61850 protocol.
6.0 Protection System

Protective system
6.1 Protection discrimination

On the occurrence of a fault on the power system network the high speed discriminating
protection systems (main protection) shall rapidly detect the fault and initiate the opening
of only those circuit breakers which are necessary to disconnect the faulted electrical
element from the network. Protection equipment associated with adjacent electrical
elements may detect the fault, but must be able to discriminate between an external fault
and a fault on the electrical element which it is designed to protect. Sequential time
delayed tripping is not permitted except in the following specific circumstances:
Protection for short connections between post current transformer housings and
circuit breakers when the technical advantages of complete overlapping of the
protection are outweighed by economic considerations, (i.e. short-zone protection)
Operation of time graded back-up protection takes place as a result of either the
complete failure of the communication links associated with the main protection
systems, or the fault resistance is substantially greater than a value which can be
detected by main protection systems.
Operation of line back-up protection to disconnect primary system faults in the case
of a circuit breaker failing to operate, (i.e. circuit breaker failure protection)
All back-up protection systems shall be able to discriminate with main protection
systems, circuit breaker fail protection and with other back-up protection systems
installed elsewhere on the transmission system.
6.2 Protection settings

A list of the settings to be applied to all protection systems together with all associated
calculations, shall be provided for review and approval not less than three months prior to
the first programmed date for commissioning. The settings for line protection shall be
such as to permit correct operation of the protection for earth faults with up to 100 ohms
fault resistance. Any limitations imposed on the power system as a result of the settings
proposed shall be explicitly stated. In the absence of system data required for calculation
purposes, assumptions may be made providing these are clearly identified as such in the
relevant calculations.
6.3 Fault clearing time

The protection equipment shall be capable of achieving the following discriminative fault
clearing times, inclusive of circuit breaker and signalling times:
One millisecond for all electrical elements whose boundary connections are defined
by circuit breakers located within a given substation.
For interconnecting tie lines in which the boundary connections of the electrical
element being protected are defined by circuit breakers located in adjacent
switching stations, an additional 20 ms fault clearance time is allowed at the
substation remote from the fault point. This additional fault clearance time is
permitted subject to the requirement that the positive sequence impedance of the
primary circuit from the switching terminal to the point of fault shall not be less
than ten ohms.
The Contractor shall supply the Project Manager with details of the operating times under
defined conditions of all protection equipment proposed. Any limitation in operating
time performance shall be declared by the Contractor, e.g. end of zone faults where
distance protection is applied, high resistance faults, faults at high X/R with significant
DC component and time constant, faults coincident with communication channel noise.
The Contractor shall specify the increase in operating time which could occur under
such conditions.
6.4 Signalling equipment operating times:

For design purposes the operating times of signalling equipment to provide a contact
signal for use with associated distance protection shall be assumed to be as follows:
Intertripping (transfer trip) not greater than:
20 milliseconds
Permissive transfer trip:
15 to 20 milliseconds
Blocking signal operate time:
10 milliseconds
Blocking signal reset time:
10 milliseconds
Protection Schemes
6.5 Line protection

General requirement for line protection relays
The line protection relays shall protect the line and clear faults on line in the shortest
possible time with reliability, selectivity and full sensitivity to all types of line fault. The
general concept for
1) 400kV and 220kV levels is to have primary and back-up protection systems
having equal performance requirement especially in respect of time as would be
provided by two Main protections called Main-I and Main-II. It is desirable that
Main-I and Main-II protection should work on two different principles of
operation and one back up dir O/C & E/F protn is envisaged.
2) For 132 kV level the concept of one main distance protection and one backup
directional O/C and E/F protection is envisaged.
3) For 33 kV level, the requirement is that of modular directional O/C and E/F
protection.
The protection requirements are summarised below, and illustrated in the single line
diagrams in the schedules.
400kV and 220kV lines
Main I Numerical
levels.
non switched distance protection meeting
performance
Main II Numerical non switched phase comparison, carrier aided or of

numerical distance using a different principle of operation
Phase segregated teleprotection facility
Power swing detection blocking and tripping
Synchronising.
Line overvoltage ( Only for 400kV and 220kV line 200kM long )
Autoreclosure
Numerical directional overcurrent and earth fault
Three phase to ground
Numerical local breaker back up
Pole discrepancy protection
6.5.1 Distance Protection Relay (Numerical IEC-61850 Protocol

compliance)
The relay shall:
1. Be static and modular in construction
2. Have high speed phase segregated non switched distance relays for three phase
systems to clear all type of line faults within the set reach of the relay.
3. Cover at least two line sections with 15% in hand margin.
4. Measure all type of faults without the need to switch the measuring elements to the
faulty phase or phases. Zone switching to extend the reach of the measuring
elements is not allowed. The reach of each zone shall be independently and
individually adjustable and shall have settings in steps of 1%. Memory circuits
with defined characteristics shall be provided in all three phases to ensure correct
operation during close-up 3 phase faults and other adverse conditions. Independent
zero sequence compensation shall be provided for each zone.
5. Have reverse reaching zone operating times as given in Table. The Carrier
transmission time has been considered as 20 ms.
6. Have stepped time-distance characteristics and at least two directional and one
non-directional independently variable time graded distance protection zones to
cover two adjacent line sections.
7. Have a maximum Zone 1 operating time from fault initiation to trip impulse from
relay (complete protection time excluding applicable carrier time) under source to
line impedance ratios and under all possible combinations of fault with CVT being
used on the line (with all filters included) and at 50% of Zone I reach as follows:
For S.I.R. 0.01 to 4: 30 ms at the nearest end and 50 ms at far end.
For S.I.R. 4 to 15: 30 ms at the nearest end and 50 ms at far end.
Carrier transmission time is considered as 20 ms. Any reduction in carrier
transmission time shall be reflected in the reduction of maximum operating time.
The trip times should not be affected by DC offset and underfrequency up to 47Hz.
8. Have a reach for Zones 1,2 and 3 to cover line length as per 3 above. The relay
shall have an adjustable characteristic angle setting range of 30 to 75 degree,
preferably adjustable dynamically following the load conditions of the power
system. It should be ensured that this long coverage is consistent with limitations
imposed by heavy loading and sound phase component of fault current. If so
characterised by system requirements, it shall be possible to have circular
characteristics of offset Mho type or Quadrilateral shaped. If the characteristics of
starting relays are such that it cannot pick-up because of very low infeed, under
voltage relays may also be used as supplementary relays.
9. Have two independent continuously variable time setting range of 0-3 seconds for
Zone 2 and 0-5 seconds for Zone 3.
10.Have a maximum resetting time of less than 35 milliseconds.
11.Have facilities for offset features with adjustment of at least 20% of Zone 3 setting.
12.Have automatic residual compensation capabilities variable from 30-150%.
13.Be such that the setting / reach should not be affected by mutual coupling effect of
double circuit line or nearby paralleled circuits. The proof of compensation should
be given if provided.
14.Operate instantaneously when circuit breaker is closed to zero volt 3 phase fault.
15.Be suitable for single and three phase tripping.
16.Have a continuous current rating of twice rated current. The voltage circuit shall be
capable of continuous operation at 1.2 times rated voltage. The relay shall also be
capable of carrying a high short time current of 70 times rated current without
damage for a period of one second.
17.Be selective between internal and external faults.
18.Incorporate three separate high speed trip relays for single phase faults and a fourth
high speed trip relay for multi phase faults. Each of these shall have adequate
contacts to meet the complete scheme requirements. The relay shall conform to the
requirements for tripping relays specified in this specification.
19.Include power swing blocking protection which shall:
be of triple pole type
have suitable setting rage to encircle the distance protection described above.
have a continuously adjustable time delay on pick up of
seconds.
setting range 0-2
block tripping during power swing conditions.

20.Include fuse failure protection which shall:
monitor all the three fuses of CVT and associated cable against open circuit.
inhibit trip circuits on operation and initiate annunciation.
have an operating time less than seven milliseconds.
remain inoperative for system earth faults.
21.Have integrated two stage overvoltage protection facilities.
22.Shall have comprehensive self test feature including diagnostics at power up.
23.Broken conductor detection facility.
24.Distance to fault locator
6.5.2 Distance to fault locator

General
Distance to fault locators shall be the inbuilt features of the distance relay for both Main
I and Main II, shall be capable of locating phase to phase and phase to earth faults. They
shall also preferably be capable of locating open circuit faults.
1. Have built-in display feature.
2. Display directly in percent of line length or kilometres without the requirement for
further calculation.
3. Have an accuracy of 3% or better for all types of faults and fault levels. This level
of accuracy should not be impaired under the following conditions:
presence of remote end infeed
predominant DC component in fault current
high fault arc resistance
severe CVT transients
4. Have facility for remote data transmission
5. Meet IEC 255 Part IV or other equivalent internationally recognised standard.

6. Have mutual zero sequence compensation unit if fault locator is to be used on
double circuit transmission line.
Table 16.3.2 Operating Times for Distance Protection
Operating Time (ms)
SIR = ZS/ZL)
Fault Position % of Impedance Setting
20
10
5 to 20
30
30
10 to 60
50
60
1 to 95
SIR = System Impedance ratio. Zs = Source impedance. Zl = Relay setting impedance
6.5.3 Line overvoltage protection relay

The line over voltage protection (59L) relay shall:
1. Monitor all three phases
2. Have two independent (59L1 and 59L2) stages
3. Have an adjustable setting range of 100-170% of rated voltage with an adjustable
time delay range of 1 to 60 seconds for the first stage. (59L1)
4. Have an adjustable setting range of 100-170% of rated voltage with an adjustable
time having setting range 100-200 seconds for the second stage. (59L2)
5. Be tuned to power frequency
6. Be provided with separate operation indicators (flag target) for each stage relays.
(59L1 and 59L2)
7. Have a drop-off to pick-up ratio greater than 95%. Integral of overvoltage feature is
also acceptable.
6.5.4 Auto reclosing relay

The auto reclosing relay shall:
1. Have single phase and/or three phase reclosing facilities. ( Single /three phase
reclosure shall be adapted for 400kV/220kV systems and 3pole trip/ reclosure for
132kV system)
2. Have a continuously variable single phase dead time range of 0.1-2 seconds in steps
of 0.1 second.
3. Have a continuously variable three phase, one shot dead time range of 0.1-5
seconds in steps of 0.1 seconds.
4. Have a continuously variable reclaim time range of 5- 50 seconds.
5. Incorporate a four-position selector switch from which single phase/three
phase/single and three phase auto reclosure and non-auto reclosure mode can be
selected.
6. Have facilities for selecting check synchronising or dead line charging features. It
shall be possible at any time to change the required feature by connection of links.
7. Be of single shot type.
8. Include check synchronising relay which shall
Have a time setting continuously variable between 0.5-5 seconds.
Have a response time within 200 milli seconds with the timer disconnected.
Have a phase angle setting not exceeding 35 degree.
Have a voltage difference setting not exceeding 10%
9. Include dead line charging Relay which shall
Have two sets of relays and each set shall be able to monitor the three phase
voltage.
Have one set connected to the line CVTs with a fixed setting of 20% of rated
voltage.
Incorporate necessary auxiliary relays and timers to give comprehensive scheme.
The scheme shall be such as to have Main I and Main II fully segregated such that
shutdown and testing on one main protection should not affect the other main protection.
The auto reclosure should then be connected to one protection. Integrated auto-reclosure
feature as part of both Main I and Main II is also acceptable.
The scheme shall have check synchronous and voltage check interlocks (25, 27). These
interlocks are supplementary to all other decision interlocks that may be required or
specified in order to ensure correct operation of the scheme.
6.6 Local Breaker Back-up protection relay (50 LBB) for circuit
breakers
The local breaker backup protection relay shall:
1. Be of triple pole type
2. Have an operating time of less than 15 milliseconds.
3. Have a resetting time of less than 15 milliseconds.
4. Have three over current elements. Each element shall be arranged to get individual
initiation from the corresponding phase of line protection.
5. Be of solid-state type having a setting range of 5-80% of rated current
6. Have a continuous thermal withstand twice the rated current irrespective of the
setting.
7. Have three separate timers, one for each phase with continuously adjustable setting
range of 0.1-1 seconds.
8. Have necessary auxiliary relays to make a comprehensive scheme.
Protective system
6.7
Unit and backup protection

Power system elements and the network shall be provided with independent high speed
discriminative protection systems. Duplicate schemes (Main I and Main II) shall be
provided for all 400kV and 220kV systems. For all other systems up to 132kV, the
protection equipment shall be divided into Main and Backup systems.
Protection schemes of different philosophy (Main I and Main II or Main and Back-up)
shall preferably be fed from different DC supplies when available in the substation. This
shall include energisation of trip coil circuits in case of 400 kV and 220 kV breakers.
However in case of 132kV system where a duplicate DC source is available, the two trip
coils shall be energised from the different sources.
Protection equipment shall not initiate a trip signal following the normal and correct
discharge operation of one or more surge arresters.
Measurement functions relays must be achieved through electronic circuits. Auxiliary
relays, repeat relays, trip relays and any other simple auxiliary or contact multiplication
function may be based on standard attracted armature or other electromechanical
techniques.
Relays based on numerical design technique shall constitute all primary protections. The
Employers intends to avail the improved benefits in the functionality, design, reliability
and cost effectiveness of integrated substation control systems in future for which relays
with numeric design only shall be required. It is the responsibility of the Contractor to
demonstrate that all relay equipment offered has a reasonable level of in-service
experience. For numerical relays, the following conditions apply :
1. The Bidder must be able to demonstrate that a minimum of 10 relays of each type
offered have been in full service without relay failures for a minimum of three
years in two different countries, one of which may be the country of manufacture.
Experience involving trial installations is not acceptable.
2. The Bidder must include a statement of the number of years of guaranteed
manufacturing and parts support which will be provided for the relays offered.
3. The Bidder is be required to state the full firmware version together with the
version of relays for which experience records are offered.
For relays which are provided with communication facilities, the communications facility
should allow all information which is available locally at the relay front panel to be
accessed remotely. It should also be possible to carry out bulk transfer of settings and
fault record information using the appropriate PC based software.
6.8
Protection discrimination
On the occurrence of a fault on the power system network the high speed discriminating
protection systems (main protection) shall rapidly detect the fault and initiate the opening
of only those circuit breakers which are necessary to disconnect the faulted electrical
element from the network. Protection equipment associated with adjacent electrical
elements may detect the fault, but must be able to discriminate between an external fault
and a fault on the electrical element which it is designed to protect. Sequential time
delayed tripping is not permitted except in the following specific circumstances:
Protection for short connections between post current transformer housings and
circuit breakers when the technical advantages of complete overlapping of the
protection are outweighed by economic considerations, (i.e. short-zone protection)
Operation of time graded back-up protection takes place as a result of either the
complete failure of the communication links associated with the main protection
systems, or the fault resistance is substantially greater than a value which can be
detected by main protection systems.
Operation of line back-up protection to disconnect primary system faults in the case
of a circuit breaker failing to operate, (i.e. circuit breaker failure protection)
All back-up protection systems shall be able to discriminate with main protection
systems, circuit breaker fail protection and with other back-up protection systems
installed elsewhere on the transmission system.
6.8.1 Codes and Standards

The equipment supplied shall generally comply with the codes and standards indicated in
relevant sections of this specification. Additionally the equipment shall also conform the
6.8.2
Environmental requirement
The protection, control and metering equipment shall operate satisfactorily under the
various atmospheric, mechanical, electrical and environmental conditions as stipulated in
the relevant sections of this Specification. The equipment shall conform to EMC Class
III.
6.8.3
Future network scada system

At some time in the future the Employer intends to introduce a network SCADA system.
All equipment to be installed under this Specification shall be suitable for future remote
operation and remote data acquisition.
The limit of responsibility with regard to this contract shall be to provide equipment
suitable for future connection to and communication with a SCADA system, either by
means of RTU or modem. Neither the RTU nor the modems form part of the scope of this
Specification.
The proposed protocol for the SCADA system is IEC 61850 compliance. Equipment
necessary to interface the Integrated Substation Control System with the SCADA system
are part of the scope of this Specification.
6.8.4
Control and monitoring levels

The substation control and monitoring system shall allow for three levels of man machine
interface. The number of levels initially employed will be limited to one i.e. substation
levels. Provision shall be made for the future implementation of the second and third
level of network control and monitoring from a system control centre via SCADA.
Selection of substation control shall be from the individual equipment basis i.e., from the
control panels.
At the station level, control panels should be located in the main control room.
A mimic diagram representing the substation lay-out in single line diagram form should
be provided. The mimic board is intended to give operating personnel an overall view of
the switchgear state. It shall be made up from the individual circuit control panels
mounted side by side. The arrangement should correspond to the primary equipment
layout.
Alarm annunciation equipment should be mounted adjacent to the mimic diagram, or
form an integral part of the control panel. Operation of an alarm should cause the
appropriate window to flash and sound an audible warning. Operation of an accept button
will silence the audible warning, steady the flashing window and prepare the
annunciation to respond to subsequent initiation. A reset button should be provided to
extinguish alarms which have reset.
A lamp test button shall be provided which will initiate steady state illumination of all
alarm windows. Trip or protection initiated alarms should have windows distinct from
others (e.g. red display instead of white). Control and selector switches should be of
approved types complying with accepted standards such as IEC 337. Control switches
shall have two independent motions or two handed operation to effect operation.
Indicating instruments should be of approved types complying with accepted standards
such as IEC 5 1.
6.9
Enclosures
Protection systems shall preferably be accommodated in rack or hinged rack cubicles and
be of modular construction with factory assembled and tested wiring. Conventional
analogue relays may be mounted on conventional relay panels which must be mounted to
allow access to the front and rear of the panel. Relays mounted on such panels shall be
flush mounted. The construction method shall offer the benefits of minimum site
construction times and circuit outage requirements.
Interconnections shall be identified in accordance with the requirements for dependent
local end marking as specified in IEC Publication 391 Sections 3.4.1.a.1 and 5.1.2. The
interconnections shall be recorded on an appropriate schedule or diagram.
For modular protection systems, means shall be provided to lock positively each
withdrawable module or unit in the service position. It shall not be possible to remove
any module without first short-circuiting all associated current transformer circuits.
6.10 Operator interface

6.10.1General
All numerical protection systems shall be provided with an integral local operator
interface facility to enable communication with the relay without the use of external
equipment. Any facilities provided for connection to an external computer shall be an
additional feature to the local operator interface. No exceptions to this requirement shall
be accepted.
6.10.2 Identification
Each protection system shall have a unique identifier which is clearly visible. If the
protection system is software operated the software reference and issue level shall be
identified.
6.10.3 Settings
Each protection system shall provide a means by which the user can easily access the
protection system to apply the required settings. This facility shall be secure from
inadvertent operation. A display of the selected settings shall be provided on the
protection system.
6.10.4 Indications
Each relay or protection scheme shall be provided with an adequate number of
indications to ensure that the appropriate faulted phase, zone, etc. can be easily identified
after a fault condition. Each indicator shall be visible and capable of being reset without
removing the relay cover.
For relays based upon numerical techniques, indication shall be provided for failures
detected in the protection relay or communications equipment. The indications provided
shall be designed to allow the defective item to be quickly identified. The status of the
DC power supplies shall be permanently indicated.
Details of the indication required for specific types of relay are provided in the individual
parts of this section of the specification covering particular types of relay.
6.11
Protection system output contacts

All protection systems shall be provided with an adequate number of contacts of suitable
rating to carry out the required tripping functions, alarm indications, fault recorder
functions and such supplementary signalling functions as may be necessary for initiation
of automatic switching control, inter tripping etc. In all cases contacts intended for
tripping duty shall be designed such that they cannot inadvertently interrupt trip coil
current.
6.12
Testing and isolating facilities

Each functional protection system shall be so arranged that operational and calibration
checks can be carried out with the associated primary circuit(s) in service.
Adequate test facilities shall be provided within the protection system to enable the
protection and auto-reclosing equipment to be tested from the front of the protection
equipment panel with the primary circuit(s) in service. The test points shall be clearly
identified and labelled.
Relays based on digital and numerical design techniques shall include supervision
facilities which provide a periodic self check of the key elements within the relay and
also provide continuous self monitoring of all internal power supplies and microprocessor
operation. A defect in any of the self supervision facilities shall not cause maloperation
of the protection relay internal self-test facilities and shall give an alarm should an
internal fault occur.
Adequate facilities shall be provided, preferably at the front of each protection equipment
panel, to isolate all DC and AC incoming and outgoing circuits so that work may be
carried out on the equipment with complete safety for personnel and without loss of
security in the operation of the switching station. The isolation points shall be clearly
identified and labelled. The labels on the isolation points shall either describe the
function or be uniquely numbered.
The Contractor shall provide a list of all of the protection and auto-reclose equipment
being offered under the contract.
The Contractor shall also provide a list of all of the test and ancillary equipment required
for commissioning and routine testing of all protection and auto-reclose equipment.
6.13
Service life and support

The protection systems shall be designed for a service life of at least 15 years, and
preferably 20 years, given that normal maintenance in accordance with manufacturers
recommendations is carried out during the lifetime of the protection system.
The Contractor shall state the service life of the protection system equipment in relation
to that of the main HV plant and apparatus so that Employer can assess the cost of any
replacement during the life of the substation.
The Contractor shall state the period for which lifetime support will be provided for the
protection system equipment and shall make recommendations for the provision of spare
parts.
The Contractor shall supply circuit diagrams for each protection system and the
associated tripping system(s). The diagrams shall provide sufficient information to
enable fault finding and maintenance to be carried out and shall not consist solely of
information used for equipment manufacture.
When the Contractor has been notified of incorrect operation, or failure to operate when
required, of any protection system supplied under the contract, the Contractor shall
investigate the incident and inform Employer of any such incidents if they result in the
necessity to modify the equipment. The Contractor shall also inform Employer of the
details of the modifications required to prevent such incidents re-occurring.
The Contractor shall offer a service to enable any faulty item of protection equipment to
be rectified or replaced within a stated period of the fault being reported. The Contractor
shall state the repair/replacement period.
The Contractor shall, when requested, offer the Employer a maintenance contract for the
protection equipment supplied under the contract. The Contractor shall supply details of
the cost of the maintenance contract and information on test procedures and test
frequencies that would be supplied under the maintenance contract.
The Contractor shall offer training for Employers personnel in the operation and
maintenance of the protection equipment.
6.14
Thermal rating of equipment

Relay equipment intended to perform a current measurement function shall be capable of
continuous operation at a current of not less than 2.4 times the nominal rating or twice the
setting value, whichever is the more onerous.
Relay equipment intended for use in a normally quiescent mode and having a short time
rating - for example, high impedance differential protection - shall be rated in accordance
with the intended function and taking account of such inherent protective devices as may
be incorporated in the design.
The short time rating for all protection relaying schemes shall be 100 times the nominal
relay rating for a duration of one second.
Voltage sensitive equipment intended for use on effectively earthed networks shall have a
continuous withstand of not less than 1.2 times nominal voltage and a short duration
withstand of not less than 1.5 times nominal phase-to-ground voltage for 30 s.
6.15
Insulation
The rated insulation voltage of circuits connected to current transformers of high
impedance relays shall be 1000 V. All other circuits shall have an insulation voltage of
2500V.
All open contacts of the protection system shall withstand a voltage of 1000V.
The protection system shall comply with the dielectric test requirements of IEC 255-5.
The test voltage shall be selected according to the rated insulation voltage of the circuits
being tested form Series C of Table 1 of IEC 255-5.
The protection system shall comply with the impulse test requirements of IEC 255-5 with
test voltage of 5 kV.
6.16
Test requirements
6.16.1 General requirements

The Contractor shall supply test results and/or in service operating evidence to confirm
compliance with the general and performance requirements as detailed in this
Specification.
6.16.2 Pre-commissioning and energisation tests

The Contractor shall submit details of all pre-commissioning and energisation tests to the
Project Manager for approval prior to the tests, and shall provide the Project Manager
with the opportunity to witness the commissioning tests.
6.16.3 Testing, inspection and test certificates

The Bidder shall enclose with his bid the reports of type and routine tests conducted on
similar equipment earlier as a proof of designing and developing similar equipment. Bid
documents, furnished without these test reports shall be considered as incomplete and
shall be liable for rejection.
All equipment furnished shall conform to the type tests and shall be subject to routine
tests in accordance with the requirements stipulated for control and relay panel
equipment. The Project Manager reserves the option to call for any or all the type tests to
be repeated on the equipment. The Project Manager further reserves the option to
intimate the type tests to be carried out on the equipment up to six months after the award
of contract. Payments would be made for the type tests actually carried out in accordance
with the rates given in the Bid Price Schedule.
The Project Manager will have the right to call for any other tests of reasonable nature to
be carried out at the Contractor's premises or at site or in any other place, in addition to
the aforesaid type and routine tests, to satisfy that the materials comply with the
Specification.
The Contractor shall advise the Project Manager three months in advance of the type tests
to be conducted on the finished equipment giving a programme for conducting the tests
and shall proceed to test the equipment only after approval of the Project Manager. All
type tests shall be performed in presence of Project Manager should he so desire.
The Contractor shall give one months notice of routine tests and inspection to be carried
out on the finished equipment. A programme for conducting the tests shall be furnished
and the Contractor shall proceed to test the equipment after approval of the Project
Manager. The tests shall be witnessed by the Project Manager should he so desire.
All inspections, type tests and routine tests shall be carried out after approval of all the
relevant drawings required under the contract.
None of the equipment to be furnished or used in connection with this contract shall be
despatched until factory tests are satisfactorily completed. Such factory tests on the
equipment shall not however relieve the Contractor from full responsibility for furnishing
equipment conforming to the requirements of this contract, nor prejudice any claim right
or privilege which the Employer may have because of the use of defective or
unsatisfactory equipment. Should the Project Manager waive the rights to inspect and test
any equipment, such a waiver shall not relieve the Contractor, in any way, of his
obligations under this contract.
Six (6) copies of test reports of successful tests shall be submitted by the Contractor to
the Project Manager for approval before shipment of equipment.
For equipment tests for which IEC recommendations or Indian Standards are available,
test reports confirming that the equipment has passed the specified type and routine tests
shall be furnished for the approval of the Project Manager by the Contractor before
shipment of the equipment.
For equipment/tests for which IEC/IS specifications do not exist, the Contractor shall
propose a test procedure for the approval of the Project Manager before conducting tests.
Test certificates for tests carried out shall be submitted for approval of the Project
Manager before shipment of the equipment.
Failure of any equipment to meet the requirements of tests carried out at works or at site
shall be sufficient cause for rejection of the equipment. Rejection of any equipment will
not be held as a valid reason for delay in the completion of the works in accordance with
the agreed programme.
The Employer reserves the right to call for field tests on the completely assembled
equipment at site.
The price for conducting all the type tests in accordance with relevant standards and
specifications shall be indicated in Bid Price Schedule and these would be considered for
bid evaluation. The break-up price of type tests shall be given in the relevant price
schedule for payment purpose only. In case Bidder does not indicate charges for any of
the type tests or does not specifically identify any test in the price schedules, it will be
assumed that the particular test has been offered free of charge. Further, in case any
Bidder indicates that he shall not carry out a particular test, his offer shall be considered
incomplete and shall be liable to rejection.
Six (6) copies of all test reports shall be supplied for approval before shipment of
equipment. The reports shall indicate clearly the standard values specified for each test,
to facilitate checking of the test reports. Fourteen (14) bound copies of test reports shall
be submitted along with the equipment after approval of test results.
6.16.4 Soak test

All solid state equipment/system panels shall be subject to the Hot Soak Test as a routine
test in accordance with the procedure detailed in the following paragraph.
All solid state equipment shall be burn-in tested for minimum of 120 hours continuously
under operational conditions. During the last 48 hours of testing, the ambient temperature
of the test chamber shall be 50C. Each panel shall be complete with all associated subsystems and the same shall be in operation during the above test. During the last 48 hours
of the above test, the temperature inside the panel shall be monitored with all the doors
closed. The temperature of the panel interior shall not exceed 65C.
6.16.5 Type tests

Impulse voltage withstand test as per Clause 6.1 of IS 8686 (for a test voltage appropriate
to Class III as per Clause 3.2 of IS-8686)
High Frequency Disturbance test as per Clause 5.2 of IS 8686 (for a test voltage
appropriate to Class III as per Clause 3.2 of IS 8686)
Type tests listed under IEC-Technical Committees recommendation `TEC-57' and
functional type tests listed under CIGRE Study Committee 34 (Protection) Report on
simulator, Network analyser or PTL as applicable.
6.16.6 Routine tests

Contact insulation resistance test as per Clause 10.5 of IS-3231.
Insulation withstand capability as per Clause 10.5 of IS-3231 on all AC/DC relays.
7.0
7.1
Protection Schemes
General
The following sections of this specification identify the protection requirements for
specific schemes. Drawings showing single line diagrams for each type of circuit are
included in this Specification. The arrangements shown on these drawings represent the
minimum requirements. Other protection arrangements may be provided but the Bidder
must clearly state the reasons for offering supplementary protection schemes.
7.2
Technical requirements of the protection and auxiliary relays, recorders and meters to be
provided as part of the scope are detailed I the following sub clauses.
The setting ranges of the equipment offered, if different from that specified shall be
acceptable if they meet the functional requirements. The Bidder shall quote for protection
equipment meeting the requirements given in these sub clauses.
The Bidder may also quote alternative or additional protections or relays considered
necessary by him for providing an effective and reliable protection scheme. These
equipments shall be quoted separately as an alternative or addition to the main offer. The
Employer reserves the right to accept or otherwise such equipment.
7.3
400kV Reactor protection

Protection requirement
The 400 kV reactors provided with the lines shall have the following protections.
Differential protection.
Restricted earth fault protection.
Backup impedance protection.
7.3.1
Differential protection relay (87R)

This relay shall :
1. Be triple pole type
2. Have operation time less than 25 milliseconds at five times setting.
3. Be tuned to system frequency.
4. Have three instantaneous high set units to ensure rapid clearance of heavy faults
with saturated CTs.
5. Have current setting range of 10 to 40% of 1 Amp.
6. Be Low impedance type.
7. Be stable for all external faults.
8. Be provided with suitable non-linear resistors to limit the peak voltage to 1000
volts.
7.3.2
Restricted earth fault protection relay (64 R)

This relay shall:
1. Be single pole type
2. Be of current/voltage operated high impedance type
3. Have a current setting of 10-40% of 1A and a suitable voltage setting range.
4. Be tuned to system frequency.
5. Be fitted with suitable non-linear resistors to limit the peak voltage to 1000 volts.
7.3.3
Back up impedance protection relay (21 R)

This relay shall:
1. Be triple pole type
2. Be single step polarised `mho' distance relay or impedance relay suitable for
measuring phase to ground and phase to phase faults.
3. Have an ohmic setting range of 20-320 ohms and shall be continuously variable.
4. Have an adjustable characteristic angle of 30 to 80 degree.
5. Have a definite time delay with a continuously adjustable setting range of 0.2 - 2.0
seconds. Shall initiate three phase tripping
7.4
Transformer protection
The following protection shall be provided for all 315MVA 400/220kV and 220/132/33
KV,160 or 100MVA autotransformers(33 kv side is delta winding and is a loaded
winding), and 220/33kV and 132/33kV double wound transformers: All the relay
shall be latest numerical version having IEC 61850 protocol compliance

1. Transformer differential protection (87AT)
2. Over fluxing protection (99AT)
3. Restricted earth fault protection (64AT)
4. Back-up directional over current protection (67/51/50) on HV side
5. Back-up directional earth fault protection (67N/51N/50N) on HV side
6. Back-up directional over current protection (67/51/50) on LV side
7. Back-up directional earth fault protection (67N/51N/50N) on LV side
8. Restricted earth fault protection (64R)
9. Transformer over load protection (51OL)
10.LBB for 400kV, 220kV and 132kV sides.
7.4.1
Transformer differential protection relay (87AT)

This relay shall :
1. Be triple pole type, with faulty phase identification/indication
2. Have an operating time not greater than 30 milliseconds at five times setting.
3. Have three instantaneous high set units to ensure rapid clearance of heavy faults
with saturated CTs.
4. Have an adjustable dual slope bias setting range of 10%-50%.
5. Be suitable for rated current of 1A.
6. Have second harmonic and fifth harmonic restraint feature and also be stable under
normal over fluxing conditions and inrush of current during charging.
7. Have at least three bias winding per phase.
8. Have an operating current setting adjustable between 10% and 50%
9. Should not require interposing transformers and the relay should correct the vector
group difference and CT primary/load current difference.
7.4.2
Over fluxing protection relay (99AT)

This relay shall :
1. Operate on the principle of voltage to frequency ratio and have two settings - for
alarm and trip.
2. Have inverse time characteristics, matching with transformer over fluxing
withstand capability curve.
3. Provide an independent àlarm' with the time delay continuously adjustable
between 0.1 to 6.0 seconds at values of v/f' between 100% to 130% of rated
values.
4. Have a set of characteristics of various time multiplier settings. The maximum

operating time of the relay shall not exceed 3 seconds and 1.5 seconds at v/f'
values of 1.4 and 1. 5 times, the rated values, respectively.
5. Have a tripping time governed by v/f' Vs. time characteristics of the relay.
6. Have an accuracy of operating time better than 10%.
7. Have a resetting ratio of 98% or better.
7.4.3
Restricted earth fault protection relay (64AT)

This relay shall:
1. Be single pole type.
2. Be of current/voltage operated high/low impedance type.
3. Have a current setting range of 10-40% of 1A and a suitable voltage setting range.
4. Be tuned to the system frequency
5. Have suitable non-linear resistor in case required to limit the peak voltage to 1000
Volts.
7.4.4
Transformer overload protection feature

The transformer overload protection shall:
1. Be a single pole type
2. Be a definite time overcurrent type
3. Have two separate sets of overcurrent relay elements, each with continuously
adjustable setting range of 50-200% of rated current independently.
4. Have two separately adjustable time delay relays, one for alarm having setting
range of 1 to 10.0 seconds, continuously. The second time delay relay should have
continuously adjustable setting range of 1.0 to 10.0 minutes for tripping.
5. Have a drop-off/pick-up ratio greater than 95%.
7.4.5
HV /LV side back-up directional over current protection

This relay shall:
1. Be single pole type.
2. Have IDMT characteristics with a definite minimum of three seconds at ten times
the setting.
3. Have a variable setting range of 50% to 200% of rated current.
4. Have a characteristic angle of 45 degrees, a directional controlled, low transient
over reach, high set instantaneous unit of continuously variable setting range of
500- 2000% of rated current.
5. Provision of highest setting in two stages.
7.4.6
HV/LV side back-up directional earth fault protection

This shall also have identical specification as at clause 0 above excepting that the
adjustable setting range shall be 20-80%.
7.5
TEE protection differential relays (87 TT1,87TT2) (applicable for

5 CT scheme)
Where a Tee Protection for a five CT system is provided the following shall be
applicable.
7.5.1
First set of differential relays
One set of differential protection relays (87 TT1) shall

1. Be triple pole type.
2. Have an operating time less than 30 milliseconds at five times setting
3. Have three instantaneous high set over current units.
4. Have an adjustable bias setting range of 20% to 50%
5. Be suitable for rated current of 1A.
6. Have three bias windings.
7. Have an operating current setting of 15% or less.
7.5.2
Second set of differential relays.

The second set of Differential relay (87 TT2) shall:
1. Be triple pole type.
2. Have operating time less than 25 milliseconds at five times setting.
3. Be tuned to system frequency
4. Have current setting range of 20 to 80% of 1A.
5. Be voltage operated, high impedance type
6. Be stable for all external faults.
7. Be provided with suitable non linear resistors across the relay to limit the peak
voltage to 1000 volts.
7.6
BUS BAR PROTECTION:

Bus bar protection schemes shall be provided for each main and transfer bus of 400 KV
and 200 KV provided in the switch yard. This shall constitute main and check features.
The overall scheme shall be engineered such that operation of both main and check
features connected to the faulty bus shall result in tripping of the same. The scheme shall
be provided with necessary expansion capacity and interfaces for adding features when
the switch yard is extended in future to its ultimate capacity. The bus bar relay shall be of
latest numerical relay having IEC protocol 61850 compliance.
7.6.1 Busbar protection(Latest version numerical having IEC-61850

protocol compliance)
Bus bar protection schemes shall be provided for each main bus of 400kV and 220kV
switchyard. The overall scheme shall be engineered so as to ensure that operation of any
one out of two schemes connected to main faulty bus shall result in tripping of the same.
However in case of transfer bus, where provided, only one busbar protection scheme
shall be required.
Each busbar protection scheme shall
1. Be of modular construction and have features of self monitoring facility to ensure
maximum availability of scheme. The scheme shall be static/ microprocessor/
Numerical based.
2. Have maximum operating time up to trip impulse to trip relay for all types of faults
of 15 milli seconds at 5 times setting value.
3. Operate selectively for each busbar.
4. Give hundred percent security up to 40kA fault level.
5. Incorporate a check feature.
6. Incorporate continuous supervision for CT secondaries against any possible open
circuit and if it occurs, shall render the relevant zone of protection inoperative and
initiate alarm.
7. Not give false operation during normal load flow in busbars.
8. Incorporate clear zone indication.
9. Be of phase segregated and triple pole type and provide independent zones of
protection for each bus (including transfer bus if any). If a bus section is provided
then each side of the bus section shall have separate busbar protection scheme.
10.Include individual high speed hand reset tripping relays for each feeder, including
future ones.
11.Be of low/medium impedance biased differential type and have operate and
restraint characteristics.
12.Be transient free in operation
13.Include continuous DC supplies supervision.
14.Shall include multitap auxiliary CT's for each bay including future bays as per SLD
and also include necessary CT switching relays wherever CT switching is involved.
15.Include protection 'in/out' switch for each zone with at least six contacts for each
switch.
16.Shall have CT selection incomplete alarm wherever CT switching is involved.
17.Have necessary auxiliary relays to make a comprehensive scheme.
At existing substations busbar scheme with independent zones for each bus will be
available. All necessary co-ordination for 'CT' and 'DC' interconnections between
existing schemes (panels) and the bays proposed under the scope of this contract shall be
fully covered by the bidder. Any auxiliary relays, trip relays, flag relays required to
facilitate the operation of bays covered under this contract shall be fully covered in the
scope of the bidder.
The Contractor shall offer all equipment to meet the requirements as above to make the
scheme full and comprehensive.
7.6.2 Weatherproof relay panels

Where required these panels shall be provided for busbar differential protection. The
panels shall include necessary number of electrically reset relays each with at least eight
contacts for isolator auxiliary contact multiplication and for changing the CT and DC
circuits to relevant zone of protection.
The panel shall be sheet steel enclosed and shall be dust, weather and vermin proof.
Sheet steel used shall be at least 3.0 mm thick and properly braced to prevent movement.
The enclosures of the panel shall provide a degree of protection of not less than IP55 (as
per IS 2147). The constructional requirements shall comply with the relevant section of
this Specification.
Two test terminal blocks required for bus coupler bay CT connection shall be supplied
and mounted inside the panel of adjacent bay.
The test terminal blocks shall be fully enclosed with removable covers and made of
moulded, non-inflammable plastic material with boxes and barriers moulded integrally.
Such blocks shall have washer and binding screws for external circuit wire connections, a
white marking strip for circuit identification and moulded plastic cover. All terminals
shall be clearly marked with identification numbers or letters to facilitate connection to
external wiring. Terminal block shall have shorting, disconnecting and testing facilities
for CT circuits.
7.7
Tripping relay (86)

High speed tripping relay shall:
1. Be instantaneous (operating time not to exceed 10 milliseconds).
2. Reset within 20 milliseconds. Not self resetting.
3. Be DC operated
4. Have adequate contacts to meet the requirement of scheme, other functions such as
auto-reclose relay, LBB relay as well as cater to associated equipment such as event
logger, disturbance recorder, fault locator, etc.
5. Be provided with operation indicators for each element/coil.
7.8
Flag relays
These shall have:
1. Hand reset flag indication
2. Two elements
3. Four contacts (NO or NC or combination as required), for each element/coil.
7.9
Trip circuit supervision relay

The relay shall be capable of monitoring the healthiness of each `phase' trip coil and
associated trip circuit of circuit breaker during ÒN' and ÒFF' conditions. The relay shall
have adequate contacts for providing connections to alarm and event logger. The relay
shall have time delay on drop-off of not less than 200 milliseconds and be provided with
operation indications for each phase.
7.10
Supply supervision relay

The relay shall be capable of monitoring the DC supply to which it is connected and
indicating failure. It shall have adequate potential free contacts to meet the scheme
requirement. The relay shall have a `time delay on drop-off' of not less than 100
milliseconds and be provided with operation indicator/flag.
7.11
Bus coupler / transfer bus coupler protection

The protection scheme for the above are to be provided with directional numerical over
current and earth fault protection scheme . The relay shall be latest version numerical and
IEC 61850 compliant for future SCADA purpose.The details as indicated under unit back
up protection relay.
All 220 kV substations shall be of Double Main (DM) or Double Main and Transfer
(DMT) busbar configuration and shall be provided with a single bus coupler circuit
breaker. In addition 220 kV DMT busbar configurations shall be provided with a transfer
bus coupler circuit breaker. The required protection equipment for these breakers
comprises overcurrent and earth fault relays. These relays shall comply with the
requirements for backup over current and earth fault protection as described elsewhere in
this section, except that the relays shall not be directional. The earth fault element shall
have a current setting range of at least 20 - 80 per cent in six equal steps.
All 132 and 33 kV substations shall be of Single Main and Transfer (SMT) busbar
configuration and a bus section isolator. Overcurrent and earth fault protection,
complying with the requirements as given elsewhere in this section but without
directional feature, shall be provided.
In DMT/SMT configurations, whenever the main breaker of a feeder or transformer is
substituted by the bus coupler or transfer bus coupler breaker, a facility for switching
over of the trip function of the feeder or transformer relays from the main breaker to the
bus coupler or transfer bus coupler breaker, shall be provided through provision of a
lockable protection transfer switch. The provision of a key interlock on the above switch
is to be so arranged that at one time only one feeder or transformer can be taken to
transfer mode.
7.12
Circuit breaker monitoring auxiliary relays

All circuit breakers shall be provided with several relay contacts for annunciation of
circuit breaker conditions such as :
Low air/hydraulic oil/gas pressure.
Lockout conditions due to abnormally low air/hydraulic oil/gas pressure.
Pole discrepancy trip.
Compressor/hydraulic pump trouble.
The exact requirements for this shall be available in the circuit breaker drawings to be
provided by the manufacturer. The programmable Inputs/Outputs of the numeric relays
shall be used as much as possible for providing annunciation in the control room for such
cases. In case this is found inadequate, suitable auxiliary flag relays may be provided in
the relay panels to provide annunciation.
7.13
Disturbance recorder (Required for 400 and 220 KV sub-station)
7.13.1 General
Where required disturbance recorders shall be provided separately. Integrated out put
from the relays memory is also acceptable.
Disturbance recorders shall be microprocessor based and shall be used to record the
graphic form of instantaneous values of voltage and current in all three phases, open delta
voltage and neutral current, open or closed position of relay contracts and breakers during
system disturbances. Necessary auxiliary VTs, to generate open delta voltage, shall be
supplied by the Bidder. The Bidder shall furnish along with the offer a typical printout for
simulated conditions, on original paper.
The disturbance recorder shall be an individual acquisition unit, one for each feeder, and
shall have at least 8 analogue and 16 event channels for acquisition of fault data and
events. The restitution unit, printer, EGA/VGA screen and key board shall be common
for the entire substation. The acquisition unit shall acquire fault data and store either on
portable magnetic cassettes or floppy discs, or instantaneously transfer data to the
restitution unit for storage in solid state non-volatile memory. The restitution unit shall be
capable of reading fault data from the magnetic cassettes or floppy discs or from its own
memory, as the case may be, and controlling the printer to give the graphic form
whenever desired by the operator. The acquisition units shall be located in the protection
panels of the respective feeders and the restitution unit along with the printer shall be
located suitably within the substation control room. Only one printer for the entire
substation is required for disturbance recording purposes.
The disturbance recorder system shall have non-volatile memory of the last ten faults of
at least 1.6 second duration each.
7.13.2 Features of the disturbance recorder.

The disturbance recorder shall incorporate the features as described below:
7.13.3 Software stability

The operation of the equipment shall be based on programme stored in non-volatile solid
state memory. The programme shall be stable and no inadvertent change of programme
shall occur.
7.13.4 Reliability
Large scale integrated circuits shall be used as far as possible to reduce the number of
components and interconnections and the amount of wiring. The components used shall
be subjected to strict quality control which shall include screening of components by heat
soaking and testing their functioning prior to assembly.
7.13.5 Simplicity of maintenance and repair

The number and type of modules employed shall be minimised. The modules shall be of
plug-in type and shall be easily accessible for maintenance and repair wherever required.
7.13.6 Immunity from the effects of hostile environment

The equipment shall be designed to operate satisfactorily even when subject to the effects
of severely hostile electrical environment such as interference signals arising from
switching transients. The equipment shall be mounted in self contained, free standing
cubicles and shall be of dust, vermin and rodent proof construction. Ventilation
arrangements shall be provided if warranted by power dissipation level of the equipment.
7.13.7 Interface with PC

The disturbance recorder should have an interface arrangement for the transfer and
storage of data to PC through its serial port. Necessary PC, software, special cables etc.
shall be part of the disturbance recorder and should be included in the Bid.
PC based user friendly, disturbance recorder evaluation software shall be provided for the
analysis and evaluation of the record data made available in the PC under WINDOWS
environment. The software features shall include:
Repositioning of analogue and digital signals
Selection and amplification of time and amplitude scales of each analogue and
digital channel
Calculation of MAX/MIN frequency and phase difference values
Recording of MAX/MIN values etc. of analogue channels
Grouping of signals to be drawn on the same axis etc.,
Listing and numbering of all analogue and digital channels and current, voltage,
frequency and phase difference values at the time of fault/tripping.
7.13.8 Power supply

Disturbance recorder equipment shall be suitable for operation from 220V DC or 110V
DC supplies as available at substation. Voltage variation of +10% and -20% can be
expected. Any other power supply that may be required for proper functioning of the
equipment including the printer shall be derived by the Bidder from his own equipment
and shall form an integral part of the disturbance recorder system.
7.13.9 Alarms and indications

All external and internal faults in the disturbance recorder equipment such as power
supply fail, printer faulty, paper exhausted, processor/memory fail etc. are required to be
indicated by means of light emitting diodes on the front of panels of the equipment if type
2 disturbance recorders are offered, or on the front of panel of the restitution unit if type 1
disturbance recorders are offered.
7.13.10 Scan rate

The frequency response shall be DC on lower side and 250 Hz or better on upper side.
The acquisition unit shall have a scan rate of 1000 Hz/channel or better.
The equipment shall have as an inherent part of it, starting sensors based on over voltage,
rate of change of current, and rate of change of frequency. These starting sensors, when
picked up, shall start the disturbance recorders to give out the graphic form of analogue
and event signals, in the case of type 2 disturbance recorders. If type 1 disturbance
recorders are offered the starting sensors, on pick up, shall preserve the fault data
acquired during the period of system disturbance, including pre-fault and post fault time,
on magnetic cassettes, floppy disks,CD or solid state memory of restitution unit, as the
case may be. Preserved fault data shall not be erased other than by the operator. Erasing
arrangement shall be provided in the restitution unit.
7.13.11 Starting sensors

The equipment shall have inherent to it starting sensors based on over voltage, rate of
change of current and rate of change of frequency. The starting sensors on pick-up shall
preserve the fault data acquired during the period of system disturbance including prefault and post fault time on magnetic cassettes,CD or floppy diskettes or solid state
restitution unit as the case may be.
7.13.12 Pre-fault and post-fault time

Pre-fault time shall not be less than 160 ms and the post fault time adjustable at a
minimum of two seconds and a maximum of not less than five seconds. If another system
disturbance occurs during one post-fault time, the recorder shall also be able to record the
same.
7.13.13 Amplitude and event resolution

Amplitude resolution shall not be less than eight bit. Event resolution shall be 2 ms or
better.
7.13.14 Print out

The print out shall contain the following:
1. Feeder identity.
2. Date and time (in hour, minute and second up to 100th of a second).
3. Identity of trigger source.
4. Graphic form of analogue and event signals of all the channels.
The print out shall be clear and legible without the help of looking glass or any such
device. Minimum acceptable paper width shall be 8-1/2 inches. (216 mm approx.)
7.13.15 Type and quantity of paper

Printer shall use plain paper. The Bidder shall provide as part of his scope of supply
sufficient consumable for 6 months operation. The arrangement of feeding and removing
paper rolls shall be quick and simple.
7.13.16 Time generator

Each disturbance recorder shall have its own time generator. The facility shall exist to
synchronise the time generator from station time synchronisation equipment having
output of following types at 30 min interval
1. Voltage signal - 3 to 50V continuously settable, with 50 ms minimum pulse
duration.
2. Potential free contact (Minimum pulse duration of 50 ms.)
3. IRIG-B
4. RS232C
At substations where station time synchronisation equipment is not available, time
generator of any one of the disturbance recorders can be taken as master. The facility
shall exist to synchronise the time generators of other disturbance recorders and event
loggers in that station with respect to it. The recorder shall give annunciation in case of
absence of `Sync'. pulse within a specified time. The clock of the time generator shall be
such that, the drift is limited to 0.5 seconds per day, if allowed to run without
synchronisation. Facility shall exist to display the time in hours, minutes and seconds on
the front of panel.
7.13.17 Inputs
The equipment shall be suitable for inputs from current transformers with 1A rated
secondary and capacitive voltage transformers with 63.5V (phase to neutral voltage) rated
secondary. Any device required for processing of input signals in order to make them
compatible to the equipment shall form an integral part of the equipment. However, such
processing of input signals shall in no way distort its wave form. The equipment shall be
carefully screened, shielded, earthed and protected as may be required for its safe
functioning. The input circuits shall withstand the following tests.
5kV impulse test in accordance with IEC 225 Part-IV.
High frequency disturbance test in accordance with IEC 255 Part-IV).
8.0
Event logger (**)

**As per the customers requirement
All 400 and 220 KV sub-station shall have separate Event Logger panel provision.
8.1
General
The event logger shall be used to record the open and close states of switch yard
equipment, relays and changes of alarms.
The function of the equipment should be based on programmes stored in it. The stored
programmes should permit some degree of flexibility of operation. Facility should be
provided to erase the existing programme and reprogram allowing changes to be made
very easily.
The number of modules and different types of modules should be minimised. The
modules should be of plug-in type and should be easily accessible to simplify
maintenance and repair.
The equipment should be designed to operate satisfactorily in severely hostile electrical
environment such as in 400kV/220kV switchyard which are prone to various interference
signals, typically from large switching transients.
The equipment should be carefully screened, shielded, earthed and protected.
Input/ Output circuits should withstand the following tests:
Impulse test in accordance with IEC 255, Part-IV.
High frequency disturbance test in accordance with IEC 255, Part-IV.
Since the equipment will be used in dedicated non-attended situations, programme
stability is vitally important. Programme must not be capable of being changed
unintentionally during normal operation.
8.2
Construction
The equipment should be constructed in clearly defined plug-in modules. A monitor
module should be provided for indicating internal faults such as processor failure,
memory failure, other internal hardware failures, and also external plant failures. These
failures should be displayed on the LED's mounted on the monitor module. The
equipment is used to record changes in digital points, i.e. operations and resetting of
alarms and switching of primary equipment within a substation. Approximately 500
points should be accommodated in a single equipment. When such changes occur, a print
out on a local teletype writer, which forms a part of this contract, should result.
The date and time should be printed to the nearest 10 ms followed by a message
describing the point which has operated. Such messages may be abbreviated or in full
English forms. Events occurring whilst a previous event is in process of being printed are
to be stored to await printing. Over 100 such events must be stored. Facility shall exist to
synchronise the internal clock system which will give a pulse output every half an hour
with a pulse duration of at least 50 milliseconds through potential free contracts.
However, if master clock system is not available, time generator of any one of the
disturbance recorder shall be taken as master and event logger(s) in that station will be
synchronised with it. The event logger shall give annunciation in case of absence of
synchronising pulse within a specified time window. The internal clock of the event
logger shall be such that the drift is limited to 0.5 seconds per day, if allowed to run
without time synchronisation. The print out of current alarm and plant stages must be
available on request by the operator. the operator should also be able to enter the date and
time from the key board.
8.3
The event recorder shall record all changes of alarms and plant states of switchyard
equipment, along with the date and time of all alarms and plant state changes to the
nearest 10 ms.
Facility shall be provided to commit 50 points of sequential memory or 25% of alarm
whichever is the greater. In addition the unit shall be capable of handling up to 40
changes in any one 10 ms interval and 500 alarms and changes of state of switchyard
equipment.
On receipt of an alarm the equipment must:
Print out a message on Printer
Set off an audible alarm.
Set off a beacon.
Allow normal inputs of
Accept
Alarm demand log
Plant state demand log
Date and time
The Bidder shall furnish along with the offer a two copies on original paper typical print
out for simulated conditions.
Only plain paper readily available in India shall be used for the printer. The arrangement
of feeding and removing paper rolls or stacks shall be quick and simple. The width of
paper shall be 216 mm approximately. The Bidder shall provide as part of his scope of
supply, consumables for up to six months operation.
Event printout of the shall contain as a minimum the following:
Station identification.
Date and time (in hour, minutes, seconds and milliseconds).
Event number.
Event description (at least 40 characters).
The auxiliary power supply required for the event logger, VDU and printer shall be either
220V DC or 110V DC (as available in the station) with voltage variation of + 10% to 20%. Any other power supply that may be required for proper functioning of the
equipment has to be derived by the Bidder from his own equipment which shall form an
integral part of the event logger station.
Bidder shall supply VDU, printer and keyboard arrangement.
At existing substations where an event logger is provided, Bidder shall provide necessary
potential free contracts of various relays/equipment for plant and alarm states and shall
co-ordinate with existing event logger for proper logging of events.
A combined solution of disturbance recorder and event logger function with a VDU, key
board and a printer is also acceptable.
9.0
Synchronising equipment
Where required synchronising equipment shall be provided along with this Contract.
The synchronising instruments shall be mounted on a synchronising trolley. The trolley
shall be equipped with double voltmeter, double frequency meter, synchroscope and
lamps fully wired. The trolley shall be of mobile type with four rubber padding wheels
capable of rotating in 360 degree around the vertical axis. Suitable bumpers with rubber
padding shall be provided around the trolley to prevent any accidental damage to any
panel in the control room while the trolley is in movement.
The trolley shall have two metre long flexible cord fully wired to the instruments and
terminated in a plug in order to facilitate connecting the trolley to any of the panels. The
receptacle to accept the plug shall be provided on the panel.
Synchronising check relay with necessary ancillary equipment shall be provided. This
shall permit breakers to close after checking the requirements of synchronising of
incoming and running supply. The phase angle setting shall not exceed 35 degree and
have voltage difference setting not exceeding 10%. This relay shall have a response time
of less than 200 milliseconds when the two system conditions are met within present
limits and with the timer disconnected. The relay shall have a frequency difference
setting not exceeding 0.45% at rated value and at the minimum time setting. The relay
shall have a continuously adjustable time setting range of 0.5-3 seconds. A guard relay
shall be provided to prevent a closing attempt by means of synchronising check relay
when control switch is kept in closed position before the two systems are in synchronism.
Suitable auxiliary voltage transformers, wherever necessary, shall also be provided for
synchronising condition. In case the synchroscope is not continuously rated, a
synchroscope cut-off switch shall be provided and an indicating lamp to indicate that the
synchroscope is energised, shall also be provided.
Each circuit for which a synchronous closure is required shall be provided with a
lockable synchronising selector switch which shall be used to select the voltage signals
(incoming and running voltage) appropriate for that circuit. The provision of a key
interlock shall ensure that at any one time only one feeder / transformer can be
synchronised.
10.0
Time synchronisation equipment for substation

The Bidder shall offer necessary time synchronisation equipment complete in all respects
including antenna, all cables, processing equipment etc. required to receive co-ordinated
universal time (UTC), transmitted through GEO Positioning Satellite System (GPS).
The time synchronising system should be compatible for synchronisation with event
loggers, disturbance recorders, relays, computer systems and all other equipment
provided in the protection, control and metering system of the substation wherever
required.
Equipment should operate up to an ambient temperature of 50C and 100% humidity. The
synchronisation equipment shall have two microsecond accuracy. Equipment should give
real time corresponding to IST (taking into consideration all factors such as voltage and
temperature variations, propagation and processing delays etc.
Equipment should meet the requirement of IEC 255 for storage and operation. The
system should be able to track the satellites to ensure no interruption of synchronisation
signal.
The output signal from each port shall be programmable at site for either one hour, half
hour, minute or second pulse, as per requirement.
The equipment offered shall have six output ports. Various combinations of output ports
shall be selected by the Project Manager, during detailed engineering, from the following:
1. Voltage signal : 0-5V continuously settable, with 50 ms. minimum pulse duration.
2. Potential free contact : minimum pulse duration of 50 ms
3. IRIG-B
4. RS232C
The equipment should have a periodic time correction facility of one second periodicity.
Time synchronisation equipment shall be suitable for operation from 220V DC as
available at substation with a voltage variation of +10% and -20%. Any other power
supply that may be required for proper functioning of the equipment shall be derived by
the Bidder from his own equipment which shall form an integral part of the system.
Equipment shall have real time digital display in hour, minute, second (24 hour mode)
and have a separate time display unit to be mounted on the top of control panels having
display size of approximately 100 mm height.
Bidder shall quote unit rates for each type of output port for the purpose of
addition/deletion.
Schedule of Quantities
11.0
General
Protection, control, metering panels and associated equipment to be located in switchyard
control rooms at various substations shall be offered as panels/systems/modules of
following description. The quantities are given at the end of this section.
Sl. No.
Description of Panels
Control
Panel type
and
designtation
Relay Panels
type and
designtation
1
1.1
2.1
Line protection panel:

400kV line-4CT,5CT (
1 1/2 breaker scheme)
220kV line-DMT
132kV lineMT
33kV lineMT
Transformer protection
panel:
400/220kV Auto-
CPF4H
RPF4H
CPF2D
CPF1M
CPF0M
RPF2D
RPF1M
RPF0M
CPH4H
RPH4H
2.2
Transformer
220/132kV Auto-
CPL2D
CPH2D
RPL2D
RPH2D
2.3
Transformer
220/33kV power
CPL1M
CPH2D
RPL1M
RPH2D
Transformer
CPL0M
RPL0M
132/33kV power
Transformer
Reactor protection
panel:
Bus reactor
Line reactor
CPH1M
CPL0M
RPH1M
RPL0M
CPR4H
CPS4H
RPR4H
RPS4H
1.2
1.3
1.4
2
2.4
3
3.1
3.2
REMARKS
4.1
4.2
4.5
11.1
Transfer bus coupler

220kV line-DMT
220kV line-T
Bus coupler
220kV line-DMT
132kV lineMT
33kV lineMT
Bus sectionaliser
CPT2D
CPT2T
RPT2D
RPT2T
CPB2D
CPB1M
CPB0M
CPZ2D
RPB2D
RPB1M
RPB0M
RPZ2D
Type designations for the various panels

The panels are designated by a alpha-numeric code consisting of five characters
(AAANA) through out this schedule in this specification to represent their use for various
applications. Their representation shall be as here under:
Character position
Character representation
12
AA
3 4
A N
5
A
H
11/2 breaker scheme
D
Double main and transfer switching
scheme
M
Main and transfer switching scheme
S
Single bus
T
Two mains bus switching scheme
R
Ring main bus switching scheme
0
1
2
4
F
H
L
R
S
T
B
Z
C
V
M
N
O
P
Q
CP
RP
KP
33kV
132kV
220kV
400kV
Feeder
Transformer High Voltage Side
Transformer Low Voltage Side
Bus reactor
Shunt(line) reactor
Transfer bus coupler
Bus coupler and Bus bar
Bus sectionaliser
Capacitor bank protection
Bus bar
Diameter with Transformer and Feeder
Diameter with Feeder and Feeder
Diameter with Feeder and Feeder
1/2 Diameter with Single Feeder
1/2 Diameter with Single Feeder with Reactor
Control panel
Relay panel
Common panel
11.2
Bill of quantities for individual panels

Each panel described above shall constitute the equipment as detailed here under . The
quantities of each type of equipment are minimum. The bidder may include additional
devices in the panels depending upon the design and requirements as per stipulations of
the specification.
Control panel (CPANA)

CPA4H / CPA2H
CPA2D /CPA1M /CPA2T
CPA1M /CPA0S / CPA0T
Sl. no
List of equipment
Quantities required for each panel

For 400kV / 220kV
For 220kV and 132kV For 33kV
and 1 1/2 breaker
scheme
1.
Ammeter
(Digital)
2.
Wattmeter
(Digital)
3 Nos. for each

bay (1 for each
bay in case of
220 kV )
+ 1No. for
reactor ( as per
requirement)
1 No. for each
bay
3.
VARmeter
(Digital)
4.
5.
6.
7.
8.
9.
1No.
(2 Nos. for Bus
section coupler)
1No.
1 No.
(2 Nos. for Bus
section coupler)
1 No.
(2 Nos. for Bus
section coupler)
1 No.
1 No. for each

bay + 1 No. for
line reactor ( as
per requirement)
Voltmeter
1 No. for each
1 No. for each
(Digital)
bay
bus bar (only in
bus coupler
panel)
Digital voltmeter with
1 set for new
1 set for new
selector switch
substation in
substation in bus
any one specific coupler panel
control panel
Digital frequency meter 1 set in any one 1 set in bus
specific control coupler panel
panel
Solid state trivector type 1 No. for each
1 No.
energy meter for
bay
(Not required in
recording export, import
bus coupler
of MWH, MVA and
panel)
MVARH with MDI.
Winding temperature
Not required
Not required
indicator
Discrepancy control
1No. for each
1No. for each
switch for breaker
circuit breaker
circuit breaker
1 No.
1 No. (only in bus

coupler panel)
Not required
1 set in bus
coupler panel
1 No.
Not required
1 No. for each
circuit breaker
13.
Ammeter selector
switch
14.
Voltage selector switch
1No. for each

isolator
one for each
earth switch
one for each
panel
one for line
reacter (as per
requirement)
one for each bay
15.
DC source selector
switch
one for each

panel
10.
11.
12.
16.
16.1.
16.2.
Discrepancy control for

isolator
Discrepancy control for
earth switch
Mimic to represent SLD
Indicating lamps
Red indicating lamps
for ON
Green indicating lamps

for OFF
16.6.
White indicating lamp

for circuit breaker
healthy
Indicating bulb for
circuit breaker control
position (Local/Remote)
(If required)
Blue indicating lamp
(for spring charge )
for annutiation D.C. fail
16.7.
for annutiation A.C. fail
16.8.
for flasher healthy
16.9.
for Busbar VT
secondary healthy
16.3.
16.4.
16.5.
1No. for each

isolator
one for each
earth switch
one for each
panel
one for each
panel
1No. for each

isolator
one for each earth
switch
one for each panel
one for each volt

meter ( only in
buscoupler Bay)
one for each
panel (as per
requirment)
one for each volt

meter ( only in
buscoupler Bay)
one for each panel
(as per
requirment)
one for each

isolator, earth
switch and
circuit breaker
one for each
isolator, earth
switch and
circuit breaker
one for each
circuit breaker
one for each

isolator, earth
switch and circuit
breaker
one for each
isolator, earth
switch and circuit
breaker
one for each
circuit breaker
one for each

isolator, earth
switch and circuit
breaker
one for each
isolator, earth
switch and circuit
breaker
one for each
circuit breaker
two for each

circuit breaker
two for each

circuit breaker
two for each

circuit breaker
one for each

circuit breaker
one in any one
specific control
panel
one in any one
specific control
panel
one in any one
specific control
pannel
one for each

circuit breaker
one in
buscoupler
pannel
one in
buscoupler
pannel
one in buscoupler
pannel
one for each

circuit breaker
one in buscoupler
pannel
three for each

bus in any one
specific control
three for each

three for each bus
bus in buscoupler in buscoupler
pannel
pannel
one for each panel
one in buscoupler
pannel
one in buscoupler
pannel
panel
17.
17.1.
Push buttons
for alarm accept
17.2.
for alarm reset
17.3.
for lamp test
17.4.
for audio alarm reset
17.5.
for annuciation D.C. fail

accept
17.6.
for annuciation D.C. fail

test
17.7.
for annuciation A.C. fail

accept
17.8.
for annuciation A.C. fail

test
18.
19.
20.
21.
22.
one for each

panel
one for each
panel
one for each
panel
one in any one
specific control
panel
one in any one
specific control
panel
one in any one
specific control
panel
one in any one
specific control
panel
one in any one
specific control
panel
one for each

panel
one for each
panel
one for each
panel
one in buscoupler
pannel
one for each panel
one in
buscoupler
pannel
one in buscoupler
pannel
one in buscoupler
pannel
one in
buscoupler
pannel
one in buscoupler
pannel
Annunciation windows
with necessary
annunciation relays
18 for each
feeders bay
24 for each
treansformer
bay
6 for each Tie
12 for each
feeders panel
18 for each
transformer panel
6 for each bus
coupler panel
Synchronising socket
one for each

circuit breaker
one for each
panel
18 for each
feeders panel
24 for each
transformer panel
6 for each Tie
and each bus
coupler panel
one for each
circuit breaker
one for each
panel
one for each
panel
not required
one for each panel
one for each new

sub-station
one for each new
one for each new

sub-station
one for each new
Bus CVT selector

switch (as per
requirment)
Protection trip transfer
switch (TTS)
Reactor de-interlocking
push button
23.
Hooter
24.
Buzzer
not required
one for each
circuit breaker
bay (where
applicale)
one for each
new sub-station
one for each
one for each panel

one for each panel
one in buscoupler
pannel
one in buscoupler
pannel
one in buscoupler one in buscoupler

pannel
pannel
Not required
one for each panel
not required
new sub-station
11.3
sub-station
sub-station
Line protection panel (RPLNA)

The line protection panel or panels may be a single panel or more panels to accommodate
all the equipments listed below. However, for bay extension, new panels must match the
existing panels in all respect.
Sl. No
Equipment
Main-I protection scheme (composite

numerical distance protection relay
with auto reclosing and check
syncronising facility)
Main-II protection scheme(composite
numerical distance protection or phase
comparision relay with auto reclosing
and check syncronising facility)
Composite numerical directional over
current and earth fault relay.
Over voltage/ Under voltage
protection scheme (if not available in
the main-I protection module)
Selector switch for carrier in/out for
main-I and main-II protection scheme
400kV
RPL3H
1 set
Quantities required
220kV 132kV 33kV
RPL2A RPL1A RPL0A
1 set
1 set
Not
require
d
1 set
1 set
Not
require
d
Not
require
d
1 set
1 set
1 set
1 set
1 set
1 set
1 set
2 Nos.
2 Nos.
1No.
Disturbance recorder (if not available

in the distance protection or main
protection module)
Distant-to-fault locator for phase and
earth faults(if not available in the
distance protection or main protection
module)
CVT selecting relays or switches
(depending on switching scheme)
1 set
1 set
1 set
1 set
1 set
1 set
Not
require
d
Not
require
d
Not
require
d
Not
require
d
1 set
1set
1set
10
Test terminal blocks for Main-I/ Main

II/other protection relay
1 set for
each
module
11
Auxiliary relays for carrier

supervision of Main-I and Main II
protection relays (depending on its
application)
Carrier receive lockout relay
1 set
1 set
for
each
module
1 set
1 set
for
each
module
1 set
1 set
1 set
1 set
3
4
12
Not
require
d
1 set
for
each
module
Not
require
d
Not
(depending on its application)

13
14
15
16
17
18
19
11.4
Breaker failure protection scheme

Trip circuit pre and post supervision
relays for trip coil I and II
DC supply supervision relay
Flag relays for circuit breaker trouble
shooting
Trip relays single/three phase for
group-A
group-B
Under Frequency Relay
1 set
1 set
1 set
1 set
1 set
1 set
require
d
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
Transformer protection panel(RPHNA and RPLNA)

The transformer protection panel or panels may be a single panel or more panels to
accommodate all the equipments listed below. However, for bay extension, new panels
must match the existing panels in all respect.
Sl. No
2
3
4
5
Quantities required
For each
For each
For each
High
High
Low
Voltage
Voltage
Voltage
panel of
panel of
Panel of
400/220kV
220/33kV
transfor
and
and
mers
220/132kV
132/33kV
transformer transformer
s
s
Main-I Transformer composite
1 set
1 set
Not
numerical protection comprising of the
required
following:
Differential protection
Restricted earth fault protection
Over fluxing protection
Main-II Duplicated numerical
1 set
Not required Not
protection as Main-I
required
Composite numerical directional over 1 set
1 set
1 set
current and earth fault protection relay
Over load protection ( if not included
1 set
1 set
1 set
in sl.no. 1 and 2 above)
Over voltage/ Under voltage
1 set
1 set
Not
protection scheme (if not available in
required
the main protection module)
Flag relays for thermal imaging,
1 set
1 set
Not
Equipment
9
10
11
12
13
14
15
11.5
MOG, WTI, OTI, Bucholz, PRV,OSR

and status indication etc.. (1.MOGAl,2.WTI,BUCH,OTI Al & Trip,3.
PRV,OSR Trip)
Solid state trivector type energy
meters for measurement of export/
import of MWH, MVA and MVARH
with MDI.
CVT selection relays (depending upon
the the switching scheme of the
system)
relays for trip coil I and II.
shooting
Trip relays three phase for group-A
Trip relays three phase for group-B
Test terminal blocks for all protection
relays
required
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 No for
each panel
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set for each
module
1 set
1 set
1 set for each
module
1 set
1 set
1 set for
each
module
Transfer bus coupler (RPT2D) / Bus coupler and Busbar (RPBNA)

protection panel
Bus bar protection panel shall be equipped to accommodate all present and future bays.
Sl. No
Equipment
RPB4H
1.
2.
3.
4.
5.
Composite numerical nondirectional and earth fault

protection
Test terminal block for all
protection relays
Not
required
Trip circuit pre and post

supervision relays for trip coil I
and II
Not
required
Flag relays for circuit breaker

trouble and status indication etc.
Not
required
Not
required
Not
required
Quantities required
RPB2A
RPB1A/
RPB0A
1 set
1 set
RPT2D
1 set
1 set for
each
module
1 set for
each
module
1 set
1 set for
each
module
1 set
1 set
1 set
1 set
1 set
1 set
1 set
6.
7.
8.
9.
10.
11.
12.
Breaker failure protection

scheme
group-A
group-B
Bus bar differential relay for BusI
Bus bar differential relay for BusII
CT switching/selection relays
Not
required
Not
required
Not
required
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
Not
required
Not
required
Not
required
Not
required
Not
required
Not
required
Not
required
Not
required
1 set
1 set
1 set
1 set
Bus bar differential relay for

Check Zone
1set
1set
At existing substations, necessary trip relays and auxiliary relays required shall be
included in the offer to accommodate the new bays for existing bus bar protection
schemes.
11.6
Common equipment (RPKNA)

Sl. No
11.7
1.
Equipment
Bus-I voltage recorder
Quantities required
1 No.
2.
Bus-II voltage recorder
1 No.
3.
Bus-I frequency recorder
1 No.
4.
Bus-II frequency recorder
1 No.
5.
Event logger
1 No.
Bus sectionalizer protection panel

Sl. No Equipment
Composite numerical non-directional
1.
and earth fault protection relay
Test terminal block for all protection
2.
relays
3.
relay for trip coil I and II
4.
5.
6.

and status indication etc.
Quantities required
2 sets
1 set
2 No
1 No
2 No
2 set
7.
Trip relays three phase for group-A
2 set
8.
Trip relays three phase for group-B
2 set
Bus bar differential relay for Bus-I

(numerical type- IEC -61850)
Bus bar differential relay for Bus-II
CT switching/selection relays
1 set
Bus bar differential relay for Check

Zone
1set
9.
10.
11.
12.
11.8
1 set
1 set
Synchronising panel
Synchronisation panels are required for new substations and addition of new voltage (
132kV and above) to existing substation.
Sl. No
1
2
3
4
12.0
12.1
12.2
Equipment
Double Voltmeter (0-150v range)
Double Frequency meter (45-55Hz)
Synchroscope
Synchronising relay
Quantities required
1 no for each panel
1 no for each panel
1 no for each panel
1 set for each panel
** ALL THE RELAYS SHALL BE OF NUMERICAL VERSION HAVING

IEC 61850 PROTOCOL COMPLIANCE.ALL CARE SHALL BE
TAKEN IN DESIGNING THE PROTECTION SYSTEM FOR
FUTURE SCADA PROVISION. THERE SHALL BE ADEQUATE
NO OF INPUT AND OUT PUT CONTACTS FOR USE. SHALL
HAVE SELF SUPERVISING AND INTERNAL FAULT
DETECTING/DIAGNOSING FACILTY. SUFFICIENT FAULT
/DISTURBANCE RECORDING FACILITIES.
ERECTION AND MAINTENANCE TOOL EQUIPMENT:
All special testing equipment required for the installation and maintenance of the
apparatus,instruments devices shall be furnished . The testing plug shall be
supplied along with the panels for conducting testing of relays. These
testing plug should be suitable for test terminal box provided in the panel.
TROPICALISATION:
Control room will be normally air-conditioned. All equipments shall however be
suitable for installation in a tropical monsoon area having hot,humid
climate and dry and dusty seasons with ambient conditions specified in the
specification. All control wiring,equipment and accessories shall be
protected against fungus growth,condensation,vermin and other harmful
effects due to tropical environment.
RELAY TEST KIT
One relay test kit shall comprise of the following equipment as detailed
hereunder.
1. Relay tools kits: 3 Sets
2. Test plugs: 2 Nos
3. Special type test plugs for using with modular
type cases(if applicable): 1 No
13.0
ADDITIONAL INFORMATION ON PROTECTION RELAYS, SWITCHES ETC.
13.1
RELAYS:
1. All relays shall confirm to the requirements of IS: 3231/IEC-60255 and IEC61850 protocol compliance. Relay shall be suitable for flush or semi-flush
mounting on the front with connections from the rear.
2. Shall be draw out or plug in type/modular cases with proper testing facilities.
Necessary test plugs/test handles shall be supplied, which is in the scope of this
contract.
3.The protective relay shall be suitable for efficient and reliable operation of the
protection scheme as indicated in the specification. Necessary auxiliary relays etc for
interlocking scheme, for multiplying contacts suiting for the scheme and monitoring
of control supplies and circuits, lockout relay monitoring circuits etc. Auxiliary
relays and timers shall have pairs of contacts as required to complete the scheme,
contacts shall be silver faced with spring action. It shall have adequate numbers of
terminals for making potential free external connection to the relay coils and
contacts, including spare contacts. All the contacts of the auxiliary relays and timers
except lock out type relays shall have self reset type contacts
4. No control relay which shall trip the power circuit breaker when the relay is
deenrgised shall be employed in the circuit.
5. Provision shall be made for easy isolation of trip circuits of each relay for the
purpose of testing and maintenance.
6. All protective relays and alarm relays shall be provided with one extra isolated
pair of contacts wired to terminals exclusively for future use.
7. The bidder shall include in his bid a list of installations where the relays quoted
have been in satisfactory operation.
8. The numerical relays shall include the followings:
i) Necessary software and hardware to up/down load the datas to/from the
relay from/to the personal computer ( supply is in the scope of this contract.).
ii) The relay shall have suitable communication facilities for future
connectivity to SCADA. The relay shall be capable of supporting IEC 870-5-103
protocol. Neither the interface hardware nor the software for connectivity to
SCADA will form part of the scope of this specification.
iii) In the numerical relays the features like disturbance recorder and event
logging function as available in these relays shall be supplied.
13.2
A) Transmission Line protection:
The line protection relays are required to protect the line and clear the faults on line
within shortest possible time with reliability, selectivity and full sensitivity to all type
of faults on lines.
1. The maximum fault current could be as high as 40 KA and minimum fault
current could be as low as20% of rated current of the CT secondary. The
starting and measuring relay characteristics should be satisfactory under
these extremely varying conditions.
2. The protective relays shall be suitable for use with capacitor voltage
transformer having non-electronic damping and transient response as per
IEC.
3. Disturbance recorder, Distance to fault locator, over voltage, auto reclose
functions are integral functional part of the relay.
4. The following protection for line protection shall be provided.
13.3
For 400 KV & 220 KV

Main I
Numerical distance protection scheme.
Main II
Numerical distance protection scheme of a make different from that
of
Main I.
Back up:
Directional Over current and Earth fault protection.
For 132 KV.
MainNumerical distance protection scheme.
Back up:
Directional over current and Earth fault protection.
13.4
MAIN-I & MAIN-II:

1. Shall be numerical type and shall be continuous self monitoring and
diagnostic feature.
2. Shall be non-switched type with separate measurements for all phase to
Phase & phase to ground faults.
3. Shall have stepped time distance characteristics and a minimum of three
independent zones & a zone for reverse reach..
4. Shall have mho /quadrilateral (if both with selection facilities) characteristics
or other suitable characteristics for the above mentioned zones.
5. Shall have following maximum operating time (including trip relay time, if
any) under given set of conditions and with CVT being used on line (with all
filters included)
13.4.1
For 400,220 KV
Source to Impedance ratio:
Relay setting (ohms)
Fault locations (as % of
Relay settings)
Fault resistance (ohms)
Maximum operating time
faults
faults
400KV
4
10/20
50
15
22
50
40ms
For all faults
220KV
45ms for Phase

60ms for all other
13.4.2
For 132 KV line:

Datas as indicated for 200 KV line
Shall remain same except maximum
Operating time:
5ms relaxation in the above
timings
6. Relay shall have independent setting of R and X and also an adjustable
relay characteristic angle having setting range from 30 -75 degree.
7. Shall have independent continuously variable time settings from 0 to 5
seconds.
8. Shall have resetting time of less than 55 miliseconds (including the reset time
of the trip relays)
9. Shall have offset features with adjustable 10 20% of zone setting.
10. Shall have variable residual compensation.
11. Shall have memory circuits with defined characteristics in all three phases to
ensure correct operation during close up 3-phase faults and other adverse
conditions and shall operate instantaneously when circuit breaker is closed to
zero volts three phase fault.
12. Shall have week end in-feed features.
13. Shall be suitable for single and three phase tripping.
14. Shall have a continuous current rating of two times of rated current. The
voltage circuits shall be capable of operation at 1.2 times rated voltage. The
relay shall have the capability to carry a short circuit current of 70 times the
rated current without damage for 1second.
15. Shall be provided with necessary self reset type trip duty contacts for
completion of the scheme.(a minimum number of such contacts shall be 4 per
phase). The making capacity of the contacts shall be 30 amps for 0.2 seconds
with an inductive load of L/R>10ms.
16. Shall have permissive under reach/over reach/blocking communication
mode.
17. Shall have sufficient number of potential free contacts for carrier aided
tripping, Auto reclosing, Event logger, Disturbance recorder & Data
acquisition system.
18. Shall have power swing blocking protection (i) suitable setting range to
encircle the distance protection (ii) block tripping during power swing
conditions.
19. Include fuse failure protection (i) monitor all three fuses of CVT and
associated cable against open circuit(ii) inhibit trip circuits on operation and
initiate annunciation(iii)have an operating time less than 7ms(iv)remain
inoperative for system earth faults.
20. Shall have directional back up Inverse Definite minimum Time earth fault
relay with normal inverse characteristics as per IEC 60255-3 as a built in
feature.
21. Shall have broken wire features having option for tripping/ annunciation.
13.5
BACK UP DIRECTIONAL O/C & E/F PROTECTION SCHEME.

1. Shall have three over current and one earth fault elements.
2. Shall be numerical type.

3. Shall have suitable VT fuse failure for relay alarm purpose.
O/C features:
4. Shall have IDMT characteristic with a definite minimum time of 3.0 seconds
at 10 times setting.
5. Shall have variable setting range up to 200% of rated current.
6. Shall have relay characteristic angle of 30/45 deg lead.
7. LED indications for different type faults.
E/F features:
8. Shall have IDMT characteristics with a definite minimum time of 3.0 seconds
at 10 times setting.
9. Shall have variable setting range up to 80% 0f rated current.
10. Shall have characteristic angle of 45/60 deg lag.
11. LED indications for all type of faults
12. Include necessary separate interposing voltage transformers or have internal
features in the relay for open delta voltage to the relay.
13. Shall have continuous self monitoring and diagnostic feature.
13.6
AUTO RECLOSING RELAY:

1. Shall have single phase and three phase reclosing facilities.
2. Shall have continuously variable single phase dead time range of 0.1 2 sec
3. Shall have continuously variable reclaim time range 5 25 sec.
4. Shall have provision of selection with single phase//three phase//single and
three phase auto reclosure and non auto reclosure mode (can be selected
through programming).
5. Shall have provision of selecting check synchronizing or dead line charging.
6. Shall be single shot type.
7. Shall have priority circuit to closing of both circuit breakers incase one and
half breaker arrangements to allow sequential closing of breakers.
8. Include check synchronizing relay which shall
I)
Have a time setting variable from 0.5 5 sec with a facility of
additional 10 sec.
II)
Have a response time within 200 ms with the timer disconnected.
III) Have a phase angle setting not exceeding 35 deg.
IV)
Have voltage difference setting not exceeding 10%
V)
Include dead line charging relay.
13.7
TRANSFORMER PROTECTION:
Transformer differential protection scheme shall be of numerical relay.
1. Shall be triple pole type with faulty phase identification/indication.
2. Shall have an operating time not greater than 30ms at 5 times the rated
current.
3. Shall have three instantaneous high set over current units.
4. Shall have an adjustable bias setting range of 10 50%.
5. Suitable for rated 1 amp current.
6. Shall have 2nd harmonics or other inrush proof features and also should be
stable under normal over fluxing conditions. Magnetising inrush proof
features shall not be achieved any intentional time delay.
7. Shall have an operating current setting of 15% or less.
8. Shall have an internal feature of the relays to take care of the angle and ratio
correction.
9. Shall have provision of self monitoring and diagnostic feature.
10. Shall have provision of recording features to record graphic from of
instantaneous values during faults and disturbances for the pre and post
fault period and during running conditions.
11. Current in all the windings in separate analog channels and voltage in one
channel.
The disturbance recorder shall have the facility to record the following external
digital channel signals apart from the digital signals pertaining to differential
relay.
a) REF protection operated.
b) HV breaker status (suitable for 1&1/2 breaker system also)
c) IV & LV breaker status.
d) Bucholtz /OLTC Bucholtz /PRV alarm/trip.
e) WTI/OTI alarm/trip
f) MOG alarm
Necessary hardware and software for automatic up-loading the data captured by
disturbance recorder to the personal computer.
12. Shall have built in features of definite time over load protection (alarm)
relay.
a) Shall be single pole type.
b) Shall have definite time O/C.
c) Shall have one set of O/C relay element, with continuously adjustable
setting up to 200%(50% -200%) of rated current.
d) Shall have adjustable time delay alarm having setting range of 1 to
10.0 sec continuously.
e) Shall have a drop-off/pick-up ratio greater than 95%
13.
Shall have feature of REF protection for three winding transformers.
a) Shall have current setting (continuously variable) range from 10%40% of 1 Amp.
b) Shall be tuned to the system frequency.
c) Shall have provision of for limiting the peak voltage (>1000Volts)
during fault condition.
14.
Shall be numerical type and shall have continuous self monitoring
and diagnostic feature.
13.8
OVER FLUXING PROTECTION:

1. Shall be latest version numerical relay.
2. Shall have the principle of voltage to frequency ratio and shall be phase
to phase connected.
3. Shall have inverse time characteristics, matching with transformer over

fluxing withstand capability curve.
4. Provide an independent alarm with the time delay continuously
adjustable between 0.1 to 6.0 seconds at values of v/f, from 100% to 130%
of rated values.
5. Shall have tripping time to be governed by v/f Vs time characteristics of
the relay.
6. Shall have a set of characteristics for various time multiplier settings. The
maximum operating time of the relay shall not exceed 3 seconds and 1.5
seconds at v/f values of 1.4 and 1.5 times, the rated values, respectively.
7. Shall have resetting ratio of 95% or better.
8. Shall be numerical type and shall have continuous self monitoring and
diagnostic feature.
9. Shall have fault recording feature.
13.9
LOCAL BREAKER BACKUP PROTECTION SCHEME:

1. Shall have triple pole type.
2. Shall be of numerical type and shall have continuous self monitoring and
diagnostic feature.
3. Shall have an operating time of less than 15ms
4. Shall have resetting time of less than 15ms.
5. Shall have three over current elements.
6. Shall be arranged to get individual initiation from the corresponding
phase of main protections of line for each over current element.
7. Shall have setting range of 20-80% of rated current.
8. Shall have continuous thermal withstand two times rated current
irrespective of the setting.
9. Shall have a timer with continuously adjustable setting range of 0.1 1
sec.
10. Shall have necessary auxiliary relays to make a comprehensive scheme.
13.10
TRIPPING RELAY:
1. High speed tripping relay.
2. Instantaneous operation(time not to exceed 10ms)
3. Reset within 20ms
4. Shall be DC operated.
5. Shall have adequate contacts to meet the requirement of scheme, other
functions like auto-reclose relay, LBB relay as well as cater to associated
equipment like event logger, disturbance recorder, fault locator etc.
6. Shall have provision of operation indicators for each element/coil.
13.11
TRIP CIRCUIT SUPERVISION RELAY:

1. The relay shall be capable of monitoring the healthiness of each phase
trip coil and associated circuit of circuit breaker during ON and OFF
conditions.
2. Shall have adequate contacts for providing connection to alarm and event
logger.
3. Shall have time delay on-drop-off of not less than 200ms and be provided
with operation for each phase.
13.12
DC SUPERVISION RELAY:
1. Shall be capable of monitoring the failure of DC supply to which it is
connected.
2. Shall have adequate potential free contacts to meet the scheme
requirement.
3. Shall have a time delay drop-off of not less than 100ms and be provided
with operational indicator/flag.
13.13
SWITCHES:
1. Control and instrument switches shall be rotary operated type with
escutcheon plates clearly marked to show operating position and circuit
designation plates and suitable for flush mounting with only switch front
plate and operating handle projecting out.
2.
The selection of operating handles for the different types of switches
shall be as follows.
Purpose
Type
Breaker, Isolator control switches
Discrepancy type
Synchronising switches
Oval, Black, keyed handle

(having common key for a
group of switches)
Synchronising selector switch
Oval or knob, block
Instrument switches
Round, knurled, black
Protection transfer switch
Pistol grip, lockable &

black
** In case the rotary switches are provided for breaker and
isolator control Semaphores are also to be provided along with
the switches.
3. The control switch of breaker and isolator shall be of spring return to
neutral type. The switch shall have spring return from close and trip
position to after close and after trip position respectively.
4. Instrument selection switches shall be of maintained contact (stay put)
type. Ammeter selection switches shall have make before break type
contacts so as to prevent open circuiting of CT secondary when charging
the position of the switch. Voltmeter transfer switch for AC shall be
suitable for reading all line to line and line to neutral voltage for non
5.
6.
7.
8.
9.
13.14
effectively earthed systems and for reading all line to line voltages for
effectively earthed systems.
Synchronising switches shall be of maintained contact (stay put) type
having a common removable handle for a group of switches. The handle
shall be removable only in the off position and it shall be coordinated to
fit into all the synchronizing switches. These shall be arranged to connect
the synchronizing equipment when turned to the on position. One
contact of each switch shall be connected in the closing circuit of the
respective breaker so that the breaker cannot be closed until the switch is
turned to the ON position.
Lockable type switches which can be locked in particular position shall be
provided when specified. The key locks shall be fitted on the operating
handles.
The contacts of all the switches shall preferably open and close with snap
action to minimizing the arcing. Contacts of switches shall be spring
assisted and contact faces shall be with rivets of pure silver or silver alloy
Springs shall not be used as current carrying parts.
The contact combination and their operation shall be such as to give
completeness to the interlock
and function of the scheme.
The contact rating of the switches shall be as follows.
Description
Contact Rating In Amperes
220 V DC
50 V DC
230 V AC
Make & carry continuously
10
10
10
Make & carry for 0.5 sec
30
30
30
Break for
i) Resistive load
3
20
7
ii) Inductive load (L/R=40ms) 0.2
-
INDICATING INSTRUMENTS, RECORDERS & TRANSDUCERS:

All instruments, meters, recorders and transducers shall be enclosed in dust proof,
moisture resistant, black finished cases and shall be suitable for tropical use. All
megawatt, megavar, bus voltage and frequency indicating instruments shall be
provided with individual transducers and these shall be calibrated along with the
transducers to read directly the primary quantities. They shall be accurately
adjusted and calibrated at works and shall have means of calibration check and
adjustment at site. The supplier shall submit calibration certificates at the time of
delivery. However no separate transducers are envisaged for digital bus voltmeters
and digital frequency meters and the indicating meters provided in the
synchronizing equipment.
13.14.1 Indicating Instruments:

1. All electrical indicating instruments shall be of digital type suitable for flush
mounting.
2. Shall have 4 digit display, display height being not less than 25mm.
3.
4.
Shall confirm to relevant IS and shall have an accuracy class 1.5and or

better watt and Var meters shall have an indication of (+) and (-) to indicate
Export and Import respectively.
Digital voltage and frequency meters shall be of 0.5 class and shall have
digital display of 5 and 4 digits respectively, with display size not less than
25mm height.
13.14.2 Bus voltage & Frequency recording instruments:

1. Shall be static/digital type frequency and voltage recorder either as
individual units or composite unit for total sub-station with time tagged
information shall also be applicable if it meets the accuracy of 1.0% span
and full span response time of less than 2 seconds. The static/digital shall also
meet the high voltage susceptibility test, impulse voltage with stand test ,high
frequency disturbance test-class III and fast transient disturbance test level
III as per IEC -60255.
13.14.3 Transducers:
1. Transducers shall in general confirm to IEC-688-1
2. Shall be suitable for measurement of active power, reactive power, voltage,
current and frequency in three phase four wire unbalanced system.
3. Transducers shall have input from sub-station current and voltage from the
instrument transformers. The output shall be in miliampere D.C
proportional to the input and shall feed the output current to the indicating
instruments /telemetry terminals.
4. Characteristic shall be linier throughout the measuring range.
5. Output shall be load independent.
6. Input and output shall be galvanically isolated.
7. Transducers should work satisfactorily at 120% of rated value continuously.
8. Shall have 4-20mAmp.
9. Response time shall be less than 1 sec.
10. Accuracy class shall be 1 or better voltage/current, 0.5 or better for watt/var
and 0.2 or better for frequency transducers.
11. Shall have a low AC ripple on output less than 1%.
12. Shall be suitable for load resistance of 1000 1500.
13. Shall have dual output.

LIMITED
JANPATH, BHUBANESWAR 751022
FOR
SPLIT TYPE INDIVIDUAL UNIT

AIR CONDITIONER
E22-AIR CONDITIONER- Page 1 of 3
TECHNICAL SPECIFICATION FOR AIR

CONDITIONING SYSTEM
1.0 GENERAL
The specification covers supply, installation, testing and commissioning and handing
over of Air conditioning system for the control room building
The AC units for control room building shall be set to maintain the following inside
conditions.
DBT 24.4 Deg C 2 Deg C
1.1 The following room shall be air conditioned
a) Control Room
b) Conference room
c) Testing lab
1.2 Air conditioning requirement of rooms indicated shall be met by using split AC units.
High wall type split AC units of required capacity as per design (to be submitted for
approval) with high wall type indoor evaporator unit shall be used. In case the area is
more than ductable split AC units may also be designed for better effect.
1.3 The exact quantity of the split AC units shall be designed taking the room area and
the same may be proposed for necessary approval. However 2 TR capacity split AC units
may be considered. The quantity shall be approximately as mentioned below.
PROPOSED NO OF UNITS
1) FOR ALL 220 KV S/S CONTROL ROOM AREA
A) 20 NOS 2 TR CAPACITY.
B) GOPINATHPUR (KEONJHAR):15 NOS 2 TR CAPACITY.
2) FOR ALL 132 KV SUB-STATION: 15 NOS 2 TR CAPACITY.
1.4 Copper refrigerant piping complete with insulation between the indoor and remote
outdoor condensers as required.
1.5 SCOPE: The scope of the equipment to be furnished and services to be provided
under the contract are outlined herein and the same is to be read in conjunction with the
provision contained. The scope shall be deemed to include all such items which although
not specifically mentioned in the bid documents and/or in bidders proposal, but are
required to make the equipment/system complete for its safe, efficient, reliable and
trouble free operation. Of hermetically sealed
1.7 PVC drains piping from the indoor units up to the nearest drain point to be done.
1.8 Power and control cables between the indoor unit and out door unit and earthing
1.9 GI brackets for for outdoor condensing unit and proper earthing.
1.10 Specification for Split AC units.
The split AC units will be complete with indoor evaporator unit, outdoor
condensing units and cordless remote control units.
Out door units shall comprise of hermetically sealed reciprocating/rotary
compressors mounted on vibration isolators, propeller type axial flow fans and copper
tube aluminium finned coils assembled in a sheet metalThe casing and the total unit shall
be properly treated and shall be weather proof type. They shall be compact in size and
shall have horizontal discharge of air.
The indoor unit shall be high wall type. The indoor unit shall be compact and
shall have elegant appearance. They shall have low noise centrifugal blowers driven by
special motors and copper tube aluminium finned cooling coils. Removable and washable
polypropylene filters shall be provided. They shall be complete with multifunction
cordless remote control unit with special features like programmable timer, sleep mode
and softy dry mode etc.
The split AC units shall be of Carrier/Blue Star/Hitachi/Voltas/Samsung/LG
make.

FOR
1-COAXIALCABLES
2-CONTROL & POWER CABLES
E23-CONTROL, POWER, COAXIAL CABLE- Page 1 of 30
ITEM- H.F. CO-AXIAL CABLE, CONTROL CABLE & TELEPHONE CABLE
SCOPE
The specification covers the design, manufacture, testing before dispatch and setting to
service of the following cables for their utility in power line carrier
communication system in OPTCL.
1.
H.F. Co-axial cable
2.
Control cable
3.
Telephone cable
4.
H.F. Co-axial cable
General:
(a) The H.F.C0-axial cable shall be offered to connect the coupling unit (Line
Matching under Symmetrical LMU) with PLC terminals. This serves
maximum transfer of power between the carrier equipment to HT lines with
minimum losses. The cable is also used for interconnection between two line
matching units.
(b) The high frequency cable to be offered shall be suitable for being laid in the
ground or in trenches or in ducts. It shall be duly armoured and confirm
IS:5802 of 1978.
(c) The center core of the cable shall consists of tinned or enameled higfh purity
copper conductor which has to be insulated by polythene sheath and shall be
screened by tinned copper braidings. This braiding shall be sheathed by a
PVC cover and GI wire enamoured and overall PVC sheathed and shall be
suitable for tropical use. The six, type and quality of insulation shall be stated
in the tender.
(d) The capacitance of the co-axial cable shall be low as to minimize attenuation
at the carrier frequency range.
Tentative Particulars:
impedance
ohm or 75 ohm unbalanced. (both shall be

quoted
e conductor
m dia
ver insulation
ness of insulation
mm
conductor
ng of tended copper (Electrolytic grade) wire

of 0.2 mm dia with 90% coverage
ex tape
Sheath
al cable grade PVC (Black/Gray) Radial

Thickness 1.2mm.
ng & Armouring
e braid of 0.3mm GI wire with 79% coverage.
ll sheath
al
eter over
cable grade PvC(Black/Gray)

thickness- 1.4 mm
Radial
16.0 mm (maximum)
mum Conductor resistance
35.33 ohms/Km.
ctric strength
to shield)
5 KV rms ro 1 minute.
cteristic capacitance at 1
KHz
36.10 pf/meter
Maximum attenuation at various frequencies

ency (KHz)
ds/KM
0.8
1.4
3.30
4.70
mum bending radios for

installation
20 CM
tion resistance
2.
Meg. Ohm/Km(Min.)
Telephone Cable:
1)
3)
4)
The telephone cables are of armoured or unarmoured type depending on

the requirements. The telephone cable shall have 0.5 or 0.6 mm annealed
tinned copper conductor, PVC insulated, cores colour coded, twisted into
pairs, laid up, taped and overall PVC sheathed confirming to ITD
specification. In case of armoured cable, it must be GI wiser/strip
armoured with inner and outer sheathed confirming to IS: 1554 (PartI)/1976.
2)
The following cables may be quoted in the tender.
(1)
25 pair Armoured telephone cable
(2)
10 pair Armoured telephone cable
(3)
10 pair unarmoured telephone cable
(4)
5 pair unarmoured telephone cable.
The following cables may be quoted in the tender.
(1)
2.5 sq.mm twin core (solid)
(2)
10 sq.mm multistrand twin
core.
tests Type Test reports shall be furnished.
TECHNICAL SPECIFICATION FOR
CONTROL AND POWER

CABLES
Technical specification for control

and power cables
PART 1 : SCOPE AND CONDITIONS
1. SCOPE
This specification covers the testing and performance requirements of power and control
cables for installation on the Distribution System of the ANANDPUR GRID S/D and Jajpur
Road 132 KV Bay extention Grid
The equipment offered shall have been successfully type tested and the design shall have
been in satisfactory operation for a period not less than two years on the date of bid opening.
Compliance shall be demonstrated by submitting with the bid, (i) authenticated copies of the
type test reports and (ii) performance certificates from the users..
The power and control cables shall conform in all respects to highest standards of
engineering, design, workmanship, this specification and the latest revisions of relevant
standards at the time of offer and the Project Manager shall have the power to reject any
work or material, which, in his judgement, is not in full accordance therewith.
2.
STANDARDS
Except where modified by this specification, the power and control cables
shall be designed, manufactured and tested in accordance with the latest
editions of the following standards.
IEC / ISO
Indian Standard
Title
IEC 811
IS-18-10810:1982
Testing cables
IEC 502
IS-7098:1985 (part 2)
LT and 3.3 - 33kVXLPE cables
IEC 502
IS - 1554:1988 (part 1)
PVC Cables .65/1.IkV
IEC 227
IS - 5819 :1970
Short circuit ratings for PVC cables
IEC 228
15-8130:1984
Conductors for insulated cables
IEC 502
IS - 6474: 1984
XLPE Cables
IEC 502
IEC 540 IS - 5831: 1984

Extruded solid dielectric insulated

power cables for rated voltages from
IkV to 30kV
Test Methods for insulation and
sheaths of electric cables and cords
IEC 287
Calculation of the continuous current

rating of cables.
IS - 3975 : 1979
Mild steel wires, strips and tapes for
armouring of cables
The Bidder may propose alternative standards, provided it is demonstrated that they give a
degree of quality and performance equivalent to or better than the referenced standards.
Acceptability of any alternative standard is at the discretion of the Project Manager. The
Bidder shall furnish a copy of the alternative standard proposed along with his bid. If the
alternative standard is in a language other than English, an English translation shall be
submitted with the standard. In the case of conflict the order of precedence shall be 1) IEC or
ISO Standards, 2) Indian Standards, 3) other alternative standards.
This list is not to be considered exhaustive and reference to a particular

standard or recommendation in this Specification does not relieve the
Contractor of the necessity of providing the goods complying with other
relevant standards or recommendations.
3.
SERVICE CONDITIONS
The service conditions shall be as follows:

maximum altitude above sea level
l1,000m
maximum ambient air temperature
50C
maximum daily average ambient air temperature
35C
minimum ambient air temperature

oC
maximum temperature attainable by an object exposed to the sun

60C
maximum yearly weighted average ambient temperature

32C
maximum relative humidity

100%
average number of thunderstorm days per annum (isokeraunic level) 70

average number of rainy days per annum

120
average annual rainfall

150cm
wind pressures as per IS 802 (Part I/ Sect.l) : 1995
Wind Zones (Orissa)
Terrain Category 1
57.4 kg/m2
73.1 kg/m2
94.3kg/m2
Terrain Category 2
49.3
62.6
80.9
Terrain Category 3
35.6
45.3
58.4
Light
Medium
Heavy
Environmentally, the region where the work will take place includes coastal areas, subject to
high relative humidity, which can give rise to condensation. Onshore winds will frequently
be salt laden. On occasions, the combination of salt and condensation may create pollution
conditions for outdoor insulators.
Therefore, outdoor material and equipment shall be designed and protected

for use in exposed, heavily polluted, salty, corrosive and humid coastal
atmosphere.
4.
SYSTEM CONDITIONS
The equipment shall be suitable for installation in supply systems of the following
characteristics:
Frequency
50Hz
Nominal system voltages
33kV
llkV
400/230V
Maximum system voltages:
33kV System
36.3kV
llkV System
12.1kV
LV System
Minimum LV voltage
476V
340V
Nominal short circuit levels:
33kV System
llkV System
25kA
12.5kA
Insulation Levels:
1 .2/50 (j.s impulse withstand voltage
(positive and negative polarity):
33kV System
170kV
llkV System
75kV
Power frequency one minute withstand

voltage (wet and dry) rms
33kV System
70kV
1 IkV System
28kV
LV System
Neutral earthing arrangements: 33kV System
3kV
solidly earthed
llkV System
solidly earthed
LV System
solidly earthed
PART 2 : TECHNICAL
All power and control cables to be used in the OPTCL distribution system shall be of the
cross-linked polyethelene (XLPE) or polyvinyl chloride (PVC) insulated with PVC
sheathing types.
8.
8.1.
1.1KV POLYVINYL CHLORIDE (PVC) INSULATED CABLES

RATED VOLTAGE AND TEMPERATURE
The rated voltage of the cable shall be l.l kV and the maximum operating voltage shall
not exceed 110% of the rated voltage.
These cables are suitable for use where the combination of ambient temperature and
temperature rise due to load results in a conductor temperature shall not exceeding 70C*
under normal operation and 160C under short circuit conditions.
*See 13.2.4 for heat resisting and general purpose applications.
8.2.
CABLE DESIGN
ALL LV Power cable shall be of XLPE insulation armoured type.

The cable offered shall be single-core, four core or multi-core armoured or unarmoured
XLPE insulated / PVC insulated, PVC sheathed to meet the following requirements:
8.2.1. Conductor
L.V System Cables (Power Cable XLPE insulated)
The conductor shall be of compacted round shape in single core cables and sector shaped
in 3.5 or 4 core cables, made up from stranded aluminum wires complying with IS 8130:1984 / IEC 228. The Cable shall be of XLPE insulated with armoured.
Cables with reduced neutral conductors shall comply with the cross-sections shown in the
table below.
Control and Panel Wiring Cables (PVC insulated)
The conductor shall be of round stranded plain copper wires complying with IS 8130:1984/IEC 228.
The conductors shall be of Flexibility Class 2 as per IS - 8130 : 1984.
8.2.2. Cross-Sectional area of reduced Neutral Conductors:
Nominal
cross-sectional 25
area of main conductor
(mm2)
35
50
70
95
120
150
185
240
300
400
500
630
Cross-sctional area of 16
reduced neutral conductor
(mm2)
16
25
35
50
70
70
95
120
150
185
240
300
8.2.3. Conductor Screening Not required

8.2.4. Insulation
The insulation shall be of Polyvinyl Chloride (PVC) compound. The 'General Purpose'
Type A shall be used for the LV cables and 'Heat Resisting' Type C for the Control and
Panel Wiring cables. Both shall conform to the requirements of IS - 5831: 1984.
Type of Insulation
Normal Continuous Operation Short Circuit Operation
General Purpose
70C
160C
Heat Resisting
85C
160C
The PVC insulation shall be applied by extrusion and the average thickness of
insulation shall not be less than the specified nominal value and the maximum value
not more than O.lmm plus 0.1 of nominal and as specified in IS - 1554(part 1): 1988.
The insulation shall be applied so that it fits closely on to the conductor and it shall be
possible to remove it without damage to the conductor.
8.2.5. Insulation Screening Not required
8.2.6. Core Identification and Laying Up of Cores
3.5 and 4 core cables shall be identified by colouring of the PVC insulation and multi core by
numbers as per IS- 1 554 (part 1): 1988
Panel wiring shall have a single colour except for power supplies which shall be as per the
above IS standard.
In multi-core cables, the cores shall be laid up together with a suitable lay as recommended in
IS - 1554 (Part 1): 1988. The layers shall have successive right and left hand lays with the
outermost layer having a right hand lay.
8.2.7. Inner Sheath
The laid up cores of the 3.5, 4 and multi core cables shall be covered with an inner sheath
made of thermoplastic material (PVC) applied by extrusion.
The thickness of the sheath shall conform to IEC 502/IS - 1554: 1988. Single core cables
shall have no inner sheath.
8.2.8. Armouring Only the 3.5 and 4 core LV cables will be armoured. The armour shall be
applied helically in a layer of steel wires over the inner sheath of the cable. The armour shall
consist of round or flat steel wires and comply with the requirements of IEC 502/IS - 1554:
1988. The steel wires shall comply with IS - 3975:
8.2.9. Outer Sheath
An outer sheath of polyvinyl chloride (PVC) shall be applied over the armour wires (where
fitted). The sheath shall be embossed at regular intervals as per the Cable Identification
clause of this specification and the minimum thickness and properties shall comply with the
requirements of IEC 502/IS - 1554: 1988. The outer sheath for cables with general purpose
insulation shall be of the type ST1 PVC compound and for cables with heat resisting
insulation type ST2 PVC compound conforming to the requirements of IEC 502/IS - 5831:
1984.
The outer serving shall incorporate an effective anti-termite barrier and shall be capable of
withstanding a l0kV DC test voltage for five minutes after installation and annually
thereafter.
Cables shall be installed as a single four core cable or three single phase cables plus neutral
in a close trefoil formation.
Current ratings shall be calculated in accordance with IEC 287 "Calculation of the continuous
current rating of cables with 100% load factor".
8.2.10. Conductor Sizes
The following conductor sizes will be used on the Employer's LV distribution system:
300, 120 and 50 mm2 single core, 300 mm2 three and a half core and 120 mm2 four core.
The following shall be used for Control and Panel Wiring:
2.5 mm2 single core, 2. 5 and 4.0 mm2 four core and 1.5 and 2.5 mm2 multicore
8.2.11. Cable Drum Length
The cable shall be supplied in 500metre lengths.
Technical Specification for Power and Control Cables

CABLE IDENTIFICATION
The manufacturer's and Employer's name or trade mark, the voltage grade, cable
designation and year of manufacture shall be indented or embossed along the whole
length of the cable. The indentation or embossing shall only done on the outer sheath.
The alphanumerical character size shall be not less than 20% of the circumference of the
cable and be legible.
The following code shall be used to designate cables:
Constituent
Code Letter
Aluminium conductor
XLPE insulation
2X
PVC insulation
Steel round wire armour
Non-magnetic round wire armour
Wa
Steel strip armour
Non-magnetic strip armour
Fa
Double steel round wire armour
WW
Double steel strip armour
FF
PVC outer sheath
Note: No code letter is required for copper conductor
10.
SAMPLING OF CABLES
10.1. Lot
In any consignment the cables of the same size manufactured under essentially similar
conditions of production shall be grouped together to constitute a lot.
10.2. Scale of Sampling
Samples shall be taken and tested from each lot to ascertain the conformity of the lot to
specification.
10.3. Sampling Rates
The number of samples to be selected shall be as follows:
Number of drums in the Lot
Number of Drums to be
taken as samples
Permissable number of
defective drums
Up to 25
26 to 50
51 to 100
101 to 300
13
301 and above
20
The samples shall be taken at random. In order to achieve random selection the procedure
for selection detailed in IS - 4905: 1968 shall be followed.
11.
NUMBER OF TESTS AND CRITERION FOR CONFORMITY
Suitable lengths of test samples shall be taken from each of the selected drums. These
samples shall be subjected to each of the acceptance tests. A test sample shall be classed
as defective if it fails any of the acceptance tests. If the number of defective samples is
less than or equal to the corresponding number given in 8.3 the lot shall be declared as
conforming to the requirements of acceptance test.
1 2.
TESTS ON 1 . 1 KV PVC INSULATED CABLES
12.1.
Type Tests
Certification of type tests already completed by independent test laboratories shall be

presented wiyh the bid for each cable type. These tests shall be carried out in accordance
with the requirements of IS -8130: 1984/IEC 502, IS - 5831:1984/IEC 540 and IEC 811
unless otherwise specified.
Type testing of 33kV,l IkV and 1.1 kV cables shall include the following:
Test
Requirement Reference
Test Method as a
Part of IS-10810/IEC 811
(a) Tests on conductor

Annealing test (copper)
IS-8130: 1984/IEC 502
Tensile test (aluminium)
IS-8130: 1984/IEC 502
Wrapping test (aluminium)
IS-8130: 1984/IEC 502
Resistance test
IS-8130: 1984/IEC 502
IS - 3975: 1979/IEC 502
36 - 42
(b) Tests for Armour wires/strips
(c) Tests for thickness of insulation and sheath IS-5831:1984/IEC 540
(d) Physical tests for Insulation

Tensile strength and elongation at break IS-5831:1984/IEC 540
Ageing in air oven
IS-5831:1984/IEC 540
11
Hot test
IS-5831:1984/IEC 540
30
Shrinkage test
IS-5831:1984/IEC 540
12
Water absorption (gravimatic) IS-5831:1984/IEC 540
33
(e) Physical tests for outer sheath

Tensile strength and elongation at break IS-5831: 1984/IEC 540
Ageing in air oven
IS-5 831: 1984/IEC 540
11
Shrinkage test
IS-5831: 1984/IEC 540
12
Hot deformation
IS-5831: 1984/IEC 540
15

Test
Requirement Reference
Test Method as a
Part of IS-10810/IEC811
Loss of mass in air oven
IS-5831: 1984/IEC540
10
Heat shock
IS-5831: 1984/IEC540
14
Thermal stability
IS-5831: 1984/IEC540
IS-5831: 1984 Appendix B
(f) Partial discharge test (11 and 33kV only)
Section 13.2 of this specification
46
(g) Bending test (11 and 33kV only)
50
(h) Dielectric power factor test (11 and 33kV only) Section 13. 4 of this specification 48
As a function of voltage
As a function of temperature
(j) Insulation resistance (volume resistivity) test IS-8130: 1984/IEC502
43
(k) Heating cycle test (11 and 33kV only)
49
(1) Impulse withstand test (11 and 33kV only) Section 13.6 of this specification
47
(m) High voltage test
45
(n) Flammability test
53
Tests (g), (h), (j), (1) and (m) are only applicable to screened cables.
Not withstanding the conditions of the above paragraph the following tests on screened 11
and 33kV cables shall be performed successively on the same test sample of completed cable.
1. Partial discharge test
2. Bending test followed by partial discharge test
3. Dielectric power factor as a function of voltage
4. Dielectric power factor as a function of temperature
5. Heating cycle test followed by dielectric power factor as a function of voltage and partial
discharge tests
6. Impulse withstand test
7. High voltage test
If a sample fails in test number 7, one more sample shall be taken for this test, preceded by
tests 2 and 5.

12.2.
Acceptance Tests
The following shall constitute acceptance tests:

Tensile test (aluminium)
Annealing test (copper)
Wrapping test
Conductor resistance test
Test for thickness of insulation and sheath
Hot set test for insulation*
Tensile strength and elongation at break test for insulation and outer sheath
Partial discharge test (for screened cables only)**
High voltage test
Insulation resistance (volume resistivity) test.
XLPE insulation only
** test to be completed on full drum of cable
12.3.
Routine Tests
Routine tests shall be carried out on all of the cable on a particular order. These tests shall be
carried out in accordance with the requirements of IS - 8130: 1984/IEC 502 and IS 5831:1984/IEC 540 unless otherwise specified.
The following shall constitute routine tests.
Conductor resistance test
Partial discharge test (for 1 IkV and 33kV screened cables only)*
High voltage test
* test to be completed on full drum of cable
12.4.
Optional Test
Cold impact test for outer sheath (IS - 5831 - 1984), which shall be completed at the
discretion of the Project Manager and at the same time as test at low temperature for PVC as
stipulated in the section on special tests.
12.5.
Special tests
Special tests shall be carried out at the Project Manager's discretion on a

number of cable samples selected by the Project Manager from the contract
consignment. The test shall be carried out on 10% of the production lengths
of a production batch of the same cable type, but at least one production
length. Special tests shall be carried out in accordance with the requirements
of IEC 502 and IEC 540 unless otherwise specified.
The following special tests shall be included:
Conductor Examination (IEC-228)
Check of Dimensions
4-Hour High Voltage Test for 11 kV and 33kV Cables only
Hot set test for XLPE Insulation
Test at low temperature for PVC

13.
DETAILS OF TESTS
13.1.
General
Unless otherwise stated, the tests shall be carried out in accordance with the appropriate part
of IS -10810/IEC 502: 1994 and the additional requirements as detailed in this specification.
13.2.
Partial Discharge Test
Partial discharge tests shall only be made on cables insulated with XLPE of rated voltages
above 1.9/3.3kV.
For multicore cables, the test shall be carried out on all insulated cores, the voltage being
applied between each conductor and the metallic screen.
The magnitude of the partial discharge at a test voltage equal to 1.5Uo shall not exceed 20pC
for XLPE and 40pC for PVC, where Uo is the power frequency voltage between the
conductor and earth or J metallic screen.
13.3.
Bending Test
The diameter of the test cylinder shall be 20 (d +D) 5% for single core cables and 15 (d+D)
5% for multicores, where D is the overall diameter of the completed cable in millimetres
and d is the diameter of the conductor. After completing the bending operations, the test
samples shall be subjected to partial discharge measurements in accordance with the
13.4.
Dielectric Power Factor Test
13.4.1. Tan as a Function of Voltage

For cables of rated voltage 1.1 kV and above
The measured value of tan at Uo shall not exceed 0.004 and the increment of tan between
0.5 Uo and 2 Uo shall not be more than 0.002.
13.4.2. Tan as a Function of Temperature For cables of rated voltage 1.1 kV and above
The measured value of tan 8 shall not exceed 0.004 at ambient temperature and 0.008 at 90C
for XLPE cables.
13.5.
Heating Cycle Test
The sample which has been subjected to previous tests shall be laid out on the floor of the test
room and subjected to heating cycles by passing alternating current through the conductor
until the conductor reaches a steady temperature 10C above the maximum rated temperature
of the insulation in normal operation. After the third cycle the sample shall subjected to a
dielectric power factor as a function of voltage and partial discharge test.
13.7. High Voltage Test
13.7.1. Type/Acceptance Test
The cable shall withstand, without breakdown, at ambient temperature, an ac voltage equal to
3Uo, when applied to the sample between the conductor and screen/armour (and between
conductors in the case of unscreened cable). The voltage shall be gradually increased to the
specified value and maintained for a period of 4 hours.
If while testing, interruption occurs during the 4 hour period the test shall be prolonged by
the same extent. If the interruption period exceeds 30 minutes the test shall be repeated.
13.7.2. Routine Test
Single core screened cables, shall withstand, without any failure, the test voltages given in
this specification for a period of five minutes between the conductor and metallic screen.
Single core unscreened cables shall be immersed in water at room temperature for one hour
and the test voltage then applied for 5 minutes between the conductor and water.
Multicore cables with individually screened cores, the test voltage shall be applied for 5
minutes between each conductor and the metallic screen or covering.
Multicore cables without individually screened cores, the test voltage shall be applied for 5
minutes in succession between each insulated conductor and all the other conductors and
metallic coverings, if any.
13.7.3. Test Voltages
The power frequency test voltage shall be 2.5 Uo + 2kV for cables at rated voltages, up to
and including 3.8/6.6kV, and 2.5 Uo for cables at higher rated voltages.
Values of single phase test voltage for the standard rated voltages are as given in the
following table:
Voltage Grade kV
Test Voltage
Between conductors
screen/armour
kV(rms)
0.65/1.1
and Between conductors kV(rms)
If, for three core cables, the voltage test is carried out with a three phase
transformer, the test voltage between the phases shall be 1.732 times the
values given in the above table.
When a DC voltage is used, the applied voltage shall be 2.4 times the power frequency
test voltage. In all instances no breakdown of the insulation shall occur.
13.8.
Flammability Test
The period for which the cable shall burn after the removal of the flame shall
not exceed 60 seconds and the unaffected portion (uncharred) from the lower
edge of the top clamp shall be at least 50mm.
14.
CABLE ACCESSORIES
The accessories are for the following types of cable:

33kV XLPE, single core round stranded plain aluminium conductor to IEC 228/IS - 8130:
1984, semi-conducting conductor screen, XLPE insulation, non - metallic semi-conducting
insulation screen with non - magnetic tape or metallic cover,inner PVC sheath, non-magnetic
wire or strip armour and PVC outer sheath.
11kV XLPE, single or three core round stranded plain aluminium conductor to IEC 228/IS 8130: 1984, semiconducting conductor screen, XLPE insulation, non - metallic
semiconducting insulation screen with non - magnetic tape or metallic cover, inner PVC
sheath , non-magnetic wire or strip armour for single core cables, and steel wire armour on
three core cables and PVC outer sheath.
LV (1100V) PVC, single, three and a half and four core round or sector shaped stranded plain
aluminium grade H4 conductor, PVC insulation, inner PVC sheath, steel wire armour for
three phase cables and P.V.C. outer sheath.
14.1. JOINTS AND TERMINATIONS
Joints and terminations shall be supplied in complete kit form with all materials and
components required to complete the installation. A complete set of instructions for the joint
or termination shall also be included in each kit.
Heat shrink pre-moulded joints and terminations shall be required for all XLPE and PVC
cables and for transition joints.
All components shall be capable of being stored without damage or deterioration at
temperatures up to 50C. The material expiry date shall be marked on all packages, where
appropriate.
Details of all equipment, tools and protective clothing required to complete the joint or
termination shall be included with each joint or termination kit.
Components shall not be adversely affected in any manner by contact with other materials
normally used in the construction of cable joints or terminations and shall not increase the
rate of corrosion of any metals with which they may come into contact.
Components supplied with adhesive coatings shall have means to prevent the coated surfaces
from adhering to each other.
Joints and terminations for armoured or screened cables shall include all items needed for
wire or tape clamping. Rings shall be provided for such application.
The recovered thickness of insulation over the connector shall be uniform and equal to or
greater than the cable insulation thickness as given in IEC 502/IS - 1554/IS - 7098.
The protection provided by the galvanised steel wire armouring shall be reinstated over the
joint (s). Electric field stress control shall be provided on all of the High Voltage joints and
terminations.
Joints shall provide waterproofing, mechanical and electrical protection, and be completely
sealed from cable jacket to cable jacket. Joints shall accommodate crossing of the cores.
Where required 33kV, 1 IkV and 1.1 kV cable joints shall be straight through joints only.
Terminations shall be designed to provide a complete moisture seal, including the crotch area
of multi-core cables and complete rejacketing of the individual cores, conforming to Class 1
terminations as per IEEE 48. They shall be generally suitable for indoor and outdoor
installation, be resistant to ultra violet radiation and chemical attack.
Minimum creepage distance for outdoor terminations shall not be less than:
Adhesives used shall have a softening temperature of not less than 90 C, be compatible with
other components and after curing shall not flow at temperatures of normal service.
1.1 kV, 1 IkV and 33kV joints and terminations shall be designed so that no insulating or
semi-conducting tapes shall be required.Reinstallation of the insulation and semi - conducting
cover shall be achieved with the use of multiple layers of heat shrinkable tubes possessing
high dielectric strength and thermal stability.
Phase identification colours shall be marked on the cable box, cable tail ends and single core
cables at all connecting points and/or any positions the Project Manager may determine.
Cable boxes shall be provided with suitable labels indicating the purpose of the supply where
such supply is not obvious or where the Project Manager may determine.
All cables shall be identified and shall have phase colours marked at their termination.
14.2. CONNECTORS/TERMINALS
Connectors and terminals shall perform without distress under normal loading, cyclic loading
and fault conditions, and shall not limit the rating of the cables which they joint.
33kV connections shall be compressed by hydraulically operated tools and 1 IkV/LV
connectors by hand operated tools. The range of connectors/terminals should be kept to a
minimum so as limit the the range of dies which may required and the use of die-less
compression tools of the tension or non-tension type shall be permitted. Only approved and
proven compression tools supplied by a reputable manufacturer shall be used.
The ends of connectors/terminals shall be suitably chamfered or coned to facilitate insertion
of the conductors. Connectors shall have a solid central barrier to facilitate the insertion of
the conductor to the correct depth.
The following items of information shall be clearly stamped on each connector/terminal:
Manufacturer's name or trade mark.
The conductor size (metric) for which the connector/terminal is suitable.
The die number or size suitable for compressing the connector/terminal.
The part of the connector/terminal surface to be compressed.
The sequence of die action from the starting point and finishing point.
Compounds or greases for improving contact between the connector/terminal and the
conductor are permitted. They must, however, be chemically neutral to the
connector/terminal and conductor materials and must be present in position in the delivered
connectors/terminals.
Cable connectors/terminals shall be able to accommodate typical variations in dimensions of
cables supplied by different manufacturers.
Connector/terminal material shall not react chemically with the cable conductors to which
they are connected.
Size and type of connectors required:

Straight through connectors for the following conductors:
300 - 300 mm2 stranded round plain aluminium
185-185 mm2 stranded round plain aluminium
120-120 stranded sector shaped plain aluminium Termination lugs for the following
conductors:
300 mm2 stranded round and sector shaped plain aluminium
185 mm2 stranded round plain aluminium
150 mm2 stranded sector shaped plain aluminium for the neutral of the 3.5 core 300 mm2
cable.
120 mm2 stranded round and sector shaped plain aluminium
Termination lugs shall be suitable for bi-metallic connections.
Terminals for pole top terminations of 33kV and 1 IkV cables shall be of the post type
capable of accepting a tap off connector. Appropriate tap off connectors shall be provided for
making connections from the cable to the line conductors.
14.3.
CONTROL/LV WIRING ACCESSORIES 14.3.1. Terminations
Control wire terminations shall be made with solderless crimping type and tinned copper lugs
which firmly grip the conductor. Insulated sleeves shall be provided at all the wire
termination. Engraved core identification plastic ferrules marked to correspond with panel
wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wire
and shall not fall off when the wire is disconnected from terminal blocks. All wires directly
connected to trip circuit breaker or device shall be distinguished by the addition of red
coloured unlettered ferrule. Numbers 6 and 9 shall not be included for ferrules purposes
except where underlined and identified as 6 and 9.
LVAC cable terminals shall be provided with adequate size crimp type lugs.The lugs shall be
applied with the correct tool, which shall be regularly checked for correct calibration. Bimetallic joints between the terminals and lugs shall be provided where necessary.
Terminals shall be marked with the phase colour in a clear and permanent manner.
A removable gland plate shall be provided by the contractor at every cable entry to
mechanism boxes, cabinets and kiosks. The Contractor shall be responsible for drilling the
cable gland plate to the required size.
Armoured cables shall be provided with suitable glands for terminating the
cable armour and shall be provided with an earthing ring and lug in order to
connect the gland to the earth bar.
PART 3 : GENERAL PARTICULARS AND GUARANTEES

15.
COMPLIANCE WITH SPECIFICATION
The power and control cables shall comply in all respects with the requirements of this
specification. However, any minor departure from the provisions of the specification
shall be disclosed at the time of bidding in the Non Compliance Schedule in this
document.
The mass and dimensions of any item of equipment shall not exceed the figures stated in
the schedules.
16.
COMPLIANCE WITH REGULATIONS
All the equipment shall comply in all respects with the Indian Regulations and Acts in
force.
The equipment and connections shall be designed and arranged to minimise the risk of
fire and any damage which might be caused in the event of fire.
17.
QUALITY ASSURANCE, INSPECTION AND TESTING
17.1. General
To ensure that the supply and services under the scope of this Contract, whether
manufactured or performed within the Contractor's works or at his sub-contractor's
premises or at any other place of work are in accordance with the Specification, with the
regulations and with relevant authorised international or Indian Standards, the Contractor
shall adopt suitable Quality Assurance Programmes and Procedures to ensure that all
activities are being controlled as necessary.
The quality assurance arrangements shall conform to the relevant requirements of ISO
9001 or ISO 9002 as appropriate.
The systems and procedures which the Contractor will use to ensure that the Plant
complies with the Contract requirements shall be defined in the Contractor's Quality Plan
for the Works.The Contractor shall operate systems which implement the following:
Hold Point
"A stage in the material procurement or workmanship process beyond
which work shall not proceed without the documented approval of designated individuals
or organisations."
The Project Manager's written approval is required to authorise work to progress beyond
the Hold Points indicated in approved Quality Plans.
Notification Point
"A stage in material procurement or workmanship process for
which advance notice of the activity is required to facilitate witness."
If the Project Manager does not attend after receiving documented notification in
accordance with the agreed procedures and with the correct period of notice then work
may proceed.
17.2.
Quality Assurance Programme
Unless the Contractor's Quality Assurance System has been audited and approved by the
Project Manager, a Quality Assurance Programme for the Works shall be submitted to the
Project Manager for approval a minimum of one month from contract award, or such
other period as shall be agreed with the Project Manager. The Quality Assurance
Programme shall give a description of the Quality System for the Works and shall, unless
advised otherwise, include details of the following:
The structure of the organisation;
The duties and responsibilities assigned to staff ensuring quality of work;
The system for purchasing, taking delivery and verification of materials;
The system for ensuring quality of workmanship;
The system for control of documentation;
The system for the retention of records;
The arrangements for the Contractor's internal auditing;
A list of the administration and work procedures required to achieve and verify Contract's
quality requirements. These procedures shall be made readily available to the Project
Manager for inspection on request.
17.3. Quality Plans
The Contractor shall draw up for each section of the work Quality Plans which shall be
submitted to the Project Manager for approval at least two weeks prior to the commencement
of work on the particular section. Each Quality Plan shall set out the activities in a logical
sequence and, unless advised otherwise, shall include the following:
An outline of the proposed work and programme sequence;
The structure of the Contractor's organisation for the Contract;
The duties and responsibilities assigned to staff ensuring quality of work for the Contract;
Hold and Notification Points;
Submission of engineering documents required by the specification;
The inspection of materials and components on receipt;
Reference to the Contractor's Work Procedures appropriate to each activity;
Inspection during fabrication/construction;
Final inspection and test.
17.4. Non-conforming product
The Project Manager shall retain responsibility for decisions regarding acceptance,
modification or rejection of non-conforming items.
17.5. Sub-contractors
The Contractor shall ensure that the Quality Assurance requirements of this specification are
followed by any sub-contractors appointed by him under the Contract.
The Contractor shall assess the sub-contractor's Quality Assurance arrangements prior to his
appointment to ensure compliance with the appropriate ISO 9000 standard and the
specification.
Auditing of the sub-contractor's Quality Assurance arrangements shall be carried out by the
Contractor and recorded in such a manner that demonstrates to the Project Manager the
extent of the audits and their effectiveness.
17.6. Inspection and testing
The Project Manager shall have free entry at all times, while work on the
contract is being performed, to all parts of the manufacturer's works which
concern the processing of the equipment ordered. The manufacturer shall

afford the Project Manager without charge, all reasonable facilities to assure
that the equipment being furnished is in accordance with this specification.
The equipment shall successfully pass all the type tests, acceptance tests and routine tests
referred to in the section on Tests and those listed in the most recent edition of the standards
given in this specification.
The Project Manager reserves the right to reject an item of equipment if the test results do not
comply with the values specified or with the data given in the technical data schedule.
Type tests shall be carried out at an independent testing laboratory or be witnessed by a
representative of such laboratory or some other representative acceptable to the Project
Manager. Routine and acceptance tests shall be carried out by the Contractor at no extra
charge at the manufacturer's works.
Type Test certificates shall be submitted with the bid for evaluation. The requirement for
additional type tests will be at the discretion of the Project Manager.
The Project Manager may witness routine, acceptance and type tests. In order to facilitate
this, the Contractor shall give the Project Manager a minimum of four weeks notice that the
material is ready for testing. If the Project Manager does not indicate his intention to
participate in the testing, the manufacturer may proceed with the tests and shall furnish the
results thereof to the Project Manager.
Full details of the proposed methods of testing, including connection diagrams, shall be
submitted to the Project Manager by the Contractor for approval, at least one month before
testing.
All costs in connection with the testing, including any necessary re-testing, shall be borne by
the Contractor, who shall provide the Project Manager with all the test facilities which the
latter may require, free of charge. The Project Manager shall have the right to select the
samples for test and shall also have the right to assure that the testing apparatus is correct.
Measuring apparatus for routine tests shall be calibrated at the expense of the Contractor at
an approved laboratory and shall be approved by the Project Manager.
The Contractor shall be responsible for the proper testing of the materials supplied by subcontractors to the same extent as if the materials were completed or supplied by the
Contractor.
Any cost incurred by the Project Manager in connection with inspection and re-testing as a
result of failure of the equipment under test or damage during transport or off-loading shall
be to the account of the Contractor.
The Contractor shall submit to the Project Manager five signed copies of the test certificates,
giving the results of the tests as required. No materials shall be dispatched until the test
certificates have been received by the Project Manager and the Contractor has been informed
that they are acceptable.
The test certificates must show the actual values obtained from the tests, in the units used in
this specification, and not merely confirm that the requirements have been met.
In the case of components for which specific type tests or routine tests are not given in this
specification, the Contractor shall include a list of the tests normally required for these
components. All materials used in the Contract shall withstand and shall be certified to have
satisfactorily passed such tests.
No inspection or lack of inspection or passing by the Project Manager's Representative of
equipment or materials whether supplied by the Contractor or sub-contractor, shall relieve the
Contractor from his liability to complete the contract works in accordance with the contract
or exonerate him from any of his guarantees.
17.7. Guarantee
The Contractor shall guarantee the following :
Quality and strength of materials used;
Satisfactory operation during the guarantee period of one year from the date of
commissioning, or 18 months from the date of acceptance of the equipment by the Project
Manager following delivery, whichever is the earlier;
Performance figures as supplied by the Bidder in the schedule of

guaranteed particulars.
18.
PROGRESS REPORTING
The Contractor shall submit for approval within four weeks of the starting date of the
contract, an outline of production, inspection, delivery (and installation) in a chart form.
Within a further period of four weeks, the Contractor shall provide a detailed programme of
the same information in a form to be agreed by the Project Manager. The Contractor shall
submit two copies of monthly progress reports not later than the 7th day of the following
month. The reports shall show clearly and accurately the position of all activities associated
with the material procurement, manufacture, works tests and transport, with regard to the
agreed contract programme.
(The preferred format for presentation of programmes is MS Project Version 4.0.
Programmes and monthly updates should be submitted on 3.5" diskettes.)
The design aspect of the progress report shall include a comprehensive statement on
drawings, calculations and type test reports submitted for approval.
The position on material procurement shall give the dates and details of orders placed and
indicate the delivery dates quoted by the manufacturer. If any delivery date has an adverse
effect on the contract programme, the Contractor shall state the remedial action taken to
ensure that delays do not occur.
The position on manufacture shall indicate the arrival of raw material and the progress of
manufacture. Any events that may adversely affect completion in the manufacturer's works
shall also be reported.
All works tests done shall be listed and test results shall be remarked upon. Any test failure
shall be highlighted.
The dispatch of each order shall be monitored on the progress report giving the date by which
the equipment will be available for transport, the estimated time of arrival on site and the
dates actually achieved.
Delays or test failures in any part of the programme which may affect any milestone or final
completion dates shall be detailed by the Contractor who shall state the action taken to effect
contract completion in accordance with the contract programme.
19.
SPARE PARTS AND SPECIAL TOOLS
The Contractor shall provide prices for spare conductor, joints and termination equipment.
The Project Manager may order all or any of the spare parts listed at the time of contract
award and the spare parts so ordered shall be supplied as part of the definite works. The
Project Manager may order additional spares at any time during the contract period at the
rates stated in the Contract Document.
A spare parts catalogue with price list shall be provided for the various cables, joints and
termination equipment and this shall form part of the drawings and literature to be supplied.
Any spare apparatus, parts or tools shall be subject to the same specification, tests and
conditions as similar material supplied under the Contract. They shall be strictly
interchangeable and suitable for use in place of the corresponding parts supplied with the
equipment and must be suitably marked and numbered for identification.
Spare parts shall be delivered suitably packed and treated for long periods in storage. Each
pack shall be clearly and indelibly marked with its contents, including a designation number
corresponding to the spare parts list in the installation and maintenance instructions.
20.
PACKING AND SHIPPING
20.1. Packing
The cable shall be wound on strong drums or reels capable of withstanding all normal
transportation and handling.
Each length of cable shall be durably sealed before shipment to prevent ingress of moisture.
The drums, reels or coils shall be lagged or covered with suitable material to provide physical
protection for the cable during transit and during storage and handling operations.
In the case of steel drums adequate precautions shall be taken to prevent damage being
caused by direct contact between the cable sheath and the steel. These precautions shall be
subject to the approval of the Project Manager.
If wooden drums are used then the wood shall be treated to prevent deterioration from attack
by termites and fungi.
Each drum or reel shall carry or be marked with the following information:
Individual serial number
Employer's name
Destination
Contract Number
Manufacturer's Name
Year of Manufacture
Cable Size and Type
Length of Conductor (metres)
Net and Gross Mass of Conductor (kg)
All necessary slinging and stacking instructions.
Destination;
Contractor's name;
Name and address of Contractor's agent in Orissa;
Country of origin;
The direction of rolling as indicated by an arrow shall be marked on a flange.
20.2. Storage
The site selected for the storage of cable drums shall be well drained and preferably have a
concrete/firm surface which will prevent the drums sinking into the ground or being
subjected to excess water thus causing flange rot.
All drums shall be stood on battens, in the upright position, and in such a manner to allow
sufficient space between them for adequate air circulation. During storage the drums shall be
rotated 90 every three months. In no instances shall the drums be stored "flat" on their
flanges or one on top of each other.
20.3. Shipping
The Contractor shall be responsible for the shipping of all cables, drums and reels supplied
from abroad to the ports of entry and for the transport of all goods to the various specified
destinations including customs clearance, offloading, warehousing and insurance.
The Contractor shall inform himself fully as to all relevant transport facilities and
requirements and loading gauges and ensure that the equipment as packed for transport shall
conform to these limitations. The Contractor shall also be responsible for verifying the access
facilities specified.
The Contractor shall be responsible for the transportation of all loads associated with the
contract works and shall take all reasonable steps to prevent any highways or bridges from
being damaged by his traffic and shall select routes, choose and use vehicles and restrict and
distribute loads so that the risk of damage shall be avoided. The Contractor shall immediately
report to the Project Manager any claims made against the Contractor arising out of alleged
damage to a highway or bridge.
All items of equipment shall be securely clamped against movement to ensure safe transit
from the manufacturer's facilities to the specified destinations (work sites.)
The Contractor shall advise the storage requirements for any plant and equipment that may be
delivered to the Project Manager's stores. The Contractor shall be required to accept
responsibility for the advice given in so far as these arrangements may have a bearing on the
behaviour of the equipment in subsequent service.
20.4. Hazardous substances
The Contractor shall submit safety data sheets in a form to be agreed for all hazardous
substances used with the equipment. The Contractor shall give an assurance that there are no
other substances classified as hazardous in the equipment supplied. The Contractor shall
accept responsibility for the disposal of such hazardous substances, should any be found.
The Contractor shall be responsible for any injuries resulting from hazardous substances due
to non compliance with these requirements.
21.
SUBMITTALS
21.1. Submittals required with the bid
The following shall be required in duplicate :

completed technical data schedule;
descriptive literature giving full technical details of equipment offered;
type test certificates, where available, and sample routine test reports;
detailed reference list of customers already using equipment offered during the last 5 years
with particular emphasis on units of similar design and rating;
details of manufacturer's quality assurance standards and programme and ISO 9000 series
or equivalent national certification;
deviations from this specification. Only deviations approved in writing before award of
contract shall be accepted;
21.2. Submittals required after contract award
21.2.1. Programme Five copies of the programme for production and testing.
21.2.2. Technical particulars
Within 30 days of contract award five bound folders with records of the
technical particulars relating to the equipment. Each folder shall contain the
following information:
general description of the equipment and all components, including brochures;

technical data schedule, with approved revisions;
calculations to substantiate choice of electrical and mechanical component size/ratings;
statement drawing attention to all exposed points in the equipment at which copper,
aluminium or aluminium alloy parts are in contact with or in close proximity to other metals
and stating clearly what protection is employed to prevent corrosion at each point;
detailed installation and commissioning instructions;
At the final hold point for Project Manager approval prior to delivery of the equipment the
following shall be submitted:
inspection and test reports carried out in the manufacturer's works;
Installation and maintenance instructions. 21.2.3. Operation and maintenance instructions
A copy of the detailed installation and commissioning instructions shall be supplied with
each type cable joint and termination equipment.
21.3. Drawings
Within 30 days of contract commencement the Contractor shall submit, for approval by the
Project Manager, a schedule of the drawings to be produced detailing which are to be
submitted for "Approval" and which are to be submitted "For Information Only". The
schedule shall also provide a programme of drawing submission, for approval by the Project
Manager, that ensures that all drawings and calculations are submitted within the period
specified above.
All detail drawings submitted for approval shall be to scale not less than 1:20. All important
dimensions shall be given and the material of which each part is to be constructed shall be
indicated on the drawings. All documents and drawings shall be submitted in accordance
with the provisions of this specification and shall become the property of the Employer.
All drawings and calculations submitted to the Project Manager shall be on international
standard size paper, AO, Al, A2, A3, or A4. All such drawings and calculations shall be
provided with a contract title block, which shall include the name of the Employer and
Consultants and shall be assigned a unique project drawing number. The contract title block
and project numbering system shall be agreed with the Project Manager.
Lettering sizes and thickness of lettering and lines shall be selected so that if reduced by two
stages to one quarter of their size, the alphanumeric characters and lines are still perfectly
legible so as to enable them to be microfilmed.
For presentation of design drawings and circuit documents IEC Publication 617 or equivalent
standards for graphical symbols are to be followed.
22.
APPROVAL PROCEDURE
The Contractor shall submit all drawings, documents and type test reports for approval in
sufficient time to permit modifications to be made if such are deemed necessary and resubmit them for approval without delaying the initial deliveries or completion of the contract
work. The Project Manager's representative shall endeavour to return them within a period of
four weeks from the date of receipt.
Three copies of all drawings shall be submitted for approval and three copies
for any subsequent revision. The Project Manager reserves the right to
request any further additional information that may be considered necessary
in order to fully review the drawings. If the Project Manager is satisfied with
the drawing, one copy will be returned to the Contractor marked with "Approved" stamp. If
the Project Manager is not totally satisfied with the drawing, then "Approved Subject to
Comment" status will be given to it and a comment sheet will be sent to the Contractor. If the
drawing submitted does not comply with the requirements of the specification then it will be
given "Not Approved" status and a comment sheet will be sent to the Contractor. In both
these cases the Contractor will have to modify the drawing, update the revision column and
resubmit for final Approval. Following approval, twenty copies of the final drawings will be
required by the Project Manager.
Any drawing or document submitted for information only should be indicated as such by the
Contractor. Drawings and documents submitted for information only will not be returned to
the Contractor unless the Project Manager considers that such drawing needs to be approved,
in which case they will be returned suitably stamped with comments.
The Contractor shall be responsible for any discrepancies or errors in or omissions from the
drawings, whether such drawings have been approved or not by the Project Manager.
Approval given by the Project Manager to any drawing shall not relieve the Contractor from
his liability to complete contract works in accordance with this specification and the
condition of contract nor exonerate him from any of his guarantees.
If the Contractor needs approval of any drawing within a period of less than four weeks in
order to avoid delay in the completion of supply, he shall advise the Project Manager when
submitting the drawings and provide an explanation of the document's late submission. The
Project Manager will endeavour to comply with the Contractors timescale, but this cannot be
guaranteed.
23.
SURFACE TREATMENT
Where galvanised steel armour wire is used then the Contractor shall indicate his galvanising
process utilised and its conformance with this specification
23.1. Galvanising
All galvanising shall be carried out by the hot dip process, in accordance with Specification
ISO 1460 or IS 2629. However, high tensile steel nuts, bolts and spring washers shall be
electro galvanised to Service Condition 4. The zinc coating shall be smooth, continuous and
uniform. It shall be free from acid spots and shall not scale, blister or be removable by
handling or packing. There shall be no impurities in the zinc or additives to the galvanic bath
which could have a detrimental effect on the durability of the zinc coating.
Before pickling, all welding, drilling, cutting, grinding and other finishing operations must be
completed and all grease, paint, varnish, oil, welding slag and other foreign matter
completely removed. All protuberances which would affect the life of galvanising shall also
be removed.
The weight of zinc deposited shall be in accordance with that stated in Standard BS 729, ISO
1460 or IS 2629 and shall be not less than 0.61kg/m2 with a minimum thickness of 86
microns for items of thickness more than 5mm, 0.46 kg/m^ (64 microns) for items of
thickness between 2mm and 5mm and 0.33 kg/m2 ( 47 microns ) for items less than 2mm
thick.
Parts shall not be galvanised if their shapes are such that the pickling solution cannot be
removed with certainty or if galvanising would be unsatisfactory or if their mechanical
strength would be reduced. Surfaces in contact with oil shall not be galvanised unless they
are subsequently coated with an oil resistant varnish or paint.
In the event of damage to the galvanising the method used for repair shall be subject to the
approval of the Project Manager or that of his representative.
Repair of galvanising on site will generally not be permitted.
The threads of all galvanised bolts and screwed rods shall be cleared of spelter by spinning or
brushing. A die shall not be used for cleaning the threads unless specifically approved by the
Project Manager. All nuts shall be galvanised. The threads of nuts shall be cleaned with a tap
and the threads oiled.
Partial immersion of the work shall not be permitted and the galvanising tank must therefore
be sufficiently large to permit galvanising to be carried out by one immersion.
After galvanising no drilling or welding shall be performed on the galvanised parts of the
equipment excepting that nuts may be threaded after galvanising. To avoid the formation of
white rust, galvanised material shall be stacked during transport and stored in such a manner
as to permit adequate ventilation. Sodium dichromate treatment shall be provided to avoid
formation of white rust after hot dip galvanisation.
The galvanised steel shall be subjected to test as per IS-2633.
24.
COMPLETENESS OF CONTRACT
All fittings or accessories, although not specifically mentioned herein, but necessary or usual
for similar equipment and their efficient performance shall be provided by the Contractor
without extra charges. The bid shall clearly indicate if any additional equipment or parts
would be necessary to give a complete offer and if so, the details and the prices shall be
included in the bid.
T
PART 4: SCHEDULES
25.
TECHNICAL DATA SCHEDULES
3. 1100V Cable Schedule
Remarks:- a) All the LV Power Cable shall be XLPE with insulated armoured
Aluminum Cable.
b) All the Central Cable shall be PVC insulated Cables.

FOR
SUB STATION LIGHTING
E24-SUBSTATION LIGHTING- Page 1 of 10
SUBSTATION LIGHTING
TABLE OF CONTENTS
1. GENERAL
2. SYSTEM DESCRIPTION
3. LIGHTING FIXTURES
4. LIGHTING POLES
5. LIGHTING WIRES & CABLES
6. TESTS AND TEST REPORTS
7. LIGHTING SYSTEM INSTALLATION WORKS
8. TECHNICAL PARAMETERS OF LIGHTING TRANSFORMERS
9. EMERGENCY PORTABLE LIGHTING FIXTURES
10. CEILING FANS AND REGULATORS
11. FOUNDATION AND CIVIL WORKS
12. GROUNDING
13. TESTING AND COMMISSIONING
10
1. GENERAL
The scope
following:
comprises design, engineering, supply, installation, testing and commissioning of the
Complete installation and lighting fixtures complete with lamps, supports and accessories;For
indoor and outdoor
Ceiling fans complete with electronic regulators, accessories;
lighting panels and lighting poles complete with distribution boxes;
Galvanised rigid steel conduits and fittings, lighting PVC ables GI Earth wire receptacles,
switchboards, switches, junction boxes, pull out boxes complete with accessories;
Lighting transformer.
Any other items required to complete the indoor and outdoor lighting in complete shape.
The details of area to be illuminated are given in Table 1. along with the required lux levels.
Area
Lux
Control Room
350
PLCC Room
300
LT Room
150
Charger Room
150
Cable Gallery
150
Heating Plant
100
Battery Room
100
Computer Room
300
Entrance lobby
150
Corridor and landing
150
Conference and display
300
Rest Room
250
AHU Room
100
DG Set Building
150
Fire Fighting Pump House
150
Switchyard - Main equipment
50
Switchyard - general equipment and balance
20
Street/Road
30
Table 1. Areas to be lit and required lux levels
Contractor shall submit detailed calculation for verifying that the required lux levels will be attained by
the proposed lighting system
Any material, cables, wire, conduits, fittings, accessories etc. whether mentioned specifically or not but
required for installation of lighting fixtures are included in the scope of Contractor.
2. SYSTEM DESCRIPTION
2.1 Normal lighting - AC
AC lights will be connected to AC lighting panels. All the lights connected to the AC lighting system
in different areas will be connected to the main lighting distribution boards to be supplied.
2.2 Emergency lighting - AC
This system will be available in control room building, switchyard and diesel generator building. AC
lighting load will be connected to this system which will be normally ON. The lighting panels of this
system will be connected to the Emergency lighting board which is fed from diesel generator during the
emergency.
2.3 Emergency lighting - DC
DC emergency lighting fixtures operated from the DC system shall be provided in strategic locations
so that the operating personnel can safely find their way during a total AC failure. These lights will be
normally OFF and will be switched ON automatically when under voltage occurs in the AC mains
lighting distribution board.
2.4 Emergency lighting - portable
Emergency portable light shall be provided as per relevant clause of this section. Three portable lights
for control room and two portable lights for PLCC room shall be provided for every substation.
2.5 Temperature Rise
All lighting fixtures and accessories shall be designed to have a low temperature rise according to IEC
598 Part-I/ IS 10322 (Part-4).Temperature rise of panels should be as per IS 8623 (Part-l)/IEC 439-1.
3. LIGHTING FIXTURES
3.1 General
Fixture shall conform to IS 10322 / IEC 598.and its latest amendment.
All fixtures shall be designed for minimum glare. The finish of the fixtures shall be such that no bright
spots are produced either by direct light source or by reflection.
All lighting fixtures shall be complete with required lamps such as Metalhalide (to be fitted inside
switch yard and all street light ), & fluorescent tube light or compact fluorescent lamp (CFL)(adopt as
per Govt nerms for energy efficiency) for indoor lighting..
Metalhalide, fluorescent and CFL lamp fixtures shall be complete with all necessary wiring and
accessories such as ballasts, ignitors, power factor improvement capacitors etc.. These shall be mounted
in the fitting assembly only. The Contractor shall indicate starting time of these lamps to attain full
light output. Curves for starting characteristics with varying supply voltage etc. are to be furnished by
the Contractor.
Flood lighting shall have suitable base plate/frame for mounting on structural steel member.
Each fixture (other than bulk head fixtures) shall have terminal blocks suitable for 2.5 mm2 stranded
flexible copper conductor. The internal wiring should be completed by the manufacturer and
terminated on the above terminal blocks. The Contractor shall specifically furnish details of internal
size of wires and type of insulation. The terminal blocks shall be as specified under General Equipment
and Substation Accessories (GESA) section of this Specification.
Each lighting fixture shall be provided with an earthing terminal suitable for connection to 16 SWG GI
earthing conductors.
All metal or metal enclosed parts of the housing shall be suitably constructed so as to ensure
satisfactory earthing continuity throughout the fixture up to the earthing terminal.
The mounting facility and conduit knock-outs for the fixtures shall be provided and shall be suitable for
20 mm conduit entry.
On completion of manufacture, all surfaces of the fixtures shall be thoroughly cleaned and degreased.
The fixtures shall be free from scale, rust, sharp edges and burrs.
The housing shall be stove-enamelled or vitreous enamelled or anodised aluminium as indicated in the
specification of the relevant fixture.
All enamel finishing shall have a minimum thickness of 2 mils for outside surface and 1.5 mils for
inside surface. The finish shall be non-porous and free from blemishes, blisters and fading.
The surface shall be scratch resistant and shall show no sign of cracking or flaking when bent through
90 degrees. over 1.5 inch die mandrel.
All light reflecting surfaces shall have optimum light reflecting coefficient so as to ensure the overall
light output as specified.
The different types of lighting fixtures to be provided shall be to the approval of the OPTCL.
3.2 Accessories
3.2.1 Reflectors
The reflectors shall be manufactured from sheet steel or aluminium more applicable of not less than 22
SWG thickness. They shall be securely fixed and of captive type.
3.2.2 Lamp holders
Lamp holders shall preferably be for Metahalide lamps and incandescent lamps etc.. Holders shall be
designed and manufactured in accordance with relevant standard to give long and satisfactory service.
3.2.3 Ballasts
Ballasts shall be designed, manufactured and supplied in accordance with IS 3021 and function
satisfactorily under site condition specified. The ballasts shall be designed to have a long service life.
The power loss in ballasts for Metalhalide lamps shall not be more than the specified watts as per
relevant standard and for the fluorescent lamps it shall be the minimum commercially available in the
industry.
Ballasts shall be mounted using self locking anti-vibration fixing and shall be easy to remove without
dismantling the fixtures. They shall be totally enclosed units.
The ballasts shall be of the inductive, heavy duty type, filled with thermosetting, insulating, moisture
repellent polyester compound filled under pressure or vacuum. The ballast wiring shall be of copper
wire. Ballasts shall be designed for maximum winding temperature rise of 55C under rated conditions.
They shall be free from hum. Ballasts for Metahalide lamps shall be provided with suitable tapping to
set the voltage within the range specified. End connections and taps shall be brought out in a suitable
terminal block, rigidly fixed to the ballast enclosure.
Separate ballasts for each lamp shall be provided in case of multi-lamp fixtures.
The Contractor shall submit general arrangement and wiring diagram with all terminal details for
approval of the OPTCL.
3.2.4 Capacitors
Capacitors shall have a constant value of capacitance and shall be connected across the supply of
individual lamp circuits.
Capacitors shall be suitable for operation at the supply voltage as specified and shall have a value of
capacitance so as to correct the power factors of its corresponding lamp circuit to the extent of 0.98 lag.
Capacitors shall be hermetically sealed in a metal enclosure.
3.2.5 Lamps
The sodium vapour lamps /Metal halide lamps to be supplied shall conform to IS 9974. Metal halide
lamps shall be colour corrected type with screwed caps. The lamps shall be suitable for use in any
position. Restrictions, if any, shall be clearly stated. The lamps shall be capable of withstanding small
vibrations with out breakage of connections at lead-in wires and filament electrodes.
The constructional features of gas discharge lamps for special applications shall be clearly brought out
in the bid.
The Bidder shall furnish typical wiring diagrams for all fittings including all accessories. The diagrams
shall include technical details of accessories i.e. ignitors, ballasts, capacitors etc.
3.3 Receptacles
All receptacles shall be of cast steel or aluminium, heavy duty type, suitable for fixing on wall or
column and complete with individual switch.
In general the receptacles to be installed are of the following types:
Type RO-15A, 240V, 2 pole, 3 pin type with third pin grounded, metal clad with gasket having
cable gland entry suitable for 2 core 6 mm2 PVC armoured cable and a metallic cover fixed to it
with a metallic chain. Receptacles shall be suitable for installation in moist location and/ or
outdoor. The switch shall be of rotary type. Receptacles shall be housed in an enclosure made
out of 2 mm thick GI sheet with hinged doors with padlocking arrangements. Door shall be lined
with good quality gaskets. This shall conform to IP 55.
Type RI-Combination of 5A and 15A, 240V, 3 pin type with third pin grounded, suitable for
flush mounting. The switch shall be of piano key type and shall be flush mounted.
Type RP-63A, 415V, 3 phase, 4 pin interlocked plug and switch with earthing contacts. Other
requirements shall be same as type RO. The receptacle shall be suitable for 3 core 35mm2 / 3
core 70mm2 aluminium conductor cable entry and shall also be suitable for loop-in-loop-out
connection of cables of identical size. Receptacle shall be suitable for outdoor application.
Receptacles shall be housed in a box made out of 2 mm thick G. I. sheet, with hinged door with
padlocking arrangement. Door shall be lined with good quality gaskets. This shall conform to IP
55.
4. LIGHTING POLES
The Contractor shall supply, the following types of hot dip galvanised steel tubular lighting poles
required for street lighting:
a) Type Al street lighting pole - for one fixture
b) Type El post top lantern pole - for one fixture
Street/flood light poles shall conform to the drawings approved by the OPTCL.
Lighting poles shall be complete with fixing brackets and junction boxes. Junction boxes should be
mounted above ground level at 1 mtr height from the ground.
The lighting poles shall be steel hot dip galvanised
The galvanised sheet steel junction box for the street lighting poles shall be completely weather proof
conforming to IP 55 and provided with a lockable door and HRC fuse mounted on a fuse carrier and
fuse base assembly. The terminals shall be stud type and suitable for two nos. 16mm2 cables.
Necessary arrangement for cable glands along with supply of double compression glands are included
in Contractors scope.
Wiring from junction box at the bottom of the pole (minimum height from the bottom of the pole shall
be 1.0mtrs) to the fixture at the top of the pole shall be 2.5 mm2 wire.
5. LIGHTING WIRES & CABLES
The wiring used for lighting shall be of 1100V grade, PVC insulated cable of standard products of
reputed manufacturers.
The conductor sizes for wires used for point wiring beyond lighting panels shall be single core 4 mm2,
6mm2 and 10mm2 stranded aluminium wires and 2.5 mm2 stranded copper wire.
The wires used for connection of a lighting fixture from area rest junction box or for loop-in loop-out
connection between two fluorescent fixtures shall be single core copper stranded conductor, 1100V
grade flexible PVC insulated cords, unsheathed, conforming to IS 694 with nominal conductor cross
sectional areas of 2.5mm2.
The Contractors scope covers supply of all wiring, cabling and accessories.
The wires shall be colour coded as follows:
Red
for R - Phase
Yellow
for Y - Phase
Blue
for B - Phase
Black
for Neutral
White
for DC (Positive)
Grey
for DC (Negative)
6. TESTS AND TEST REPORTS

Type tests, acceptance tests and routine tests for the lighting fixtures and accessories covered by this
specification shall be carried out as per the relevant standard for the respective fixtures and their
accessories.
Manufacturers type and routine test certificates shall be submitted for the fixtures and accessories.
Type test certificates shall be furnished along with the bid.
Rates for type tests for all types of fixtures and accessories for light fittings as required under relevant
section of this specification shall be provided in the relevant price schedules.
7. LIGHTING SYSTEM INSTALLATION WORKS
7.1 General
In accordance with the specified installation instructions as shown on manufacturers drawings or as
directed by Project Manager. Contractor shall supply, erect, install, test and put into commercial use all
the electrical lighting equipment included in the contract. Equipment shall be installed in a neat,
workmanlike manner so that it is level, plumb, square and properly aligned and oriented. Tolerances
shall be as established in manufacturers drawings or as stipulated by Project Manager.
The Contractor shall prepare the lighting layout and erection drawings and obtain the Project Managers
approval before commencing the erection works.
7.2 Flood lights.
Contractor shall install flood lights on switchyard structures to be erected inside switchyard. The GI
structural are also suitable for protection from lightening by providing spikes cones at all the column
peak. Proper design in this respect to be carried out along with numbers of such towers required.
Plotting of lightening protection area showing details of equipment installed in switch yard. A platform
provided in the mast tower shall be used for fixing of lighting fixtures.
Fixtures shall be mounted on galvanised making use of shop provided holes or by suitable clamps. No
cutting or drilling of galvanised structure is permitted.
The Contractor shall mount the assembled fittings and install necessary cabling.
7.3 Lighting fixtures for flood lights
Flood lights shall be mounted on steel base facing the tentative direction shown on drawings. Fixing
holes shall be provided with slot to turn the fixture by approximately 5 degrees on both sides. Bolts
shall be finally tightened with spring washer. The Contractor shall supply and install the steel base,
channels, angles etc. for fixing the flood light on the flood light towers. Terminal connection to the
flood light shall be through flexible conduits, and these flexible conduits shall be included in the
installation rate of fixture itself.
The scope of Contractor shall include the supply of necessary brackets and sundry material, for
installation of lighting fixtures.
7.4 Lighting panels
Lighting panels shall be erected at the locations to be indicated in the approved drawings.
Necessary foundations and/or supporting structures for all outdoor type lighting panels and necessary
supporting structures for indoor lighting panels shall be provided by the Contractor.
7.5 Street lighting poles
Street lighting poles shall be installed as per the approved drawings.
Steel tubular hot dip galvanised pole,s which are specified for the above purpose are to be installed as
per the approved lay out for street lighting system. Contractor shall erect the poles (including
foundation works), mount the assembled fittings and install necessary cabling.
8. TECHNICAL PARAMETERS OF LIGHTING TRANSFORMERS
i)
Type of transformer
Dry type natural air
ii)
Rating
1 00 kVA or 75kVA
iii)
Voltage ratio
415/415 volts
iv)
No. of phase
Three
v)
Frequency
50Hz
vi)
Winding connection
Dyn 1
vii)
Class of insulation
B class
viii)
Percentage Impedance 4%, 10%
ix)
No. of taps and steps
5 in steps of 2.5%
x)
Reference standard
IS 2026
xi)
Any latest amendment standards of the above.
Transformers shall be located in ACDB room, in separate enclosure. Enclosure shall have degree of
protection not less than IP 42 as per IS 2147.
9. EMERGENCY PORTABLE LIGHTING FIXTURES
The portable emergency lighting fixtures supplied shall have a built in battery rated for six hours and be
complete with battery chargers and solid state inverters, and be supplied with all necessary supporting
brackets of galvanised steel suitable for wall/column mounting..
The portable emergency lighting fixtures shall be of a single unit, completely tropicalised, suitable for
prolonged use with no maintenance, and shall light up automatically in the event of failure of normal
supply.
The Contractor shall submit schematic along with all details and general arrangement drawing for
approval.
10. CEILING FANS AND REGULATORS
The Contractor shall supply 1400 mm sweep ceiling fans complete with electronic regulator and switch,
suspension rod, canopy and accessories.
The Contractor shall supply the switch, electronic regulator and board for mounting switch and
electronic regulator.
Winding of the fans and regulators shall be insulated with Class-E insulating material. Winding shall
be of copper wire.
Electronic regulator with smooth control shall be provided.
Precautions shall be taken in manufacture of fans and regulators to ensure reasonable degree of silence
at all speeds.
Type tests, acceptance tests and routine tests for the fans and regulators shall be carried out as per latest
relevant standard.
Fans and electronic regulators shall be from established manufacturers or brands.
11. FOUNDATION AND CIVIL WORKS
All foundations and civil works shall be included in the Contractors scope of work. Civil works shall
be in accordance with the relevant part of this specification.
12. GROUNDING
All lighting panels, junction boxes, fixtures, conduits etc. shall be grounded in compliance with the
provision of I.E. Rules.
Ground connections shall be made from nearest available station ground grid. All connections to
ground grid shall be done by arc welding.
Lighting panels shall be directly connected to ground grid by two 50 x 6mm G.S. flats.
A continuous ground conductor of 16 SWG GI wire shall be connected to each panel ground bus. All
junction boxes, lighting fixtures shall be connected to this 16 SWG ground conductor.
All lighting poles shall be earthed as per standard. 16 SWG GI wire shall be taken up to junction box
from the lighting fixture.
13. TESTING AND COMMISSIONING
On completion of erection work, the Contractor shall request the OPTCL to undertake the inspection as
required by this Specification.
The OPTCL 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 tested and commissioned in the presence of the Contractor and OPTCL
The Contractor shall provide all men, material and equipment required to carry out the tests.
All rectification, repairs or adjustment work found necessary during inspection, testing and
commissioning shall be carried out by the Contractor, without any extra cost to the Employer.
The Contractor shall measure and furnish to the Project Manager, the actual lux level in all the areas of
the substation to prove compliance to this specification.
** Armoured PVC cables are to be used for the switch yard lighting, street lighting and any other
out door lighting system.
** For indoor lighting ,each fixture shall be controlled by one switch.
** Minimum two nos 5 Amp multi purpose power sockets with switch are to be provided in each
switch.

FOR
TESTING INSTRUMENTS AND MAINTENANCE KITS
OTHER TOOLS & PLANTS
&
FURNITURE
E25-TESTING INSTRUMENTS- Page 1 of 10
TESTING INSTRUMENTS AND MAINTENANCE KITS AND OTHER T&PS & FURNITURE
TABLE OF CONTENTS
1. GENERAL
2. TRAINING
3. CLIMATIC CONDITION
4. 100 KV TRANSFORMER OIL BREAKDOWN VOLTAGE TEST SET
5. INSULATION RESISTANCE TESTER (MEGGER)
6. OIL SAMPLING BOTTLE
7. RELAY TOOLS KITS
8. SF6 GAS LEAK DETECTOR
9. DIGITAL MULTIMETE
10. DIGITAL CLAMP METER
11. DIGITAL EARTH TESTER
12. DISCHARGE ROD
13. RUBBER HAND GLOVES
14. PORTABLE EMRGENCY LIGHT
14. SCHEDULE OF REQUIREMENTS OF MAINTENANCE EQUIPMENT -
ANNEXURE - I
15. OTHER TOOLS & PLANTS - ANNEXURE - II
16. OFFICE FURNITURES
8
10
1.
GENERAL
The testing and maintenance equipment covered here are generally meant for carrying out testing and
measurement at site and shall be complete with all materials and accessories. These shall be robust in
design, so that they give accurate results even in adverse site conditions.
All equipment furnished shall be of reputed make, type tested and shall be subjected to acceptance and
routine tests in accordance with the requirements stipulated under respective equipment specification.
At least two sets of descriptive leaflets, catalogues, outline drawing, principles of operation etc. shall be
sent along with the offer, for all the equipment offered. Weight and dimensions of items should also be
mentioned.
Four sets of inspection and calibration report, operation and maintenance manual shall be sent along
with Despatch documents. One set will be kept inside the equipment.
In the event of bidder offering equipment manufactured by different manufacturers, it will be his
responsibility to fully co-ordinate the activities of each manufacturer in such a way that the complete
equipment contracted for, is manufactured, supplied and guaranteed for successful operation.
2.
TRAINING
Necessary training shall be provided to Employer's personnel for using and maintaining the equipment
at Employer's premises.
3.
CLIMATIC CONDITION
The equipment covered under this specification shall be suitable for operation under climatic condition
stated else where in the specification. The offered equipment as such shall be suitable for satisfactory
operation under the tropical climate.
3.
100 KV TRANSFORMER OIL BREAKDOWN VOLTAGE TEST SET
The equipment offered shall be suitable for determination of electric strength (breakdown voltage) of
insulating oil upto 100 KV to IS:335 when measured in accordance with IS:6792.
The test cell shall be as per IS:6792 suitable for BDV upto 100 KV without external flashover.
The unit shall be of composite type having control unit and high voltage transformer in a common
cabinet with necessary partition. HV chamber interlocking and zero start interlocking shall be provided.
The unit shall have motorised drive to increase voltage linearly as per the rate specified in IS:6792.
Provision should also be available for manual increase of voltage. The unit shall be complete with test
cell, stirrer and "GO" and "NO GO" gauge for adjusting the gap.
The instrument shall have
a) Operating temperature: 0 50 deg C
b) Humidity > 90% and nearly equals to 99%
c) Low/High level interlocking for drive motor. Earth open interlocking,reverse interlocking.
d) Protection: Quick acting D.C relay to isolate the H.T.
e) Test cup: The test cup with cover shall be made of Methyle Mathacrylate(Acrylic) having oil
between 300 and 500 ml, with adjustable and removable mushroom head and ground to adjust
the electrode gap distance.
f) Motorised and manual operation.
g) A linear scaled A.C rectifier voltmeter marked kV to measure output voltage.
h) Shall have magnetic strainer provision for removing the bubbles.

The equipment shall be suitable for operation at 240 volts 50 Hz. Single phase AC supply.
4.
INSULATION RESISTANCE TESTER (MEGGER)
The equipment offered shall be used for measurement of insulation resistance of electrical equipment.
4.1
4.2
Technical Requirements
Rated voltage selection
: 1, 2, 3, 4, and 5 kV (DC Volts)
Rated resistance (megohms)
0 to 100000 multi-range type. Resistance range

for each rated voltage shall be indicated in the
offer.
Type
Portable, compact and direct reading type of multivoltage with multi-rated resistance ranges. The
tester shall be suitable for hand operation as well
as operation by a continuously rated motor with
AC mains supply of 230V, single phase, 50 Hz.
Ambient temperature
0 to 50C
Infinity adjustment
There should be provision
leather carrying case
The instrument shall be supplied with 7 metre long

mains leads (shall have insulation level as per
required) and leather carrying case.
Standards
The tester shall generally comply with the

requirements of IS:2992-1987 and IS:11994-1986
and latest.
Preferable make
The equipment offered shall be of reputed make

preferably Megger/ Avo International make or
equivalent(on approval of OPTCL)
Other required spec.
High voltage indication by LED for user safety
Auto discharge of capacitive load with indication

after the IR test.
Recessed terminals and shrouded leads for

enhanced user safety.
Linear and accurate reading
Protected against accidental connection to 230/440

V AC supplies.
Portable and light weight suitable for field and

Lab use.
Test Requirements
Type test certificate for all ten tests as per Cl.11.1 of IS:2992.
All routine tests as per Cl.11.3 of IS:2992 shall be conducted.
5.
OIL SAMPLING BOTTLE
Oil Sampling bottles shall be suitable for collecting oil samples from transformers, for testing of the oils
(BDV, Dissolved Gas Analysis, resistivity etc). Bottles shall be robust enough, so that no damage
occurs during frequent transportation of samples from site to laboratory.
Oil sampling bottles shall be made of stainless steel having a capacity of 1 litre.
Oil sampling bottles shall be capable of being sealed gas-tight and shall be fitted with cocks on both
ends.
The design of bottle and seal shall be such that loss of hydrogen shall not exceed 5% per week.
An impermeable oil-proof, plastic or rubber tube of about 5 mm diameter, and of sufficient length shall
also be provided with each bottle along with suitable connectors to fit the tube on to the oil sampling
valve of the equipment and the oil collecting bottles respectively.
6.
RELAY TOOLS KITS (ALSO REFER THE SPECIFICATION OF PCM)
The relay test kit shall consist of the following minimum items:
1. Test plugs for use with testing equipment
2. Special type test plugs for using with modular type cases
3. Screw driver set with multiple fixing feature
4. Long nose pliers
5. Wire cutting pliers and stripper
6. Ordinary pliers
7. Adjustable wrench
8. Soldering irons of
Watts rating - 1 No.
9. De-soldering pump
10. Printed Circuit Card-extender; Printed circuit card - `Puller' Suitable for all supplied relays
11. Test leads (Pair with 2 Mts. length) - 1 set
12. Shorting plugs, `pistol' prods (2 Nos.) - 1 set
7.
SF6 GAS LEAK DETECTOR
The SF6 gas leak detector shall meet the following requirements
The detector shall be free from induced voltage effects.
The sensing probe shall be such that it can reach all the points on the breaker where leakage is to be
sensed .Latest standard in this effect may be followed..
8.
Digital Multimeter
The digital multi meter shall have a LCD screen for displaying 3 and 3/4 digits and having auto ranging
facility. Instrument shall have single rotary selection switch. Instrument shall have automatic polarity,
low battery and over range indication and a range of 0.1mV to 1000V DC, 0.1mV to 750V AC, 0 -10A
DC , 0-10 A ,AC and 0-10 mega ohm . Instrument shall have auto selection of AC/DC ampere and
AC/DC Voltage. It shall have auto power off and data hold facility. Instrument shall have rugged casing
and other measurement facilities (resistance, diode, continuity etc measurement) as per standard.
9.
Digital clamp-on- meter: (AC)
The digital clamp meter shall have LCD screen for displaying 3 and 3/4 digits, multifunction, 1000
Ampere range of AC current at (i) 0.01 Amp to 20 Amp, (ii) to 200Amp and (iii) to 1000Amp; AC/DC
voltage range 0.01 V to 200V and in the other scale up to 1000V, Provision of measurement of
resistance up to 0 10 mega ohms at different scale selection and also other facilities. Instrument shall
have single rotary selection switch. It shall have auto power off and data hold facility. Instrument shall
have rugged casing and other measurement facilities (resistance, diode, continuity etc measurement) as
per standard.
10. Digital Earth Tester.
The digital earth tester shall have 4 points ,three range ( 0 .01 ohms to 20 ohms, 200 ohms and
up to 2000 ohms) type. Battery operated type instrument.3 and 1/2 digit LCD display with maximum
reading 1999 ohms. Instrument shall have rechargeable internal Ni-MH Battery. Instrument shall be of
4 wire soil resistivity measurement. Type tested as per IS-9223.Instrument shall have low bat
indication and data hold facility. Instrument shall have over range indication. Single, measuring time
below 1 minute. Instrument shall consist of required nos of standard length of spikes (minimum 1
mtr), flexible copper PVC wires of required length (minimum length shall be 30mtrs two pieces and 15
mtrs two pieces ,and two more pieces for connecting to the instrument), one no. suitable hammer for
hammering the spike for inserting into the earth. There shall be crocodile clamps on one side of each
wire and round clips on the other side for connecting to the instrument.
11. Discharge Rods:
Discharge rods shall be good quality and as per the latest relevant standard. Required length of
PVC good insulation flexible copper cable, required clamp connected at the end of wire shall be
connected. The top portion of the discharge rod shall be adjustable to fit in for proper gripping by
screwing from the bottom side. The entire handle shall be of latest insulating materials for the safety of
the user. The discharge rod shall be reliable, durable and shall meet the safety requirement of the users.
12. Rubber Hand Gloves:

Good quality rubber gloves for using during operation of isolators and earth switch. Latest
standard for the rubber gloves shall be followed. The gloves shall be reliable, durable and shall meet
the safety requirement of the users.
13 Portable Emergency Light:

Reputed make (BPL/CGL/Bajaj) portable emergency light, having twin tube, shall be supplied
to each sub-station. It shall have chargeable battery (durable) and having provision of selection switch
for selecting single or double tube. It shall have chargeable feature during not in use and automatically
switch on in the event of power failure. CFL tubes are preferred. It shall have provision of wall
hanging/table mounting and shall be durable one. Latest standard in this effect shall be followed.
14.
SCHEDULE OF REQUIREMENTS OF MAINTENANCE TESTING EQUIPMENT

ANNEXURE I
Item nos.
Units ALL
132/33KV
ALL
220/132/33
KV S/S
220/33 KV
S/S
Gopinathpu
r(keonjhar)
100 kv transformer oil breakdown Nos

voltage test set
Insulation resistance tester (megger)
Nos
Oil sampling bottle
Nos
SF6 gas leak detector
Nos
LCD, digital multimeter
Nos
Analogue Multimeter(features same as Nos

digital multimeter)
LCD, clamp on meter
Nos
Digital earth tester
Nos
Discharge rod as per standard for Nos

carrying out the switch yard
maintenance work
Rubber gloves of operation of isolators Pairs

and earth switch
Relay tools kit
Sets
Portable emergency light
Nos
Latest version desktop PC of reputed Set

make with all its accessories including
CPU, Monitor, UPS and having all
latest loaded software and also its back
up in shape of CD and separate pen
drive . suitable for loading of software
as recommended by the relay
manufacturer. It includes supply of one
no portable laser printer of reputed
make.
Make of PC and printer: HP/DELL
** The multimeters (both digital and analogue), clamp on meters, earth tester shall preferably of
Motwane make. Prior approvals of OPTCL for all the testing equipments are to be taken.
15. OTHER TOOLS AND PLANTS (T&PS) REQUIREMENT:

(ANNEXURE- II)
Following T&Ps of reputed make are also in the scope of this contract.
Quantity against Each Package
Sl
Description of Items
unit
No
ALL
132/33 KV
ALL
220/132/33
KV S/S
220/33 KV
S/S
Gopinathp
ur(keonjh
ar
Set of D spanner(6mm Set

42mm)
Set of Ring spanner(6mm Set

42mm)
Socket
wrench
with Set
sockets,handles,and
other
attachment(6mm-42mm)
Insulated cutting plier
Nos
Insulated nose plier
Nos
Monkey plier
Nos
Circlip plier
Nos
Pipe wrench
a)12 inch 1 no
Set
b)18 inch 1 no
9
Sly wrench
a)12inch 2 nos
Set
b)18inch 1 no
10
Insulated handle screw drivers Set

of different sizes as per
required
a)12inch plain head 2 nos
b)8inch plain head 2 nos
c) 12inch star head 1 no
d) small size6inch plain and
star head 2 each
e)Complete set of different
head in one box/set -1set
11
L-N keys set of different Set

sizes in one box/set
12
M.S Files(12inch and 6inch set

sizes)
Set
set
Round files and flat files-one

each of different sizes)
13
Hammar with handle

a)1 lb 2 nos
b)1/2 lb-2 nos
c)2 lb-1 no
14
Crow bar
a)5 ft 2nos
b)3ft-2 nos
15
Steel scale(12inch)
Nos
16
Steel tape
Set
a)5 mtrs-2 nos

b)30mtrs-1 no
17
Oil cane
Nos
18
Spirit level (8inch)
No
19
Plumb head with string and No

attachment
20
Maintenance safety belt with Set

all
attachment
and
helmets(complete one set)
21
Hand drill machine with No

different bits and key.(Wolf
make)
22
Vacuum cleaner having hot No

blower provision with all
attachments (Eureka Forbes
make)
23
230-250VAC,80W,450mm
No
sweep,1400 rpm stand(rugged)
FAN
Make: Almonard,CGL
** All the T&Ps shall be of Taparia make. The hand drill and vacuum cleaner shall be wolf and Eureka
Forbes make.
16. OFFICE FURNITURE:

Supply and installations of the office furniture are in the scope of this contract. All the furniture
shall be of Godrej & Boyance make. Before supply of the furniture to the sub-station, approval from
OPTCL is required. Details of the scope of supply are as indicated below.
ANNEXURE III.
Sl
No
Description of Items
unit
Quantity against Each Package
ALL
132/33 KV
ALL
220/132/33
KV S/S
220/33 KV
S/S
Gopinathpu
r(keonjhar
5ftX3ft executive table with Nos

drawer both sides
3ftX2&1/2ft Table with one Nos

side drawer
Computer
table
suitable Set
keeping monitor,CPU,UPS and
printer with two nos revolving
arm chair suitable for computer
use.
Executive
revolving Nos
,adjustable(height) chairs with
arm
Cane gutting S type steel Nos

chairs with arm
18
24
18
6ftX3ft conference table
Nos
Cushion arm steel chairs for Nos

conference table purpose
6ft height steel almirah (only Nos

with selves) for keeping
records and other valuable
items
6ft height steel almirah with Nos

glass doors for library purpose
10
6ft height (having minimum 6 Nos

lockers facility) steel cupboard
with locking arrangement
11
4ft steel rack (minimum three Nos

selves) for keeping the files
and other items
10

LIMITED

FOR
CONSTRUCTION OF
1)132 KV SC/DC,
2)220 KV SC/DC AND
3)400 KV DC
TRANSMISSION LINE
E26-TRANSMISSION LINE- Page 1 of 91
FOR CONSTRUCTION OF
1) 400 KV,
2) 220 KV and
3) 132 KV
TRANSMISSION LINES
Nature of work
The work covered by this Specification is for 400 kV and/or 220 kV and/or 132 kV
transmission lines as specified herein and in the attached Schedules. The overhead
transmission lines will form part of the OPTCL Transmission System.
General particulars of the system

The following are the general particulars governing the design and working of the
complete system of which the Works will form a part
a) Electrical energy is generated at interconnected power stations as three-phase
current at a frequency of 50 Hz, and transmitted therefrom by means of overhead
lines.
b) The system will be in continuous operation during the varying atmospheric and
climatic conditions occurring at all seasons
1.0 SCOPEConstruction of 400 KV, 220 KV and 132 KV

Package
Name of the Line No
LILO on Existing
No.
(for LILO)
Line
Loc
132 KV DC Line for Samuka Khurda Puri line (LILO)

Length of the line 11 KM
132 KV DC Line for Chandpur Khurda Balugaon line
Package - 1 Length of the line 2.5 KM
132
KV
DC
(LILO)
Line
for Aska
Chatrapur
line
Purushottampur Length of the line (LILO)

3.21 KM
132 KV SC Line on Dc Tower for Karadagadia S/S Banki
Banki Length of the Line 19.69 S/S (New Line)
Package - 2
KM
132 KV DC Line for IIT Argul Karadagadia S/S IIT
Length of the Line 19.337 KM
Argul S/S (New Line)
132 KV DC Line for Udala Length Balasore-Baripada DC

Package - 3 of the Line 39.728 KM
line-Near
Belanati
(Nuagaon) LILO
132 KV DC Line for Kalunga Budhipadar-Tarkera

Package - 4
DC
line (LILO)
220 KV DC Line for Gopinathpur TTPS

Line
(LILO)
JODA Ckt-1
220 KV DC line for Lapanga Budhipadar Burla Ckt- Location

Package - 5
Length of the line 1.42 Kms
DC line (LILO)
No. 51
132 KV DC line for Lapanga BurlaBudhipadar Ckt-DC Location

line (LILO)
No. A123
132 KV SC line for Lapanga SambalpurRajgangpur

Package - 6
Location
Ckt-SC (LILO)
220KV DC line for Kuanrmunda BudhipadarTarkera

Length of the line 15 Kms
No. J121
DC
line (LILO)
220KV DC line for Karadagadia NarendrapurMendhasal

Package - 7
DC line (LILO)
132KV DC Multicircuit line on Khurda S/S to Karadagadia

Multicircuit
Towers
for S/S (New Line)
Karadagadia Length of the line

11 Kms
Important: Contractor has to obtain project license from the competent authority in
respect of the mentioned works prior to commencement of the works.
The expenses towards the project license have to be borne by the
contractor.
2.0
SURVEY (detail & check, estimating of quantities & spotting of towers)
2.1.1
General: Preliminary route alignment in respect of the proposed transmission lines

has been fixed by the employer subject to alteration of places due to way leave or
other unavoidable constraints. The Right of way shall be solved by the contractor
and all expenses there of shall be borne by him. However, OPTCL shall render all
helps in co-ordination with law and order department for solving the same. Forest
clearance if any shall be arranged by OPTCL.
2.1.2
Provisional quantities/numbers of different types of towers have been estimated

and indicated in the BOQ Schedule given. However final quantities for work shall
be as determined by the successful bidder, on completion of the detail survey,
preparation of route profile drawing and designing of the different types of towers
as elaborated sin the specification and scope of work.
2.1.2.1 The contractor shall undertake detailed survey on the basis of the tentative
alignment fixed by the employer. The said preliminary alignment may, however,
change in the interest of economy to avoid forest and hazards in work. While
surveying the alternative route the following points shall be taken care by the
contractor.
(a)
The line is as near as possible to the available roads in the area.
(b)
The route is straight and short as far as possible.
Good farming areas, religious places, forest, civil and defence

installations, aerodromes, public and private premises, ponds, tanks, lakes,
gardens, and plantations are avoided as far as practicable.
(d)
The line is far away from telecommunication lines as reasonably possible.

Parallelism with these lines shall be avoided as far as practicable.
(e)
Crossing with permanent objects are minimum but where unavoidable

preferably at right angles.
(f)
Difficult and unsafe approaches are avoided.
(g)
The survey shall be conducted along the approved alignment only in

accordance with IS: 5613 (Part-II/Section-2), 1985.
(h)
For river crossing/ Crossing of Nallas : Taking levels at 25 metre interval

on bank of river and at 50 metre interval at bed of river so far as to show
the true profile of the ground and river bed. The levels may be taken with
respect to the nearest existing towers, pile foundation of towers, base or
railway/road bridge, road culvert etc. The levels shall be taken at least 100
m. on either side of the crossing alignment. Both longitudinal and cross
sectional shall be drawn preferably to a scale of 1:2000 at horizontal and
1:200 vertical.
After completing the detailed survey, the contractor shall submit the final profile and
tower schedule for final approval of the employer. The final profile and tower
schedule shall incorporate position of all type of towers. To facilitate checking of
the alignment, suitable reference marks shall be provided. For this purpose,
concrete pillars of suitable sizes shall be planted at all angle locations and suitable
wooden/iron pegs shall be driven firmly at the intermediate points. The contractor
shall quote his rate covering these involved jobs.
Only approved sag template shall be used for tower spotting and the final profiles.
However preliminary survey has been done by OPTCL and any further survey
required shall be done by the contractor.
2.1.2.2 PROFILE PLOTTING AND TOWER SPOTTING
The profile shall be plotted and prepared to the scale 1 in 2,000 for horizontal and 1 in
200 for vertical on squared (mm) paper. If somewhere the difference in levels be
too high, the chart may be broken up according to the requirements. A 10 mm
overlap shall be shown on each following sheet. The chart shall progress from left
to right for convenience in handling. The sheet size may be conveniently chosen.
With the help of sag template, final tower location shall be marked on the profiles
and while locating the tower on survey chart, the following shall be kept in mind:
(a) The number of consecutive span between the section points shall not
exceed 10 in case of straight run on a more or les plain stretch.
(b) Individual span shall be as near as to the normal design ruling span.
In different crossing the contractor shall take into consideration the
prevailing regulations of the respective authorities before finalizing
type and location of the towers. While carrying out survey work, the
contractor has to collect all relevant data, prepare and submit drawings
in requisite number for obtaining clearance from the PTCC, road,
aviation, railways, river and forest authorities.
The contractor shall remain fully responsible for the exact alignment of the line. If after
erection, any tower is found to be out of alignment, the same shall have to be
dismantled and re-erected after corrosion by the contractor at his own cost, risk
and responsibility, including installation of fresh foundation, if belt necessary by
the employer.
After peg marking of the angle tower or tension towers, the contractor shall obtain
approval from the employer and thereafter pegging of suspension type tower shall
be done by the contractor and pegging of all the four legs of each type of towers
at all the locations shall be done.
2.1.2.3 SCHEDULE OF MATERIALS
When the survey is approved, the contractor shall submit to the employer a complete
detail schedule of all materials to be used in the line. Size and length of conductor
etc. are also to be given in the list. This schedule is very essential for finalizing
the quantities of all line material. The contractor shall furnish the same.
2.1.2.4 CHECK SURVEY
The contractor shall undertake the check survey during execution on the basis of the
alignment profile drawing and tower schedule approved by the employer. If
during check survey necessity arises for minor change in route to eliminate way
leave or other unavoidable constraints, the contractor may change the said
alignment after obtaining prior approval from the employer.
The contractor, while carrying out the check survey, shall peg mark the power position on
ground conforming to the survey charts. In the process, it is necessary to have the
pit centers marks according to the excavating marking charts to be prepared by
the contractor and approved by the employer. The levels up or down of each pit
center with respect to the center of the tower location shall be noted and recorded
for determining the amount of earth work required to meet the design. At the
charting point of the route survey, an angle iron spite shall be driven firmly into
the ground showing a little above the ground level.
2.1.2.5 WAY-LEAVE AND TREE CUTTING
Way-leave permission which may be required by the contractor shall be arranged at his
cost. While submitting final-survey report for approval, proposals for way-leave
right of way shall be submitted by the contractor. Employer may extend help to
get the permission within a reasonable time as mutually agreed upon for which
due notice shall be given by the contractor in such a way so that obtaining
permission from appropriate authority do not hinder the continued and smooth
progress of the work.
The employer shall not be held responsible for any claim on account of damage done by
the contractor or his personnel to trees, crops and other properties.
The contractor shall take necessary precaution to avoid damage to any ripe and partially
grown crops and in the case of unavoidable damage, the employer shall be
informed and necessary compensation shall be paid by the contractor.
All the documents required for application to the statutory authorities must be prepared
by the contractor & submission to the employer for Submission of the application
towards approval of PTCC, Railway Crossing etc. However, the responsibilities
lies with the contractor to get the clearance.
Trimming of tree branches or cutting of a few trees en-route during survey is within the
scope of survey to be done by the contractor. Contractor shall arrange for
necessary way-leave and compensation in this regard. During erection of the line,
compensation for tree cutting, damage caused to crops, actual cutting and felling
of the trees including way-leave permission for such route clearance shall be
arranged by the contractor at his cost. The contractor will identify the number of
trees and detail of obstructions to be removed for erection of the line and intimate
the employer well in advance in case of any help. Other related works like
construction of temporary approach roads, etc. as required, shall be done by the
contractor and the same will lie within the scope of contractors work and such
cost shall be considered to be included in the rates quoted by him.
While quoting the rate for detailed and check survey as per bidding activity schedule, the
contractor shall include all costs involved in different activities described herein
earlier.
2.0
SUB-SOIL INVESTIGATION
To ascertain soil parameters in various stretch inter, the contractor shall carry out sub-soil
investigation through reputed soil consultant as approved by the employer.
2.1
SCOPE OF WORK
The scope of sub-soil investigation covers execution of complete soil exploration for the
transmission line under this contract including boring, drilling, collection of
undisturbed soil sample where possible, otherwise disturbed samples, conducting
laboratory test of soil samples to find out the various parameters as detailed in this
specification and submission of detailed reports in 6 copies along with specific
recommendation regarding suitable type of foundation for each bore-hole along
with recommendation for soil improvement where necessary.
2.1.1 QUALIFYING REQUIREMENTS OF SOIL CONSULTANTS
The soil consultants shall provide satisfactory evidence concerning the following as and
when asked for.
That, he/they has/have adequate technical knowledge and previous practical experience
in carrying out complete soil investigation jobs in any kind of soil.
That he/they has/have well equipped, modernized soil testing laboratory of his/their own.
If asked for by the employer, the contractor shall arrange inspection of such
laboratory of the soil consultant by the representative of the employer.
If in the opinion of the employer, the soil consultant (proposed by the contractor) is not
well equipped or capable to undertake the sub-soil investigation job relating to
this contract, then such soil consultant shall not be engaged to undertake the job.
In that case, they shall have to engage other agency as will be approved by the
employer.
2.1.3
TEST BORING
The boring shall be done at the major locations/crossing, special towers. However, it is
desirable that there should be at least one sub-soil investigation bore-hole for the
line. Such locations for sub-soil investigation shall be selected and finalized in
consultation with the employer.
The test boring through different layers of all kinds of soil shall have to be carried out by
the contractor through the approved soil consultant as briefed hereunder.
(a) Method of boring, selection of sampling tubes, sampling, recording of
boring, protection, handling, leveling of samples shall be done as specified
in IS: 1892/1977, if any, after obtaining approval from the employer. The
contractor/consultant shall furnish in the soil report in details, the
equipment and method of boring actually adopted.
(b) Depth of boring below ground level shall be 15 M. only unless continuous
bedrock is encountered earlier. In case rock is encountered at any depth
within 15 M. adequate study of rock and assessment of strength
characteristics shall be done and recommendation shall be given.
(c) Undisturbed soil samples shall be obtained for the initial 4M depths at
every 1.5M interval and at change of strata. After these initial 4M depths,
samples shall be obtained preferably at every 3M or where there is a
change of strata, or as advised by the employer.
(d) In case collection of undisturbed samples becomes difficult/impossible
detailed soil testing on remoulded soil samples is to be considered and
reported in the soil report.
(e) Standard penetration test as per IS: 2131 with latest amendment shall have
to be conducted in different strata and recorded properly.
(f) The ground water table shall be recorded during boring operation and
incorporated in the bore log. If possible, the position of the water table just
after monsoon period be ascertained from local people and indicated in the
report.
(g) Plate Load test shall have to be conducted at special tower location.
3.0
LABORATORY TESTS OF SOIL SAMPLES
The method and procedure of testing of soil sample to be followed shall be as per
relevant IS codes. Adequate volume of test samples shall be collected from site.
Ample shall be properly sealed immediately after recovery as specified in relevant
IS code and transported carefully to laboratory for carrying out necessary
laboratory tests to find out the following parameters of every samples. Data and
time of taking of the sample shall be recorded in the test report.
(a)
(b)
(c)
(d)
(e)
(f)
(l)
Natural moisture content, Liquid limit, Plastic limit and Plasticity index.
Bulk, dry and buoyant density of soil.
Void ratio (e-long P curve shall be submitted)
Specific gravity.
Grain size distribution (Sieve analysis and hydrometer analysis)
Tri-axial and consolidation tests (consolidation undrained and
consolidated drained as and when application in table, graph and drawing.
Permeability tests
Chemical tests for both water and soil samples at different layers.
Evaluation of safe bearing capacity at different strata for square footings
shall be done for a maximum value of 25-mm. settlements.
At depts. From 3M to 10M be different strata.
Factor of safety shall be considered as 3 for evaluation of safe bearing
capacity of soil.
Unconfined compression test for cohesive soil (=0) if encountered.
3.1
REPORT ON SUB-SOIL INVESTIGATION
(g)
(h)
(i)
(j)
(k)
The contractor shall make analysis of soil samples and rock cores as collected by him in
the field and approved by the employer as collected by him in the field and
approved by him in the field and approved by the employer as well as field tests
and laboratory tests. A comprehensive report shall have to be prepared by him,
finally incorporating all the data collected in proper tabular forms or otherwise
along with the analysis.
The 3(three) copies of report in the draft form shall be submitted for employers
approval. 6(six) copies of final report incorporation employers comments, if any
shall be submitted within 3(three) weeks after completion of this work.
Recommendations shall include but not be limited to the following items (a) to (p)
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
Geological information of the region.

Past observations and historical data, if available, for the area or for other
areas with similar profile or for similar structures in the nearby area.
Procedure of investigations employed and field and field as well as
laboratory test results.
Net safe bearing capacity and settlement computation for different types of
foundations for various widths and depths of tower and building.
Recommendations regarding stability of slopes, during excavations etc.
Selection of foundation types for towers, transformers and buildings etc.
Bore hole and trial pit logs on standard proforma showing the depths,
extent of various soil strata etc.
A set of longitudinal and transverse profiles connecting various boreholes
shall be presented in order to give a clear picture of the site, how the
soil/rock strata are varying vertically and horizontally.
(i)
(j)
(k)
(l)
(m)
(n)
(o)
3.1.2
Modulus of sub grade reaction from plate load test for pressure ranging up
to 6 kg/cm. The recommended values shall include the effect of size,
shape and depth of foundations.
Deformation modulus from plate load test in various test
depth/stratification.
Coefficient of earth pressure at rest.
Depth of ground water table and its effect on foundation design
parameters.
Recommendations regarding stability of slopes, during shallow excavation
etc.
Whether piles are necessary or not. If piles are necessary, recommendation
of depth, diameter and types of piles to be used.
Recommendations for the type of cement to be used and any treatment to
the underground concrete structure based on the chemical composition of
soil and sub-soil water.
MEASUREMENT OF SOIL RESISTIVITY
For the purpose of grounding design, soil resistance measurement shall be taken in the
locations as stated under clause 1.0 above and based on which the value of soil
resistance shall be derived.
Wenners four (4) electrode method shall be used for earth resistance measurement in
accordance with the procedure and the calculation detailed in IS:3043 1987. At
least 8(eight) test direction shall be chosen from the center of the locations to
cover the whole site.
The employer reserves the right to carry out separate soil investigation at his cost by
engaging a separate agency for cross checking the result obtained by the
contractor.
In case the results are at variance, the soil parameters to be adopted for final design will
be at the sole discretion of the employer and such will be binding upon the
contractor.
IMP:-The material and services covered under these specifications shall be

performed as per requirements of the relevant standards and codes referred
hereinafter against each set of equipment and services. In case of a conflict between
such codes and/or standards and the Specifications, the latter shall govern. Other
Internationally acceptable standards which ensure equal or higher performance
than those specified shall also be accepted.
--------------------------------------------------------------------------------------------------SL.
Indian
Title
International &
No.
Standards
Internationally
recognised
Standards.
-------------------------------------------------------------------------------------------------1.
2.
3.
4.
-------------------------------------------------------------------------------------------------1.
IS 209-1979
Specification for
ISO/R/752-1968
Zinc
ASTM B6
2.
IS 226-1975
Structural steel
(Standard quality)
ISO/R/630-1967
CAN/CSA G40.21
BSEN 10025
3.
IS 269-1976
Ordinary rapid hardening and low heat

Portland cement.
ISO/R/597-1967
4.
IS 383-1970
Coarse and fine aggregates from natural

sources for concrete.
CSA A23.1 /A23.2
5. a)
IS 398-1982
Part-I
Specification for
aluminium conductors for overhead
transmission purposes
IEC 1089-1991
BS 215-1970
b)
IS 398-1982
Part-II
Aluminium conductor
galvanised steel
reinforced
BS 215-1970
IEC 1089-1991
c)
IS 398-1994
Part-IV
Aluminium alloy
stranded conductor
BS 3242-1970
IEC 1089-1991
ASTM 8393M86
d)
IS 398-1982
Part-V
Aluminium conductor galvanised steel

reinforced for Extra
High Voltage (400kV
and above)
BS 215-1970
IEC 1089-1991
6.
IS 278-1978
Specification for
barbed wire.
ASTM A 121
7.
IS 406-1964
Method of chemical
analysis of Zinc slab
8.
IS 432-1966
(Part 1 & 11)
Mild steel and medium

tensile bars and hard
drawn steel wire for
concrete reinforcement.
9.
IS 456-1978
Code of practice for

plain and reinforced concrete.
ISO 3893-977
10.
IS 731-1971
Porcelain insulators
for overhead power
BS 137-1982
(Part-I & II )
BS 4449
CSA G-30.
BS 4482
lines with nominal

voltage greater than
1000 Volts.
11.
IS 800-1962
Code of practice for use

of structural steel in
general building consruction.
12. a) IS 802-1995
(Part-I/Sec.I)

use of structural
(Part-I/Sec.II)
-1992
steel in overhead
transmission Line:
materials, loads and
permissible stresses.
IEC 383-1993
(Part-I& II )
CSA S 16.1
BS 5950
IEC 826
ANSI/ASCE 10-90
(1991)
b) IS 802-1978
BS 8100
ANSI/ASCE 10-90
(1991)
(Part-II)
c) IS 802-1978
use of structural
steel in overhead
transmission line:
Fabrication, galvanising, inspection
and packing.
Code of practice for use of
ANSI/ASCE 10-90
structural steel in overhead transmission line

towers: Testing.
IEC 652
(1991)
(Part-III)
13.
IS 1139-1966
Hot rolled mild steel,

medium tensile steel
and high yield strength
deformed bars for concrete reinforcements.
14.
IS 1367-1967
Technical supply conditions

for threaded fasteners
15.
IS 1489-1976
Portland pozzolena cement.
ISO/R 863-1968
16.
IS 1521-1972
Method of tensile testing

of steel wires
ISO 6892-1984
17.
IS 1573-1976
18.
IS 1786-1966
Electroplated coating of
zinc on iron and steel
Cold twisted steel bars for
concrete reinforcement.
19.
IS 1778-1980
Reels and drums for bare

conductors
BS 1559-194
20.
IS 1893-1965
Criteria of earthquake
resistant design of
IEEE 693
CAN/CSA G30.18
ASTM A615
BS 4449
structures.
21.
IS 2016-1967
Plain washers
ISO/R 887-1968.
ANSI B18.22.1
22.
IS 2071
Part-I-1974
Part-II-1974
Part-III-1976
Method of high voltage

testings
IEC 60
23.
IS 2121
Specification for conductor

and earthwire accessories for
overhead power lines.
Armour rods, binding wires
and tapes for conductors.
Mid-span joints and repair
sleeve for conductors.
Accessories for earthwire.
Non-tension joints.
a) Part-I -1981
b) Part-II -1981
c) Part-III-1992
d) Part-IV-1991
24.
IS 2131-1967
Method of standard
penetration test for
soils.
ASTM D 1 883
25.
IS 2551-1982
Danger notice plates
26.
IS 2486
Specification for insulator

fittings for overhead power
greater than 1000 Volts.
Part-I
General requirements and

tests.
BS 3288
IEC 1284
Part-II
Dimensional requirements
IEC 120-1984
Part-III
Locking devices
IEC 372-1984
27.
IS 2629-1966
Recommended practice
for hot dip galvanising of iron and steel.
28.
IS 2633-1972
Method of testing
uniformity of coating
of zinc coated
articles.
29.
IS 3043-1972

earthing(with amendment No.1 and 2).
ASTM A123
CAN/CSA G 164
BS 729
ASTM A123
CAN/CSA G164
30.
IS 3063-1972
Single coil rectangular DIN 127-1970

section spring washers
for bolts nuts, screws.
31.
IS 3188-1965
Dimensions for disc
IEC 305-1978
insulators.
32.
IS 4091-1967

design and construction
of foundation for transmission line towers and poles.
33.
IS 4826-1979
Galvanised coating on
round steel wires.
34.
IS 5358-1969
Hot dip galvanised coatings on fasteners.
IS 5613
35.
90(1991)
36.
(Part-II/Sec-1)
-1985
(Part-III/Sec.1)
-1989
design, installation and

maintenance of overhead
power lines (Section-l:
Designs)
IS 5613
(Part-II/Sec-2)
-1985
(Part-III/Sec.2)
-1989

design, installation and
power lines (Section 2:
Installation and maintenance)
ASCE/IEEE 691
IEC 888-1987
BS 443-1982
CAN/CSA G 164
ASTM A153
ANSI/ASCE 10-
37.
IS 6610-1972
Specification for heavy

washers for steel structures.
38.
IS 6639-1972
Hexagonal bolts for steel

structure.
ISO/R 272-1968
ASTM A394
CSA B33.4
39.
IS 6745-1972
Methods for determination

of weight of zinc coating
of zinc coated iron and
steel articles.
ASTM A90
ISO 1460
40.
IS 8263-1976
Method of radio interference

tests on high voltage insulator
IEC 437-1973
NEMA 107-1964
41.
IS 8269-1976
Method of switching impulse

tests on HV insulators.
IEC 506-1975
Specification for weldable

structural steel (medium and
high strength qualities)
BSEN 10025
42.
IS 8500-1977
43.
IS 9708-1980
Specification for Stock Bridge

vibration dampers for overhead
power lines.
44.
IS 9997-1988
Aluminium alloy redraw rods
IEC 104-1987
Hard drawn aluminium wires for

overhead line conductors.
IEC 889-1987
45.
46.
Thermal mechanical performance

tests and mechanical performance
tests on string insulator units.
IEC 575-1977
47.
Salt fog pollution voltage

withstand tests.
IEC 507-1991
48.
Residual strength of string

insulator units of glass or
ceramic material for overhead
lines after mechanical damage
of the dielectric.
IEC 797-1984
49.
Guide for the selection of insulators in respect of polluted

conditions.
IEC 815-1986
50.
Tests on insulators of ceramic

material or glass for overhead
greater than 1000 Volts.
IEC 383-1993
(Part I and II )
51.
Ozone test on elastomer
ASTM D-1171
52.
53.
IS 1363
Hexagonal head bolts,

screws and nuts of product
Grade - C
Part - 1
Hexagonal head bolts
ISO 4016
Part - 3
Hexagonal nuts
ISO 4034
IS 1367
Technical supply conditions

for threaded steel fasteners
Part
III
Part
VI
Mechanical properties and test

methods for bolts, screws
and studs with full loadability
Mechanical properties and
test methods for nuts with
full loadability
54.
Indian Electricity Rules - 1956
55.
Indian Electricity Act - 1910
ISO 898-1
ISO/DIS 898/II
56.
IS 1498-1970
Classification and identification of soil

for general engineering purposes
57.
IS 1888-1982
Method of load test on soils
58.
IS 1892-1979
Code of practice for subsurface

investigation for foundation
59.
IS 2911-1979
Code of practice for design and
(Part-I)
construction of pile foundations
60.
IS 4453-1980
Code of practice for exploration

by pits, trenches, drifts and shafts
61.
IS 6935-1973
Method for determination of water

level in a bore hole
62.
IS 8009-1976
(Part-I)
Code of practice for calculation of

settlement of foundation subjected
to symmetrical vertical loads
(Shallow Foundation)
63.
IS 2386-1963
(Part-3)
Methods of test for aggregates for

concrete : Specific gravity, density,
voids, absorption and bulking
64.
IS 14000-1994
Quality management and quality

assurance standards
GRIDCO Safety Manual (draft)-1997
Composite insulators for a.c. overhead
lines with a nominal voltage greater than
1000 V : Definition, test methods and
acceptance criteria
65.
66.
ISO 9000-1994
IEC 1109-1992
ANSI C29-11
IEEE 987
----
SUPPLY OF TOWER STRUCTURES FOR THE

TRANSMISSION LINES
1.0
SCOPE
1.1
This specification provides for design, proto fabrication, galvanizing and delivery
FOR (destination) of transmission line towers including super-structure stubs,
tower extensions, stub-templates, tower accessories (Hangers, U-bolts, bird
guards, anti-climbing devices), bolts and nuts, step bolts, flat and spring washers
etc. as described hereinafter in this volume.
THE PRELIMINARY SURVEY WORK HAS ALREADY DONE AND THE
FOLLOWING TOWERS HAVE BEEN DECIDED.
The contractor shall design the tower foundation and the concreting shall be
done by M-20 grade concrete.
a)
b)
Wind effects:
Tower shall be designed for reliability Level-I, Terrain category-I &
Wind Zone-V Design wind pressure on towers, conductors, earth wire and
insulator string in the range of 30.45 mt. And above 45 mt. Height shall be
computed as per IS-802(Part/Sec-I) 1995 Bidder shall furnish the maximum wind
pressure adopted in their design against each component mentioned above.
Design Temperatures:
The following temperature range for the power conductor and ground wires shall
be adopted for the line design:
(i)
Minimum temperature:
5 deg. C
(ii)
Everyday temperature of conductor:
32 deg. C
(iii)
Maximum temperature of :
a) Conductor:ACSR
75 deg. C for ACSR
Moose/Zebra/Panther
90 deg. C for AAAC.
(**Double Moose conductor in 400 KV system)
b) Ground wire exposed to sun. 53 deg. C
The above values are subject to latest revision if any made in IS-802 (part-I/Sec-I)
1995
Maximum Tension:
Maximum tension shall be based on either:
a)
at 5 deg. C with 2/3rd. full wind pressure or
b)
at 32 deg. C with full wind pressure whichever
is more stringent.
Conform to IS 802-1995
Part-I/Sec-I-Clause No.10.3
Factors of Safety & Span details:

Factor of Safety:
Should conform to IS-802 Part-I-1995
Normal span:
The normal span of the ine shall be 350 meters of 220KV and 320
meters for 132 KV.
Wind & Weight Span: The wind and weight span to be adopted in the design of the
structures shall be as follows:
(i)
Wind span: The wind span is the sum of the two half spans adjacent to the
support under consideration. In case of towers located on a perfectly horizontal terrain,
this shall be the normal span. For design purpose the wind on conductor shall be
calculated on a wind span of at least 1.1 times the normal span.
Weight Span: The weight span is the horizontal distance between the lowest point of the
conductors on the two spans adjacent to the tower. All C and D type towers shall be
designed for uplift spans (minimum weight spans in the following table) also. These are
applicable both for pointed and square cross arms.
For details of cross arms and towers , the span limits given below shall prevail.
132 KV
Tower 400KV/220 KV
type.
Normal
Broken wire
Normal condition. Broken wire
condition.
condition.
condition.
Max.
Min.
Max.
Min.
Max.
Min.
Max.
Min.
A/DA
525
100
315
100
500
100
300
100
&
B/DA
C/DC
600
100
360
100
500
100
300
100
&
D/DD
1.1.1
The design of towers and their extensions shall be done conforming to the
design parameters specified herein, the scope of design also includes
supply of design calculation for towers and extensions including detailed
structural/shop drawings of towers extensions and stub setting templates.
The bidder, who has already type tested the various tower viz: 0-2, +3,
+6; 0-15, +3, +6; 0-30, +3, +6; 0-60, +3, +6 ( 400/220/132 KV) in any
nationally or internationally recognized laboratories, and conforming to
our specification, may also offer the same.
1.1.2 STANDARDS
Except as modified in this specification, the material and work covered under this
specification, shall conform to the latest revision with amendments thereof of the
following of Indian Standards and equivalent International Standards whenever
indicated below.
Sl. Bureau of Title
No. Indian
standards
(BIS)
International
&
Internationally
recognized
standard
1.
IS:209
Specification for Zinc
ISO/R/752
2.
IS: 2062
Structural steel (Standard quality)
ISO/R/660
3.
IS: 432
Mild steel and medium tensile bars and BS-785CSA-G-30

for concrete reinforcement
4.
IS: 802
Code of practice for use of structural
steel in overhead transmission line

Part-I/Section-I & Section2:
Load and permissible stresses
Part-II: Fabrication Galvanizing
Inspection and Packing
PART-III: TESTING
5.
IS: 1367
Technical supply
conditions for threaded
fasteners
6.
IS: 1893
Criteria of Earthquake
resistant design
structures
7.
IS: 2016
Plain washers
8.
IS: 2551
Danger Notice Plates
9.
IS: 2629
Recommended practice
for hot dip galvanizing of
iron and steel
10.
IS: 2633
Method of testing
uniformity of casting of
zinc coated articles
11.
IS: 3063
Single coil rectangular

section spring washers
for bolts, bolts, screws
12.
IS: 5358
Hot dip galvanized

coatings on fasteners
13.
IS:5613
Part-1 & 2
Of Section-I
Code of Practices for

design, installation &
power line
14.
IS: 6610
Specification for heavy

washers for stell
structures.
ISO/R/987
DIN-127
15.
IS: 6745
Methods of
determination of weight
of zinc coating of zinc
coated iron and steel
articles.
16.
IS: 12427
Hexagonal bolts for steel

structures
17.
INDIAN ELECTRICITY
RULES 1956
18.
Publication for
Regulation for electrical
crossing or railway tracks
1.1.3
The standards mentioned above are available from
Reference/
Abbreviation
Name and Address from which

the Standards are available
IS
BUREAU OF INDIAN STANDARDS

Manak Bhavan,
9, Bahadur Shah Zafar Marg,
NEW DELHI(India)
ISO
INTERNATIONAL
ORGANISATION
FOR STANDARDISATION,
Danish Board Standardisation,
Danish Standardisening Street,
Aurehoegbvej-12,
DK-2900, Helleprup, DENMARK
CSA
CANADIAN
STANDARD
ASSOCIATION
178, Rexdale Boulevard, Rexdale,
Ontario, CANADA
M9W IR
BS
BRITISH STANDARDS
British Standard Institution,
101, Pentonvile Road,
N-19-ND-UK
DIN
DEUTSCHES INSTITUTE FIIR NOR

Gurggrafenstrasse 5-10
Post Fach 1107
D-1000, Berlin 30
INDIAN ELECTRICITY RULES

1956, REGULATION FOR
ELECTRICAL CROSSING OF
RAILWAY TRACKS
KITAB MAHAL
Baba Kharak Singh Marg,
NEW DELHI 110 001
(INDIA)
1.1.4
1.1.5
Electrical System Date:
a)
System voltage (kV rms)
400/220/132
b)
Max. voltage (kV rms)
420/245/145
c)
Lightning
impulse
withstand
voltage (dry & wet) (kVp)
1550/1050/650
d)
Power frequency withstand voltage

(wet) (KV rms)
630/395/275
e)
Short circuit level

(KA for 1 sec.
1.1.6
1.1.7
40/40/31.5
Line data
Conductor
a)
Name
ACSR
Zebra
ACSR
Moose
ACSR
Panther
b)
Strength & wire dia

i) Aluminium
54/3.18
54/3.53
30/3.00
ii) Steel
7/3.18
7/3.53
7/3.0
c)
Conductors per phase

1) 400 KV
2)220 KV
3)132 KV
Double
Single
d)
Spacing
between
the
conductors of same phase
(sub-conductor
spacing)
(mm)
----
As per
standard
e)
Inter-phase spacing (mm)
8,400
8,400
f)
Configuration
i) Single circuit
Delta
Delta
ii) Double circuit
Vertical
Vertical
528.5
Single
----
6800
Delta
Vertical
g)
Nominal Aluminium area

(mm)
420
h)
Section area of Aluminium

(mm)
Total sectional area (mm)
428.90
484.50
597
j)
Calculated resistance at 20
c (Max.) ohm/km per
conductor
0.06915
0.05552
0.140
k)
Approx. calculated breaking

load (KN)(Minimum)
130.32
161.2
89.67
l)
Modulus
(GN/M)
69
69
m)
-6
Co-efficient of linear exp. 19.3X10
Per degree cent.
n)
Mass of zinc in gms/sqm
275
o)
Overall diameter (mm)
28.62
i)
of
elasticity
597
212.1
261.5
19.3X10-6
31.77
262
82
17.8X10-6
21.00
p)
Weight (kg/km)
q)
Minimum ultimate tensile 130.32

strength (KN)
r)
Conductor tension at 32 C
without external load
1.1.8
1621
2004
974
161.2
89.67
i) Initial unloaded tension
..35%
ii) Final unloaded tension
25%.
Galvanized Steel Ground Wire
a)
Size (no. of strands/strand dia)
b)
Overall diameter (mm)
7/3.15 for 132 and 220 KV, and

7/3.66 for 400 KV
9.45(7/3.15) and 10.98(7/3.66)
c)
Standard weight (Kg/km)
432(7/3.15) and 583(7/3.66)
d)
Location of ground wire
One continuous ground wire

Wire to run horizontally on the top
of the towers for 132 and 220 KV
and two ground wire for 400 KV
lines.
e)
Tensile load in each ground wire

(to be furnished by the Bidder)
i) At min. temp. of 5 C and in still
air (kgs)
ii) At every day temp. of 32 C and
still air (kgs)
iii) At 5 C and 2/3rd of full wind

(kgs)
1.1.8.1
a)
Span lengths in metres

ACSR
Moose
300
52
250
52
20
20
20
V-zone
v-zone
i) Ruling design span

Wind load (kg/sqm) on conductor
c)
Shielding angle with vertical
d)
Towers to be designed for heavy V-zone

wind zone
Insulator Strings
Sl.
No.
Particulars
1.
No. of standard Discs

(nos)
1) 400 KV
2) 220 kV
3) 132 Kv
2.
3.
ACSR
Panther
ACSR
Zebra
300
52
b)
1.1.8.2
4.0
Towers
Size of Disc
(400kv/220kV/132kv)
Electromechanical
strength (kg)
(400 KV/220 kV/132
KV)
Single
Double
Single
Suspension suspension Tension
string
string
string
1X25
1X15
1X10
2X25
2X15
2X10
255X145
254X146
255X145
254X146
11,500
11,500
9000
2X11,500
2X11,500
2X9000
Double
Tension
string
1X25
1X15
1X10
2X25
2X15
2X10
285
285
11,500 2X11,500
11,500 2X11,500
2X9000
9000

4.1 Tower Design General
The employer is looking for a structurally safe design of transmission line towers to be
installed on EHV lines keeping the loadings and line parameters detailed in this
specification and in compliance with IS: 802 (Part-1/Sec-1)-1995, IS: 802(Part1/Sec-2)-1992.
The Bidder may offer economical designs with rational sections or offer towers of
recent design, proven in service and accepted by other reputed Central and State
Sector Utilities and by OPTCL (Previously OSEB) confirming to this technical

specification.
The technical particulars for vibration analysis and damping design of the system are as follows:
FOR 400kV LINES.
---------------------------------------------------------------------------------------------------------SL.
Description
Technical Particulars
No.
---------------------------------------------------------------------------------------------------------1.
Configuration
Double Circuit
Twin ACSR Moose 54/7//3.53 mm,
conductor bundle per phase in
horizontal formation and all three
phases of each circuit in vertical
configuration on each side of tower.
2.
Span length in meters

(i)
3.
(ii)
Ruling design
span
Maximum span
(iii)
Minimum span
Tensile load in
each sub-conductor
for ruling span
400 meters
1100 meters
100 meters
Wind Zone : 5 (50 m/s).
a) At temperature
of 5 deg-C and
still air
3267 Kgf.
b) At temperature
of 5 deg.C and
36% full wind
4646 Kgf.
c) At temperature
of 32 deg.C and
full wind
4.
Armour rods used
5.
Maximum permissible
dynamic strain
7805 Kgf.
Standard preformed armour

rods/AGS
+/- 150 micro strains
FOR 220 kV and 132 kV LINES

------------------------------------------------------------------------------------------------------SL.NO.
Description
------------------------------------------------------------------------------------------------------220kV
132kV
ACSR ZEBRA
ACSR PANTHER
54/7/ 3.18mm
30/7/3.0mm
1.
Configuration
Double Circuit
Double Circuit
Single ACSR
Single ACSR
conductor per
conductor per
phase in vertiphase in vertical formation
cal formation
2.
Span length in metres

(I) Ruling design
span
350 metres
300 metres
(ii) Maximum span
1100 metres
1000 metres
(iii) Minimum span
100 metres
100 metres
Tensile load in
each conductor
for ruling span
Wind Zone:5
(50 m/s.)
Wind Zone:5
(50 m/s.)
a) At temperature
of 5 deg.C and
still air
b) At temperature
of 5 deg.C and
36% full wind
2919 Kgf.
1791Kgf.
4090 Kgf.
2735Kgf.
c) At temperature
of 32 deg-C and
full wind
6551 Kgf.
4469 Kgf.
4.
Armour rods used
Standard performed
armour rods/AGS
5.
Maximum permissible
dynamic strain
150 microstrains
3.
Standard performed
armour rods/AGS
150 microstrains
Bundle spacer (only for 400kV lines )

Armour grip bundle spacers shall be used to maintain the spacing of 450 mm
between the two sub-conductors of each bundle under all normal working conditions.
Spacers offering equivalent or better performance shall also be accepted provided offer
meets the qualifying requirements stipulated in the Specification.
The offer shall include placement charts recommending the number of spacers per phase
per span and the sub span lengths to be maintained between the spacers while installing
on the twin bundle conductors.
The placement of spacers shall be in such a way that adjacent sub spans are sufficiently
detuned and the critical wind velocity of each sub span shall be kept more than 30 km/hr
and to avoid clashing of sub conductors. The placement shall ensure bundle stability
under all operating conditions.
The placement chart shall be provided for spans ranging from 100m to 1100m. The
number of spacers recommended for a nominal ruling span of 400m shall however be
not-less than six.
The Bidder shall also furnish all the relevant technical documents in support of their
placement charts along with the Bid.
Jumpers at tension points shall also be fitted with spacers so as to limit the length of free
conductor to 3.65 m and to maintain the sub conductor spacing of 450 mm. Bidder shall
quote for rigid spacer for jumper. It shall meet all the requirements of spacer used in line
except for its vibration performance. Spacers requiring retaining rods shall not
be
quoted for jumpers. For slack span also rigid spacers shall be used with maximum
spacing of 30 metres.
The spacer offered by the Bidder shall satisfy the following requirements:
Spacers shall restore normal spacing of the subconductors after displacement by wind,
electromagnetic and electrostatic forces under all operating conditions, including the
specified short circuit level, without permanent deformation or damage either to
conductor or to the assembly itself. They shall have uniform grip on the conductors.
For spacers requiring preformed retaining rods, the retaining rods shall be designed for
the specified conductor size. The rods shall be made of high strength special aluminium
alloy of type 6061 or equivalent aluminium alloy having minimum tensile strength of 35
kg/sqmm. The ends of retaining rods shall be ball ended. The rods shall be heat-treated
to achieve specified mechanical properties and give proper resilience and retain the same
during service.
Four rods shall be applied on each clamp to hold the clamp in position. The minimum
diameter of the rods shall 7.87 +/- 0.1 mm. and the length of the rods shall not be less
than 1100 mm.
Where elastomer surfaced clamp grooves are used, the elastomer shall be firmly fixed to
the clamp. The insert shall be forged from aluminium alloy of type 6061 or equivalent
aluminium alloy having minimum tensile strength of 35 kg/sqmm. The insert shall be
duly heat treated and aged to retain its consistent characteristics during service.
Any nut used shall be locked in an approved manner to prevent vibration loosening. The
ends of bolts and nuts shall be properly rounded for specified corona performance or
suitably shielded.
Clamp with cap shall be designed to prevent its cap from slipping out of position when
being tightened.
The clamp grooves shall be in uniform contact with the conductor over the entire
clamping surface, except for rounded edges. The groove of the clamp body and clamp
cap shall be smooth and free of projections, grit or other material, which may cause
damage to the conductor when the clamp is installed.
For the spacers involving bolted clamps, the manufacturer must indicate the clamp bolt
tightening torque to ensure that the slip strength of the clamp is maintained between 2.5
kN and 5kN. The clamp when installed on the conductor shall not cause excessive stress
concentration on the conductor leading to permanent deformation of the conductor
strands and premature fatigue failure in operation.
Universal type bolted clamps, covering a range of conductor sizes will not be permitted.
No rubbing, other than that of the conductor clamp hinges or clamp swing bolts shall take
place between any parts of the spacer. Joints incorporating a flexible medium shall be
such that there is no relative slip between them.
The spacer shall be suitably designed to avoid distortion or damage to the conductor or to
themselves during service.
Rigid spacers shall be acceptable only for jumpers.
The spacer shall not damage or chafe the conductor in any way which might affect its
mechanical and fatigue strength or corona performance.
The clamping system shall be designed to compensate for any reduction in diameter of
conductor due to creep.
The spacer assembly shall not have any projections, cuts, abrasions or chattering parts
which might cause corona or RIV.
The spacer tube shall be made of aluminium alloy of type 6061 or equivalent aluminium
alloy. If fasteners of ferrous material are used, they shall conform to and be galvanised
conforming to relevant Indian Standards. The spacers involving ferrous fasteners shall
not have magnetic power loss more than one watt at 600 amps., 50 Hz alternating current
per subconductor.
Elastomer, if used, shall be resistant to the effects of temperature up to 85 deg.C,
ultraviolet radiation and other atmospheric contaminants likely to be encountered in
service. It shall have good fatigue characteristics. The physical properties of the
elastomer shall be of approved standard.
The electrical resistance between the sub-conductor across the assembly in case of spacer
having elastomer clamp grooves shall be suitably selected by the manufacturers to ensure
satisfactory electrical performance and to avoid deterioration of elastomer under all
service conditions.
The spacer assembly shall have complete ease of installation and shall be capable of
removal and reinstallation without any damage.
The spacer assembly shall be capable of being installed and removed from the energised
line by means of hot line techniques.
Spacer damper (only for 400kV lines )
As an alternative to vibration dampers and bundle spacers combination, suitable spacer
dampers for twin bundle AAAC 61/3.45 conductor may be offered. The spacer damper
covered by this Specification shall be designed to maintain the bundle spacing of 450mm
under all normal operating conditions and to effectively control aeolian vibrations as well
as subspan oscillations to nominal conductor spacing after release of any external extraordinary load.
The spacer damper shall restore the normal subconductor spacing due to displacement by
wind, electromagnetic and electrostatic forces including the specified short circuit level
without permanent deformation or damage either to bundle conductors or to spacer
damper itself.
The design offered shall be presented as a system consisting of a recommended number
of spacer dampers together with their spacing schedule for spans ranging from 100m to
1100 m.
Under the operating conditions specified, the spacer damper system shall adequately
control Aeolian vibrations throughout the life of the transmission line in order to prevent
damage to conductor at suspension clamps, dead end clamps and at the spacer clamps.
The spacer damper system shall also control the sub span oscillations in order to prevent
conductor damage due to chafing and due to severe bending stresses at the spacer damper
clamps as well as suspension and dead end clamps and to avoid wear to spacer damper
components.
The spacer damper shall consist of a rigid central body called the frame, linked to the
conductors by two articulated arms terminated by suitable clamping system. The dynamic
characteristics of the articulations shall be maintained for the whole life of the
transmission line.
The clamping system shall be designed to provide firm but gentle and permanent grip
while protecting the conductor against local static or dynamic stresses expected during
normal operating conditions. The clamping system shall be designed to compensate for
any reduction of conductor diameter due to creep.
The clamp of the spacer damper, when installed, shall not cause excessive stress
concentration on the conductor leading to permanent deformation of the conductor
strands and premature fatigue failure in operation. The slip strength of the clamp shall be
maintained between 2.5kN to 5kN. The tightening torque for the bolts, if applicable, shall
be specified by the manufacturer to achieve the above slip strength.
Bolted type clamps shall allow installation without removal of the bolts or the clamps
from clamp body. Locking mechanism shall be suitable to prevent bolt loosening. Clamp
locking devices using small loose components shall not be accepted.
Bolts and nuts shall be of mild steel, stainless steel, or high strength aluminium alloy in
accordance with the design of the spacer damper.
Where elastomer surfaced clamps are used, the elastomer elements shall be firmly fixed
to the clamp. The insert should be forged from aluminium alloy of type 6061 or
equivalent aluminium alloy having minimum tensile strength of 35 kg/sqmm. The insert
shall be moulded on the insert surface. The insert shall be duly heat treated and aged to
retain its consistent characteristics during service. The grain flow of the forged insert
shall be in the direction of the maximum tension and compression loads experienced.
If clamps involving preformed rods are used, these rods shall be designed for
specific conductor size. They shall be made of high strength aluminium alloy of type
6061 or equivalent aluminium alloy having a minimum tensile strength of 35 kg/sqmm.
The rods shall be ball ended. The rods shall be heat treated and aged to achieve specified
mechanical properties and to retain the same during service.
The spacer damper body shall be cast/forged from suitable high strength corrosion
resistant aluminium alloy. The aluminium alloy shall be chosen in relation with the
process used. However a combination of aluminium alloy and steel shall also be
accepted.
The rubber components like damping elements involved in the design shall be
made with rubber compound selected specifically for that particular application. The
Bidder shall submit a complete list of physical and mechanical properties of the
elastomer used. This list shall make reference to all applicable ASTM or other
Internationally recognised standards.
The rubber compounds used shall have good resistance to the effects of
temperature up to 85 deg.C and to ultra violet radiation, ozone and other atmospheric
contaminants. The rubber shall have good wear and fatigue resistance and shall be
electrically semi-conductive.
The spacer damper involving ferrous material shall not have magnetic power loss
more than one watt at 600 amps., 50 Hz alternating current per sub conductor.
The spacer damper assembly shall have electrical continuity. The electrical
resistance between the subconductors across the assembly in case of spacer damper
involving elastomer surfaced clamps shall be suitably selected by the manufacturer to
ensure satisfactory electrical performance and avoid deterioration of elastomer under
service conditions.
The spacer damper assembly shall have complete ease of installation and shall be
capable of removal and reinstallation without any damage.
The spacer damper assembly shall be capable of being installed and removed
from the energised line by means of hot line techniques.
The Bidder shall recommend the spacing between spacer dampers on the line
which shall ensure the most satisfactory fatigue performance of the line as specified. The
scheme shall indicate the number of spacer dampers per phase per span and the sub-span
lengths to be maintained between spacer dampers when installed on the twin bundle
conductors.
The number of spacer dampers and their spacing shall be provided for spans
ranging from 100 to 1100m. The number of spacer dampers for a nominal ruling span of
400 m shall be not less than six.
No sub-span shall be greater than 70m and no end sub-span shall be longer than
40 metres.
The proposed scheme shall be such that the spacer dampers be unequally
distributed along the span to achieve sufficient detuning of adjacent sub-spans for
oscillations of sub-span mode and to ensure bundle stability for wind speeds up to 30
kms/hr (8.33 m./sec.).
The Bidder shall furnish all the relevant technical documents in support of the
staggering scheme recommended for the spacer damper.
The Bidder in the latter case shall forward documentation of proto type tests
conducted and acceptance given by the user authorities as also performance report
for such towers in service.
Vibration dampers
All the requirements for vibration damper suitable for line conductors, shall also
be applicable for galvanised steel earthwires (7/3.66mm. for 400kV and 7/3.15mm. for
220kV/132kV lines). Minimum one damper on each side per earth wire at suspension
point and two dampers on each side at tension point shall be used for ruling design span.
Bidders may offer damping systems involving a greater number of dampers for ruling
design span; however, suitable price compensation shall be considered for evaluation.
The vibration analysis of the system, with and without dampers, dynamic characteristic of
the damper as detailed shall be submitted by the Bidder along with his bid. The technical
particulars for vibration analysis and damping design of the system are as follows :
For 400kV Lines
-----------------------------------------------------------------------------------------------------------Sl. No.
Description
----------------------------------------------------------------------------------------------------------1.
Configuration
Two galvanised steel
earthwires
in horizontal configuration
2.
3.
Ruling design span
400 meters
Maximum span
1100 meters
Minimum span
Tensile load in each
1 00 meters
Wind Zone : 5
earthwire for ruling span
(50m/s)
a) At temperature of 5 C and still air
o
1368 Kgf
b) At temperature of 5o C and 36% full wind 2056 Kgf
4.
c) At temperature of 32o C and full wind
3593 Kgf
Maximum permissible dynamic strain
+/- 150 micro strains
For 132kV and 220kV Lines

-----------------------------------------------------------------------------------------------------------Sl. No.
Description
-----------------------------------------------------------------------------------------------------------1.
Configuration
One galvanised steel earthwire in
horizontal configuration .
2.
3.
220 kV Line
Ruling design span
350 meters
300 meters
Maximum span
1100 meters
1000 meters
Minimum span
100 meters
100 meters
Tensile load in
each earthwire
for ruling span
Wind Zone:5
(50m/s)
Wind Zone:5
(50m/s)
1120 Kgf.
1120 Kgf.
a) At temperature
of 5 deg.C and
still air
132 kV Line
b) At temperature
of 5 deg.C and
36% full wind
1667 Kgf.
1606 Kgf.
c) At temperature
of 32 deg.C and
full wind
2815 Kgf.
2625 Kgf.
4.
Maximum permissible
dynamic strain
+/- 150 micro

strains
+/- 150 micro

strains
Flexible copper bond

At suspension and tension towers the earth wire suspension and tension clamps
shall be securely bonded to the tower steelwork by means of a multi-strand flexible
copper bond wire. The copper bond shall be sufficiently flexible to allow movement of
the suspension clamp under all operating conditions and terminated with compression
lugs.
The flexible copper bond shall be of nominal 34 sq.mm equivalent copper area and not
less than 500 mm in length. It shall consist of 259 wires of 0.417 mm dia. tinned copper
conductor. It shall be laid up as seven stranded ropes, each of 37 bunched wires. The
tinning shall be as per IS 9567. Two tinned copper connecting lugs shall be press jointed
to either ends of the flexible copper cable. One lug shall be suitable for 12 mm, dia. bolt
and the other for 16 mm dia. bolt. The complete assembly shall also include one 16 mm
dia., 40 mm long mild steel bolt hot dip galvanised with nut and lock washers
Arcing horn
The arcing horn shall be either ball ended rod type or tubular type and shall be formed from galvanised
mild steel and of approved types. The arcing horns shall be attached in an approved manner to all
suspension and tension insulator sets. The horns shall be attached to the insulator fittings, but not directly to
conductor clamps or to the caps of insulator units. The design of the arcing horns shall be such as to reduce,
as far as reasonably possible, damage to the line conductors, clamps, insulator strings and arcing horns
themselves under all flashover conditions. The general shape and method of attachment of the live end
arcing horn shall also not restrict the replacement of insulators under live line conditions.
The total effective arcing distance shall be 1530mm., 2130mm. and 3050 mm. for 132kV, 220kV and
400kV respectively under nominal dimensions of insulator.
Arcing horns shall be provided on tower and/or line side as indicated on the enclosed string sketches,
however, same has been tabulated below for ready reference :
------------------------------------------------------------------------------------------------------------------SL.No. Voltage
Types of Strings
Arcing horns to
Min. Arcing dist.
Level
be provided on
to be maintained(mm)
------------------------------------------------------------------------------------------------------------------1.
2.
3.
4.
5.
1.
132kV
and
220kV
1.
2.
Single I suspension strings
2.
3.
Line side only
1530(for132kV)&
2130(for 220kV)
4.
Both on line side
and tower side
5.
-do-
Double suspension strings
1530(for132kV)&
2130(for 220kV)
3.
-do-
Single tension
strings
Line side only
-do-
4.
-do-
Double tension
strings
Both on line side

and tower side
-do-
5.
400kV
Single I suspension and pilot

strings
Tower side (corona/grading rings

on line side )
3050
6.
-do-
Double suspension strings
-do-
-do-
7.
-do-
Single tension
strings
-do-
-do-
8.
-do-
Double tension
-do-dostrings
--------------------------------------------------------------------------------------------------------------------
4.1.1
Transmission Towers
4.1.2
General Description
The towers shall be of the following types:
(b) Double Circuit (A, B, C & D)

(c) Special Towers (River Crossing, Railway Track Crossing, Power Line
Crossing etc.)
Types Of Towers
The towers shall normally be of the following standard types, and as stated in
Schedule C.
----------------------------------------------------------------------------------------------------------Type of Tower
Deviation Limit
Typical Use
(1)
(2)
(3)
-----------------------------------------------------------------------------------------------------------DA/OA/PA
0deg- 2deg
a) To be used as tangent tower
with suspension strings.
b) Also to be designed for specified
broken wire conditions.
DB /0B/PB
0 deg- 15deg
a) Angle towers with tension

insulator string
b) Also to be designed for unbalanced
tension resulting from unequal ruling
span of 400m and 200m (for 400kV),
of 350m and 250m (for
220kV) and of 300m and
200m (for 132kV )on
each side of the tower.
c) Also to be designed for uplift
forces resulting from an up-lift
span of 200m under broken
wire conditions.
d) Also to be designed for specified
e) Also to be designed for anticascading condition.
DB/OB/PB
0 deg.
f) To be used as section tower.
DC/OC/PC
15 deg-30 deg.
a) Angle tower with tension

insulator strings.
b) Also to be designed for unbalanced

of 350m and 250m (for 220kV ) and of
300m and 200m (for 132kV )on each side of the tower.
c) Also to be designed for uplift forces
resulting from an up-lift span of 200m
under broken wire conditions.
e) Also to be designed for anti-cascading
condition.
DC/OC/PC
DD
0 deg.
30 deg-60 deg
f) To be used as transposition tower with

modifications (only where specified)
a) Angle tower with tension insulator string
b) Also to be designed for the unbalanced
of 350m and 250m (for 220kV) and of
300m and 200m (for 132kV) on each side
of the tower.
c) Also to be designed for uplift forces
resulting from an uplift span of 300m(for
400kV) and 200m (for 132kV and20kV)
under broken wire conditions.
e) Dead end with 0 deg to 15 deg
deviation on line and 0 deg to 30 deg for
sub-station side (slack span side).
DD
0 deg
f) Complete dead end.
g) For river crossing anchoring with

longer wind span with 0 deg deviation on
crossing span side and 0 deg to
30 deg deviation on other sides .
Note: The above towers can also be used for longer span with smaller angle of
deviations. (To be decided as per the tower spotting data to be submitted by the
Contractor and approved by Project Manager.)
4.1.3
The towers shall be of the self-supporting type, built up of lattice steel sections or
members and designed to carry the power conductors with necessary insulators.
Ground wires and all fittings under all loading conditions. Outline diagrams of the
towers required are to be furnished by the Bidder.
4.1.4
The towers shall be fully galvanized structures built up of structural mild steel
sections. All members shall be connected with bolts, nuts and spring washers.
For design of structure weight span limits given in Table 5.1 shall prevail.
TABLE 5.1 (a)
For 132 kV Line
Normal Condition
Max.
Min.
(m)
(m)
Tower
Type
Broken Wire Cond

Max.
Min.
(m)
(m)
DA
450
150
270
100
DB, DC & DD
450
270
-200
Tower
Type
DA
TABLE 5.1 (b)

For 220 kV Line
Normal Condition
Max.
Min.
(m)
(m)
525
DB, DC & DD
Tower
Type
DA
DB, DC
DD
525
Max.
(m)
600
600
600
Broken Wire Cond

Max.
Min.
(m)
(m)
200
315
100
315
-200
TABLE 5.1 (c)

For 400 kV Line
Normal Condition
Min.
(m)
200
0
0
Max.
(m)
360
360
360
Broken Wire Con

Min.
(m)
100
-200
-300
However, for calculating the tower height, an allowance of 150mm shall be provided,
over and above the specified ground clearances, at still air and maximum conductor
temperature, to account for any stringing error.
TABLE
Situation
System voltage (kV):
Normal ground (open country)
*
Road crossings, road level
Rail crossings, rail level:
River crossings, bank level
River crossings, navigable rivers, above highest
as specified by the Authority
flood level;(data to be obtained from Navigation
Authority)
Above trees
Buildings, poles, structures and walls, etc.
upon which a man may stand : horizontal
clearance
Same above : vertical clearance
Power lines
Minimum clearance
(metres)
132 220 400
6.10 7.015 8.84
7.00 7.90 9.7
17.9 17.9
19.3
4.0
4.6
2.9
4.6 5.5
5.5 7.3
3.8 5.6
3.1 4.6 6.1

*Any road which is normally maintained by Government and/or other
recognised public authority.
4.1.5
Stubs and Superstructures:

(i) The stub shall mean a set of four stub angles fully galvanized from the
and shall include cleats, gussets, bolts and nuts, etc. the black portion of
the stub being cast in foundation footings. Stub length shall correspond to
foundation depth of 3-0 metres from ground level.
(ii) Superstructure shall mean the galvanized tower assembly above the stubs
which includes structural members like angle sections, cross arms, ground
wire peaks, accessories and fittings such as gusset plates, pack washers,
spring, washers, ladders, step bolts, anti climbing devices and such other
items which are required for completing the towers in all respect. Steel
and zinc required for manufacturing these items will be arranged by the
supplier.
(iii)Supply of bolts and nuts and spring washers, hangers/D-shackles for
attaching suspension strings and U bolts for attaching ground wire
suspension assemblies are included in the supply of tower.
(iv) The following provisions shall apply in connection with the procurement
of steel and zinc by the supplier.
(a) The steel used for fabrication of tower parts extensions, templates etc.
shall be of mild steel of tested quality as per IS:2062 GRA.
(b) The Bidder shall take into account the fabrication wastage while
quoting the rates. The employer will not accept any liability in
connection with the wastage of steel during fabrication or otherwise.
(c) The Bidder shall indicate in his offer the sizes of steel sections which
are proposed to be used by him in the design of towers.
(d) Substitutions, if any, of steel sections of the tower parts by higher
sizes, due to non-availability or otherwise shall be to the suppliers
account. The employer will not accept any liability on this account.
(e) The steel shall be procured exclusively from the main steel producers.
However, sections not rolled by main producers, can be procured from
re-rollers provided.
-
Re-rolling of structural steel sections is done from

billets/ingots of tested quality.
Re-rolled sections are duly tested as per relevant standard.
(f) The zinc used for galvanizing fabricated material shall be of High
Grade Electrolytic zinc.
4.1.6
Extensions:
a) The towers shall be designed so as to be suitable for adding 3 metres, 6
metres, 9 metres extensions for maintaining adequate ground clearances
without reducing the specified factor of safety in any manner.
b) The Buidder shall have to design leg extensions for all types of towers
ranging from minus 3 metres to plus 9 metres at intervals of 1.5 metres
and such leg extensions shall be suitable for being fitted to a normal tower
as well as a tower with extensions. This is to enable tower spotting in hilly
terrain.
4.1.7
Stub setting Templates:

Stub templates shall be designed and supplied by the supplier as per
requirement for all types of towers with or without extensions. Stub templates
for standard towers and towers with extension shall be fined type. The stub
templates shall be painted with anti-corrosive paints.
4.1.8
Fasteners: Bolts, Nuts & Washers
4.1.9 All bolts shall be of property class 5.6 and nuts of property class 5.0 IS: 1367
(Part 3) 1991 and IS: 6639-1972 shall conform to IS: 12427, they shall be galvanized
and shall have hexagonal heads and nuts, the heads being forged out of solid steel rods
and shall be truly concentric and square with the shank. The shank shall be perfectly
straight.
4.1.10 ully threaded bolts shall not be used, the length of bolts should be such that the
threaded portion shall not extend into the place of contact of the members.
4.1.11 ll bolts shall be threaded to take the full depth of the nut and threaded far enough
to permit firm gripping of the members, but not any further. It shall be ensured
that the threaded portion of each bolt protrudes not less than 3 mm and not more
than 8 mm when fully tightened. All nuts shall fit hand tight to the point where
the shank of the bolt connects to the head.
4.1.12 lat and tapered washers shall be provided wherever necessary. Spring washers
shall be provided for insertion under all nuts. These washers shall be of electrogalvanized steel and of the positive lock type. Their thickness shall be 2.5 mm for
12 mm dia bolts, 3.5 mm for 16 mm dia bolts and 4.5 mm for 20 mm dia bolts.
4.1.13 he Bidder shall furnish bolt schedules giving thickness of members connected,
size of bolts and nuts, the length of the shank, the length of the threaded portion of
bolts, sizes of bolt holes, thickness of washers and any other special details of this
nature.
4.1.14 To obviate bending stress in bolts or to reduce it to a minimum, no bolt shall
connect aggregate thickness of more than three (3) times its dia.
4.1.15 he bolt positions in assembled towers shall be as per IS: 5613 (Part-I/Section-I)
(Part-II/Section-2)-1985.
4.1.16 olts at the joints shall be so staggered that nuts may be tightened with spanners
without fouling.
5.0
5.1
Tower Accessories
Step Bolt Ladders: These bolts shall be of property class 4.6 conform to IS: 66391972.
5.1.1 Each tower shall be provided with step bolts on one of the main legs, of not less
than 16 mm diameter and 175 mm long, spaced not more than 400 mm apart and
extending from about 2.5 metres above the ground level to the top of the tower. Each step
bolt shall be provided with two nuts on one end to fasten the bolt security to the tower
and button head at the other end to prevent the feet from slipping away. The step bolts
shall be capable of withstanding a vertical load not less than 1.5 KN and shall be used as
a ladder for climbing.
5.1.2
Anti-climbing devices: This shall conform to IS: 5613 (Part-I/Sec I), 19085.
Fully galvanized barbed wire type anti-climbing device shall be provided at a
height of approximately 3 metres as an anti-climbing measure. Four layers of
barbed wires will be provided each inside and outside the tower in horizontal
plane, spacing between the layers being 140 to 150 mm. The towers to be
designed by the supplier shall have provision to fixed the barbed wire as
indicated above. Thus the angle pieces with notches for accommodating
barbed wire shall be designed and supplied with the towers along with
provision for suitable bolt holes on leg members for fitting bolt holes on leg
member for fitting the angles. The scheme of the anti-climbing device shall be
submitted along with the tower drawing. Barbed wire shall be included in the
scope of bidder.
5.1.3
Insulator strings and ground wire clamp attachments

(a) For the attachment of suspension insulator strings a suitable swinging
hanger on the tower shall be provided so as to obtain requisite
clearance under extreme swinging conditions and free swinging of the
string.
The hanger shall be designed to withstand an ultimate tensile strength
of 11.500 kg.
5.1.4
(a)For ground wires at suspension towers suitable U Bolts strong enough to

withstand the full designed loads shall be provided to accommodate the hook of
the ground wire suspension clamps.
(b) At tension towers, horizontal strain plates of suitable dimensions on
the underside of each power cross-arm tip and at the top ground wire
peak shall be provided for taking the D Shackles of the tension
insulator strings or ground wire tension clamps, as the case may be.
Full details of the attachments shall be submitted by the supplier for
the employers approval before commencing with mass fabrication.
5.1.5
Phase Plate
Phase plate shall be of mild steel of 16 gauge vitreous enameled at back and
front, circular in shape and diameter 75 mm. One set of phase plate shall be
consisting of 3 plates red, yellow and blue coloured accordingly to indicate
the phase of the conductor. There shall be one fixing bolt on the plate. This
shall conform to IS: 5613 (Part-II/Section01) of latest edition.
5.1.6
Number Plate
The number plate shall be mild steel vitreous enameled at back and front, 200
mmx 150 mm, rectangular shape and inscribed thereon shall be the number of
the tower location preceded by letter corresponding to the short name of the
line and the type of towers. There shall be two fixing bolts on both end of the
plates. The dimension and details of the number plate shall be as per IS: 5613
(Part-II/Section1 & Section-2), 1985.
5.1.7
Danger Plate
These shall be of mild steel vitreous enameled at back and front 250 x 200
mm rectangular shape and inscribed thereon shall be in signal red the work
DANGER with its Oriya and Hindi translation and also with the inscription
of Bone and Scull and voltage of the line. There shall be two holes on the
plates for fixing. This shall conform to IS: 2551 (latest edition).
5.1.8
5.1.9
Details to Tower Fabrication Workmanship

Except where hereinafter modified details of fabrications shall confirm to IS: 802
(Part-II)-1978.
5.1.10 But splices shall generally be used such that the inside cleat angle and outside
plates are designed to transmit load. The inside cleat angle shall not be less than
half the thickness of the connected heaviest member plus 2 mm. Lap splices may
also be used for connecting members of unequal size in such a manner that the
inside angle of the lap splice shall be rounded at the heel to fit the fillet of the
outside angle. All splices shall develop full stress in the members connected
through bolts. But as well as lap splices shall be made as above and as close to
and above the main panel point as far as possible.
5.1.11 Points shall be so designed so as to avoid eccentricity. The use of gusset plates for
joining tower members shall be avoided as far as possible. However, where
connections are such that the elimination of the gusset plates would result in
eccentric joints then gussets plates and spacer plates may be used in conformity
with modern practices. The thickness of the gusset plate, required to transmit
stress, shall not be less than that of the thinnest of connected member but not less
than 5 mm in any case.
The use of filler in connection shall be avoided as far as possible. The
diagonal web members in tension may be connected entirely to the gusset
plate where necessary so as to avoid the use of filler and it shall be connected
at the point of inter-section by one or more bolts.
5.1.12
The tower structures shall be accurately fabricated to bolt together easily at

site without any strain on the bolts.
5.1.13
No angle member shall have the two leg flanges brought together by closing
the angle.
5.1.14
The diameter of the hole shall be equal to the diameter of bolt plus 1.5 mm.
5.1.15
The structure shall be designed such that all parts are accessible for inspection
and cleaning. Drain holes shall be provided at all points where pockets of
depressions are likely to hold water.
5.1.16 All similar parts shall be made strictly interchangeable. All steel sections before
any work is done on them, shall be carefully leveled, straightened and made true to
detailed drawings by methods which shall not injure the materials so that when
assembled, the different matching surfaces are in close contact throughout. No rough
edges shall be permitted any where in the structure.
5.1.17 Drilling and Punching
(a) Before any cutting work is started, all steel sections shall be carefully
straightened and trued by pressure and not by hammering. They shall
again be trued after being punched and drilled.
(b) Holes for bolts shall be drilled of punched with a jig but drilled holes are
preferred. The following maximum tolerance of accuracy of punched
holes is permissible.
(i)
(ii)
(iii)
Holes must be perfectly circular and no tolerance in this respect is

permissible.
The maximum allowable difference in diameter of the holes on
the two sides of plates or angle is 0.8 mm i.e. the allowable taper in
punched holes should not exceed 0.8 mm on diameter.
Holes must be square with the plates or angles and have their walls
parallel.
All burrs left by drills or punches shall be removed completely. When the
tower members be truly opposite to each other. Drilling or reaming to
enlarge defective holes is not permitted.
5.1.18
Erection Mark:
Each individual member shall have an erection mark conforming to the
component number given to it in the fabrication drawings. This mark shall be
done with marking dies of 16 mm size before galvanizing and shall be legible
after galvanising.
The erection mark shall be A-BB-CC-DDD where
5.1.19.1
Employer code assigned to the supplier (Alphabet).
BB
Suppliers Mark (Numerical)
CC
Tower type (Alphabet)
DDD
Number mark to be assigned by Supplier (numerical).
Galvanizing
The super structure of all towers and stubs upto 150 mm below plinth level
(Top of concrete pedestal) shall be galvanized. Galvanizing of tower members
and stub shall be in conformity with IS: 4759-1984 and shall be done after all
fabrication work has been completed except that the nuts may be tapped or
return after galvanizing. Threads of bolts and nuts after galvanizing shall have
a neat fit and shall be such that they can be turned with fingers throughout the
length of the threads of bolts and they shall be capable of developing the full
strength of the bolts. Spring washers shall be electro-galvanized as per Grade
4 of IS: 1573 1986. Galvanizing for fasteners shall conform to IS: 1367
(Part-XIII) 1978.
5.1.19.2
Quantities and Weights
5.1.20 The quantities stated in Annexure I are only provisional. Final quantities will be
informed by the employer to the supplier on completion of detailed survey.
However, bids will be evaluated based on quantities indicated in the Annexure
I.
5.1.21 The employer reserves the right to order for the final quantities at the rates quoted
in the bid, which shall be valid throughout the pendency of the contract.
5.1.21.1
The unit weight of each type of tower stubs, super structure and extension
be furnished by the Bidder. The weight of tower shall mean the weight of tower
calculated by using the black section(ungalvanized) weight of steel members
including stubs, of the sizes indicated in the approved fabrication drawings and
bills of materials, without taking into consideration the reduction in weights due
to holes, notches, cuts, etc. but taking into consideration the weight of special
fittings.
5.1.21.2
Tower designs Superstructure
5.1.21.3
Wind Pressure
The wind pressure on towers, power conductors and earth wire shall be as per
IS: 802 (Part-I/Sec-I) 1995.
280
5.1.21.4
Design Temperatures
The following temperature range for the power conductor and ground wires
shall be adopted for the line design confirming to IS: 802 (Part I/Sec I)
1995.
i) Minimum temperature 50C.
ii) Every day temperature 32C
iii) Maximum temperature of:
a) Conductor
75C for ACSR Moose/Zebra/Panther

90C for AAAC (Moose equivalent)
b) Ground wire
exposed to Sun.
53C
5.1.21.5 Factors of Safety & Span details

a) Factory of safety.
The factor of safety based on crippling strength of struts and elastic limit
of tension members shall not be less than 2(two) under normal condition
and 1.5 (one and a half) under broken wire conditions for all the members
of the towers and their cross arms.
b) Normal Span
The normal span of the line shall be 300 metres for 400 KV and 220 kV
and 250 meters for 132 kV.
c) Wind and weight spans
The wind and weight spans to be adopted in the design of the structures
shall be as follows:
i)
Wind Span
The wind span is the sum of the two half spans adjacent to the
support under consideration. In case of towers located on an
perfectly horizontal terrain, this shall be the normal span. For design
purposes the wind on conductor shall be calculated on at least 1.1
times the normal.
ii)
Weight Span
The weight span is the horizontal distance between the lowest point
of the conductors on the two spans adjacent to the tower.
All C and D type towers shall be designed for uplift spans
(minimum) weight spans in the following table also. These are
applicable both for pointed and square cross arms.
For details of cross arms and towers, the span limits given below
shall prevail.
WEIGHT SPANS
Tower
Type
A&B
C&D
400/220 KV
Normal
Broken
Condition
wire
condition
Max. Min. Max. Min.
525 100 300 100
600 100 300 100
132KV
Normal
Broken wire
Condition
condition
Max.
320
320
Min. Max. Min.

100 250 100
100 250 100
5.1.21.6 Conductor and Ground wire Configuration

For single circuit towers the three phases shall be Delta formation. One
number of ACSR conductor shall be used for each phase. One galvanized
steel wire shall be used as ground wire. The ground wire shall be continuous
and shall be provided above the conductors at suitable elevation to offer
effective shielding and safe clearances. For double circuit towers the phases
shall be in vertical formation with phase to phase horizontal spacing of not
less than 8.4 meters and vertical 4.9 meters for 220 kV.
5.1.21.7Loads on Towers
i) Transverse Loads:
Transverse load due to wind on towers conductors and under broken wire
earthwire shall be calculated in accordance with IS: 802(Part-I/Sec-I)1995.
ii) Longitudinal Loads due to wind on towers conductors and shield shall be
calculated as per IS: 802 (Part-I/Sec-I)-1995.
iii) Vertical Loads:
The vertical load due to conductors and ground wire shall also include 150
kg. As weight of a Lineman with tools. These loads are in addition to the
vertical loads due to insulator fittings and the dead weight of the structure.
The weight of a Lineman with tool should not be considered in minimum
vertical load calculation. An additional erection load of 3.5 KN shall also
be considered for the design of the tower. The stringing procedure shall
ensure that the above vertical loads are not exceeded. For calculating
vertical loads the following insulator weights may be considered.
400/220/132
KV
Each single suspension insulator string
Each double suspension insulator string
Each double tension insulator string
Pilot string for 60 tower
160 kg
320 kg
420 kg
160 kg
iv) Broken Wire condition

a) Suspension Tower Type A/DA
Breaking of any one power conductor in one phase only, resulting in
instanceous unbalance tension of 50% of conductor tension at 32C
without wind or breaking of one earthwire resulting in an unbalance
tension equal to the maximum tension of the ground wire whichever is
more stringent is to be considered for design along with appropriate
impact factor.
b) Tower Type B & C
Breakage of two phases on the same side and on the same span or
breakage of any one phase and any one ground wire on the same span
whichever combination is more stringent along with appropriate
impact factor for a particular member.
c) Tower Type D/DD
Breakage of all the three phases on the same side and on the same span
or breakage of two phases and any one ground wire on the same span,
whichever combination is more stringent along with appropriate
impact factor for a particular member. Cross arms for angle tower shall
be of equal length for both sides.
v) Design Load
Employers requirement for design longitudinal and transverse loads shall
confirm to IS: 802(Part-I/Sec-I)-1995.
The Bidder shall furnish the details of design loads proposed to be adopted
in the tower design in accordance with this specification.
The design criteria and other special requirements as stipulated for special
towers shall be applicable for river crossing/special towers.
5.1.21.8Tower Steel Sections:
i) Steel sections of tested quality in conformity with IS: 2062 GRA are to be
used in towers, extensions and stub setting templates. No individual
members shall be longer than 6000 mm.
For designing of towers only rationalized steel sections shall be used.
During execution of the project, if any particular section is not available,
the same shall be substituted by higher section at no extra cost. However,
design approval for such substitution shall be obtained from the employer.
ii) Thickness of Members
The minimum thickness of angle sections used ion the design of towers,
shall be kept not less than the following values:
a) Main corner leg members excluding the ground wire peak and main
cross arm 6 mm.
b) For all other main members 5 mm.
c) Redundant members 4 mm.
iii) Bolt Arrangement

The minimum bolt spacing and rolled edge distance and sheared edge
distances of sections from the centers of the bolt holes shall be provided as
furnished in Table-1.
Dia of
Bolts
(mm)
Hole
Dia
(mm)
Min. bolt
Spacing
(mm)
Min. rolled
Distance
(mm)
Min. Sheared
Edge distance
(mm)
12
13.5
30
16
19
16
17.5
40
20
23
20
21.5
50
25
27
Bolts sizes mentioned above shall only be used. The minimum width of
flanges without bolt holes shall be 30 mm.
For the purpose of calculating stress and bearing stress for bolts refer
clause 14.4 and 14.5 of IS: 802 (Part-I/Sec-2)-1992.
iv) Allowable Stress:
Structural steel angle section manufactured according to the latest ISL:
808(Part-V & VI) and tested according to the latest edition of IS:2062 and
having its yield strength not less than 255 N/mm. sq. shall be used in the
fabrication of tower members.
v) Axial Stress in tension:
The estimated tensile stress in various members multiplied by the
appropriate factors of safety shall not exceed the value given by the
formula specified in Clause 9.2.1 of IS:802(Part-I/Sec-2)-1992.
vi) Axial Stress in Compression
The estimated compressive stress in various members multiplied by the
appropriate factors of safety shall not exceed the value given by the
formula specified in Clause 9.2.1 of IS:802(Part-I/Sec-2)-1992.
vii) Slenderness ratio:

Slenderness ratio for members shall be computed in accordance with
IS:802(Part-I/Sec-2)-1992. Slenderness ratio for compression and tension
members shall not exceed the values specified therein. The following
maximum limits of the slenderness ratio shall be adopted i.e. the ratio of
unsupported length of the section in any place to the appropriate radius of
gyration.
a)
For main corner leg member including the corner 150

members of earth wire peak and the lower corner
members of the arms
b)
For other members having calculated stresses.
200
c)
For redundant members.
250
d)
For members having tensile stress only.
375
viii) Erection Stress

Where erection stresses combined with other permissible co-existent
stresses could produce a working stress in any member appreciably above
the specified working stress, then additional materials shall be added to the
member or such other provision made so as to bring the working stress
within the specified limit. For the purpose of this clause the specified
working stress shall be the ultimate stress divided by the factor of safety of
2.0.
ix) Design calculation and Drawings
The following design calculations and drawings are required to be
furnished to the employer.
a) Along with the Bid:
Detailed design calculations and drawing for each type of tower.
b) On award of Contract
The supplier shall submit design of tower extension, stub templates
and loading/rigging arrangement of tower testing to enable the
employer to make preliminary check regarding structural stability of
tower tests.
Upon successful testing of tower and subsequent approval of designs,

drawings and bill of materials, the supplier shall furnish Photostat
copies of the following in 6(six) copies to the employer for necessary
distribution along with one copy of reproducible print.
a) Detailed design calculations along with drawings of towers
and foundations.
b) Detailed structural drawings indicating section size, length of
member. Sizes of plate along with hole to hole distances,
joint details etc.
c) Bill of materials indicating cutting and bending details
against each member.
d) Shop drawings showing all details relevant to fabrication.
e) All drawings for the tower accessories.

The supplier is required to submit four copies of the drawings
with Photostat copies mentioned above for approval by the
employer while submitting the designs, structural drawings. Bill
of materials and any other drawings pertaining to the subject
transmission line. The supplier shall clearly indicate in each
drawing the project code number, if any, specification no.;, name
of transmission line, letter reference no. and date on which the
submissions are made. The said procedure is to be followed
while submitting the distribution copies.
5.1.21.9 Statutory Electrical Clearances:
i) Ground Clearances:
The minimum ground clearance from the bottom conductor shall not be
less than 7.00 metres for 220 kV at the maximum sag conditions i.e. at
maximum temperature and in still air. However, to achieve the above
clearance the height of the tower shall be increased in the following
manner:
a) An allowance of 4% of the maximum sag shall be provided to account
for errors in stringing.
b) Conductor creep shall be compensated by over tensioning the

conductor for a temperature of 26C lower than the stringing
temperature.
In case of rail track crossings the minimum height above rail level of
the lowest portion of any conductor under conditions of maximum sag,
in accordance with the regulations for Electrical Crossing of Railway
Tracks are given in Table 5.
TABLE 5
Type of work
a)
b)
Inside stn.
Limits(mm)
Outside stn.
Limits(mm)
For unelectrified track and tracks

electrified on 1500 V.DC
i) For metre/narrow gauge
10,00017,600
ii) For broad gauge
11,200
8,800
Tracks electrified on 25 kV AC
for metre, narrow and broad
gauge
15,300
13,300
Minimum clearance between the subject power line and any other
power line crossing shall not be less than 7000 mm.
ii) Live Metal Clearance:
The minimum live metal clearance to be provided between the live parts
and steel work of superstructure shall be as given in IS:5613 (Part-2/SecI).
The Bidder may adopt separate cross arm design and length for D type
towers under dead end conditions provided adequate live metal clearance
is available with at least 15 angle and also provided that all the other
specified conditions of this specifications are fulfilled. In case pilot
insulator strings are proposed to be used, the angle of swing to be
considered shall be minimum of 15.
In computing live metal clearances, the dimensions of suspension and
tension string shall be taken as given in drawings attached herewith. The
design of the towers shall be such that it should satisfy all the above
conditions when clearances are measured from any live point of the
insulator strings.
iii) Angle Shielding
The angle shielding, defined as the angle formed by the line joining the
center lines of the ground wire and outer conductor in still air, at tower
supports, to the vertical line through the center line of the ground wire
shall not be more than 30. The drop of the ground wire clamp which is
employer supplied item should be considered while calculating the
minimum angle of protection. For estimating the minimum angle of
protection the drop of ground wire suspension clamp along with U-bolt
may be taken as 150 mm.
iv) Mid Span Clearance
The minimum vertical span clearance between any of the earthwire and
the nearest power conductor under all temperatures and in still air
condition in the normal ruling span shall be 8.10 metres for 220 kV.
Further the tensions of the earthwires and power conductors, shall be so
co-ordinated that the sag of earthwires shall be at least 10% less than that
of the power conductors under all temperatures and loading conditions.
5.1.21.10 Packing
Angle sections shall be wire bundled, cleat angles, gusset plates, blackets,
filler plates, hanger and similar other loose items shall be netted and bolted
together in multiples or securely wired together through holes.
Bolts, nuts, washers and other attachments shall be packed in double gunny
bags, accurately tagged, in accordance with the contents.
The packings shall be properly done to avoid losses/damages during transit.
Each bundle or package shall be appropriately marked.
5.1.21.11 Special Towers:
i) Special towers are to be used for major river crossing requiring very long
spans. These towers shall form part of the Bidders scope.
Unit rates for design, fabrication, galvanizing, testing and supply for such
towers shall be quoted in the appropriate schedule of Volume IB.
Anchoring of major river crossing towers, shall be with D or DD type
towers.
All the requirements as meant for standard towers shall apply for such
special towers except those noted in the following clauses.
ii) Shielding Angle:
The shielding angle shall not be greater than 30.
iii) Clearances:
The minimum clearance of lowest point of power conductor from the
highest flood level in navigable rivers for crossing towers shall be
obtained from the navigation authority.
The minimum electrical clearances between live parts and tower body and
cross arm member shall be the same as for normal towers.
iv) Stub Location:
The approximate height of foundation on which stub for river cross towers
are to be set, over the highest flood level of the river shall be fixed only
after employers approval.
v) Angle of Deviation
The minimum angle of deviation to be considered for special towers is 2
and all live material clearances are to be computed considering double
suspension insulator strings as per drawing enclosed.
vi) Factors of Safety:
Towers:
The minimum factors of safety for towers shall be:
a) Under normal conditions 2.0
b) Under broken wire conditions 1.;5
vii) Conductor and Earth wire:
The minimum factor of safety for conductors and ground wire shall be 2.5
maximum tension corresponding to 2/3rd full wind pressure at minimum
temperature or full wind pressure at the mean annual temperature such that
the initial unloaded tension at the mean annual temperature do not exceed
30% of the ultimate strength of conductor and ground wire respectively.
viii) Wind Loads:
a) The procedure for wind load calculation on conductor and ground wire
shall be the same as for normal structures.
b) The wind pressure values on tower shall be based on IS:802(PartI/Sec-I)-1995.
ix) Longitudinal Loads:
a) The longitudinal loads due to power conductors and earth wires for
suspension towers shall be nil under normal conditions and 100% of
the maximum tension of bundled conductors or earth wire under
b) Under normal conditions, unbalanced longitudinal pull due to
difference in tension in ruling span for river crossing towers on one
side and span of the line on the other wise shall also be considered for
the design of anchor towers.
5.1.22 TESTS
5.1.23 General
a) All standard tests including quality control tests in accordance with
IS:802(Part-III)-1978 shall be carried out.
b) A galvanized tower of each type complete with 6 metres extension shall be
subjected to design and destruction test. The tower shall be tested with nuts
and bolts of the same make and type which are proposed to be used on the
line. The supplier shall submit to the employer for approval, a detailed
programme and proposal for testing the towers showing the method of
carrying out the tests and the manner of applying the loads. The supplier on
receipt of such approval shall intimate the employer about carrying out of
the tests at least 30 days in advance of the scheduled date of tests during
which time the employer will arrange to depute his representatives to
witness the tests. Six copies of the test reports thereof shall be submitted to
the employer for approval.
c) In case of premature failure, the tower shall be retested and steel already
used in the earlier test shall not be used again. The supplier shall provide
facilities to the employer for inspection of materials during manufacturing
stage and also during testing of the same.
d) No part of any tower subject to test shall be allowed to be used in the work.
The prices to be quoted for such type tests shall be after allowing rebate for
the scrap value of the tested tower which is to be retained by the supplier
e) The supplier shall ensure that the specification of materials and
workmanship of all towers actually supplied conform strictly to the towers
which have successfully undergone the tests. In case any deviation is
detected the supplier shall replace such defective towers free of cost of the
employer. All expenditure incurred in erection, to and fro transportation, any
other expenditure or losses incurred on this account shall be fully borne by
the supplier.; No extension in delivery time shall be allowed on this account.
The employer, however, reserves the right to waive off the testing of the
towers, provided the supplier had earlier successfully tested, erected and
commissioned similar towers and certificates for such tests carried out
earlier are furnished duly certified by the employer and are found
acceptable.
f) Each type of tower to be tested shall be a full scale prototype galvanized
tower and shall be erected vertically on rigid foundation with the stub
protruding above ground level as provided in the design/drawing between
ground level and concrete level.
g) The suspension tower to be tested shall be with hanger and U Bolt as per
approved design/drawings. The tension tower to be tested shall similarly be
with the strain plate as per approved design/drawings.
h) In case of any premature failure even during waiting period, the tower shall
be retested with rectified members. However, if the failures are major in
nature and considerable portion of tower is to be re-erected then in such
cases all the tests which have been carried out earlier are to be reconducted
to the entire satisfaction of the employer.
i) The sequence of testing shall be at the discretion of the employer.
5.1.23.1Test for Galvanization
Galvanization of the members of the tower shall withstand tests as per IS:2633.
5.1.24 INSPECTION
5.1.24.9The supplier shall keep the employer informed well in advance of the
commencement of manufacture, progress of manufacture thereof and fabrication
of various tower parts at various stages. So that arrangements could be made for
inspection by the employer.
5.1.24.10
The acceptance of any batch of items shall in no way relieve the supplier
of any his responsibilities for meeting all the requirements and intent of this
specification and shall not prevent subsequent rejection if any item of that batch
is later found defective.
5.1.24.11
The employer or his authorized representatives shall have free access at all
reasonable time to all parts of the suppliers works connected with the fabrication
of the material covered under the contract for satisfying themselves that the
fabrication is being done in accordance with the provisions of this specification.
5.1.24.12
Unless specified otherwise, inspection shall be made at the place of
manufacture prior to dispatch and shall be conducted so as not to interfere
unnecessarily with the operation of the work.
5.1.24.13
Should any member of the structure be found not to comply with the
approved design, it shall be liable for rejection. No member once rejected shall be
resubmitted for inspection except in cases where the employer or his authorized
representative considers that the defects can be rectified.
5.1.24.14
Defects which occur during fabrication shall be made good with the
consent of and according to the procedure to be laid down by the employer.
5.1.24.15
All gauges and templates necessary to satisfy the employer for conducting
tests shall be made available at the test site by the supplier.
5.1.24.16
The correct grade and quality of steel shall be used by the supplier. To
ascertain the quality of steel the employer may at his discretion get the material
tested at an approved laboratory.
5.1.25 SCHEDULE OF REQUIREMENTS
5.1.25.1The schedule of requirements of different types of towers is indicated in VolumeIII. The quantities indicated therein are tentative and based on preliminary survey
conducted by the employer. The exact quantity will be informed to the supplier
on completion of detailed survey.
5.1.25.2The time frame for executing the work is also indicated in this schedule. The
supplier has to match the supply and delivery of stubs, tower-parts etc. to
complete the work within the time schedule desired by the employer.
5.1.25.3The supplier shall, as far as possible, dispatch the tower material as completed
towers in order to enable erection of complete tower structures at site. Payment
for the initial dispatches, to the extent of 30% of the total ordered quantity will be
released on the basis of weight (i.e. Metric tones of steel supplied). Beyond this
limit, however, payment will be released only for material supplied to complete
towers.
5.1.26 SCUEDUALE OF PRICES
5.1.26.1The prices for supply of materials shall be furnished in the relevant schedule in
the manner specified in Volume-III.
5.1.27 GENERAL TECHNICAL REQUIREMENTS
Line voltage
No. of circuits
Particulars
Design details
-
foundation
400/220132 kV
Double/Double/Double
a) Properties of soil for bidding purpose only
Sl.
Details
No.
Soft
Loose
Mud
Hard
Soil
Soft
Rock
Hard
Rock
1.
Angle of repose of
soil(in degree)
30
15
2.
Ultimate
bearing
strength of earth (T/M)
10
20.0
50.0
125.0
b) Properties of concrete
Weight of foundation concrete 1:2:4 mix for design purpose shall be taken
as 2400 kg/cu.m in dry location.
c) Factor of safety for foundation against over turning due to up-lift and thrust.
i) Normal condition 2.2
ii) Broken wire condition 1.65
d) Concrete Mixture
i) pad 1:4:8
ii) Pyramid or stepped part of foundation 1:1:5:3
iii) Chimney 1:1:5:3
e) Minimum thickness of chimney 300 m
f) Minimum thickness of concrete over stub
Dry soil 100 mm
Wet & WBC 150 mm

g) Minimum length of stub 2000 mm
in concrete.
h) Distance above ground level of 450 mm
Tower stub and super structure
5.1.28 .Foundation General Description
5.1.29 Design, construction and other relevant drawings shall be furnished by the tower
designer for all types of towers (including special towers) for different kinds of soil as
detailed below. According to the locations foundations for towers shall be normally of the
following types:
a)
b)
c)
d)
Soft/Loose Soil
Mud
Hard/Dense soil
Hard/Disintegrated rock
5.1.30 For rock foundations the holes in rocks shall be made in an approved manner so
as to eliminate the possibility of serious cracking of the rock. The concrete block shall be
properly secured to rock base by adequate no. of anchor bolts and further secured by
concrete lodge section by the sides.
ERECTION OF
400/220/132 KV
D.C. TRANSMISSION LINES
CONSTRUCTION OF TOWER FOUNDATION

AND ERECTION OF TOWER
1.0
1.1
ERECTION OF TOWER AND TOWER FOUNDATION

SCHEDULE OF ERECTION PROGRAMME
After due approval of the detailed and check survey, the contractor shall submit to the
employer a complete detailed schedule of erection programme with a Bar-Chart
for construction of the lines indicating therein the target date of completion.
1.1.1 DRAWINGS FOR TOWER AND FOUNDATIONS
The same shall be supplied by the contractor.
1.1.2
TAKING OVER
Tower and tower accessories received at site stores are to be stored item-wise and
mark-wise to facilitate joint inspection of the materials (with reference to packing
list and detailed order).
If the materials/equipment or any part thereof is damaged or lost during the
transit, the replacement of such materials shall be effected by the contractor
timely so as to maintain programme of work. However, the line under erection
shall be taken over by the purchaser only when the entire line is completed in all
respect and made ready for commissioning at rated voltage. Partly erected line
will not be taken over.
Taking over of the line shall be in no way relieve the contractor from his
responsibility for satisfactory operation of the erected line in terms of the
guarantee clause of the specification.
1.1.3
MATERIALS HANDLING AND INSURANCE

The contractor shall deliver all equi9pment/materials against this contract to his
site stores under cover of Transit Insurance to be taken in his name. Cost of such
insurance is to be borne by the contractor.
Cost of transportation of materials from contractors store to the site of work shall
be borne by the contractor irrespective of made of transportation and site
condition.
The contractor has to bear the cost of premiums for all materials, tower
accessories, total erection cost of the line including cement, torsteal for
foundation.
It will be the responsibility of the contractor to report to the concerned Police
Station about all incidents of thefts and lodge, pursue and settle all claims with
Insurance Company in case of damage/loss due to theft, pilferage, flood and fire
etc. and the employer of the work shall be kept informed promptly in writing
about all such incidents. The loss, if any, on this account shall be recoverable
from the contractor if the claims are not lodged and properly pursued in time or if
the claims are not settled by the insurance company due to lapses on the part of
the contractor. The contractor shall have to replenish promptly damaged, stolen
tower members and accessories conductors, earth wire, hardwares etc. and
repair/re-erect the damaged lines, free of cost to the employer so as to maintain
the programme of work. The employer will not be responsible in any way for
such loss of materials.
1.1.4
EXCAVATION FOR FOUNDATION PITS, DE-WATERING AND SHORING

SETS
The contractor shall execute the open excavation job in the foundation pits in all
type of soil including latterite and or bounder mixed soil as detailed abelow
including removing, spreading and/or stacking the excess spils (as directed by the
employer). The item includes the necessary trimming of the sides, leveling,
dressing and ramming (as necessary) the bottom of the pits including bailing out
water, dewatering by manual and/or mechanical means by emplying water pumps
including removing of slushes from foundation pits and nominal open plank
shoring with vertical poling boards placed at suitable intervals as directed with
required runners, struts, battens for framing as required complete. While quoting
the unit rate for foundation as per the activity schedule, the contractor shall
include cost of design, all cost of labour, materials, tools, plants, incidentals for
earth excavation, dewatering, cement, water, sand, coarse and find aggregates,
steel reinforcement, steel angles, forms, mixing, finishing, protection and curing
of concrete, back-filling with carried earth, if necessary, disposal of surplus,
spoils, stub setting and template. The contractor shall also include in the quoted
unit rate for foundation, all charges/costs for preparing the pit marking and
foundation layout drawing, grounding of towers including supply of pipe/concrete
pipe, earthing, measurement of ground resistance before often growing etc.
1.1.5
CEMENT CONCRETE (PLAIN OR REINFORCED), STUB SETTING

GROUNDING AND BACK FILLING
A)
Materials
All materials whether to be consumed in the work or used temporarily
shall conform to relevant IS specification, unless stated otherwise, and
shall be of the best approved quality.
B)
Cement
Cement to be used in the work under the contract shall generally conform
to IS:269/455-1989. Cement bags shall be stored by the contractor in a
water tight well ventilated store sheds on raised wooden platform/dunnage
(raised at least 150 mm above ground level) in such a manner as to prevent
deterioration due to moisture or intrusion of foreign matter. Sub-standard

or partly set cement shall not be used and shall be removed from the site
by the contractor at his cost on receipt of approval from the Engineer.
C)
Coarse Aggregates Stone chips or stone ballast
General Technical Particulars

C. 1 - Span Lengths
132kV
300
220kV
350
400kV
400
Suspension towers
300
350
400
Tension towers
300
350
400
Suspension towers
450
525
600
Tension towers
450
525
600
Suspension towers
100
100
100
Tension towers (uplift net)
-200
-200
-200 (for
DB&DC)
-300
(forDD)
Normal span
Tower design spans:
Wind spans:
Maximum weight spans:
Minimum weight spans:
C . 2 - Line Conductor ( 132 kV Construction )
Complete line conductor:

mm2
Actual area (total) per single conductor

Number of conductors per phase
288.3
ONE
Horizontal distance between conductor centres of

one phase
mm
Each single conductor:

Equivalent to ACSR conductor of code name
ACSR PANTHER
IEC STANDARD No
INDIAN STANDARD No
IEC 1089
IS 398 (Pt 4)
1994
Material of conductor
AlumIminium
Number and diameter of wires:

Aluminium
Total area of conductor
Overall diameter of stranded conductor
Mass of conductor per kilometre
Ultimate strength of conductor
No./mm
30/3.0
mm2
261.5
mm
21
kg
974
Newton
89670
Assumed equivalent modulus of elasticity of

conductor
N/mm2
81580
Assumed equivalent coefficient of linear expansion

of conductor
per C
17.8x 10-6
km
2.4+/-5%
Maximum length of conductor supplied on one drum

mm2

484.5
ONE

one phase
mm

ACSR ZEBRA
IEC STANDARD No
INDIAN STANDARD No
IEC 1089
IS 398 (Pt 4)
1994
Aluminium

Aluminium
No./mm

54/3.18
mm2
428.9
mm
28.62
kg
1621
Newton
130320

conductor
N/mm2
81580

of conductor
per C
19.3 x 10-6

km
1.8 +/- 5%

mm2
597.00
TWO

one phase
mm

450
ACSR MOOSE
IEC STANDARD No
INDIAN STANDARD No
IEC 1089
IS 398 (Pt 4)
1994
Aluminium

Aluminium alloy
No./mm

54/3.53
mm2
597
mm
31.77
kg
2004
Newton
161200

conductor
N/mm2
68600

of conductor
per C
19.3 x 10-6
km
1.8 +/- 5%
**ALL THE CONDUCTORS ARE ACSR CONDUCTORS HAVING 7 STRANDS

OF GI STEEL WIRE.
C . 5 - Earth Wire (132 kV And 220 kV Constructions)

GSW
Complete earth conductor:
Appropriate Indian Standard No
398(Part-2)
Appropriate British Standard No
183
galvanised steel
Number and diameter of wires
No./m
m
Overall diameter of conductor
mm
9.45
kg
428

Newto
n
mm
Lay length
Direction of the lay of the outer layer
Chemical composition of the steel wire
Carbon
Manganese
Phosphorous
Sulphur
Silicon
56000
160 +/- 15
Right hand
%
not more than 0.55
0.4 to 0.9
not more than 0.04
not more than 0.04
0.15 to 0.35
Purity of Zinc for galvanising
Galvanising after stranding

a) Minimum weight of Zinc coating per sq. m. of the
uncoated wire surface
b) Minimum no. of one minute dips that the
galvanised wire can withstand in Standard Preece
Test
Maximum length of conductor on drum #
D.C. resistance at 20 o C
7/3.15
gms
99.95
240
3 and 1/2
km
ohms/k
m
4 +/- 5%
3.375
C . 6 - Earth Wire (400 kV Construction )

GSW
Complete earth conductor:
Appropriate Indian Standard No
398(Part-2)
Appropriate British Standard No
183
galvanised steel
Number and diameter of wires
No./mm
7/3.66
Overall diameter of conductor
mm
10.98
kg
Newton
Lay length
mm
Direction of the lay of the outer layer
68400
160 +/- 15
Right hand
Chemical composition of the steel wire

Carbon
Manganese
Phosphorous
Sulphur
Silicon
Purity of Zinc for galvanising

Galvanising after stranding
a) Minimum weight of Zinc coating per sq. m. of
the uncoated wire surface
b) Minimum no. of one minute dips that the
galvanised wire can withstand in Standard Preece
Test
Maximum length of conductor on drum #
D.C. resistance of the complete earthwire at 20OC
583
not more than 0.55

0.4 to 0.9
not more than 0.04
not more than 0.04
0.15 to 0.35
gms
99.95
240
3 and 1/2
km
ohms/k
m
4 +/- 5%
2.5
C.14 * - Disc Insulator Units ( Anti-Fog Type )
Size and designation of the ball

pin shank
mm
70kN
16
Diameter of the disc
mm
280/305
280/305
280/305
280/305
13/15
13/15
13/15
13/15
145
145
145
170
Tolerance on the diameter

Ball to ball spacing between
disc
Tolerance on ball to ball
spacing
+/-mm
mm
+/-mm
90kN
16
120kN
20
160kN
20
Minimum creepage distance of

a single disc **
mm
430
430
430
475
Steepness of the impulse

voltage which the disc unit can
withstand in Steep Wave Front
Test
kV per
micro
sec.
2500
2500
2500
2500
Purity of Zinc used for

galvanising
99.95
99.95
99.95
99.95
Purity of Zinc used for sleeve
99.7
99.7
99.7
99.7
6
6
6
6
6
6
6
6
No. of dips in Standard Preece

Test
1) Cap socket
2) Ball pin
*The parameters specified are for disc insulator unit only. For the Bids offering
composite insulator units, the parameters may be suitably selected by the Bidder so
as to meet the overall requirements of the respective strings and same shall be
guaranteed at Schedules 13A and 14A of the Technical Data Requirement
Schedules, Section X.
** The minimum creepage distance of single composite insulator unit shall be such
that it matches with the total creepage distance of the respective strings with disc
insulator units.
C . 15 - Insulator Strings (Suspension Sets For 132 kV Lines )

voltage of the string with arcing
horns and corona control rings /
grading rings under wet
conditions
Impulse withstand voltage (peak)
under dry conditions
1) Positive
2) Negative
Minimum corona extinction
voltage under dry conditions
dry conditions at 1MHz, at 105kV
Mechanical strength of the

complete insulator string along
with all hardware fittings
Maximum voltage (in percentage)
across any disc in the complete
insulator string under phase to
earth voltage *
Single I
Suspensio
n
Strings
275
Double I
Suspensio
n
Strings
275
Pilot
Suspensio
n
Strings
275
Kv
kV
650
650
650
650
650
650
kV(rms)
105
105
105
not more
than
1000
not more
than
1000
not more
than
1000
kN
70
2x70
70
20
20
20
2x9
99.95
99.95
99.95
kV(rms)
Micro
Volts
Number of insulator units in each

string **
galvanising
Minimum No. of one minute dips

No.
6
6
6
the ferrous parts can withstand in
Standard Preece Test
* Voltage distribution criteria is not applicable for strings with composite insulator
units.
** It is preferrable to have single piece composite insulator unit for each limb of the
string. In case, more than one units are used per limb, same shall be indicated by the
Contractor.
C . 16 - Insulator Strings ( Tension Sets For 132 kV Lines )
Power frequency withstand voltage of the

string with arcing horns and corona control
rings / grading rings under wet conditions
Impulse withstand voltage (peak) under
dry conditions
1) Positive
2) Negative
dry conditions
Radio interference voltage under dry
conditions at 1MHz, at 105kV
Single
Tension
Strings
275
Double
Tension
Strings
275
kV
kV
650
650
650
650
kV(rms)
105
105
not more
than
1000
not more
than
1000
kN
90
2x90
22
22
10
2x10
99.95
99.95
kV(rms)
Micro
Volts
Mechanical strength of the complete

insulator string along with all hardware
fittings
Maximum voltage (in percentage ) across
any disc in the complete insulator string
under phase to earth voltage *
Number of insulator units in each string **
Purity of Zinc used for galvanising
Minimum No. of one minute dips the
ferrous parts can withstand in Standard
Preece Test
%
No.
units.
Contractor.

voltage of the string with arcing
horns and corona control rings /
grading rings under wet
conditions
Impulse withstand voltage
(peak) under dry conditions
1) Positive
2) Negative
Minimum corona extinction
voltage under dry conditions
dry conditions at 1MHz, at
154kV
Mechanical strength of the
complete insulator string along
with all hardware fittings
Maximum voltage (in percentage
) across any disc in the
complete insulator string under
phase to earth voltage *
Single I
Suspensio
n
Strings
460
Double I
Suspensio
n
Strings
460
Pilot
Suspensio
n
Strings
460
kV
kV
1050
1050
1050
1050
1050
1050
kV(rms)
154
154
154
not more
than
1000
not more
than
1000
not more
than
1000
kN
70
2x70
70
13
13
13
14
2x14
14
99.95
99.95
99.95
kV(rms)
Micro
Volts
Number of insulator units in each

string**
galvanising
Minimum No. of one minute dips
the ferrous parts can withstand
in Standard Preece Test
No.
units.
Contractor.

dry conditions
1) Positive
2) Negative
dry conditions
Single
Tension
Strings
460
Double
Tension
Strings
460
kV
kV
1050
1050
1050
1050
kV(rms)
154
154
not more
than
1000
not more
than 1000
kN
120
2x120
14
14
15
2x15
99.95
99.95
kV(rms)
Micro
Volts

fittings
Preece Test
%
No.
units.
Contractor.

Single I
Suspension
Strings
kV(rms)
680
Pilot
Suspension
Strings
680
Switching surge withstand voltage (peak)

under wet conditions
1) Positive
2) Negative
kV
kV
1050
1050
1050
1050

dry conditions
1) Positive
2) Negative
kV
kV
1550
1550
1550
1550
kV(rms)
320
320
not more
than
1000
not more
than
1000
kN
120
120
23
23
99.95
99.95

dry conditions
Micro
Volts

fittings
Preece Test
%
No.
units.
Contractor.

Switching surge withstand voltage (peak)
under wet conditions
1) Positive
2) Negative
dry conditions
1) Positive
2) Negative
dry conditions
SingleTensio
n
Strings
(Low Duty)
kV(rms)
680

1050
1050
1050
1050
kV
kV
1550
1550
1550
1550
kV(rms)
320
320

Preece Test
not more
than 1000
kN
120
2x160
10
10
24
2x23
99.95
99.95

680
kV
kV
Micro not more than

Volts
1000

fittings
Double
Tension
Strings
%
No.
units.
Contractor.
C . 21 - Tower Design Particulars (132 kV Construction)

Minimum clearance between live metal and tower
steelwork:
i. with suspension insulator set swing 0
with suspension insulator set swing 15
mm
mm
mm
mm
mm
1530
1530
1370
1220
1070
ii. with jumper loop swing 0

with jumper loop swing 10
mm
mm
mm
mm
mm
1530
1530
1070
1070
-
Insulator suspension set, unobstructed transverse swing

angle
from vertical
degrees
0 - 60
Earth conductor suspension clamps, unobstructed

transverse
swing angle from vertical
degrees
0 - 50
Earth conductor maximum shielding angle from vertical

at
tower attachment point over outer line conductors
degrees
30

steelwork:
mm
mm
mm
mm
mm
2130
1980
1830
1675
-

mm
mm
mm
mm
mm
2130
1675
1675
-

angle
from vertical
degrees
0 - 45

transverse
degrees
0 - 50

at
degrees
30

steelwork:
mm
mm
mm
mm
mm
3050
3050
1860
-

mm
mm
mm
mm
mm
3050
3050
3050
1860
1860

angle
from vertical
degrees
0 - 30

transverse
degrees
0 - 50

at
degrees
20
C . 25 - Particulars Of Double Circuit Towers (132 kV Construction )

Type Of Tower
Type of insulator sets
Maximum angle of deviation
DA
DB
Suspensio Tension
n
DD
Tension
0 - 2
0 - 15
15 - 30
30 - 60
300
300
300
300
6.42
6.42
6.42
6.42
Minimum height of earth conductors

above
upper line conductor at mid-span
6.1
6.1
6.1
6.1
Vertical spacing between line

conductors
at tower (minimum)
3.9
3.9
3.9
3.9
4.5
4.5
4.5
4.5
Normal span length

Minimum ground clearance of line
conductor at 85C, normal ground
Minimum Clearance between

conductors of one circuit and tower
climbing leg of the other circuit.
degre
e
DC
Tension
C . 26 - Particulars Of Double Circuit Towers (220 kV Construction )

Type Of Tower
DA
DB
Suspensio Tension
n
DC
Tension
DD
Tension
degre
e
0-2
0 - 15
15 - 30
30 - 60
350
350
350
350
7.23
7.23
7.23
7.23

above
8.5
8.5
8.5
8.5

conductors
at tower (minimum)
4.9
4.9
4.9
4.9
5.5
5.5
5.5
5.5
Normal span length

conductor at 85 C, normal ground

C . 27 - Particulars Of Double Circuit Towers ( 400 kV Construction )

Type Of Tower
DA
DB
Suspensio Tension
n
DD
Tension
0 - 2
0 - 15
15 - 30
30 - 60
400
400
400
400
8.84
8.84
8.84
8.84

above
9.0
9.0
9.0
9.0

conductors
at tower (minimum ) .
8.0
8.0
8.0
8.0
6.5
6.5
6.5
6.5
Normal span length

conductor at 85 C, normal ground

degre
e
DC
Tension
C . 28 - Foundation Design Particulars

Assumed density of Plain Cement Concrete (PCC) for foundation
in dry soil
kg/m3
2240
Assumed density of Plain Cement Concrete (PCC) for foundation

in presence of sub-soil water
kg/m3
1240
Assumed density of Re-inforced Cement Concrete (RCC) for

foundation in dry soil
kg/m3
2400
Assumed density of Re-inforced Cement Concrete (RCC) for

foundation in presence of sub-soil water
kg/m3
1400
28 day concrete cube strength (characteristic strength for M-20

concrete)
N/mm2
20
28 day concrete cube strength (characteristic strength for M-15

concrete)
Minimum proportion of stub load to be allowed for in the design of
stub cleats
Density of all type of soils :
1) under dry conditions
2) in presence of surface water
3) in presence of sub-soil water
Ultimate bearing capacity of the soil :
1) normal soil under dry condition
2) normal soil in presence of surface as well as sub-soil
water
3) wet black cotton soil
4) fissured rock ( both for dry and wet )
5) hard rock
Angle of repose for :
1) dry soil
N/mm2
15
100
kg/m3
kg/m3
kg/m3
1440
1440
840
kN/m2
kN/m2
214
107
kN/m2
kN/m2
kN/m2
107
400
750
Degre
e
Degre
e
Degre
e
Degre
e
Degre
e
kN/m2
30
2) wet soil due to presence of surface/ sub-soil water

3) wet black cotton soil
4) dry fissured rock
5) wet fissured rock
Ultimate bond between steel and concrete
15
0
20
10
0.147
Note : All the soil parameters furnished above are subject to verification by actual soil
investigations. The Contractor shall be required to carry-out field test for each type of
foundation, as per the quoted rates in Price Schedules, to prove the design parameters
considered.
The foundation classification criteria shall be as given below, depending upon type of soil
and sub-soil water level / presence of surface water :
Normal Dry : To be used for locations where normal dry cohesive or non-cohesive soils
are met without encountering sub-soil water table within the depth of foundation.
Wet : To be used for locations,
a) where sub-soil water is met at 1.5 m. or more below the ground level;
b) which are in surface water for long periods with water penetration not exceeding
one metre below the ground level e.g. , the paddy field.
Partially Submerged : To be used for the locations where sub-soil water table is met
between 0.75 to 1.5 m. below the ground level;
Fully Submerged : To be used for locations where sub-soil water table is met at less than
0.75 m. below the ground level;
Black Cotton Type : To be used at locations where soil is clayey type, not necessarily
black in colour, which shrinks when dry and swells when wet, resulting in differential
movement. For designing the foundation for such locations, the soil is to be considered as
fully submerged.
Fissured Rock : To be used at locations where decomposed or fissured rock, hard gravel,
kankar, lime-stone, laterite or any other soil of similar nature is met. Under-cut type
foundation is to be used for such locations.
In case of fissured rock locations where water table is met at 1.5 m. or more below
ground level, wet type fissured rock foundations shall be adopted.
Hard Rock : To be used for the locations where chiselling, drilling or blasting is required
for excavation . For these locations rock anchoring is to be provided to resist the uplift
forces.
PILE FOUNDATION-
a)
SCOPE- The work involved is to take up the pile foundation work of
including
stub setting of special type tower. The detailed survey, soil investigation and the design
has to be done bidder and the design is to be approved by OPTCL, which shall be strictly
followed by the contractor. The contractor shall cast the foundation including stub setting
as per the design, the schedule of quantities enclosed and direction of engineer in charge.
b) 1. The pile foundation shall be of RCC, Cast-in-situ bored piles as per IS:2911 . Pile boring
shall be done using Rotary Hydraulic Rigs. Two stage flushing of pile bore shall be
ensured by airlift technique duly approved by the Employer
2. Minimum diameter of pile shall be 450 mm The.
3. Only straight shaft piles shall be used. Minimum cast length of pile above cutoff level
shall be 1.0 m.
4. The bidder shall furnish design of piles (in terms of rated capacity, length, diameter,
termination criteria to locate the founding level for construction of pile in terms of
measurable parameter, reinforcement for job as well as test piles, locations of initial test
piles etc.) for Engineers approval.
5. The piling work shall be carried out in accordance with IS:2911 (Relevant part) and
accepted construction methodology. The construction methodology shall be submitted by
the Contractor for Engineer's approval.
6. Number of initial load tests to be performed for each diameter and rated capacity of pile
shall be subject to minimum as under.
Vertical
Lateral
Uplift
Minimum of 2 Nos. in each mode
7. The initial pile load test shall be conducted with test load upto three times the estimated
pile capacity. In case of compression test (initial test) the method of loading shall be
cyclic as per IS:2911 (relevant part).
8. Load test shall be conducted at pile cut of level (COL). If the water table is above the
COL the test pit shall be kept dry through out the test period by suitable de-watering
methods. Alternatively the vertical load test may be conducted at a level higher than
COL. In such a case, an annular space shall be created to remove the effect of skin
friction above COL by providing an outer casing of suitable diameter larger than the pile
diameter
9. Number of routine pile load tests to be performed for each diameter/allowable capacity of
pile shall be as under :
(i) Vertical : 0.5% of the total number of piles provided.
(ii) Lateral : 0.5% of the total number of piles provided.
10. The routine tests on piles shall be conducted upto test load of one and half times the
allowable pile capacity. Piles for routine load tests shall be approved by the Employer.
11. In case, routine pile load test shows that the pile has not achieved the desired capacity or
pile(s) have been rejected due to any other reason, then the Contractor shall install
additional pile(s) as required and the pile cap design shall accordingly be reviewed and
modified, if required.
12. Testing of piles and interpretation of pile load test results shall be carried out as per
IS:2911 (Part-4). Contractor shall ensure that all the measuring equipment and
instruments are properly calibrated at a reputed laboratory / institute prior to their use.
Settlement / movement of the pile top shall be made by Linear Variable Differential
Transducers (LVDT) having a least count of 0.01mm.
13. The test load on initial test piles shall be applied by means of reaction from anchor piles /
rock anchors alone or combination of anchor piles / rock anchors and kentledge.
14. Low Strain Pile Integrity test shall be conducted on all test piles and job piles. This test
shall be used to identify the routine load test and not intended to replace the use of static
load test. This test is limited to assess the imperfection of the pile shaft and shall be
undertaken by an independent specialist agency. The test equipment shall be of TNO or
PDI make or equivalent. The process shall confirm to ASTM.
15. Contribution of frictional resistance of filled up soil if any, shall not be considered for
computation of frictional resistance of piles.
c) MATERIALS-
Contractor shall supply cement, steel rod and stubs and all other
materials required. All coarse aggregates, fine aggregates are to be of very good quality
and to be approved by the engineer in charge.
d) Watch and Ward-
The
cost
of
watch
and
ward,
site
store,
making
of
Islanding/platform for the pile boring, stabilization of bore hole and all other activities
incidental to successful construction of the pile foundation are to be included in the cost
of the tender and no additional cost shall be paid separately on any additional component.
The cement, steel shall be supplied to the contractor at the nearest tore and the
contractor shall have to receive the same at designated stores and transport to site at his
own cost.
The piling shall be done in presence of the engineer in charge and due
certification to be done at the spot only.
Standard followed and to be followedIndian
Standards(IS)
Title
IS:1080-1990
Codes of Practice
for Design and
Construction of
Simple Spread
Foundations
IS: 1498-1992
Classification and
ASTM D 2487/
Identification of ASTM D 2488
Soils for General
Engineering
Purposes.
IS: 1892-1992
Code of Practice
For Design and
Construction of
Foundation in
Soils : General
Requirements.
IS: 2131-1992
Method of Standard
Penetration Soils
ASTM D 1586
IS: 2132-1992
Code of Practice
For Thin Walled
Sampling of Soils
ASTM D 1587
IS: 2720-1992
Method of Test ASTM D 420

For Soils (Relevant Parts.
International and
Internationally
Recognize
Standard/Code
IS: 2809-1991
Glossary of Terms
And symbols
Relating to Soil
Engineering
ASTM D 653
Indian
Standards(IS)
Title
International and
Internationally
Recognize
Standard/Code
IS: 2911-1980
Code of Practice
For Design and
Construction of
Pile Foundations
(Relevant Parts).
IS: 3025
Methods of Sampling
And Testing (Physical
And Chemical) for
Water used in industry.
IS: 3043-1991
Code or Practice for

Indexing and Storage
Of Drill Cores.
IS: 4091-1987
Code of Practice for

Design and Construction
Of Foundations for
Transmission Line Towers
and Poles.
IS: 4434-1992

in-situ Vane Shear
Test for Soils.
IS: 4453-1992

Exploration by Pits,
Trenches, Drifts and
Shafts.
IS: 4464-1990

Presentation of Drilling
Information and core
Description in Foundation
Investigation
ASTM D 2573/
ASTM D 4648
IS: 4968 Method for Subsurface

(Part-II) 1992 sounding for soils,
dynamic method using
cone and Bentonite slurry

IS: 5313-1989
Guide for Core Drilling

Observations.
Indian
Standards(IS)
Title
IS:6403-1990

Diamond Core Drilling
for Site Investigation
for River Valley Projects.
IS: 6935-1989
Method of Determination
of water level in a Bore
Hole.
IS: 7422-1990
Symbols and Abbreviations

for use in Geological Maps
Sections and subsurface
Exploratory Logs (Relevant
Parts).
IS:8009
(Part-I)-1993
International and
Internationally
Recognize
Standard/Code

Calculation of Settlements
of Foundations (Shallow
Foundations subjected
to symmetrical Vertical
Loads).
IS:8764-1991
of Point Load Strength
Index of Rocks.
IS: 9179-1991
of Unconfined compressive
Strength of Rock Materials.
IS: 9179-1991
Method of Preparation ASTM D 4543

of Rock Specimen for
Laboratory Testing.
IS: 9259-1992
Specification for Liquid ASTM D 4318

Limit apparatus.
IS: 9640-1992
Specification for Split
ASTM D 2938
ASTM D 1586
Spoon Sampler
IS: 10050-1992 Method of Determination
ASTM D 4644
of Slake Durability Index
of Rocks.
IS: 11315Description of Discontinuities
(Part-II)-1991
in Rock Mass-Core Recovery
TESTS
Tests as indicated in this specification and as may be requested by the
Owner, shall be conducted. There tests shall include but may not be
limited to the following :
a)
Tests of undisturbed and disturbed samples

Visual and engineering classification;
Sleeve analysis and hydrometric analysis;
Liquid, plastic and shrinkage limits;
Specific gravity;
Chemical analysis
Swell pressure and free swell index determination
Proctor compaction test.
b) Tests of undisturbed samples:
Bulk density and moisture content;
Relative density (for sand),
Unconfined compression test;
Box shear test (for sand);
Tri-axial shear tests (depending on the type of soil and
field conditions on undisturbed or remoulded samples):
i)
Unconsolidated untrained;
ii) Consolidated drained test;
Consolidation.
c)
Tests on rock samples
Visual classification:
Moisture content, porosity and density:
Specific gravity;
Hardness
Stake durability;
Unconfined compression test (both saturated and at insitu water content;
Point load strength index;
Deformability test (both saturated and dry samples)
STANDARD DRAWINGS

OPTCL Technical Specification

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ORISSA POWER TRANSMISSION

CONSTRUCTION OF SUB-STATION ALONG

NTPC ELECTRIC SUPPLY COMPANY LIMITED

CONTENTS OF THE BIDDING DOCUMENTS

CONTENTS OF THE BID- Page 1 of 2

EARTHING OF LIGHTNING MAST

CONTENTS OF THE BID- Page 2 of 2

ORISSA POWER TRANSMISSION CORPORATION LIMITED

2. GENERAL PARTICULARS OF SYSTEM

3. DRAWINGS ATTACHED WITH TENDER DOCUMENT

4. GUARANTEES TECHNICAL PARTICULARS

5. COMPLIANCE WITH SPECIFICATION

6. TEST AND MAINTENANCE EQUIPMENT

ERECTION AT SITE AND ACCOMMODATION

SITE CONSTRUCTION SUPPLIES

SUPERVISION AND CHECKING OF WORK ON SITE

RESPONSIBILITY FOR THE RUNNING OF PLANT BY CONTRACTOR

COMPLIANCE WITH REGULATIONS

MAINTENANCE AND CLEARING OF SITE

PROTECTION OF MONUMENTS AND REFERENCE POINTS

WORK AND SAFETY REGULATIONS

Substation site selection

1.3 Interfacial point for line termination at substation

3. DRAWINGS ATTACHED WITH TENDER DOCUMENT

Installation and commissioning techniques.

8.1 Hardware maintenance

Course name and identification.

Short description of the curriculum.

Level of competency required for each course.

Date and duration.

Maximum number of staff that can attend.

Other important information.

ERECTION AT SITE AND ACCOMMODATION

Workmen's Compensation Insurance

Workmens Compensation As per statutory provisions

As per statutory provisions

* According to the Govt. rules.

Comprehensive automobile insurance

Rs. 100,000/- each person

Rs. 200,000/- each occurrence

Rs. 100,000/- each occurrence

* As per latest prevailing Govt. rules.

Comprehensive General Liability Insurance

16 PROTECTION OF MONUMENTS AND REFERENCE POINTS

Fatal injury or accident causing death.

Rs. 100,000/- per Applicable for injury or death to

* As per prevailing Govt. rules.

ORISSA POWER TRANSMISSION CORPORATION LIMITED

OFFICE OF THE SR. GENERAL MANAGER,

E2-GENERAL TECHNICAL CLAUSE- Page 1 of 34

GENERAL TECHNICAL CLAUSES

2. DESIGN AND STANDARDISATION

3.2. Quality assurance programme

3.3. Quality plans

3.4. Inspection and testing

3.5. Non-conforming product

3.6. Monitoring of quality arrangements

3.8. Method statement

4. HEALTH, SAFETY AND ENVIRONMENT (HSE) PLAN

4.2. Content of HSE Plan

4.3. General structure of HSE Plan

4.4. Section 6 of HSE Plan

4.5. Standards, Procedures and Guidelines

4.6. Supervision strategy