cable laying specification 08-06-2017 r0 · the desired minimum depth of laying from ground surface...

GN101-03-SP-06-02

Index

General Specification .................................................................................................3 1.0.0 Codes & standards ............................................................................................3 2.0.0 Design Guidelines & Parameters for Cable laying.............................................3 3.0.0 General Guidelines for Laying Cables...............................................................7 4.0.0 Testing ..........................................................................................................................14 5.0.0 Progress Reporting .........................................................................................15 6.0.0 Drawing, Data & manuals.............................................................................................15 7.0.0 Deviations........................................................................................................16 Annexure # 1 – DEVIATION REPORT FORMAT......................................................16 Annexure # 2 – DC HIGH VOLTAGE TEST .............................................................16 Annexure # 3 – CABLE TRENCH DETAILS .............................................................17 Annexure # 4 – STANDARD ROAD PROFILE .........................................................18 Annexure # 5 – ROAD RESTORATION SECTIONAL DRAWINGS..........................20 Annexure # 6 – DRAWINGS (CABLE TRENCH AND RCC CABLE COVER)..........23 Annexure # 7 – BARRICADING AND SAFETY…………………….………………….38 Annexure # 8 – ROUTE MARKER AND BARRICADING DRAWING……………….38

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General Specification

1.0 Codes & standards

Materials, equipment and methods used in the Laying of 11/33/66KV Cable shall conform to the

latest edition of following –

S. No.

Reference No. Name of Standard

1 Indian Electricity Rules, 1956 2 Indian Electricity Act, 1910 3 Indian Electricity Supply Act, 1948 4 Electricity Laws Act, 1991 5 National Electrical Code ( Indian standards Institution) 6 IS 1255 Code of practice for installation and maintenance of Power Cable upto

and Including 33KV rating. 7 IS 1554 PVC Insulated Electrical Cables upto 11KV 8 IS 2274 Code of Practice for electrical wiring installation – system voltage

exceeding 650V 9 IS 7098 Part II Crosslinked Polyethylene Insulated PVC sheathed cables for working

voltages from 3.3KV upto and including 33KV 10 IS 7098 Part III Crosslinked Polyethylene Insulated PVC sheathed cables for working

voltages from 66KV upto and including 220KV 11 IS 5820 Specification of precast concrete Cable cover.

2.0 Design guidelines and Parameter for cable laying‐

S. No.

Parameter Details

2.1 Selection of Cable Route

The cable route selection shall be done by the concerned supervising engineer by first conducting route survey and selecting a route along with contractor keeping followings in mind: ‐The side of road which presents the least obstacles and the fewest roadways crossings. ‐The future consumers and existing cables in the route may influence the cable route. ‐Railway, road crossings, MCD and other government agencies may also influence in selection of cable route. ‐Plans for future building projects should be considered. ‐The route shall be as far as possible away from parallel running gas, water pipes and telephone/telecommunication cables.

2.2 Site Preparation a) Barricading: • The identified cable route shall be barricaded continually

before excavation. • Barricading shall be as drawing laid • Open Trench method shall be adopted as far as possible for

trench preparation. b) Excavated Earth:

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• The excavated earth shall be so stored at site, that it shall not cause trouble to running traffic

• All excavated earth shall be stored within the barricaded area.

• c) Full height fence, barriers, barricades etc. shall be erected

around the site in order to prevent the working area from the risk of accidents due to speedy vehicular movement. Same the way barricades protect the road users from the danger due to construction equipment and temporary structures.

d) The structure dimensions of the barricades , material and composition, its colour scheme, BSES logo and details shall be in accordance with specification and drawing laid down in the tender documents.

e) All the barricades shall be erected as per the design requirements of employer, numbered painted and maintained in good condition and also barricade in charge maintain a barricade register at site.

f) All barricades shall be conspicuously seen in the dark/night time by the road users so that no vehicle hits the barricades. Conspicuity shall be ensured by affixing retro reflective strips of required size and shape at appropriate angle at bottom and middle portion of the barricades at a minimum gap of 1000 mm. In addition minimum one red light /red blinker and red beacon light should be placed at the top of each barricade.

g) PPP to be provided by vendor to all workers and engineers. h) Also refer Annexure‐ 7: Barricading and Safety

2.3 Clearance The desired minimum clearances are as follows – ‐ Power cable to power cable – A minimum clearance equal to diameter shall be maintained. Trench drawings shall be referred to for guidance. ‐ Power Cable to control cables – 0.2 M ‐ Power cable to communication cable – 0.3M ‐ Power cable to gas/water main – 0.3 M

2.4 Depth of Cable Laying

The desired minimum depth of laying from ground surface to the top of cable shall be: 650 / 1100V grade XLPE Cables – 75 cm 6.35 / 11KV grade XLPE Cables – 90 cm Low voltage and Control cable ‐ 75 cm 19 / 33KV grade XLPE Cables ‐ 1.2 M 38 / 66KV grade XLPE Cables ‐ 1.5 M Cables at Road crossing ‐ 1.0 M (min.) Cables at railways level crossings (measured from bottom of sleepers to the top of Pipe) ‐ 1.0 M (min.) Whenever there is any obstacle at the laying depth, the cable should be lowered/ raised to cross the obstacle. However variation in the depth is to be approved by BSES. The Contractor shall provide the same in deviation report.

2.5 Width of Cable The width and depth of Cable Trenches shall depend upon number of

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trenches circuits and Voltage Grade. Annexure # 3 and drawings of this specification shall be followed.

2.6 Bending Radius of Cables

While pulling of the Cable from the drum or during laying following minimum bending radius shall be maintained so that the cable, in particular the insulation does not get damaged – A) Single Core Cables ( PVC & XLPE)

Upto 1.1KV grade – 15 X D Above 11KV grade ‐ 20 X D

B) Multi Core Cables ( PVC & XLPE) Upto 1.1KV grade ‐ 12 X D Above 1.1KV grade – 15 X D

Where ‘D’ is overall diameter of the cable. 2.7 Maximum

permissible Tensile Strength for Cables

For cables pulled with Stocking PVC and XLPE SWA Armoured cables P = 30 X D PVC and XLPE AWA Armoured cables P = 20 X D

Where P= pulling force in Kgrm, D= Diameter of Cable in mm For Cables pulled by Cable eyes

Aluminium conductor – 30 N/mm2 = 3 Kg/sq. mm Copper conductors ‐ 50N/mm2 = 5 Kg/sq. mm

Permissible force is calculated by multiplying the above values by cross sectional area (CSA) of conductor of each core and then number of cores.

2.8 Methods of Laying

a) Cables shall be laid in direct in ground, in trenches excavated therein and shall be protected with covers as given in the drawing. Cables shall also be drawn into pipes of ducts or laid in the formed trenches or troughs or on racks or supported in trays or cleats as required by the site exigencies. Where the cables are laid in the formed trenches, the installation shall include removal and replacement of the trench covers and the provision of temporary protective covers on the trenches where they cross the access ways.

b) HDPE ( 200 mm) or RCC ducts shall be used where cable cross

roads and railways tracks. Spare ducts for future extensions should be provided. Spare duct should be sealed off. Buried ducts or ducting blocks shall project into footpath or upto the edge of road, where there is no footpath, to permit smooth entry of cable without undue bending. The diameter of the cable conduit or pipe or duct should be at least 1.5 times the outer diameter of the cable. Angular alignment of the duct across road crossings shall be predetermined to maintain safe bending radius when direction of cable trench changes before or after the road.

c) The contractor shall lay cable by Horizontal direct drilling (HDD)

in main roads and highway with heavy traffic, passage to public property where excavation is not possible. Contractor shall take approval for laying of cable by means of HDD wherever required from the supervising engineer. The cable laid by HDD shall be

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minimized so that it doesn’t exceed by 12% of total route length. This is to avoid De‐rating of Cables.

d) Unless approved by BSES, the contractor shall lay the cables,

direct in ground, in single layer. The cables shall be laid with the pre‐determined and approved cable route.

e) Spacing shall be maintained uniformly between the cables all

along the length including the bends, as approved by BSES. To maintain the spacing, suitable non‐metallic formers shall be placed uniformly with spacing not exceeding 5 meters. Every bend shall have at least one spacer.

f) 75 mm of the sand bed shall be placed at the bottom of cable

trench.

g) After the cables have been laid the trench shall be filled with the sand and shall be well rammed to a level not less than 75 mm above the top of the cables all throughout the route.

h) To protect the cables against external mechanical damage, which may be caused by other agencies, the cable shall be protected by suitable cover. (for drawing of RCC cable cover refer annexure VI).

i) The type of the covers shall be as under ‐ 1.1KV Cables – Single layer of brick thickness not less than 75 mm ( 3 inch) ‐ 11KV Cables – sand stone of thickness not less than 75mm ( 3 inch). ‐ 33KV Cables shall be protected by reinforced concrete cover of width 300 mm as per attached drawing with thickness not less than 50mm. ‐ 66KV Cables shall be protected by reinforced concrete cover as per attached drawing with thickness not less than 50mm.

The RCC cable cover shall be embossed as “BSES EHV CABLE”.

j) Back fill to be filled up to 75mm and the warning tape shall be installed continuously. The tape shall be yellow in colour with Black / Red lettering of minimum 20mm height. The approved warning message shall be written in English and Hindi/ local language. The minimum thickness and width of the tape should be 300 microns and 150 mm respectively.

k) The trench shall be filled‐up by loose soft soil (300mm) and

Excavated soil as indicated in drawings. 2.9 Cable over On Bridges the cables are generally supported on wooden cleats and

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Bridges clamped on steel supports at regular intervals. The cables laid on bridges shall be provided with Sun shield. Approval from appropriate authorities (PWD/railways) as applicable shall be taken by contractor.

2.10 Laying of Single Core Cables

a) The single core cables shall be laid in trefoil formation. Single core cables can be laid individually in 200mm HDPE pipe in case of HDD only.

b) For single core cables laid in trefoil formation, plastic cable ties

shall be used at interval of 1.0 (one) meter throughout the cable length to maintain the trefoil arrangement.

c) To balance the inductance, the phase sequence in trefoil format

shall be maintained by vendor ( for double circuit)

d) To prevent magnetic losses (eddy current and hysteresis losses), the base plate of the panels or the terminal box of the equipments, shall have aluminium plate. In case the entry into the building is through GI pipe, a “slit” in the GI pipe shall be necessary. Alternatively GI pipes may altogether be avoided and non‐metallic pipes such as PVC or HDPE pipe shall be used. Concrete pipes having steel reinforcement (RCC pipe) are not to be used.

2.11 Earthing of Single Core Cables

a) Single point bonded earthing shall be employed to prevent flow of induced circulating current in the armour and screen and consequential de‐rating of cables for feeder less than 2.0 KM.

b) For feeder length more than 2 KM, mid point earthing shall be

provided. 2.12 Violation of

barricading guideline and safety norms

On violation of barricading guideline and safety norms, a fine of Rs.5000 /day shall be imposed. BRPL inspector/engineer in‐charge shall be empowered to impose the above penalty.

3.0 General guidelines for Laying Cables

S. No.

Parameter Details

3.1 General a) Laying of the cables and handling of the same shall be undertaken, at all times, by adequate staff suitably trained and supplied with all the necessary plant, equipment and tools.

b) The contractor shall be responsible for all the route survey, establishment of the position of the joints as per the site exigencies and the drum lengths of cables to be laid. While carrying out the route survey the contractor shall take into account the obstacles on the route whether above or below ground. The cable shall be planned to be laid in an orderly formation, free from unnecessary bends and crossings

c) The contractor shall submit a drawing for the complete scheme

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showing the entire route, road crossings, location of joints and also the arrangement of cables to be laid. In case due to site exigencies, cables have to cross over within the trench, the same shall be shown in the drawing. For each and every job, these drawings shall be approved by BSES, prior to commencement of work.

d) BSES shall arrange for all the material and manpower required for jointing and end termination. The Contractor shall provide pit, carry out excavation for creation of working space required for jointing by the jointer. All civil works, structural work, clamping and earthing shall be carried out by the contractor, so that the cables and accessories perform satisfactorily during the entire life time.

e) The entry and exit of the cables into the building shall be through RCC or GI pipe except for single core cables, which shall be properly sealed and shall be duly supported as per the method and technique approved by BSES, so that the outer sheath of the cable does not get damaged at the entry and exit points. The sealing should be of adequate length so that it minimizes the risk of spreading of fire or ingress of water.

3.2 Handling and Storage of Cable drums (All empty drums are returnable)

a) The cable drums shall be transported upright, so that the weight is distributed on both the flanges. Under no circumstances the cable drum may be laid on its side. During transportation the drums must be properly secured. The cable drums should never be dropped from Lorry or a trailer, so as to prevent damage to the cable drum and also to the cable. Ramp may be used for unloading. The drums may be rolled over short distance, provided the correct direction of rolling as provided on the drum is observed. Alternatively, a mobile crane should be used for lifting and lowering the drum. A chain‐pulley arrangement may also be used to lift the drums and deposit the same on ground if required.

b) In case the drums are to be stored prior to cable laying, they should be arranged in such a way to leave some space between them for air circulation. It is desirable that the drums stand on battens placed directly under the flanges. Overhead covering is not essential except in heavy rainfall areas or during monsoon. Cable should however be protected from direct rays of sun by leaving the battens on or by providing some form of sunshade. In no case the drums shall be stored in a flat position with flanges horizontal.

c) For transportation of the cable drums from storage site to work site, the drum should be mounted on a trailer or an open lorry and unloaded by mobile cranes.

d) After cable laying, empty cable drums shall be taken return back by vendor from site at their own risk and cost. Cost of empty drums shall be deducted from vendor account during final settlement.

3.3 Cable Laying a) The ground over which the drum is positioned at site should be

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properly consolidated and jacks placed on both sizes of the drum to make the pay‐off arrangement stable. Suitable arrangement be made to stop the drum rotation, during cable laying preferably by square wooden poles kept temporarily pivoted over cable roller under the flanges which when required can be applied on the flange as a brake by personnel manning the drum.

b) The cable should always be paved off from the top of the drum. The drum must be positioned in such a way that the arrow on the drum points opposite to the direction of rotation marked on the drum.

c) It must be ensured that the cable is not dragged over sharp object or on the road surface, so as to avoid damage to the outer sheath of the cable.

d) The pulling method to be used shall be approved by BSES. Cable supplier’s recommended maximum pulling tension shall not be exceeded.

e) Rollers shall be placed at intervals and the cable shall be pulled over the rollers. The rollers shall be kept lubricated so that they rotate freely, minimize friction to the cable in motion. Rollers shall be positioned at the bends to minimize side wall friction. The contractor shall ensure that PVC/HDPE sheath of cable is free from damage due to abrasion.

f) The cable should not be pulled out from the drum by lifting of the coil while the drum is lying flat on the flange. This leads to twisting of the armour and cores resulting in permanent damage to the cable.

g) To avoid ingress of moisture, it must be observed that the end capping of the cables is not damaged. Cut pieces of the cables must be capped immediately, before laying of the same is taken‐up.

3.4 Excavation of the Trenches

a) The excavation of the trenches shall be commenced, with proper co‐ordination with BSES, so that all the necessary clearances for the route are already obtained from the competent authorities, well in time.

b) Before opening of the section of the trench, the contractor shall satisfy himself that the line of the trench is clear of underground obstructions, by taking out trial pits on the line of the trench.

c) The exact location of each trench shall be approved on site by BSES. The trenches shall be kept as straight as possible and each trench shall be excavated to approved formation and dimensions. If necessary, the trenches shall be adequate shored by wooden planks and bracing to avoid trench cave‐ins which would cause injury to the persons and also damage the cables laid.

d) The bottom of each trench shall be firm and of smooth contour. The contractor shall take reasonable precautions to prevent damage to the highway or ground surface from a slip or breaking away of the sides of the trench.

e) The trench excavation and filling in shall be so executed that all

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walls, roads, sewers, drains, pipes, cables, structures, places and things shall be reasonably secured against risk of subsidence or injury and shall be carried out to the satisfaction of the authorities concerned. Should, however, a damage to an existing or other services be made, the Contractor will arrange and pay for any necessary repair, to make good the damages.

f) Where trenches pass from a footway to a roadway or at other positions where a change of level is necessary, the bottom of the trench shall rise or fall gradually. The rate of rise or fall shall be approved by BSES.

g) Contractor shall ensure that during excavation and until restoration has been completed, for reasonable access of persons and vehicles to property or places adjacent to the route.

h) When the excavation of the trenches has been accurately executed, the contractor shall inform BSES for approval. Laying of cables or building of structure shall not be started until the contractor has been advised by BSES to proceed with the work.

3.5 Excavated material

a) The materials excavated from each trench shall be placed so as to prevent nuisance or damage to adjacent ditches, drains fences, gateways and other property or things. Excavated material shall be stacked so as to avoid undue interference with traffic.

b) Where, owing to traffic or for reasons of safety or other considerations, this is not permissible, the excavated material shall be removed from the site and returned for refilling the trench on completion of laying; surplus material shall be disposed off by the contractor at his own cost.

3.6 Pipes and Ducts

a) Care shall be taken to make the bend of the pipes or duct lines as easy as practicable and in no case of radius less than 3 meters. Where approved, split pipes may be used on bends, the pipes being fitted round the cable after laying.

b) All road crossings shall be ducted. This applies to present and future roads as indicated on the route plans. The pipes and the ducts shall be laid in an approved manner and shall be surrounded by 150 mm of PCC (1:2:4)

c) Ducts under the road shall be provided by the contractor, by non‐disruptive method, if road cutting is not permitted by the concerned authorities Cable laying shall be done by Horizontal Direct drilling method (HDD).

d) The cables shall be suitably protected at entry and exit from the pipes, so that the outer sheath does not come in contact with the edges of the pipes / ducts. The pipes and ducts shall have slope so that the seepage water can drain through the small opening provided on the lower side of the pipe sealing.

e) The pipes and ducts shall be secured to the base at both ends and at regular interval, throughout the length, so that at no point the ducts or pipes get suspended over the threaded cable, and damage the same, thus defeating the very purpose of providing the pipe / duct.

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f) At all road crossings at least one spare duct / pipe shall be provided for future use. The pipe shall be thoroughly cleaned of obstructions. A draw wire or rope shall be left in each pipe to facilitate the drawing in of the cables. The duct end shall be sealed temporarily to prevent the entry of foreign matter. End caps and permanent markers shall be placed flush with footpath / roadways at both the ends. The pipes and ducts shall be cleaned again immediately before the cables are drawn in.

g) The internal diameter of the pipe / duct should be such that the cables occupy only 40% of the area of the pipe / duct to avoid de‐rating.

3.7 Joint Bays The contractor shall provide all help so as to enable jointers to carry out their work efficiently and expeditiously. The method of securing and supporting cable joints and cables also the bonding and earthing thereof, shall be detailed on the drawing. The details shall be approved by BSES prior to commencement or work. The joint position should be staggered.

3.8 Back filling of trenches

a) Filling in of trenches shall not be commenced until BSES has inspected and approved the cables and accessories at site. The inspection should be got done on daily basis so that the trenches do not remain open unnecessarily, to avoid inconvenience to public.

b) The trench shall be backfilled after putting all protections for cables.

c) Soft soil shall be backfilled for 300 mm above the cable protection cover.

d) Caution Tape shall be laid all along the cable route above the soft soil filling.

e) Complete backfilling shall be done above the caution tape. 3.9 temporary

Reinstatement a) Where cables routes are in public highways, footpaths, gardens

etc., the method of reinstatement will be subject to approval by MCD. All costs incurred will be at the contractor’s expenses.

b) The contractor shall be responsible for proper permanent reinstatement of the upper levels, which shall be carried out to the satisfaction of BSES and the MCD authorities concerned.

c) Before finally leaving site, permanent reinstatement shall be executed by the contractor to the approval of MCD and the property owners and all costs incurred shall be to the contractor’s account.

3.10 Permanent Reinstatement of Public Road,

a) In public roads and footways the surfaces and foundations shall be temporarily reinstated by the contractor. After settlement, temporary reinstatement material shall be removed as necessary and the permanent reinstatement shall be carried out to the approval of the appropriate highway authority / MCD. Stone and pre‐cast concrete paving kerbs and channels shall also be finally reinstated by the contractor.

b) Temporary reinstatement shall be maintained by the contractor until commencement of final reinstatement to ensure that the surface is always safe for the passage of pedestrians and vehicular traffic.

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3.11 Identification All cables shall be identified below the gland at each end, at joint position and at approved positions by means of bands engraved or punched with cable no. feeder name, size of cable, number of cores, phase colour etc. The bands shall be secured fastened in a permanent manner, and shall be made of material able to resist corrosion, dampness and mechanical damage.

3.12 Cable Route Markers

All cables routes shall have markers at suitable location with a gap not exceeding 30 meters. The route markers shall be approved design. Additional markers shall be provided at joint locations with approved markings.

3.13 Cable supports / Clamps

a) The contractor shall supply and install all the supports, racks, trays, cleats, saddles, clips and other parts required to carry and secure the cables, without risk so that there is no undue mechanical load or stress due to weight of the cable at each end. Cleats, saddles and clips shall be of the design as approved by BSES. No cable shall be laid on the trench floor. They shall be run in a neat and orderly manner and the crossing of cables within the trench shall be avoided as far as possible. Where cable runs unavoidably cross, a suitable supporting arrangement shall be provided to maintain an adequate gap between the cables

b) Every cable shall be supported at a point not more than 500 mm from its termination.

3.14 Installation of Cables in tunnels / basement / below the panels etc

a) The design of cable support for cables installed in air in cable tunnels, basements etc. shall consist of vertical steel members spaced at approved interval and secured to the walls, floors and ceilings as necessary by means of bolts either cemented in position or expanded into cored holes. Each vertical support shall have bolted to it a number of steel brackets spaced at the intervals and designed to support and retain trays constructed of galvanized sheet steel of adequate section to carry the weight of the cables, plus space for an additional quantity of future cables at least 25% by weight and dimensions in excess of the cables installed under the contract and an additional load of 100 kg at the extremity without distortion. The trays shall be designed with raised edges to retain the cables and shall incorporate an interlocking feature so as to prevent movement between supports.

b) The design and construction of all cable cleating and supporting arrangements shall suit the cable system design. The spacing of cable supports shall be approved by BSES.

c) Cable run on trays shall be neatly dressed and where not provided with cleats shall be secured by heavy gauge, type approved metal reinforced, clips or saddles. Not more than six cables shall be embraced by one clip.

d) Mild steel of appropriate sections, duly painted in an approved manner, shall be used for fabrication of cable supports. The steel shall be free from blisters, scales, laminations or other defects. Before final painting, the steel sections shall be provided with double coat of red primer.

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3.15 Cable Protection at overhead Towers or Poles

Where the cables terminate on overhead line poles or towers located outside substation compounds the contractor shall provide suitable cable supporting galvanized steel work attached to the pole or tower and comprising backboard, runners, sheet, steel cover of not less than 3.0mm thickness, stays, cable cleats, anti climbing guard and all incidental items to provide secure protection for the cables. Isolators and Lightning arrestor if required to be installed shall be provided as free issue item to the contractor, however the erection and steel structure required shall be in scope of the contractor.

3.16 Sun Shades All cables shall be protected from direct solar radiation by ventilated sun shields as approved by BSES.

3.17 Route Plan a) BSES intents to show all the cable routes, location of joints and other underground obstructions on a GPS map.

b) During the progress of the contract works the contractor shall record on a set of route plans and cross section drawings of an approved form, these details so that the same can be transferred on the GPS maps. Such particulars will allow an accurate reference to be made in the case of any fault or projected modification. These records shall show, amongst other data, both indoors and outdoors the exact position of every joint, cable end termination and also the particulars of the depth of the trench, the arrangement of the cables, with cable numbers and the position of all obstructions revealed during the course of excavations. These completed records shall be submitted to BSES within 15 days of completion of any particular route/feeder. The final bill shall not be processed by BSES unless this activity has been completed to the entire satisfaction of BSES

3.18 Site Facilities to be maintained by the Contractor

a) The contractor shall arrange for all the tools and tackles required for cable laying as per this specification. BSES shall arrange for all the material and manpower required for jointing and end termination.

b) Illumination and Power supply shall be arranged by the contractor so that the work can be carried out round the clock.

c) The contractor shall maintain functional dewatering pumping facility with suitable power supply so as to protect the cables and the joints from ingress of water due to rain or otherwise

d) The contractor shall make arrangement to provide suitable scaffolding arrangement to carry out the termination work

e) The contractor shall carry out proper barricading of the dug cable route and the joint bays and shall take all necessary precautions to avoid any public hazard

f) Also refer Annexure‐7: Barricading and Safety. 3.19 Type of Roads

and guidelines for road restoration

The typical section of type of Roads (based on width) under PWD and MCD are :‐ ‐ 20 Feet Wide road ‐ 30 Feet wide road ‐ 40 to 60 Feet Road ‐ Other ( which include Kota stone, Agra stone, Cement concrete, interlocking paving tiles, brick road, chequered tiles

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and asphalted road) The drawing are shown in annexure IV The guidelines for road restoration for various type of roads and surfaces are indicated in annexure V as :‐ ‐ Bituminous road Type I (category I & II) ‐ Bituminous road Type II (category III) ‐ Cement concrete road ‐ Kota/Rajasthan stone Road ‐ Brick Road ‐ Interlocking paving tiles. ‐ Agra stone road ‐ Chequered tiles road ‐ Asphalted road

4.0 Testing

S. No.

Parameter Details

4.1 Tests to be carried out during and after completion of Cable Laying

Testing of cable before jointing – ‐ Cable shall be tested for Insulation Resistance prior to laying by opening the end and resealing end properly. Testing on complete Cable Installation –

a) Insulation resistance of each core shall be measured against all the other cores and the metal screen connected to earth.

b) The resistance of the conductor shall be measured. c) DC High voltage. For old cables test voltage shall be 1.5 times

rated voltage or less depending on age of cable.(refer annexure # 2 for values)

d) Charging of Cable at No‐Load at Nominal working voltage for 24 Hours.

e) After laying and before termination of cable a sheath test shall be conducted for 66KV Single core Cable as under :‐ At both ends the cable shall be raised from ground. From the end graphite coat applied over the outer PVC jacket shall be removed with a piece of glass for a length of 300mm. A spiked steel rod with an eye for attaching a wire shall be driven into the ground and connected to a nearby water or hydrant pipe. Insulation resistance of PVC jacket shall be measured between the aluminium wire armour and the spike with a 500/1000V insulation tester. Measured resistance shall not be less than 2.5M OHM per KM. Thereafter 10KV DC shall be applied for one minute in the same way. After the test the armour shall be kept earthed to the steel spike for 15 minutes for discharging residual charge.

4.2 Statutory a) Road cutting permission

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clearance Road cutting permission shall be taken from competent authority by vendor. How ever official fees shall be paid by BRPL. b) Electrical inspector clearance Electrical Inspector clearance shall be in vendor scope. How ever official fees shall be paid by BRPL.

5.0 Progress Reporting:

S. No.

Parameter Details

5.1 Detailed Progress report

Progress report to be submitted by Contractor to BSES once in a Week containing i) Excavation status ii) Cable laying status iii) Status of preparedness for Jointing iv) Reason for any delay in total programme v) Details of damage to cable during laying. vi) Progress on final completion / Constraints / Forward path

6.0 Drawing, Data & Manuals:

S. No.

Parameter Details

6.1 To be submitted After Completion of the Job

As the works is completed the following reports in quadruplicate shall be submitted to BSES for record purpose and shall be incorporated in the ‘As constructed Records’. a) Feeder details ( sending end, receiving end, SAP number of project etc) ‐ Type of cables, cross section area, rated voltage. Details of construction, cable number & drum number. ‐ Year and month of laying. ‐ Actual total route length, cable length, length between joint to joints or end. ‐ Location of cables and joints in relation to certain fixed reference points, for example buildings, hydrant, boundary stones etc. ‐ Jointing reports detailing the date, weather conditions, jointers and supervising Engineers names, details of type of cable and type of joint or termination, location and joint bay number, ambient temperature. ‐ Results of original electrical measurements and testing on cable installation. ‐ Full written reports will be required of any damage occurring to cable or equipment together with remedial action proposed which will be subject to the approval of BSES.

6.2 Drawing and document sizes

Standard size paper A0, A1, A2, A3, A4

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7.0.0 Deviations Deviations from this Specification shall be stated in writing by the contractor. Written approval shall be obtained from BSES by the contractor. In absence of such a statement, it will be assumed by BSES that the Contractor complies fully with this specification during execution of the job. Deviation mentioned in any other submitted tender docs like in GTP, QAP, Old PO, old WO, BRPL Standard, vendor standards etc. shall not be considered as a deviation at any stage of contract. The format for approval of deviation attached in annexure # 1 Annexure # 1 – DEVIATION REPORT FORMAT S. NO.

Clause No. of Specification

Details about deviation

Reason for deviation

Approved by (Sign & Name)

Annexure # 2 – DC HIGH VOLTAGE TEST

Rated Voltage of cable in KV

Test Voltage Between Duration in Min.

Any conductor and metallic sheath / Screen / armour

Conductor to conductor (for unscreened Cables)

0.65 / 1.1 3 3 6.35 / 11 18 30 19 / 33 60 ‐‐‐‐ 38 / 66 90 ‐‐‐‐

15 Min

Reference value for DC High voltage Test.

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GN101-03-SP-06-R2

Annexure # 3 – CABLE TRENCH DETAILS S. No. Cable Size Trench Cable Trench drawing

reference Width (mm) Depth (mm) 1 1.1 kV LT Cables

a 3.5Cx150 mm2 ‐ Single Circuit

400 875 A – 1 (Drg. # 9)

b 3.5Cx150 mm2 ‐ Double Circuit

400 875 A – 1 (Drg. # 9)

c 3.5Cx150 mm2 ‐ Triple Circuit

400 875 A – 1 (Drg. # 9)

d 3.5Cx300 mm2 ‐ Single Circuit

400 875 A – 1 (Drg. # 8)

e 3.5Cx300 mm2 ‐ Double Circuit

400 875 A – 1 (Drg. # 8)

f 3.5Cx300 mm2 ‐ Triple Circuit

400 875 A – 1 (Drg. # 8)

2 11 KV Cables

a 3Cx150 / 300 mm2 ‐ Single Circuit

400 1055 A – 2 (Drg. # 6)

b 3Cx150 / 300 mm2 ‐Double Circuit

650 1055 B – 1 (Drg. # 7)

3 33 kV Cables

a 3Cx400 mm2 ‐ Single Circuit 400 1235 A – 3 (Drg. # 3) b 3Cx400 mm2 ‐ Double

Circuit 650 1235 B – 2 (Drg. # 4)

c 3Cx400 mm2 ‐ Quadruple Circuit

650 1235 B – 2 (Drg. # 5A)

d 3Cx400 mm2 ‐ Quadruple Circuit

650 1545 B – 3 (Drg. # 5B)

e 3Cx400 mm2 ‐ Quadruple Circuit

1200 1235 C – 1 (Drg. # 5C)

4 66 kV Cables

a 1Cx630/1000 mm2 ‐ Single Circuit

650 1445 B – 4 ( Drg. # 1)

b 1Cx630/1000 mm2 ‐ Double circuit

1200 1445 C – 2 (Drg. # 2)

c 3Cx300 mm2 ‐ Double circuit 1200 1445 C – 2 (Drg. # 2A)

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Annexure # 4 – Standard Road Profile

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GN101-03-SP-06-R2

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GN101-03-SP-06-R2

Annexure # 5 – Road Restoration Sectional Drawing

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GN101-03-SP-06-R2

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GN101-03-SP-06-R2

Annexure # 6 – DRAWINGS ( CABLE TRENCH AND RCC CABLE COVER)

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GN101-03-SP-06-02

Annexure-7: Barricading and Safety

1. Dimensions of barricading- Height- 2 mtr, Length- 1.5 mtr. Refer drawing enclosed with tech spec for more details.

2. There shall not have any gap in between two barricades. Edge to edge shall be intact.

3. LED Bacon light shall be placed at 1st and 4th barricade and same shall be continue

4. Name, painting, colour, clean ness etc. shall be done on regular basis. 5. Vendor to ensure that traffic management shall not be excuse of work

execution. The contactor shall not undertake loading and unloading at carriageways obstructing the free flow of vehicular traffic and encroachment of existing roads by the contactor applying the excuse of work execution.

6. Full height fence, barriers, barricades etc. shall be erected around the site in order to prevent the working area from the risk of accidents due to speedy vehicular movement. Same the way barricades protect the road users from the danger due to construction equipment and temporary structures.

7. The structure dimensions of the barricades , material and composition, its colour scheme, BSES logo and details shall be in accordance with specification and drawing laid down in the tender documents.

8. All the barricades shall be erected as per the design requirements of employer, numbered painted and maintained in good condition and also barricade in charge maintain a barricade register at site

9. All barricades shall be conspicuously seen in the dark/night time by the road users so that no vehicle hits the barricades. Conspicuity shall be ensured by affixing retro reflective strips of required size and shape at appropriate angle at bottom and middle portion of the barricades at a minimum gap of 1000 mm. In addition minimum one red light /red blinker and red beacon light should be placed at the top of each barricade.

10. No dust deposit at the front side of barricades. 11. Cable drum shall be returnable and vendor shall take it back (by bye back

process) from site at their own risk and cost. 12. Once cable lying complete of a drum, within two days empty drum shall be

removed from site by bye back process. 13. Trained traffic marshal with all PPE and traffic control light (Red and Green)

shall be placed at site for 24x7. 14. No excuse of theft (beyond 6 hrs. of FIR) shall be acceptable. 15. During execution of job, any damage to other agency’s properties shall be

counted in vendor account and necessary action shall be taken by vendor to recover, repair etc.

16. Excess earth shall be removed from site after back filling. Site to be cleared to avoid flowing of dust. Barricades to be removed from site with in 24 hrs. after completion of job.

17. During non working hrs. vendor to ensure presence of supervisor for controlling any event from locals.

18. PPEs

• Helmets

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GN101-03-SP-06-02 • Mask • Jacket • Shoes • First Aid Box etc.

Shall be available at site 24x7. Zero tolerance on absence of PPEs to the working personnel. No excuse shall be acceptable in this regards.

19. EPR/Scanning shall be done by vendor of whole the route and same shall be

submitted to BRPL. This work shall be done by vendor before execution of job.

20. Jointing TAT- Jointing to start within 48 hrs. and shall be completed by 96 hrs.+1 day.

21. Lifting of cable drums with hydraulic machine, pulling of cable from top end of drum with pulling machine (hydraulic winch) is mandatory.

22. Violation on barricading guideline and safety norms, a fine of Rs.5000 /day shall be imposed. BRPL inspector/engineer in-charge shall be empowered to impose the above penalty.

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Annexure # 8 – ROUTE MARKER AND BARRICADING DRAWING

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BSES Bhawan, Nehru Place, New Delhi- 19

\

1.0

Prepared by Javed Ahmed Rev: 2

Reviewed by

Abhinav Srivastava Date: 29.03.2017

Approved by Vijay Panpalia

TECHNICAL SPECIFICATION OF 66KV CONTROL & RELAY PANEL FOR NEW GRIDS

Specification no – SP-CRP-01-R1

BSES Bhawan, Nehru Place, New Delhi- 19 Volume – I Technical Specification for 66KV Control & Relay Panel

Revision Record

S.No. Rev.No. Item/Clause

No.: Nature of change Approved By

1 R1 4 Width of cubicle shall be 1250mm KA 2 R1 5.7 Spare terminal in each type of terminal. KA 3 R1 6 Test terminal block for numerical relays

and meter. KA

4 R1 8 Mimic diagram alignment with discrepancy type control switch.

KA

5 R1 11.4 Multifunction meter with digital output with modbus communication.

KA

6 R1 11.4.3 Communication protocol IEC 61850 metering equipment.

KA

7 R1 12.1.5 Communication protocol IEC 61850 in Numerical Relays.

KA

8 R1 12.1.9 All necessary converters shall be consider for communication of numerical relays in case of optical fiber.

KA

9 R1 12.1.16 Digital input and output of Numerical relays

KA

10 R1 12.2.1.2 Line current differential with distance relays in Line control and relays panel.

KA

11 R1 12.2 Optical fiber communication in line current differential relays with distance relays in Line control and relays panel.

KA

12 R1 12.4 Auxiliary relays shall NO/NC contact shall be as per BSES requirement.

KA

13 R1 13.0 Minimum no. of annunciation window shall be 24Nos.

KA

14 R2 18.4.1 Addition of Alstom Make Relays VP


2.0 SCOPE OF SUPPLY

2.1 This specification covers design, manufacture, testing at manufacturer’s works, packing and delivery of control and relay panel for substation equipments.

2.2 The control and relay panel shall be complete with all components and accessories, which are necessary or usual for their efficient performance and trouble free operation under the various operating and atmospheric conditions as specified in the Annexure A of data sheet.

2.3 Such parts which may have not been specifically included, but otherwise form part of the CRP as per standard trade and/or professional practice and/or are necessary for proper operation of control and relay panel, will be deemed to be also included in this specification.

3.0 CODES & STANDARDS:

Control and Relay panel should be designed and manufactured in accordance with the following standards – National Standard Standard Code Standard Description IS‐1248, Part 1‐ 1993 Direct acting indicating analogue electrical measuring

instruments and their accessories. IS‐3231, Part 1‐ 1986 Part 2 &3 ‐1987

Electrical relays for power system protection

IS‐9000 Part 1 ‐1988 Basic environmental testing procedures for electronics & electrical items

IS‐13703 1993 Low voltage fuses for Voltages not exceeding 1000V AC or 1500 V DC

IS‐13947 Part 1 ‐ 1993 Low voltage switchgear & control gear IEC‐60255 ‐ 1989 Specification for electrical relays IEC 60688 1997 Electrical measuring transducers

4.0 PANEL CONSTRUCTION Description Requirement / Rating

4.1 Panel Type Simplex panels of standard dimensions. Equipment shall be mounted on the front of the panel and doors for wiring access shall be at the back of panels.

4.2 Enclosure type Completely metal enclosed and dust, moisture and vermin proof. Degree of protection not less than IP‐4X in accordance with IS 13947

4.3 Enclosure material Cold‐rolled sheet steel of thickness not less than 2.0 mm. Stiffeners shall be provided wherever necessary.

4.4 Doors Doors shall be at the rear. For panels having width should


be more than or equal to 1250mm, double leaf doors shall be provided. Doors shall have handles with either built‐in locking facility or be provided with padlock.

4.5 Gland Plate At least two separate gland plates of removable type shall be provided for each panel. They shall be of sheet steel of thickness not less than 3.0 mm.

4.6 Cable Entry Shall be from the bottom

4.7 Gaskets All doors, removable covers and panels shall be gasketed all around with neoprene gaskets.

4.8 Ventilating louvers Ventilating louvers, if provided shall have screens and filters. The screens shall be made of either brass or GI wires mesh.

4.9 Foundation

The panels shall be fixed on the embedded foundation channels with intervening layers anti vibration strips made of shock absorbing materials. Base frames shall be supplied along with panels.

4. 10 Mounting

Equipment on front of panel shall be flush mounted. Cutouts if any, provided for future mounting of equipment shall be properly blanked off with blanking plate no equipment shall be mounted on the doors.

4.11 Mounting level

The center lines of switches, push buttons and indicating lamps shall not be less than 750mm and that for relays, meters and recorders shall be not less than 450 mm from the bottom of the panel.

4.12 Appearance

The center lines of switches, push buttons and indicating lamps shall be matched to give a neat and uniform appearance. Like wise the top lines of all meters, relays and recorders etc, shall be matched.

5.0 WIRING

5.1 Internal wiring 1100V grade, single core, stranded copper conductor wires with PVC insulation.

5.2 Size 4 sqmm for CT circuits, 2.5 sqmm for PT and control circuits.

5.3 Colour Code R ph ‐ Red, Yph ‐ Yellow, B ph ‐ Blue, Neutral ‐ Black for CT and PT circuits. DC ‐ Grey, AC ‐ Black and Earth ‐ Green

5.4 Ferrules

Ferrules marked to correspond with panel wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wire. Wires directly connected to trip circuit shall be distinguished by the addition of red colored unlettered ferrule.

5.5 Termination Fork type, pin type and ring type (as applicable) tinned copper lugs to be used. Insulated sleeves shall be provided at all the wire terminations.

5.6 Wiring Enclosure Plastic channels to be used as enclosures. PVC sleeves to be used for inter panel wiring.


5.7 Spare Contacts Spare contacts of relays and contactors etc. should be wired upto the terminal block

5.8 Inter panel wiring

When panels are arranged adjacent to each other inter panel wiring of common bus wires between the panels shall be furnished. These adjacent inter panel wiring shall be clearly indicated in the wiring tables.

5.9 Auxiliary supply

Auxiliary bus wiring for AC and DC supplies, voltage transformer circuits, annunciation circuits and other common services shall be provided on the same set of terminals in all the panels with proper segregation.

6.0 TERMINAL BLOCKS

6.1 Rating and Type

1100 V grade, minimum 10 amps continuous rating, Nylon 66, molded piece, complete with insulated barriers, stud type terminals, washers, nuts and lock nuts. White fiber markings strip with clear plastic, slip‐on / clip‐on terminal covers to be provided.

6.2 CT & PT Terminals

Terminal Blocks (TB) for current transformer and voltage transformer secondary leads shall be Stud Type provided with test links and isolating facilities. Also current transformer secondary leads shall be provided with short‐circuiting and earthing facilities.

6.3 Spare Terminals 20% in each type of TB row

6.4 Clearance with gland plate Minimum 250mm

6.5 Clearance between two TBs Minimum 150mm

6.6 Test Terminal Blocks Screw driver operated stud type for each type of numerical relays and metering

6.7 Suitability

Unless otherwise specified, terminal blocks shall be suitable for connecting the following conductors of cable on each side: a) All circuits including current / voltage transformer circuits: 4 sq.mm copper. b) AC / DC power supply circuits: one no. of 10 mm2 Al./ 6 sq.mm Cu.

6.8 Arrangement

Arrangement of the terminal block assemblies and the wiring channel within the enclosure shall be such that a row of terminal block runs in parallel and close proximity to each side of the wiring duct. The side of the terminal block opposite the wiring duct shall be reserved for the external cable connection.


7.0 PAINT

7.1 Paint Type Powder coated. Pure Polyester base Grade‐A, structure finish.

7.2 Paint Shade RAL7032 ‘Siemens Grey’ 7.3 Paint Thickness Minimum 50 microns

8.0 MIMIC DIAGRAM

8.1 System Representation

Colored mimic diagram and symbols showing the exact representation of the system shall be provided in the front of control panels and it shall be properly align with all discrepancy type control switch of panels.

8.2 Material

Mimic diagram shall be made preferably of painted Aluminum or plastic of approved fast color material, which shall be screwed on to the panel and can be easily cleaned. Painted overlaid mimic is also acceptable. The mimic bus shall be 2‐3 mm thick. The width of the mimic bus shall be 12mm for bus bars and 10 mm for other connections.

8.3 Mimic Indications Discrepancy type switches are to be used for breaker and isolator control indication and semaphore indicators shall be used for earth switch position.

9.0 NAME PLATES & MARKINGS

9.1 Provision of Nameplates

All equipment mounted on front side as well as equipment mounted inside the panels shall be provided with individual name plates with equipment designation engraved. Also, large and bold name plate carrying the feeder identification numbers shall be provided for circuit / feeder designation on the top of each panel on front as well as rear side. 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 easy tracing of the wiring.

9.2 Nameplate Material

Non‐rusting metal or 3 ply lamicoid. Nameplates shall be black with white engraving lettering. Stickers are not allowed.

9.3 Markings

Each switch shall bear clear inscription identifying its function. Similar inscription shall also be provided on each device whose function is not other wise identified. If any switch or device does not bear this inscription separate nameplate giving its function shall be provided for it. Switch shall also have clear inscription for each position indicating e.g. Trip‐


Neutral close, ON‐OFF, R‐Y‐B OFF etc. 10.0 EARTHING

10.1 Panel Earthing All panels shall be equipped with an earth bus securely fixed.

10.2 Material The material and the sizes of the bus bar shall be 25 x 6 mm copper flat unless specified otherwise.

10.3 Earth Bus joints All bolted joints in the bus will be affected by connection of two bolts.

10.4 Hinged Doors Earthed through flexible copper braid.

10.5

Instrument and Relay Earthing

All metallic cases of 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 mm2. The color code of earthing wires shall be green

10.6 CT and PT circuit Earthing

VT and CT secondary neutral shall be earthed at one place only at the terminal blocks through links.

11.0 INSTRUMENTS

11.1 Mounting Flush Mounting

11.2 Scale

Instruments dial shall be with white circular scale and black pointer, black numerals and lettering with red marks at values corresponding to rated values.

11.3 Ammeters and Voltmeters Taut Band, Moving iron type 11.3.1 Size 96x96mm 11.3.2 Provision All panels 11.3.3 Selector switch to be provided 11.3.4 Accuracy Class 0.5 or better.

11.4 Multifunction meter Three phase 4 Wire ‐ digital type with Modbus Output.

11.4.1 Provision All panels except bus‐coupler 11.4.2 Accuracy Class 0.5 or better.

11.4.3 Communication Capability Provision as per IEC 61850 Protocol with serial port communication to be made.

11.4.4 Additional facility Scrolling facility with LCD display for parameters like power factor, kW, kWh, kVA, kVAR, current, voltage etc.


12.0 RELAYS

12.1 Protective Relays ‐ General features

12.1.1 Technology and Functionality

Microprocessor based with provision for multifunction protection and control, metering, monitoring, User machine interface, communication interface, self‐diagnosis functionalities.

12.1.2 Mounting Flush Mounting, IP5X

12.1.3 Architecture

Hardware and software architecture shall be modular and disconnect able to adapt the protection and control unit to the required level of complexity as per the application.

12.1.4 Programming and configuration

Relay shall utilize a user friendly setting and operating multilingual software in windows environment with menus and icons for fast access to the data required.

12.1.5 Relay Communication

Serial communication interface for data transfer and configuration PC and SCADA using appropriate protocols as per IEC 61850. And in case of communication through optical fiber then necessary converter needs to be considered.

12.1.6 User Machine Interface

UMI with an alphanumeric key pad and graphical LCD display with backlight indicating measurement values and operating messages. Capability to access and change all settings and parameters.

12.1.7 Relay Characteristics

Relay shall integrate all necessary protections for different applications in accordance with IS and IEC. Relay shall provide wide setting ranges and choice of all IEC, IEEE and other tripping curves through a minimum of two setting groups.

12.1.8 Fault recording Facility for recording various parameters of faults with option to set the duration of fault record with maximum no. of data storage facility

12.1.9

General Features of Numerical Relays

Measurement of Event Recording , Disturbance Recording, Harmonic Distortion , RMS Current values & Frequency, Peak and Rolling Current Values, Max. and Average current Values, Phase and or Neutral Angles , Max. and average voltage, Power and Energy, Apparent Power and Apparent Power and Apparent Energy with Time Synchronization.


12.1.10 Self diagnosis Relay shall be able to detect internal failures. A watchdog relay with changeover contact shall provide information about the failure.

12.1.11 Reset Contacts Self reset contacts except for lockout relays 12.1.12 Operation Indicators LEDs with pushbutton for resetting. 12.1.13 Auxiliary supply As per requirement

12.1.13 Operational Data Bidder shall provide the reference list of the type of relays offered

12.1.14 Spare Contacts Minimum 20% Spare contacts 12.1.15 Test Facility Inbuilt with necessary test plugs.

12.1.16 DI / DO of Numerical relay

No. of Digital input / Digital output of any type of relay which shall be used in control and relay panel shall be as per BSES requirement and signal list only. Refer the attached tentative signal list of all feeders (Incoming/Out going, Trasformer & Transformer Monitoring Unit, Buscoupler & Bus PT).

12.1.17 Contacts for Transformer NIFPS

Contacts of NIFPS shall be provided in Transformer panel

12.2 Protective Relays ‐ Requirement 12.2.1 For 66kV 12.2.1.1 Bus Bar Protection Numerical type, mounted on a separate panel

with fault recording. CT wise supervision to be provided. Relay‐1 Line current Differential function suitable through optical fiber communication, Distance Protection with multiple characteristics i.e Mho , Quadrilateral etc. Relay‐2 Directional and non‐ Directional 3‐phase over current and earth fault Protection Combining the functions of Relays‐1 & Relays‐2 in single relay is not acceptable Synchronizing Check Relay

12.2.1.2 Line Panel

Broken Conductor Protection 12.2.1.3 Bus Coupler 3 Phase Over current protection ,

Earth fault protection Three phase over current protection Earth fault protection Neutral unbalance (separate relay) Under voltage relay Over Voltage relay Timer for ON time delay.

12.2.1.4 Capacitor feeder

Under Current protection


Relay – 1 • Differential protection, with software based ratio and vector correction without ICT. • REF protection for the star side. Relay – 2 • Overcurrent protection • Earth fault protection • Standby Earth fault protection Relay – 3 Transformer monitoring relay including AVR Features or equivalent & the no. of DI / DO Shall be as per BSES Requirement

12.2.1.5 Transformer Feeder/Panel

Relay 1, 2 &3 are separate relays. Combining all the functions of relay 1, 2&3 in a single relay is not acceptable

12.3 Auxiliary relays - General Features 12.3.1 Type Static or electromechanical. 12.3.2 Reset Characteristic Self reset contacts except for lockout relays

12.3.3 Operation Indicators Hand reset operation indicators or LEDs with pushbutton for resetting.

12.3.4 Lockout relay Manual reset type 12.3.5 Auxiliary supply As per requirement

12.3.6 Operational Data Bidder shall provide the reference list of the type of relays offered

12.3.7 Spare Contacts As per requirement of BRPL 12.4 Auxiliary relays ‐ Requirement

12.4.1 Each Panel To be provided with anti‐pumping (94), Lockout (86), DC fail (80) and trip circuit supervision (95) relays.

12.4.2 Each Panel

Provision for multiplication of auxiliary contact of breakers, isolators and earth switches to be made in each panel using latching relays. Multiplied contacts to be used for interlocks and indications. NO / NC Contact which shall be use for contact multiply shall be as per protection scheme requirement.

12.4.3

Incoming and Outgoing Feeder Panels

Provision of PT supply supervision and suitable automatic selection scheme between Line PT and Bus PT supplies for uninterrupted metering.

13.0 ANNUNCIATION

13.1 Type Static type along with alarm. Annunciations shall be repetitive type and shall be capable of registering the fleeting signal. Facia test facility


should also be provided 13.2 Mounting Flush mounted

13.3 Facia Minimum 24 Nos. Facia along with appropriate labels on each facia.in each panel

13.4 Push Buttons Push buttons for test, accept and reset to be provided

13.5 Potential Free Contacts To be provided for event logger Sequence of operation of the annunciator shall be as follows:

S No Alarm Condition Fault Contact Visual

Annunciation Audible Annunciation

1. Normal Open Off Off 2. Abnormal Close Flashing On 3. Accept Close Steady on Off 4. Return to normal Open Steady On Off 5. Reset Open Off Off 6. Reset before

return to normal Close Flashing On

14.0 INDICATIONS

14.1 Indicating Lamps Flush mounted Clustered LED type with rear terminal connections. Lamp Cover to be screwed type an moulded from heat resistant material

14.1.1 Breaker On Red 14.1.2 Breaker Off Green 14.1.3 Spring Charged Blue 14.1.4 DC control supply fail Amber 14.1.5 Auto trip Amber 14.1.6 Heater Circuit healthy Yellow 14.1.7 Trip Circuit Healthy White 14.1.8 PT supply R, Y, B 14.1.9 Hooter with isolation switch For AC and DC supply failure

14.2 Position Indicators Semaphore type indicators shall be provided for mimic diagrams

15.0 SELECTOR SWITCHES & PUSH BUTTONS

15.1 Selector Switch All the selected selector switch shall be only discrepancy type Flush Mounted with shrouded terminals

15.1.1 TNC Switch Pistol Grip type, Lockable with spring return to normal position

15.1.2 Local/SCADA selector switch 4 pole 15.1.3 Ammeter selector switch 6way 7 position 15.1.4 Voltmeter selector switch 6 way 7 position


15.1.5 Rotary On/Off Switches For heater/illumination circuit 15.1.6 Rating of switches 16 A 15.2 Push button Flush Mounted with shrouded terminals 15.2.1 Accept Push Button Black Color-Trip alarm/DC fail alarm 15.2.2 Reset Push Button Yellow Color- Trip alarm/DC fail alarm 15.2.3 Test Push Button Blue Color 15.2.4 Rating 10A

16.0 ACCESSORIES

16.1 Space heaters Thermostat controlled with switch for isolation

16.2 Socket and switch 240V, 5A socket to be provided in each panel with on-off switch

16.3 MCBs and Fuses

Provision for receiving, distribution, isolation and fusing of DC and AC supplies to various control circuits should be made using MCBs and Fuses of appropriate ratings.

16.4 Panel illumination 240V AC illumination lamp controlled by panel door switch to be provided in each panel

17.0 TESTING & INSPECTION

17.1 Type tests Product must be type tested as per Indian Standards or IEC

17.1.1 Type test report validity Last five years from the date of bid submission

17.2 Acceptance and Routine tests

As per specifications and relevant standards. Charges of these tests shall be deemed to be included in the equipment price. Purchaser reserves the right to witness all the tests.

17.3 Notice to Purchaser for conducting tests At least three weeks in advance

17.4 Test reports of acceptance and routine test before dispatch Six copies to be submitted.

17.5 Stage and Final Inspection All the Qty. of Panels will be inspected by BSES as per approved QAP .

17.6 Submission Of QAP QAP will be submitted by suppliers with submission of Schematic Drawings. 1.As Built Drawing of panel 6 Sets 2. Maintenance Manuals – 2CD / DVD Soft Copy , 6 Set of Hard Copy 3. Relay and equipments Catalogues & Manuals 4. Relay Settings & Maintenance Manuals

17.7

Deliverable

5. Relays software and connection/ communication cables

17.8 Training Training on relays and equipment operations

shall be provided to the officials of BRPL will be in the Scope of Suppliers.


18.0 DRAWINGS & DATA SUBMISSION

18.1 Submissions along with the bid

18.1.1 Duly filled GTP and copy of specification/ Bill of material 2 copies + 1 soft copy

18.1.2 GA/ Cross sectional drawing of panel/SLDs/ Wiring diagrams 2 copies + 1 soft copy

18.1.3 Calculations for MCBs, MCCBs, Fuses and stabilizing resistors etc 2 copies + 1 soft copy

18.1.4 Catalogues and Manuals for all equipments 1 copy 18.1.5 Test Reports 2 copies 18.1.6 Deviations from this specification

18.1.7 Type test report For type, size and rating of equipment offered.

18.1.8 Reference List of customers For last five years with units of similar design and rating

18.1.9 Recommended spares and consumables For five years of operation along with price list

18.1.10 Manufacturer's quality assurance program To be provided 18.2 Submissions after award of contract

18.2.1 Duly filled GTP and copy of specification/ Bill of material 4 copies

18.2.2 GA/ Cross sectional drawing of panel/SLDs/ Wiring diagrams 4 copies

18.2.3 Calculations for sizing of various equipment 4 copies 18.2.4 Catalogues and Manuals for all equipments 1 copy

18.2.5 Deviations from this specification Approved in writing before award of contract

18.2.6 Foundation Plan

18.2.7 Calculations for sizing of various components Showing all views and sections

18.2.8 Type test reports For all brought out items 18.3 Submissions prior to dispatch

18.3.1 Inspection and test reports/ compliance report by manufacturer 1 set

18.3.2 As Built drawings/GA/SLDs and Wiring diagrams 6 copies + 1 soft copy

18.3.3 Calculations for sizing of various equipment 6 copies + 1 soft copy 18.3.4 Catalogues and Manuals for all equipments 6 copies + 1 soft copy 18.3.5 Test certificates 6 copies + 1 soft copy 18.4 Drawing and document sizes Standard size paper A3 and A4 18.4.0 Approved Make of components for 66

KV Switchgear Panel 18.4.1 Numerical Relays ABB / SIEMENS/Schneider /Alstom

Note: Approval of Selection of Relay Type , make and its Cortex code shall be taken during bid evaluation.

18.4.2 Auxiliary Electromechanical Relays ABB / Areva / Schneider 18.4.3 Contactor / Auxiliary Relays Schneider Electric / Siemens / ABB


18.4.4 Analog Ammeter / Voltmeter AE / Rishabh 18.4.5 Indication Led , Lamp Teknic 18.4.6 Push Button Teknic 18.4.7 Field Terminal Block Phoneix / Elemex / Connect well 18.4.8 MCB Schneider / Siemens / L&T/ABB 18.4.9 Hooter Alan 18.4.10 Panel Light Philips / Bajaj / Surya 18.4.11 Power Socket Anchor / Reputed make 18.4.12 Multifunction Meter Rishab / Socomec 18.4.13 Wires for wiring KEI / Polycab / Finolex 18.4.14 Test Terminal Block Areva / IMP/Nelster 18.4.15 Control Switch Areva / Switron 18.4.16 Annuciator Window Alan / Minilec 18.4.17 Discrepancy switch Multimode/As per approved BRPL

makes during drawing approval.

19.0 INSPECTION Cost of Inspection including flight tickets and lodging (Hotel minimum 3 Star) shall be in scope of Vendor

20.0 TRAINING AND COMMISSIONING SUPPORT a) Supervision of Erection, Testing and Commissioning inclusive of all testing equipment/ instruments shall be included in the bid/proposal. All Hardware and softwares including Relay setting files and other support shall be in the scope of Vendor. b) Training of buyers officials (6 officials) on operation and maintenance including relay setting/operations at site (after installation) shall be included in the proposal/bid

21.0 DEVIATIONS Deviation from this specification, if any, shall be clearly brought out in the offer. Unless owner explicitly accepts such deviations, it shall be considered that the offer fully complies with the specification.


Prepared by Rev: 0

Reviewed by Date:

Approved by

TECHNICAL SPECIFICATION

FOR

STRUCTURAL WORK

BSES Bhawan, Nehru Place, New Delhi- 19 Volume – I Technical Specification Structural Work

1.0 GENERAL

1.1 The scope of specification covers design fabrication, proto assembly, supply and erection of galvanized steel structures for towers, girders, and equipment support structures, towers which shall be lattice type structures fabricated from structural steel conforming to IS: 2062(latest) The scope shall include supply and erection of all types of structures including bolts, nuts, washers, hangers, shackles, clamps, anti climbing devices, bird guards, step bolts, inserts in concrete, gusset plates equipment mounting bolts, structure earthing bolts, foundation bolts, spring and flat washers, fixing plates and any other items as required to complete the job.

1.2 The connection of all structures to their foundations shall be by base plates and embedded anchor/foundation bolts. All steel structures and anchor anchor/foundation bolts shall be galvanized. The weight of the zinc coating shall be at least 0.610 Kg/m2 for anchor bolts/foundation bolts and for structural members. One additional nut shall be provided below the base plate which may be used for the purpose of leveling.

2.0 DESIGN REQUIREMENTS FOR STRUCTURES 2.1 For design of steel structures loads such as dead loads, live loads, wind loads etc. shall be

based on IS: 802 Part 1 Sec 1

2.2 For material and permissible stresses IS: 802, Part-1, Section-2 shall be followed in general. However additional requirements given in following paragraphs shall be also considered.

2.3 Minimum thickness of galvanized tower member shall be as follows:

Member Minimum thickness (mm) Leg members, ground wire 5 Peak members/main members Other members 4 Redundant members 4

2.4 Maximum slenderness ratios for leg members, other stressed members and redundant members for compression force shall be as per IS-802

2.5 Minimum distance from hole center to edge to adjacent hole shall be minimum 1.5 X bolt diameter. Minimum distance between center to center of holes shall be 2.5 x bolt diameter.

2.6 The minimum bolt diameter shall be 16 mm.


2.7 Step Bolts

In order to facilitate inspection and maintenance, the structures shall be provided with climbing devices. Each tower shall be provided with step bolts not less than 16mm diameter and 175mm long spaced not more than 450mm apart, staggered on faces on one leg extending from about 0.5M above ground level to the top of the tower. The step bolt shall conform to IS: 10238

2.8 Design Criteria a) All structures 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, importance factor of 1.5, loads due to deviation of conductor, load due to unbalanced tension in conductor, torsion load due to unbalanced vertical and horizontal forces, erection loads, short circuit forces shall be calculated considering a fault level of 31.5KA for 3 secs. IEC-865 may be followed for evaluation of short circuit forces.

b) Switchyard girders structure shall be designed for the two conditions i.e. normal condition and short circuit condition. In both conditions the design of all structures shall be based on the assumption that stringing is done only on one side i.e. all the three (phase) conductors broken on the other side. Factor of safety of 2.0 under normal conditions and 1.5 under short circuit condition shall be considered on all external loads for the design of switchyard structures, which are of lattice type.

c) 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. Weight of man with tools shall be considered as 150KGs for the design of structures.

d) Terminal / line take off girders shall be designed for a minimum conductor tension of

1000Kg per sub conductor per phase for 66KV. The distance between terminal girders and the dead end tower shall be taken as per standard. The design of these terminal girders shall also be checked considering +/- 30 deg deviation of conductor in both vertical and horizontal planes. For other girders the structural layout requirements shall be adopted in design.

e) The girders shall be connected with lattice columns be bolted joints.

f) All support structures used for supporting equipments shall be designed for the worst

combination of dead loads, erection load. Wind load/seismic forces, short circuit forces. Short circuit forces shall be calculated considering a fault level of 31.5KA for 3 seconds.

g) Foundation bolts shall be designed for the loads for which the structures are designed


3.0 DESIGN DRAWINGS, BILL OF MATERIAL & DOCUMENTS 3.1 The contractor shall furnish design, drawing and BOMs to the Owner after award of the

contract. However contractor shall have to prepare and submit any other drawings, bill of material additionally required during design and construction stage which the Owner feels necessary. In case Owner feels that any design drawing, BOM are to be modified even after its approval, contractor shall modify the design & drawings and resubmit the design drawing, BOM as required in the specification.

3.2 The fabrication drawings are to be provided and furnished by the contractor shall be based on design approved by Owner. These fabrication drawings shall be based on the design approved by the Owner. These fabrication drawings shall indicate complete details of fabrication and erection including all erection splicing details, lacing details, weld sizes and lengths. BOM in the Performa approved by the Owner shall be submitted. Bolt details and all customary details in accordance with standard structural engineering practice whether or not given by the Owner.

3.3 The fabrication work shall start only after the final approval to the design and drawings is

accorded by the Owner. The design drawing should indicate not only profile, but section, numbers and sizes of bolts and details of typical joints.

3.4 Such approval shall however not relieve the contractor his responsibility for the safety of the

structure and good connections and any loss or damage occurring due to defective fabrication design or workmanship shall be borne by the contractor.

4.0 FABRICATION OF STEEL MEMBERS 4.1 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.

5.0 PROTO – ASSEMBLY

5.1 The component parts shall be assembled in such a manner that are neither twisted not

otherwise damaged and shall be so prepared that the specific camber, if any, is provided. In order to minimize distortion in member the component parts shall be positioned by using the clamps, Clips, lugs, jigs and other suitable means and fasteners (bolts and weld) shall be placed in a balanced pattern. If the individual components are to be bolted, paralleled and tapered drifts shall be used to align the part so that the bolts can be accurately positioned.

5.2 Sample towers, beams and lightning masts and equipment structures shall be trial assembled in the fabrication shop and shall be inspected and cleared by contractor based on the design approval accorded by the Owner before mass fabrication.


5.3 Pursuant to above the BOM’s along with proto-corrected fabrication drawing shall be

prepared and submitted by the main vendor to Owner as document for information. Such BOM, which shall be the basis for the Owner to carry out inspection.

6.0 BOLTING

6.1 Every bolt shall be provided with two flat and one spring washer under the nut so that no part of the threaded portion of the bolt is within the thickness of the parts bolted together. Locking nut shall be provided with each grouting bolt.

6.2 All steel items, bolts, nuts and washers shall be hot dip galvanized.

6.3 2.0% extra nuts and bolts shall be supplied for erection. 7.0 WELDING

7.1 The work shall be done as per approved fabrication drawings, which clearly indicate various

details of joints to be welded, type of weld, length and size of weld, whether shop or site weld etc. 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 joints due to constructional difficulties.

8.0 FOUNDATION BOLTS

8.1 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.

8.2 The contractor shall be responsible for the correct alignment and leveling of all steel work on site to ensure that the towers/structures are plumb.

8.3 All foundation bolts for lattice structures are to be supplied by the contractor.

8.4 All foundation bolts shall be fully galvanized so as to achieve 0.610 kg. Per Sq.m. of Zinc

coating as per specifications.

8.5 All foundation bolts shall conform to IS 5624 but the material shall be MS conforming to IS 2062.

9.0 STABILITY OF STRUCTURES The method of grouting the column bases shall be subject to approval of Owner and shall be such as to ensure complete uniformity of contact over the whole area of the steel base. The contractor will be fully responsible for the grouting operations.


10.0 GROUTING The method of grouting the column bases shall be subject to approval of Owner and shall be such as to ensure complete uniformity of contact over the whole area of the steel base. The contractor will be fully responsible for the grouting operations. 11.0 GALVANISING 11.1 All structural steel works and support shall be galvanized after fabrication.

11.2 Zinc required for galvanizing shall have to be arranged by the manufacturer. Purity of zinc to

be used shall be 99.95% as per IS 209.

11.3 The contractor shall be required to make arrangement for frequent inspection by the Owner as well as continuous inspection by a resident representative of the Owner, if so desired for fabrication work.

12.0 TOUCH UP PAINTING The touch up primers and paint shall consist of Zinc phosphate / Zinc chromate conforming to the requirements of IS 2074 with a pigment to be specified by the Owner. 13.0 INSPECTION BEFORE DESPATCH

13.1 Each part of the fabricated steel work shall be inspected as per approved quality plans and

certified by the Owner or his authorized representative as satisfactory before it is dispatched to the erection site.

13.2 Such certification shall not relieve the contractor of his responsibility regarding adequacy and completeness of fabrication.

14.0 TEST CERTIFICATE

Copies of all test certificates relating to material by the contractor for the works shall be forwarded to the Owner.

15.0 ERECTION

The contractor should arrange on his own all plant and equipment, welding set, tools and tackles, scaffolding, trestles equipments and all other accessories and ancillaries required for carrying out erection without causing any stresses in the members which may cause deformation and permanent damage.


16.0 SAFETY & PRECAUTION

The contractor shall strictly follow at all fabrication, transportation and erection of steel structures, raw m, materials and other tools and tackles, the stipulations contained in Indian standard code for safety during erection of structural steel work.



Prepared by Rev: 1

Reviewed by Date:

Approved by


FOR

OUTDOOR SWITCHYARD MATERIAL

BSES Bhawan, Nehru Place, New Delhi- 19 Volume – I Technical Specification Outdoor Switchyard Material

1.0 INTENT OF SPECIFICATION

1.1 This specification is intended to cover the design, manufacture, assembly, testing at manufacturer’s works, supply & delivery, properly packed for transport F.O.R site of 66KV Outdoor Switchyard Material and Hardware complete with all accessories for efficient and trouble free operation.

1.2 In the event of any discrepancy between listed documents, the stipulation of this specification shall govern.

1.3 The specification shall be read and constructed in conjunction with other sections of bidding

document.

2.0 SCOPE OF WORK

2.1 Scope of Supply

Type, rating, connections etc. of the materials shall be as detailed in the drawings and annexure. The materials shall be furnished in strict compliance with the same.

2.2 Following materials and hardware’s are to be furnished: a) ACSR ZEBRA Conductor b) Disc Insulator & Post Insulators c) Conductor Spacers, Clamps, Connectors.

Any material or accessory, which may not have been specifically mentioned but which is usual and / or necessary shall be supplied free of cost to the Owner.

3.0 GENERAL REQUIREMENTS 3.1 Codes and Standards

i) All equipment and materials shall be designed, manufactured and tested in

accordance with the latest applicable Indian Standards (IS) & IEC Standard except where modified and / or supplemented by this specification.

ii) Equipment and material conforming to any other standard, which ensures equal or

better quality, may be accepted. In such cases, copies of the English version of the standard adopted shall be submitted along with the bid.


iii) The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Codes of Practice. In addition other rules or regulations applicable to the work followed. In case of any discrepancy, the more restrictive rule shall be binding.

4.0 DESIGN CRITERIA 4.1 All the ACSR conductors, disc and string insulators, clamps & connectors, hardware’s etc.

will be used in extra high voltage system having characteristics as listed in the annexure.

4.2 All equipments, conductors, hardware’s, insulators & clamps etc. will be installed outdoor in a hot, humid & tropical atmosphere.

4.3 The maximum temperature in any part of the clamps, connectors, conductors etc at specified

rating shall not exceed the permissible limit as stipulated in the relevant standards.

4.4 All equipments, conductors, clamps, connectors, insulators etc shall be capable of withstanding the dynamic & thermal stresses of maximum short circuit current without any damages or deterioration.

4.5 In order to avoid concentration of stresses, all sharp edges of clamps, connectors etc. shall

be rounded off.

4.6 Bi-metallic connectors shall be used for any connection between dissimilar materials.

5.0 SPECIFIC REQUIREMENT 5.1 Equipment & Materials

i) Equipment & material shall comply with description, rating etc. as detailed in this

specification and annexure. ii) All accessories, fittings, supports, bolts etc. which form part of the equipment or

which are necessary for safe and satisfactory installation and operation of the equipment shall be furnished.

iii) All parts shall be made accurately to standard gauges so as to facilitate replacement and repair. All corresponding parts of similar equipment shall be interchangeable.

iv) After the treatment of steel surfaces damaged during transit sufficient quantity of anti-corrosive paint shall be applied and subsequently finished with two coats of final paint of approved shade.


5.2 ACSR Conductor i) The Aluminum Standard conductor and steel reinforced shall have the technical

parameters matching with the requirements given in Annexure. ACSR conductors shall conform to the latest revision of IS-398.

ii) The material for ACSR conductor shall conform to the following: Aluminum The Aluminum strands shall be hard drawn from electrolytic Aluminium rods having purity not less than 99.5% and a copper content not exceeding 0.04%. Steel The steel wire strands shall be drawn from high carbon steel wire rods and shall conform to the following chemical composition: Element -% Composition Carbon - 0.50 to 0.85 Manganese - 0.50 to 1.10 Phosphorous -not more than 0.035 Sulphur -not more than 0.045 Silicon - 0.10 to 0.35 Zinc The zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity. It shall conform to and satisfy all the requirements of IS: 209-1979.

5.3 Clamps and connectors i) All clamps, connectors and hardware’s shall be designed manufactured and tested

as per relevant standards.

ii) All clamps & connectors for connection with ACSR conductors shall have high tensile Aluminum alloy grade A6 body. U- Bolt and nut for the clamp shall be made of non-magnetic material e.g. chromium steel.

iii) Bolt, nut, washer, shackle etc. required for other purpose shall be of forged steel with

adequate strength and the surface shall be so protected as to offer maximum resistance to corrosion. Malleable iron wherever used for any part shall be of best quality and shall correspond to latest amendments of relevant IS.

iv) Various fittings & accessories of the clamps & connectors shall be so designed as to

eliminate sharp edges & maintain bright smooth surface. All bolts, nuts, rivets etc. shall have round profiles.

5.4 Disc Insulator

i) All disc insulators shall be dimensioned appropriately so as to have the required

Electro- Mechanical strength for EHV outdoor duties.


ii) Suspension and tension insulators shall be wet process porcelain with ball and

socket connection. Glazing of the porcelain shall be uniform brown colour, free from blisters, burrs and other similar defects. Insulators shall be interchangeable and shall be suitable for forming either suspension or strain strings. Each insulator shall have rated strength markings on porcelain printed and applied before firing.

iii) When operating at normal rated voltage there shall be no electric discharge between

conductor and insulator which would cause corrosion or injury to conductors or insulators by the formation of substances due to chemical action. No radio interference shall be caused when operating at normal rated voltage.

iv) Insulating shall be co-ordinated with basis impulse level of the system. The creepage

distance shall correspond to very heavily polluted atmosphere (31mm/KV)

v) Porcelain used in insulator manufacture shall be homogeneous, free from lamination, cavities and other flaws or imperfection that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture.

vi) The design of the insulator 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: 209. The zinc coating shall be uniform, adherent, smooth, reasonably bright, continuous and free from imperfection such as flux, ash, rust stains bulky white deposits and blisters.

vii) Bidder shall make available data on the essential features of design including the

method of assembly of discs and metal parts, number of discs per insulators, the manner in which mechanical stresses are transmitted through discs to adjacent parts, 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.

viii) Insulator hardware shall be of forged steel. Malleable cast iron shall not be accepted

except for insulator disc cap. The surface of hardware must be clean, smooth, without cuts, abrasion or projections. No part shall be subjected to excessive localized pressure. The metal parts shall not produce any noise generating corona under operating conditions.

ix) The insulator hardware assembly and clamps shall be designed for 120KN Tensile

load. The clamps shall be designed for 700 Kg tensile load. Earth wire tension clamp shall be designed for 1000 Kg tensile load with a factor of safety of two (2).

x) The tension string assemblies shall be supplied along with suitable turn buckle.


6.0 TESTS

6.1 Routine Tests

i) During manufacture and on completion of all equipment, conductors, insulators,

clamps, connectors and accessories shall be routine tested as per applicable standards at manufacture’s works.

ii) The suspension and tension strings, insulator discs and hardware shall be subjected

to the following, acceptance tests and routine tests:

a) Visual examination b) Verification of Dimensions as per Cl no. 10.5 of IS: 731 c) Temperature cycle test as per Cl no. 10.6 of IS: 731 d) Puncture test as per Cl no. 10.10 of IS: 731 e) Galvanizing test as per Cl no. 10.12 of IS: 731 f) Mechanical performance test as per IEC-575 Cl. 4 g) Test on locking device for ball & socket coupling as per IEC-372 (2) h) Porosity test as per Cl no. 10.11 of IS: 731

Acceptance Tests

a) Visual examination as per CI. 5.10 Of IS: 2468 (Part-1) b) Verification of Dimensions as per CI. 5.8 Of IS: 2468 (Part-1) c) Galvanizing / Electroplating test as per CI. 5.9 Of IS: 2468 (Part-1) d) Slip strength test as per CI. 5.4 Of IS: 2468 (Part-1) e) Shore hardness test for the Elastomer (if applicable as per the value guaranteed

by the Bidder) f) Mechanical strength test for each component (including grading rings and arcing

horns). g) Test on locking devices for ball and socket coupling as per IEC: 372 (2)

Routine Tests on Disc Insulator / Long rod Insulator

a) Visual Inspection as per CI No. 10.13 of IS: 731 b) Mechanical Routine Test as per CI No. 10.14 of IS: 731 c) Electrical Routine Test as per CI No. 10.15 of IS: 731

Routine Tests on Hardware Fittings

a) Visual examination as per CI. 5.10 Of IS: 2468 (Part-1) b) Mechanical strength Test as per CI. 5.11 Of IS: 2468 (Part-1)

Test during manufacture on all components as applicable on Disc Insulator


a) Chemical analysis of zinc used for galvanizing: Samples taken from the zinc ingot shall be chemically analyzed as per IS: 209. The purity of zinc shall not be less than 99.95%. b) Chemical analysis, mechanical hardness tests and magnetic particle inspection

for malleable casting:

The chemical analysis, hardness tests and magnetic particle inspection for malleable casting will be as per the internationally recognized procedure for these tests. The sampling will be based on heat number and heat treatment batch

Test during manufacture on all components as applicable on hardware fittings

a) Chemical analysis of zinc used for galvanizing Samples taken from the zinc ingot shall be chemically analyzed as per IS: 209. The purity of zinc shall not be less than 99.95%. b) Chemical analysis, mechanical hardness tests and magnetic particle inspection

for malleable casting:

The chemical analysis, hardness tests and magnetic particle inspection for malleable casting will be as per the internationally recognized procedure for these tests. The sampling will be based on heat number and heat treatment batch c) Chemical analysis, mechanical hardness tests and magnetic particle inspection

for fabricated hardware.

The chemical analysis, hardness tests and magnetic particle inspection for fabricated hardware will be as per the internationally recognized procedure for these tests. The sampling will be based on heat number and heat treatment batch.

iii) The following, acceptance & routine tests and tests during manufacturing shall be carried out on the conductor.

Acceptance Tests

a) Visual check for joints, scratches etc. and length of conductor

b) Dimensional check on steel and Aluminum strands

c) Check for lay ratio of various layers d) Galvanizing test on steel strands


e) Torsion and Elongation test on steel strands

f) Breaking load test on steel and Aluminum strands

g) Wrap test on steel and Aluminum strands IS: 398(Part-V) 1982 Clauses 12.5.2, 12.7 & 12.8

h) DC resistance test on Aluminum strands

i) UTS test on welded joint of Aluminum strands

NOTE: All the above tests except test mentioned at (i) shall be carried out on Aluminum and steel strands after stranding only Routine Tests

a) Check to ensure that the joints are as per specification b) Check that there are no cuts, fins etc. on the strands

iv) The following type, routine & acceptance tests and tests during manufacturing shall

be carried out on the earth wire.

Acceptance Tests

a) Visual check for joints, scratches etc. and length of Earth wire b) Dimensional check c) Galvanizing test d) Lay length check e) Torsion test f) Elongation test g) Wrap test h) DC resistance test : IS: 398 (Part lll) 1976 i) Breaking load test j) Chemical Analysis of steel

Routine Tests

a) Check that there are no cuts, fins etc. on the strands. b) Check for correctness of stranding


6.2 Type Test

Test certificates for type tests shall be from CPRI/ERDA/NABL approved lab, as stipulated in Indian Standards carried out on similar equipment shall be furnished. If test certificate for any of the type test is not available, the same shall be carried out free of cost from CPRI/ERDA/NABL.

6.3 Test Witness Tests shall be performed in presence of Owner’s representative if so desired by the Owner. The contractor shall give at least fifteen (15) days advance notice of the date when the tests are to be carried out.

6.4 Test Certificates

i) Certified copies of all tests carried out at works shall be furnished in requisite no. of

copies as stated in the condition of contract for approval of the Owner. The certificates shall furnish complete identification, date including serial number of each material and accessory.

ii) Equipment shall be dispatched from works only after receipt of Owner’s written approval of shop test reports.

iii) Type test certificate on any equipment, if so desired by the Owner, shall be furnished.

Otherwise, the equipment shall have to be type tested, free of charge, to prove the design.

7.0 SPARES The Bidder shall submit a list of recommended spare parts for three (3) years of satisfactory and trouble free operation, indicating itemized price of each item of the spares.


8.0 DRAWING & DOCUMENTS TO BE FURNISHED

8.1 To be submitted with each copy of the Bid i) Typical general arrangement drawing of the equipment / items. ii) Technical leaflets on equipment / items expending constructional features. iii) Type test certificates on similar equipment / items.

8.2 To be submitted for Approval and Distribution

i) Dimensional general arrangement drawing showing disposition of various fittings for

equipment, accessories, components etc. ii) Assembly drawing for erection at site with part numbers and schedule of materials. iii) Type & Routine test certificates iv) Technical leaflets on equipment / items v) Back-up calculation for:

a) Selection of equipment / material ratings. b) Sag-Tension of ACSR. c) Lighting protection system d) Selection of rigid bus support spacing.

vi) Any other relevant drawing, documents, calculations and data necessary for

satisfactory installation, operation and maintenance.



RATINGS & REQUIREMENTS

1.0 CONDUCTORS 1.1 ACSR Conductor 1.1.1 Reference standard : IS 398 1.1.2 Code Name : ZEBRA 1.1.3 Type : ACSR 1.1.4 Overall diameter 28.62mm 1.1.5 Stranding no. of wire and diameter : 54/3.18 (Al) 7/3.18 (St)

Number of strands Core 1 1st Layer 6 2nd Layer 12

3rd Layer 18

4th Layer 24

1.1.6 Sectional area of Aluminum : 428.9 sq.mm 1.1.7 Total Sectional area : 484.5 sq.mm 1.1.9 Ultimate Strength (min) : 130.32 KN 1.1.10 Calculated DC resistance at 20 Deg C : 0.06868 ohm/Km

NOTE – The 66KV Main Bus Shall be with TWIN ZEBRA. The equipment bay shall be Single Zebra.

2.0 GALVANISED STEEL SHIELD WIRE 2.1 Reference standard : IS 398

2.2. Number of strands Steel core-1, outer Steel layer-6

2.3 Total sectional area 54.55 sq.mm 2.4 Overall diameter 9.45 mm 2.5 Approximate weight 428 kg/km 2.6 Calculated DC. resistance at 200C 3.37 ohms/km 2.7 Minimum ultimate tensile strength 56 KN 2.8 Direction of lay of outer layer Right hand 2.9 Minimum tensile strength 110 Kgf/mm2 3.0 CONNECTORS / PG CLAMP ASSEMBLY / SPACER 3.1 Reference standard : 3.1.1 Clamp / Connector IS 5561 3.1.2 Spacer IS 10162 3.2 Material Aluminum Alloy A6

3.3 Continuous current carrying capacity (r.m.s) at 50deg C ambient temp. 2000A (min)

3.4 Short time current carrying capacity 31.5KA for 3 sec 3.5 Maximum temperature rise over Ambient of 50 35 deg C


deg C 4.0 INSULATORS 4.1 Reference standard 4.1.1 String Insulators/Insulator fittings IS 731/ IS 2486 4.1.2 Post Insulators IS 2544 4.2 Type Post Insulator- Cylindrical solid Core type, Suspension & Tension Insulator 4.3 Service Outdoor 4.4 System details 4.4.1 Voltage 66/72.5KV (Nom/Max) 4.4.2 Nos. of phases 3 4.4.3 Frequency 50Hz 4.4.4 System neutral earthing Effectively earthed 4.5 Insulation Level 4.5.1 Dry power frequency withstand 140KV r.m.s 4.5.2 Wet power frequency withstands 140KV r.m.s 4.6 Impulse withstand 325KV 4.7 Creepage 31mm/KV

Bus Post Insulators shall have minimum cantilever strength of 800Kg and minimum torsion moment of 500 Kg. FITTINGS AND ACCESSORIES OF INSULATORS Each insulator shall be furnished complete with the fittings and accessories as listed below according to requirement 1. Suspension top fitting 2. Suspension clamp fitting 3. Conductor suspension clamp 4. Tension end fitting 5. Tension (anchor) clamp adopter 6. Conductor tension (anchor) clamp 7. Top metal fitting 8. Bottom metal fitting 9. Nuts, Cotter pin, security clips etc. 10. Forged pin, studs etc.

Other standard accessories which are not specifically mentioned but usually provided with insulator of such type and rating for efficient and trouble free operation.


Prepared by Pronab Bairagi Rev: 1

Reviewed by AS Amit Tomar Date: 27nd May, 2015

Approved by VP


FOR

GROUNDING & LIGHTNING PROTECTION SYSTEM

BSES Bhawan, Nehru Place, New Delhi- 19 Volume – I Technical Specification Grounding and Lightning Protection

1.0 GROUNDING & LIGHTNING PROTECTION SYSTEM:

1.1 GROUNDING SYSTEM Earthing Installation shall be carried out as per IS 3043/IEEE 80-2000/IEC-517. The Station Earth mat shall be designed to meet required minimum area of cross section, current Density, Resistance, Touch & Step voltage criteria’s mathematically before installation and shall be tested after installation to ensure the resistance of earth mats to be less than 0.5Ohms. Bare Earthmat conductors (Strips/ Rods) to be installed below the ground as per safe designed to spacing in a grid pattern. Each junction of the grid shall be bonded by an electric arc welding process. Each bond has to be painted by Anti corrosive Paint (Bitumen).All ground wires installed in conduits shall be insulated. Bare ground conductors shall penetrate concrete through a PVC Sleeve. Equipment shall be generally being furnished with two separate ground pads with tapped holes, bolts, nuts & spring washers etc. Metallic frame of all electrical equipment shall be earthed by two separate and distinct connections to earthing system, each 100% capacity. Steel Columns, metallic stairs, hand rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one Earthing. Metallic Sheaths, Screens and armour of all multi core cables shall be earthed at both ends. Sheaths and armour of single core cables shall be earthed at switch gear end only All ground wires installed in conduit shall be insulated. Bare ground wires shall penetrate concrete through a PVC sleeve. Earthing of equipment shall generally be furnished with two separate ground pads with tapped holes, bolts, nuts and spring washers etc. Equipment ground connections, after being checked and tested shall be coated with anti-corrosive paint. Metallic frame of all electrical equipment shall be earthed by two separate and distinct connections to earthing system, each of 100% capacity. Steel columns, metallic stairs, hand rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing. Metallic sheaths, screens, and armour of all multi core cables shall be earthed at both ends. Sheaths and armour of single core cables shall be earthed at switchgear end only unless otherwise instructed by Owner. Every alternate post of the metallic fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the earthed post. Rail for transformers within the plant area shall be bonded across fish plate and connected to earthing grid at several locations. For prefabricated cable trays, a separate ground conductor shall run along the entire length of cable tray and shall be suitably clamped on each cable tray at periodic intervals. Each continuous laid out lengths of cable tray shall be earthed at minimum two places by GS flats to Owner's earthing system, the distance between earthing points shall not exceed 30 metre. Wherever earthmat is not available Contractor shall do the necessary connections by driving an earth electrode in the ground. Neutral points of transformer shall be solidly earthed by means of 2 Nos 75X10mm GI flat. Neutral Earth Electrode dimension shall be calculated by Long duration overloading of the


Soil (i.e.) 40 A/sq.mtr as per IS 3043-1987 Clause 10.3.a Each earthing lead from the neutral of the Transformers shall be directly connected to two electrodes in treated earth pits which in turn shall be connected to station earthing grid. Neutral connections and metallic conduits/pipes shall not be used for the equipment earthing. Lightning protection system down conductors shall not be connected to other earthing conductors above the ground level. Connections between earth leads and equipment shall normally be of bolted type. Contact surfaces shall be thoroughly cleaned before connections. All ground conductor connections shall be made by electric arc welding and all equipment earth connections shall be made by bolting with the earthing pads through flexible insulated cable leads. Ground connections shall be made from nearest available station ground grid risers. Suitable earth risers approved by Engineer shall be provided above finished floor/ground level, if the equipment is not available at the time of laying of main earth conductor Resistance of the joint shall not be more than the resistance of the equivalent length of conductor. For rust protection the welds should be treated with red lead compound and afterwards thickly coated with bitumen compound. Earthing conductors buried in ground shall be laid minimum 600 mm below grade level unless otherwise indicated in the drawing. Earthing conductor’s crossings the road shall be installed at 1000 mm depth and where adequate earth coverage is not provided it shall be installed in Hume pipes. Earthing conductors embedded in the concrete floor of the building shall have approximately 50mm concrete cover. Minimum earth coverage of 300mm shall be provided between earth conductor and the bottom of trench/foundation/underground pipes at crossings. Wherever earthing conductor crosses on runs at less than 300mm distance along metallic structures such as gas, water, steam pipe lines, steel reinforcement in concrete, it shall be bonded to the same. Earthing conductors along their run on columns, walls, etc. shall be supported by suitable welding/cleating at interval of 750mm. Electrodes shall be embedded below permanent moisture level. Minimum spacing electrodes shall be decided by calculation referred in IEEE-80 based on soil resistivity value .If soil resistivity is poor and desired reduction in ground resistance is not achieved by adding more Grid Conductor Earth pits shall be treated with Permanent maintenance free artificial treatment compounds as per IEEE 80-2000 Clause14.5d. On completion of installation, continuity of earth conductors and efficiency of all bonds and joints shall be checked. Earth resistance at each termination shall be measured as per


IEEE81-1983 (Wenner 3 point method). Earth resistance at earth terminations shall be measured in presence of Owner's representatives. Thickness of galvanizing shall be atleast 610gm/sq.m or 86 microns for all galvanized steel conductors.

1.2 The grounding/Earthing material shall be Terec++ or Marconite.

1.3 Ground Electrode shall be 3M long MS rod of required size. These are to be fabricated and driven into the ground by the side of mat conductors. All connection to the conductors shall be done by arc welding process.

1.4 Risers are required for connecting the equipment and structures with the ground mat. These

will be MS rod, laid from ground mat to above ground level properly clamped or supported along the outer edge of the concrete foundation. Connection to the ground mat shall be done by arc welding and the other end is to be kept free, at least 300 mm above ground level.

1.5 All steel Structures are required to be grounded at two points from ground mat. Laying

supporting and connection at both end are within the scope of this specification. All Earth Pits provided at the grid substation shall be interconnected with each other by MS Rod/Flat of adequate size as per symmetrical fault current.. The GI flat shall be buried in the earth at a minimum depth of 300 mm. Minimum ground coverage of 300mm shall be maintained between main earth grid and bottom of trench, tunnels, underground pipes other services / foundations. The earth grid conductor shall be run along the building column wall etc. with adequate and suitable supports at 750mm interval, if site conditions warrant so. The riser for equipment earthing shall be 75X10 mm GI flat. The orientation of these risers shall be such that minimum earthing strip is consumed for equipment earthing. All the further joints / connection of GI Flat shall be arc welded.

1.6 To ensure good welding, it should be carried out only after scratching off the galvanization, dirt, grease etc by thorough cleaning of contact surface. After welding it will be made with anticorrosive zinc rich paint. The equipment connection with GI Flat shall be bolted connection. Each bolted connection shall be taken through two numbers bolts at each joint to ensure tightness and avoid loosening with passage of time. In case the GI flat is to cross any obstruction, it shall be laid below the obstruction. At the crossing of building walls, floors etc the earth conductor shall pass through PVC conduit. Both ends of conduits shall be sealed after laying of conductor to prevent ingress of water. Contractor shall use GI strip of following specification: - The GI flat will have minimum 610 gm/mm2 Zinc coating and minimum 86 microns thickness. The galvanization provided shall be as per IS 2629. The galvanized surface shall consist of a continuous and uniform thick coating of zinc, firmly adhering to the surfaces of steel. The finished surface shall be clean and smooth and shall be free from defects like discolored patches, bare spots, and unevenness of coating, spiky deposits, and blistered surfaces, flaking or peeling off. All hardware like bolts, nuts, spring and flat washers shall be galvanized; Stainless Steel or Zinc passivated shall be arranged by contractor.


2.0 EQUIPMENT EARTHING

All the equipment should be grounded with double run earth strip directly connected to earth mat at two different points.

2.1 The table provides the guidelines for Selection of Cross section of Earth conductor as per IEEE 80-2000 Clause 11.3.1 Equation 37 & Mild Steel as an Earth Conductor. S. No Fault current Level (KA) Minimum Required Area of Cross Section (Sq.mm) 2.1.1 5 54 2.1.2 10 108 2.1.3 15 163 2.1.4 20 217 2.1.5 25 271 2.1.6 30 325 2.1.7 35 379 2.1.8 40 433

For various Equipments such as Power Transformer, Station Transformer, 11 KV Switch gear, 415V Panel, Light panel, Junction box, Street Lighting pole, Metallic fence, Isolator, Gantry tower & Electronic Earthing different cross sections of Earth conductor shall be selected as per the fault level. For switch gear rooms, a local earth conductor of adequate size of G.I flat may be run around the room below floor level to facilitate earthing of equipments in switchgear room.


2.2 However the table below provides general guidelines for selection of Earth Conductor for

each Equipment

2.2.1 Description/location Size

2.2.2 Earth mat 40 mm (min) to be selected by the contractor based on the calculations.

2.2.3 Power Transformer 100 X 8mm 2.2.4 Station transformer 50x6mm 2.2.5 11KV Switchgear 50x6mm 2.2.6 415V panel 50x6mm 2.2.7 Lighting panel 25x3 mm 2.2.8 Junction box 7/8 SWG 2.2.9 Street lighting pole 25x3 mm 2.2.10 Metallic fence 25x3 mm 2.2.11 Transformer yard fence and gate 50x6 GI flat with the help of flexible copper braid.

2.2.12 HV/LV/ LV Neutral cable box 50x6 GI flat 2.2.13 OLTC Drive mechanism body 25X3 GI flat 2.2.14 Battery charger panel 25X3 GI flat 2.2.15 DCDB 25X3 GI flat 2.2.16 Capacitor Bank Structure 50 X 6 GI flat 2.2.17 Capacitor unit and reactors 50 x 6 GI flat 2.2.18 Outdoor Circuit breaker, CT, PT &

CVT 50 X 6

2.2.19 Secondary terminal Box of outdoor CT, PT & CVT

25 X 6 mm

2.2.20 Isolator Mechanism box, earth switch box

25 X 6 mm

2.2.21 Gantry tower and structure 75 X 10 mm 2.2.22 Electronic Earthing Separate design and installation for all

communication devices and electronic equipments including SCADA RTU, MOXA, Router/Switch. As per recommendation of SCADA vendor

The most stringent size of conductor among the two tables above shall be selected

2.3 For switchgear rooms, a local earth conductor of size 50x 6 mm GI flat may be run around the room below floor to facilitate earthing of equipments in switchgear room. This grid shall be connected to the main earth grid at minimum two points. Size of the conductor shall be selected considering the provisions in clause 2.1 and 2.2 above.


2.4 It is to be ensured that all the switchgears and transformers earth points/ connections are connected to earth grid and all the main and auxiliary earth grids are interconnected at minimum two points. With the above arrangement, the return path to the respective transformer neutral will have a predominantly metallic path. (i.e. Cable armour >>switchgear earth bus>>external earth flat>>earth grid>>transformer neutral.).

2.5 Where a 66 kV overhead line terminates at the substation, a metallic continuity between the

end tower and the substation earth grid should be established with two independent connections.

2.6 The GI Flat shall be laid minimum 300 mm below the ground level but for the indoor location,

it shall be embedded in the concrete floor; 50mm below the FFL. .

2.7 The GI flat shall be welded after scratching off the galvanization locally and thorough cleaning of contact surface. After welding or bolting arrangement the joint shall be provided with anticorrosive Bitumen compound or zinc Phosphate paint. Wherever bolted connection is taken, it shall be taken through two bolts at each joint to ensure tightness and avoid loosening with passage of time.

2.8 Details of welding, bolting arrangement for various types of joints shall be as per Indian Standard.

2.9 Two separate and distinct earth connections shall be used for safety earthing of non-current

carrying metallic enclosure of all equipments.

2.10 Two separate and distinct earth connections shall be used for earthing of Lightning / surge absorber.

2.11 Neutral bushing of oil/dry type Station transformer shall be connected to two independent

earth pits by two no’s separate GI strips.

2.12 Transformer yard fence, structures shall also be connected with the earth mat by 50X6 GI Flat with the help of flexible copper braid.

2.13 All damages to the galvanized finishes shall be made perfect with zinc rich or bitumen paint.

2.14 RTU, marshalling box of SCADA or any other equipment installed in substation for SCADA

shall not be connected to the earth grid, it shall be connected to separate two earth pits connected at two separate points of the panel.


3.0. LIGHTNING PROTECTION

DESIGN OF LIGHTNING PROTECTION

3.1 Direct stroke lightning protection (DSLP) shall be provided in the EHV switchyard by shield wires. The final arrangement shall be decided after approval of the DSLP calculations. The Contractor is required to carry out the DSLP calculations and submit the same to the Owner for approval of the same at detailed engineering stage after award of contract.

3.2 The lightning protection system shall not be in direct contact with underground metallic service ducts and cables.

3.3 A 40 mm dia. 3000mm long MS earth electrode with test links, CI frame & Cover shall be

provided to connect down conductor of towers with peak. The test joint shall be directly connected to the earthing system.

3.4 Conductors of the lightning protection system shall not be connected with the conductors of

the safety earthing system above ground level.

3.5 Down conductors used for lightning protection shall be cleated on the structures at 2000mm interval.

3.6 Connection between each down conductor and rod electrodes shall be made via test joint

(pad type compression clamp) located approximately 150 mm aboveground level.

3.7 Lightning conductors shall not pass through or run inside G.I. conduits.

3.8 All metallic structures within a vicinity of 2000 mm in air and 5000mm below ground shall be bound to the conductors of lightning protection system.

3.9 In addition to Earth wires above the EHV switchyard, ESE Lightning conductor shall provides zone of Protection. Snapping of Earth wire does not make accidental situations during Lightning.

3.10 This ESE Lightning Protection system requires an Air terminal, down conductor, Lightning Counter & an Earthing System. If the structure is more than 30m height then 2 no’s of down conductor shall be used for side flashing. The Earthing system should not exceed more than 10Ω.

3.11 A 40mm dia M.S Earth Electrodes with Test Links, HDPE Cover shall be provided to connect down conductor. The test Link shall be directly connected to earthing system

3.12 Conductors of Lightning Protection system shall not be connected with conductors of Safety earthing system above ground level. Lightning Earth Pits shall be connected other earthing conductor below ground level by using Equipotential bonds which will not allow Surge current to flow from Lightning pits to other Earth pits


3.13 Connection between each down conductor & Test link shall be located approximately 2000mm above ground Level.

3.14 The Down conductor should be high conductivity bare copper tape with minimum size of 75 Sq.mm

3.15 Constructional Features

3.15.1 Galvanized Steel (Applicable for exposed G.S. flats)

a) Steel conductors shall be galvanized according to IS: 2629. b) The minimum weight of zinc coating shall be 610gm/sq. m. and minimum thickness

shall be 86 microns. c) The galvanized surfaces shall consist of a continuous and uniformly thick coating of

zinc, firmly adhering to the surfaces of steel. The finished surface shall clean and smooth and shall be free from defects like discolored patches, bare spots, unevenness of coating, spelter which is loosely attached to the steel globules, spiky deposits, blistered surfaces, 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.

3.16 Tests

3.16.1 The Contractor shall perform all tests and inspection to ensure that material and workmanship are according to the relevant standards. Contractor shall have to demonstrate all tests as per specification and equipment shall comply with all requirements of the specification.

a) The galvanized steel shall be subjected to four one-minute dips in copper sulphate solution as per IS: 2633.

b) Zinc Coating thickness : As per IS: 4759 c) Uniformity of zinc coating : As per IS: 2633 d) Adhesion Test : As per IS: 2629 e) Mass of zinc coating : As per IS: 6745 f) Chemical Analysis: As per IS: 513 & IS: 1079

3.16.2 The accessories for GSS Groundwire such as Tension Clamps, Copper braided wire etc.

shall conform to & meet the test requirements of IS: 2121.

4.0. DEVIATIONS Deviation from this specification, if any, shall be clearly brought out in the offer. Unless owner explicitly accepts such deviations, it shall be considered that the offer fully complies with the specification.


Prepared by K A SENTIL KUMARAN Rev: 4

Vishal Natani Reviewed & Approved by

Date: 30-03-2017

NEW GRID


FOR

SCADA INTERFACE WORK & AUTOMATION

BSES Bhawan, Nehru Place, New Delhi- 19 Volume – I Technical Specification for SCADA interface work & Automation

1.0 INTENT OF SPECIFICATION:

This specification is intended to cover the supply and execute work related to interface of all

electrical equipments with RTU panel complete with all materials and accessories for efficient

and trouble free operation. In the event of any discrepancy with the listed documents, the

stipulation of this specification shall govern.

2.0 SCOPE OF WORK

For substation, it is proposed to lay and terminate panel wirings / control cables if any

between the outdoor equipments such as CT, PT, Circuit Breaker, Isolators, 11 KV

Switchgear, 66,33,11 KV Control & Relay Panels, Power Transformer & its sensors – OTI,

WTI, TPI, AVR, etc, REGDA relay, Capacitor Bank,NIFPS,Smoke Detectors and Battery

Charger.

The scope of work under this category would include:

• Supply of SCADA materials - Bay Control Units, Remote Terminal Units with Basic + PLC

Licenses (Basic License - IEC 870‐5‐101,103,104, Modbus, IEC 61850‐8‐1,IEC ‐104

Master ,IEC 104 Slave + PLC License),Panels for RTU,Data Concentrator Units,Ethernet

Switches with panels,MFM,Cables- FO, CAT-6, RS485, Control Cables,Connectors and

GPS for time synchronization should be in SCADA vendor’s scope.

• Installation,Testing & Commissioning of SCADA equipments.

• Laying and Termination of armored Communication cables (Ethernet, Fiber Optic Patch

Cards/Cable,RS 485 cables) between grid devices (Numerical Relays/BCPU,

Transformer Monitoring Modules, Smoke detector, NIFPS panel, MFM, Battery Charger)

to RTU/DCU/Gateway.

• Laying and termination of control cables between grid equipments (control and relay

panel, NIFPS, Battery Units) to RTU for hardwired signals.

• Installation of cable trays with accessories or trench as required for the cabling work.

• Preparation of cable schedule, Wiring diagrams and Interconnection as built drawings.

• Separate earthing bus bars to be provided for RTU panel and it will be directly connected

to grid earthing.


• Seprate earth pit with connections for Electronic cards,gateway,Switches,DCU.,etc..

earthing.

• All internal wiring between BCU and C&R Panel terminals, All Numerical relays,MFM

(Multifunctional meters) and other grid equipment integration should be under SCADA

vendor’s scope.

• Hardware & software integration of RTU, Bay Control Units along with other equipments

viz. Battery Chargers, Multi Function Meters, Fire Fighting System Signals, Transformer

relays (for OTI, WTI, TPI, AVR, etc.),Smoke Detector Panels, Numerical Relays,

11&33&66KV Control and Relay panel signals etc. shall be in Vendor’s scope.

• FAT and Training arrangements for BSES SCADA team – Travel ,Boarding,

accommodation and local conveyance etc..shall be under SCADA Vendor’s Scope.

2.1 Cables

The following types of cables / wirings will be required for extending signals and commands.

• 2.5 mm2, multi-stranded flexible copper wire, FRLS 1.1KV HRPVC for AC & DC Supply &

1.5 mm2 multi strand cables for other internal wiring for RTU.

• Red(P)and Black(N) color cable core to be used for AC and DC wiring.

• Fiber Optic Cables (GLASS&PLASTIC Types) & Ethernet cables (CAT6) with conduit

pipe for internal connections and Armored Cables for external connections.

• 2 C X 2.5 MM2 cables for external AC / DC Power Supply

• 16 C x 1.5 mm2 for DI (Digital input)

• 3P X 1.5 mm2 for DO (Digital output)

• 2P X 0.5 mm2 Screened Armored PVC cable for external (RTU to BCUs

/MFM/BATT.CHG/Transformer Monitoring Devices) RS 485 connections.

The supplied cable shall be as a latest IS, also refer control cable specification.

Cable Gland

Single Compression cable glands (PVC for RS 485 cables & Brass for Control Cables) of

different sizes for cable entry into the DAU & DCU Panels

Cable Trays and NS cable Support

Perforated / ladder type (galvanized Iron) with cover for laying the cables.


2.2 Multifunction Meters (Accuracy – 0.5)

To extend the current / voltage / active and reactive power, power factor, etc. to RTU, MFMs,

installed in the C & R panel, should be integrated. (Make: RISHABH or Equivalent with

MODBUS). The outputs of these meters (in groups of 5) connections should be made using

twisted pair screened cable (Typically 22gauge Belden 8761 or equivalent) & two wires (A

and B) connections are daisy chained together and integrated with RTUs. All hardware’s or

protocol converters for having Modbus Protocol output should be in Vendor’s scope.

These should be installed in C & R Panel individually for each feeder/ breakers. All CT & PT

wirings to MFMs and its Configuration should be in Vendor‘s scope.

For the protection of MFMs and RTU cards against Surges and electrical leakages, it is

necessary to install Surge Protection Devices in RTU or C&R Panel and placed in between

RTU & MFM serial loops. The typical diagram for this connection is mentioned in the System

Architecture diagram. (5 MFMs per loop with SPD)

The following parameters of MFM must be available for communication with RTU.

Phase Voltages (L1-N, L2-N, L3-N)

Line Voltages (L1-L2, L2-L3, L1-L3)

Line Currents (IL1 , IL2, IL3)

Active Power & Reactive Power

Maximum Demand (KW) & Frequency

Power factor

Active Energy

THD mean current & THD mean Voltage

Neutral Current.

Phase Angles

2.3 Numerical Relays with BCU or Bay Control Protection Units for all feeders (11,33,66KV)

Numerical Relays & Bay Control Units should be integrated with Remote Terminal Units. All

hardware’s and protocol converters if required for compatibility with SCADA shall be in

Vendor’s scope.


The respective BCUs of individual Relays/Breakers will be connected to Data concentrator

Unit/Remote Terminal Units through IEC 61850 compatible industrial grade switches over

IEC 61850 protocol (RSTP Protocol with 61850 – To form a Ring Network b/w relay to relay

connections).

The respective BCU must have dual redundancy communication ports (Fiber or Ethernet

port-RJ45) for SCADA connections.

Hot Standby/Dual Power Supply Unit & Redundancy in power source for BCU/BCPU -

Possibility to increase the BCU availability by having a second power supply card in case the

first one fails , if any one Power supply card fails the other one should keep the bay control unit continuous live.

The following signals are to be taken from Numerical Relays to the BCUs through internal

hard wiring. This list is indicative and signals should not be limited to this. Additional signals

can be taken based on this. – Refer Para 2.8 for detail signals list with data types.

Online Currents / Voltage & Relay General trip signal

All breaker,Isolators,Control & Relay Panel indications and commands

Fault current and phase indication of faulty phase viz. R,Y,B, Earth, Unbalance(O/C

& E/F Relay).

Fault Differential and Bias current in Line and Transformer Differential Relay

Fault voltage and phase indication of faulty phase viz. R,Y,B (Voltage Protection

Relay).

Post fault currents (R, Y, B phase separately) measured value & Relay Internal Fault

Fault distance (in case of distance relays - R, Y, B Phase separately)

Unbalance Current (in case of neutral displacement relay of capacitor feeders).

2.4 Transformer Signal

OTI, WTI, TPI, AVR and Transformer auxiliary protection signals should be integrated with an

RTU through serial communication (RS 485 cables) via TMD (REGDA, A-EBERLE relays)

having IEC 61850 Protocol output.


All field installations of these sensors and its wiring/cabling and configuration along with

hardware’s or protocol converters, if any, should be in Contractor‘s scope. - Refer Para 2.8 for detail Transformer & Transformer Monitoring Device signal’s list with data types.

2.5 Battery Charger

All signals of Battery Chargers should have MODBUS Protocol output and integrated with an

RTU through serial communication (RS 485) cables.

Laying communication cables through conduit pipe and battery charger signals (Soft & Hard

Signals) integration with an RTU shall be in Vendor’s Scope. - Refer Para 2.8 for detail Battery Charger signal's list with data types.

2.6 Data Concentrator, Bay Control Units & Remote Terminal Units

For extending the signals from the grid to the Master Control Centre & Backup Control

Centre, BCUs and RTUs are to be installed. BCUs needs to be initially physically integrated

with Numerical relays of respective breakers to enable soft signals and commands for

breakers to be configured there and respectice BCU or BCPU integrated with Remote

Terminal Units through IEC – 61850 protocol. However the options for IEC-60870-103

protocol along with the MODBUS protocol option is required BCUs can be of ABB, Siemens,

Areva,Schneider Electric, etc ., make depending on the type/ make of switch gears. Remote Terminal Units need to be installed for interface between the BCUs and Control Centers (Main and Backup) through IEC – 60870 – 104 Protocol. The size of RTU will

depend on the size of the substation, no. of the feeders/ number of signals and command

outputs along with sufficient spares (20%) for future requirement.

All associated equipments and Supply of accessories including software &Operating tool /

multiple user licenses for RTU & BCU, MCBs for DC and AC Supply, DC to DC Converter (in

case station battery voltage level is 220 volts DC), etc. should be in Vendor’s scope.

Hardware & software integration of RTUs, BCU along with other equipments viz. Battery

Chargers, Multi Function Meters, Fire Fighting Systems, Signals, Transformer relays (for OTI,

WTI, TPI, AVR, etc.), Numerical Relays, etc. should be in Vendor’s scope.

In case of more than one BCPU,RTU,DATA Concentrator than these units must be able to

communicate with other units on internal local IPs (Ex – 192.168.0.1) other than LAN IP(Ex-

10.125.107.1) series.


Approved RTU makes – ABB ,Synergy Systems Solution,Siemens and Schneider Electric

India Limited.

RTU,Data Concentrator Unit Features & Performance capabilities

2.6.1 RTU,DCU Size and Expandability

20% Spare for RTU,DCU - Provision for 20 % (Basic IO Count +20% Spare) of the total DI /

DO signals (hard/soft) as a spare should be made available for future requirement.

Spare Ports – 20% Spare ports (Minimum – 3 to 4 No’s Serial ports are essential) for IEC

103/Mod Bus Protocol Connections

20% Spare for BCU,BCPU - Each Control and Relay panel BCU must have 20% (Basic +

20% Spare) of the particular bay DI/DO signals as a spare should be available.

Panel Size & Hardware Capacity - The RTU panel sizing should be capable of

accommodating additional 50% of the basic I/O counts by way of addition of hardware such

as modules, racks, panels, Terminal Blocks of basic I/O counts.

Software Capacity - The RTU software and database generation should be sized to

accommodate for additional 50% of the basic I/O count without requiring software or

database regeneration or License.

2.6.2 Remote database, downloading of RTU from master station/SCADA control center.

2.6.3 RTU shall have the capability of automatic start-up and initialization following restoration of

power after an outage without the need for manual intervention. All restarts shall be reported

to the connected master stations.

2.6.4 Act as a data concentrator on IEC60870-5-101/104/MODBUS/IEC 61850 protocols and

Support for IEC 60870-5-103, IEC 60870-5-101, IEC 61850/MODBUS protocols & ability to

act as a gateway for Numerical relays.

2.6.5 Security

As the SCADA system will use public domain, such LAN/VSAT/GPRS/CDMA etc. therefore it

is mandatory to guard the data/ equipment from intrusion/damage/breach of security & shall

have SSL/VPN based security.

2.6.6 Internal battery backup to hold data in SOE buffer memory & also maintaining the time &

date.

2.6.7 RTU must have the capability of time synchronization with a GPS receiver and the GPS at

the control room will be used for this synchronization purpose. In case of failure of the GPS

receiver, the RTUs time synchronization should be through the Master’s SCADA clock.


2.6.8 GPS for Time Synchronization - The RTU must have inbuilt (or) external GPS with antenna

& internal real time clock to synchronize the IEDs connected to it over their respective

protocol.

2.6.9 Main Processor(CPU in RTU) HOT Retundancy for MCC & BCC communication

Main processor (DCU) /RTU should have adequate capacity for data handling / processing

and main processor/CPU must have required number of communication ports for

simultaneous communication with Master Stations (MCC & BCC), /MFTs and RTU

configuration & maintenance tool.RTU main processor must have HOT redundancy cards

and features for control center communications.

2.6.10 Hot Standby/Dual Power Supply Unit & Redundancy in power source for RTU and BCU/BCPU - Possibility to increase the RTU,BCU main rack availability by having a second

power supply card in case the first one fails , if any one Power supply card fails the other one should keep the system continuous live.

2.6.11 CPU/RTU Soft Configuration Future (Communicate to multiple master stations simultaneously on IEC60870-5-104.)

RTU/DAU must have multiple location (minimum 5 Locations) data transmission facility VAZ

Master Control Centre, Backup Control Centre, etc.

2.6.12 Protection Devices for RTU,BCPU – All modules (all Digital, Analog Input modules) and

ports (Serial and Ethernet ports) must have in-built or external surge protection devices

and optical isolation

2.6.13 Diagnostic Software & Multi user tool/License for RTU/(Numerical Relay) BCU -

Diagnostic Software tool with licensed version shall be provided to continuously monitor the

operation of the RTU and report RTU hardware errors to the connected master stations. The

software shall check for memory, processor, and input/output ports errors and failures of

other functional areas defined in the specification of the RTU. If any system tries to connect

to RTU for download/ Upload files,itshould be stored as a log in RTU.

2.6.14 RTU Panels

At least 50% of the space inside each enclosure shall be unused (spare) space that shall be

reserved for future use. The Contractor shall provide required panels conforming to IEC 529

for housing the RTU modules/racks, relays etc. and other required hardware. The panels

shall meet the following requirements:


Shall be free standing, floor mounted and height shall not exceed 2200 mm.

All doors and removable panels shall be fitted with long life rubber beading.

All non load bearing panels/doors ,top and bottom portion, rear cover shall be fabricated

from minimum 2.0 mm thickness steel sheet and all load bearing panels, frames, top &

bottom panels shall be fabricated from minimum 3.0 mm thickness steel sheet.

Shall have maintenance access to the hardware and wiring through lockable full height

doors.

Shall have the provisions for bottom cable entry.

All panels shall be supplied with 230V AC, 50 Hz, single-phase switch and 15/5A duplex

socket arrangement for the maintenance.

All panels shall be provided with an internal maintenance lamp, space heaters and gaskets.

All panels shall be indoor, dust-proof with rodent protection, and meet IP54 class of Ingress

protection.

FAN with Filters for RTU panel cooling.

There shall be no sharp corners or edges. All edges shall be rounded to prevent injury.

Document Holder shall be provided inside the cabinet to keep test report, drawing,

maintenance register etc.

All materials used in the enclosures including cable insulation or sheathing, wire troughs,

terminal blocks, and enclosure trims shall be made of flame retardant material and shall not

produce toxic gases under fire conditions.

2.6.15 RTU Grounding

The safety ground shall be isolated from the signal ground and shall be connected to the

ground network. Safety ground shall be a copper bus bar. The contractor shall connect the

panel’s safety ground to the grid grounding network. Separate grounding is created for

communication equipments and Signal ground shall be connected to the communication

equipment signal ground.

2.7 Ethernet /Fiber Switch

The Ethernet/Fiber optic switches Should be a managed switch and are intended to be

installed in the control room and shall be complaint to IEC-61850 electrical substation

networks and IEEE 1613 standards. Provisions for additional feeders on the Ring

Configuration should be provided on the same switch.


Laying of Ethernet/Fiber cables for relay/BCU port to the RTU via switch through conduit pipe

and integration with an RTU shall be in Vendor’s Scope.

Switch, Standard Features

Switch design should withstand for power substation automation applications that operate in

extremely harsh environments (High and medium voltage S/Stn environments) and it also

withstands vibration, electrical surges, fast transients, electrostatic discharge, and extreme temperatures and humidity.

Switch features and configuration should be easy to user interface and it must directly

integrate with any other IEC-61850 devices.

The FO switch shall support Multimode fiber and single mode fiber in 10/100Mbps and 1000

Mbps ports on an SFP (simple form factor pluggable), for ease of functionality and

maintenance.

Hot Standby/Dual PSU & Redundancy in power source - Possibility to increase the switch

availability by having a second power source in case the first one fails & should be available

with 48VDC.Each PSU should be connected with a different power source, if any one power source or Power supply card fails the other one should keep the switch continuous operation.

20% Spare ports - Each switch must have 20% spare ports for future/back up

requirements.

Link Failure contact alarm - Failure contact alarm shall be achieved by hardware contact

that is activated when a link problem occurs.

Logs and alarms with Time Stamp - Statistics about link status alarms are to be stored with

the accurate timestamp duly tracing all events.

Advanced security features - The FO switches shall support different user levels with

different passwords, including the facility to work with different VLANs, following the

802.1Q standard, port security based on MAC addresses, possibility to disable unused ports,

authentication protocols shall be provided.


High Speed Implementation of RSTP protocol - The FO switches shall support STP and

RSTP protocols, and shall facilitate for recovery and the fault recovery times shall be within 5

-10msec per switch, always fulfilling the RST protocol.

Time Synchronization to RTU/Server and Connected IED/BCU - The FO switch shall

have an internal clock and shall be synchronized from a network SNTP/NTP server, so all

time stamped events shall be with a reliable time reference.

Tools with License - Diagnostics tool, other necessary tools with a multi user license to be

provided along with the switch.

Mounting Options - Switch should be DIN Rail Mountable & also need to quote for Optional

Wall/Rack Mountable kit.

Local USB port for emergency boot is Mandatory.

Network based distributed security by having a firewall on each port of the switch for all the

standard Industrial protocols like MODBUS, IEC-101, IEC-104, DNP3, IEC-103, IEC-61850

should be available.

The FO switch shall have the facility of Port mirroring and the user shall configure one port to

replicate traffic flows of different ports, so the system administrator can monitor the incoming,

outgoing, or all kinds of traffic that is going through the ports under study.

ITU-T G.8032 support for Ethernet Ring redundancy, ensuring fast failure detection is

preferred.

They FO switches shall sustain the stringent levels in temperature range and

electromagnetic immunity defined in the 61850-3, but also the advanced functional

requirements defined for operation with other IEC-61850 devices. The Switch should be

certified on IEC-61850, functional & Environmental specifications by KEMA.

The FO switches shall have advanced security features to be implemented to avoid

unauthorized access to the system Such as RADIUS/TACACS & VPN gateway support with

IP Sec & SSH.


2.8 SIGNAL LIST (11/33/66KV)

List of Abbreviations

AI ‐ Analog Input/Analog Values MV ‐ Measured Value MFM ‐ Multi Function Meter DCO ‐ Double Command Output DPI ‐ Double Point Indication SCO ‐ Single Command Output SPI ‐ Single Point Indication RTU ‐ Remote Terminal Units BCU ‐ Bay Control Units

Signals ‐ 11KV Out Going Feeders Digital

Input/AI soft through N.Relay/BCU

Digital Out Put soft through N.Relay/BCU

Digital Input Hard Wire to RTU

Additional signals Hard wire to RTU for backup

Signal Type

N.Relay

Protocol

Breaker ON √ Breaker OFF

√ √ DPI

Trip Ckt Healthy √ SPI Spring Charge √ SPI Breaker in service √ SPI Breaker in Test SPI Auto Trip(86) Operated √ √ SPI Panel DC Fail √ SPI L/R Switch in Local SPI L/R Switch in SCADA

√ √ SPI

Relay Int Fault. √ SPI Over Current Operated √ SPI Earth Fault Operated √ SPI BKR Close COMMAND BKR Open COMMAND

√

√ DCO

AutoTrip(86) relay reset from Remote √ SCO

3Phase R,Y,B ‐ Current & Voltage,Active Power,Reactive Power,Power Factor,Max.Demand,Neu.Current

√

AI/MV

Fault current and phase indication of faulty phase viz. R,Y,B, Earth, Unbalance(O/C & E/F Relay).Disturbance Records, Fault Graphs for Remote diagnosis purpose

√

AI

Total Signals ‐ BCPU & RTU 11 DI + Analog , Measurand Values

3 DO 2DI 5DI + 2 DO

Essential inbuilt Spare in BCPU,BCU 3 DI 2 DO

IEC‐61

850


Signals ‐ 11KV Incomers Digital Input/AI soft through N.Relay/BCU


Digital Input/Output Hard Wire to RTU


Signal Type

N.Relay

Protocol


√ √

DPI

Trip Ckt Healthy √ SPI Spring Charge √ SPI Breaker in service SPI Breaker in Test

√ SPI

Auto Trip(86) Operated √ √ SPI VT fuse Blown ‐ Metering. √ SPI VT fuse Blown ‐ Protection √ SPI Panel DC Fail √ SPI L/R Switch in Local SPI L/R Switch in SCADA

√ √ SPI

Relay Int Fault. √ SPI Over Current Operated(All stages) √ SPI Earth Fault Operated (All stages) √ SPI Under Voltage Prot.Operated √ SPI Over Voltage Prot.Operated √ SPI REF Operated √ SPI BKR Close COMMAND √ BKR Open COMMAND

√ √ DCO

AutoTrip(86) relay reset from Remote √ SCO

3Phase R,Y,B ‐ Current & Voltage,Active Power,Reactive Power,Power Factor,Max.Demand,Neu.Current

√

AI/MV

Fault current and phase indication of faulty phase viz. R,Y,B, Earth, Unbalance(O/C & E/F Relay).Fault voltage and phase indication of faulty phase viz. R,Y,B (Voltage Protection Relay). Disturbance Records, Fault Graphs for Remote diagnosis purpose

√ AI


3 DO 2DI 5DI + 2 DO


IEC‐61

850


Signals ‐ 11KV Bus Coupler

Digital Input/AI soft through N.Relay/BCU




Signal Type N

.Relay

Protocol


√ √ DPI


√ SPI

Auto Trip(86) Operated √ √ SPI Panel DC Fail √ SPI L/R Switch in Local SPI L/R Switch in SCADA

√ √ SPI

Relay Int Fault. √ SPI PT MCB ‐ Metering operated √ SPI PT MCB ‐ Protection operated √ SPI Over Current Operated √ SPI Earth Fault Operated √ SPI BKR Close COMMAND BKR Open COMMAND

√

√ DCO

Fault current and phase indication of faulty phase viz. R,Y,B, Earth, Unbalance(O/C & E/F Relay).Disturbance Records, Fault Graphs for Remote diagnosis purpose

√

AI

Total Signals ‐ BCPU & RTU 13DI + Analog , Measurand Values

3 DO 2DI 5DI + 2 DO


IEC‐61

850

Signals ‐ 11KV Capacitors Digital Input/AI soft through N.Relay/BCU



Additional signals Hard wire to RTU for backup Signal

Type

N.Relay

Protocol

Breaker ON √

Breaker OFF √

√ DPI Bank ISO ON Bank ISO OFF

√ DPI


√ SPI

Master Trip(86) Operated √ √ SPI Bus PT fuse Blown ‐ Metering. √ SPI Bus PT fuse Blown ‐ Protection √ SPI Panel DC Fail √ SPI L/R Switch in Local SPI L/R Switch in SCADA

√ √ √ SPI

Over Current Operated √ SPI

IEC‐61

850


Earth Fault Operated √ SPI Under Voltage Prot.Operated √ SPI Over Voltage Prot.Operated √ SPI Neg.Phase.sequence Operated √ SPI Timer Relay operated/Normal √ DPI Relay Int Fault. √ SPI BKR Close COMMAND BKR Open COMMAND

√

√ DCO

BANK ISO OPN BANK ISO CLS

√ DCO

Master trip (86)reset from remote √ SCO 3Phase R,Y,B ‐ Current&Voltage,Reactive Power,Neu.Current

√ AI/MV

Fault current and phase indication of faulty phase viz. R,Y,B, Earth, Unbalance(O/C & E/F Relay).Fault voltage and phase indication of faulty phase viz. R,Y,B (Voltage Protection Relay). Disturbance Records, Fault Graphs for Remote diagnosis purpose

√

AI


5 DO 2DI 5DI + 2 DO


Signals ‐ 33 & 66KV Incomers/Out Going Digital Input/AI soft through N.Relay/BCU



Additional Spare signals (Hard wire to RTU for backup)

Signal Type

Protocol


√ √

DPI

Front Bus (89A) ISO ON(In‐Case of O/D) Front Bus (89A) ISO OFF (In‐Case of O/D)

√

DPI

Rear Bus (89B) ISO ON (In‐Case of O/D) Rear Bus (89B) ISO OFF (In‐Case of O/D)

√

DPI

LINE ISO (89L) ON (In‐Case of O/D) LINE ISO (89L) OFF (In‐Case of O/D)

√

DPI

Earth Switch (89LE) ‐1 ON (In‐Case of O/D) Earth Switch (89LE) ‐1 OFF (In‐Case of O/D)

√

DPI

Earth Switch (89LE) ‐ 2 ON (In‐Case of O/D) Earth Switch (89LE) ‐ 2 OFF (In‐Case of O/D)

√

DPI

Breaker in service (In‐case of I/D BKR) √ SPI Breaker in Test (In‐case of I/D BKR) √ SPI Trip coil Ckt Healthy ‐ 1 & 2 √ SPI Spring Charge √ SPI Master trip(86) Operated √ √ SPI SF6 Pressure Low & SF6 Lock Out √ SPI VT fuse Fail √ SPI Panel DC Fail √ SPI

IEC‐61

850


L/R Switch in Local √ L/R Switch in Remote √ √

DPI

LBB Operated √ SPI Relay Int Fault. √ SPI Over Current Operated (All stages) √ SPI Earth Fault Operated (All stages) √ SPI DIFF.Prot Operated √ SPI DIST.Ptot Operated √ SPI BKR CLS COMMAND √ BKR OPN COMMAND

√ √

DCO

Front Bus (89A) ISO OPNCOMMAND (In‐Case of O/D)

Front Bus (89A) ISO CLS COMMAND (In‐Case of O/D)

√

DCO

Rear Bus (89B) ISO CLS COMMAND (In‐Case of O/D)

Rear Bus (89B) ISO OPN COMMAND (In‐Case of O/D)

√

DCO

LINE ISO (89L) OPN COMMAND (In‐Case of O/D)

LINE ISO (89L) CLS COMMAND (In‐Case of O/D)

√

DCO

Master Trip(86) relay reset from Remote √ SCO

3Phase R,Y,B ‐Current&Voltage,Active&Reactive Power,PowerFactor,Max.Demand,Neu.Current etc √ AI/MV

Fault current and phase indication of faulty phase viz. R,Y,B, Earth, Unbalance(O/C & E/F Relay).Fault voltage and phase indication of faulty phase viz. R,Y,B (Voltage Protection Relay). Fault Differential and Bias current in Line and Transformer Differential Relay ,Fault distance (in Distance Relay) ,Disturbance Records, Fault Graphs for Remote diagnosis purpose

√ AI


9 DO 2DI 5DI + 2 DO


Signals ‐ 33 & 66KV Transformer Digital Input/AI soft through N.Relay/BCU




Signal Type

Protocol


√ √

DPI


√

DPI


√

DPI

TRF ISO (89T) ON (In‐Case of O/D) √ DPI

IEC‐61

850


TRF ISO (89T) OFF (In‐Case of O/D) Earth Switch (89LE) ‐1 ON (In‐Case of O/D) Earth Switch (89LE) ‐1 OFF (In‐Case of O/D)

√

DPI

Earth Switch (89LE) ‐ 2 ON (In‐Case of O/D) Earth Switch (89LE) ‐ 2 OFF (In‐Case of O/D)

√

DPI

Breaker in service (In‐case of I/D BKR) Breaker in Test (In‐case of I/D BKR)

√

DPI

Trip coil Ckt Healthy ‐ 1 & 2 √ SPI Spring Charge √ SPI Auto Trip(86) Operated √ √ SPI Differential Operated √ SPI LBB Operated √ SPI REF/SEF Prot Operated √ SPI SF6 Pressure Low & SF6 Lock Out √ SPI Panel DC Fail √ SPI L/R Switch in Local √ L/R Switch in Remote √ √

DPI

Relay Int Fault. √ SPI Over Current Operated √ SPI Earth Fault Operated √ SPI BKR CLS COMMAND √ BKR OPN COMMAND

√ √

DCO



√

DCO



√

DCO

Trf ISO (89T) OPN COMMAND (In‐Case of O/D)

Trf ISO (89T) CLS COMMAND (In‐Case of O/D)

√

DCO

Mastertrip (86) relay reset from Remote √ SCO 3Phase R,Y,B ‐Current&Voltage,Active&Reactive Power,PowerFactor,Max.Demand,Neu.Current √ AI/MV


√ AI


9 DO 2DI 5DI + 2 DO



Transformer ‐ RTCC/A‐Eberle Signals Digital Input/AI soft through TMM

Digital Out Put soft through TMM


Analog Input soft through TMM

Signal Type

Protocol

A‐Eberle Unit Faulty/DC Fail √ SPI Oil Temp Alarm √ SPI Oil Temp trip √ SPI Winding Temp Alarm √ SPI Winding Temp Trip √ SPI Buchholz Alarm √ SPI Buchholz Trip √ SPI PRV TRIP √ SPI OLTC OSR √ SPI MOG/LOW Oil level Alarm √ SPI SPR Trip √ SPI OSR Main Tank √ SPI L/R Switch in Local √ L/R Switch in Remote √

DPI

Auto Mode √ Manual Mode √

DPI

Fan Fail √ SPI Tap Changer Fail √ SPI OLTC Out of Step/Stuck Up/Motor trip √ SPI

Tap Rise/Tap Low Command √ Tap Rise/Tap Low Command √

DCO/RCO

Oil Temp √ AI Winding Temp √ AI Tap Position √ AI

Total Signals ‐ BCPU & RTU 19 DI 2 Command 1 DI 3 Analog , Measurand Values


IEC‐61

850

Signals ‐ 33 & 66KV BusCoupler Digital Input/AI soft through N.Relay/BCU




Signal Type

Protocol


√ √

DPI


√

DPI


√

DPI

Earth Switch (89AE‐1) ‐ ON (In‐Case of O/D) √ Earth Switch (89AE‐1) ‐ OFF (In‐Case of O/D)

DPI

Earth Switch (89AE‐2) ‐ ON (In‐Case of O/D) Earth Switch (89AE‐2) ‐ OFF (In‐Case of O/D)

DPI

Earth Switch(89BE‐3) ‐ ON (In‐Case of O/D) √ Earth Switch(89BE‐3) ‐ OFF (In‐Case of O/D)

DPI

Earth Switch(89BE‐4) ‐ ON (In‐Case of O/D) Earth Switch(89BE‐4) ‐ OFF (In‐Case of O/D)

DPI

IEC‐61

850


Breaker in service (In‐case of I/D BKR) Breaker in Test (In‐case of I/D BKR)

√

DPI

Trip coil Ckt Healthy ‐ 1 & 2 √ SPI Spring Charge √ SPI Auto Trip(86) Operated √ √ SPI SF6 Pressure Low √ SPI SF6 Lock Out √ SPI VT fuse‐1 Blown √ SPI VT fuse‐2 Blown √ SPI Panel DC Fail √ SPI L/R Switch in Local √ L/R Switch in Remote √ √

DPI

LBB Operated √ SPI Relay Int Fault. √ SPI Over Current Operated (All stages) √ SPI Earth Fault Operated(All stages) √ SPI BKR CLS COMMAND √ BKR OPN COMMAND

√ √

DCO



√

DCO



√

DCO

AutoTrip(86) relay reset from Remote √ SCO 3Phase R,Y,B ‐ Current ,BUS PT‐01 & BUS PT02 3Phase votages. √ AI/MV


√ AI


9 DO 2DI 5DI + 2 DO



Signals ‐ 33 & 66KV CAP Bank Digital Input/AI soft through N.Relay/BCU




Signal Type

Protocol


√ √

DPI


√

DPI


√

DPI

CAP Bank ISO ON (In‐Case of O/D) CAP Bank ISO OFF (In‐Case of O/D)

√

DPI

Earth Switch ON (In‐Case of O/D) Earth Switch OFF (In‐Case of O/D)

√

DPI

Trip coil Ckt Healthy ‐ 1 & 2 √ SPI Spring Charge √ SPI Auto Trip(86) Operated √ √ SPI SF6 Pressure Low & SF6 Lock Out √ SPI VT fuse Blown √ SPI Cap Discharge Time √ SPI Netural Displacement √ SPI Panel DC Fail √ SPI L/R Switch in Local/Remote √ √ DPI LBB Operated √ SPI Relay Int Fault. √ SPI Over Current Operated √ SPI Earth Fault Operated √ SPI Under Voltage Prot.Operated √ SPI Over Voltage Prot.Operated √ SPI BKR CLS COMMAND √ BKR OPN COMMAND

√ √

DCO



√

DCO



√

DCO

CAP Bank ISO OPN COMMAND ( In‐case of O/D)

CAP Bank ISO CLS COMMAND ( In‐case of O/D)

√

DCO

3Phase R,Y,B ‐ Current&Voltage,Reactive Power,Neu.Current √ AI/MV

IEC‐61

850



√ AI


9 DO 2DI 5DI + 2 DO


Signals ‐ BUS PT‐1&2 Digital Input/AI soft through N.Relay/BCU




Signal Type

Protocol

BUS A (89A) ON BUS A (89A) OFF

√

DPI

BUS B (89B) ON BUS B (89B) OFF

√

DPI

Earth Switch (89LE) ‐ 1 ON Earth Switch (89LE) ‐ 1 OFF

√

DPI

Earth Switch (89LE) ‐ 2 ON Earth Switch (89LE) ‐ 2 OFF

√

DPI

BUS‐A ISO OPN COMMAND BUS‐A ISO CLS COMMAND

√

DCO

BUS‐B ISO OPN COMMAND BUS‐B ISO CLS COMMAND

√

DCO

Total Signals ‐ BCPU & RTU 8 DI 4 DO

Essential Spare in BCPU,BCU 2 DI 1 DO

IEC‐61

850

Signals ‐ Smoke Detector ‐ ALL Sensors,Manual Call Points Integration with RTU over MODBUS TCPIP Protocol.

Soft Signals Signal Type

Protocol

All Sensors Alarm operated Signals ( 10 to 20 Sensors)

√ SPI

All Manual Call Points ‐ MCP‐1,MCP‐2.etc… √

SPI MODBUS TCP/IP Protocol.


Signals ‐ Battery Charger

Digital Input/AI soft through RTU


Signal Type

Protocol

Battery CHG Mains AC Fail √ SPI Charger A AC MCCB Trip √ SPI Charger A DC MCCB trip √ SPI Charger B AC MCCB Trip √ SPI Charger B DC MCCB Trip √ SPI

Charger A/B In boost √ SPI Charger A /B rectifier Capacitor Fuse Blown √ SPI Battery MCCB Trip

DC system Earth √ SPI Insulation fault √ SPI Charger A Current √ AI Charger A Voltage √ AI Charger B Current √ AI Charger B Voltage √ AI Battery Current √ AI Battery Current √ AI

Modbus

Signals ‐ LT Board Digital Input

Hard Wire to RTU

MFM data through Modbus protocol

Signal Type

LT AC Fail √ SPI R,Y,B Phase Current √ AI

Signals ‐ Fire Fighting(All Transformers)


Signal Type

SYSTEM OPERATED √ SPI SYSTEM OUT OF SERVICE √ SPI TCIV CLOSED √ SPI FIRE DETECTOR TRIP √ SPI N2 CYLINDER PRESSURE LOW √ SPI FIRE SYSTEM ALARM √ SPI DC SUPPLY FAIL √ SPI

MFM ‐ BUS PT ‐1 ,2 Signals (Front & Rear BUS)

Data Type Protocol

R‐Phase Current MV/MFI Y‐Phase Current MV/MFI B‐Phase Current MV/MFI

Modbus


Neutral Current MV/MFI R‐Y Phase Voltage MV/MFI Y‐B Phase Voltage MV/MFI B‐R Phase Voltage MV/MFI

MFM ‐ Signals ‐ All Feeders (Including Bus Section/Coupler)

Data Type Protocol

R‐Phase Current MV/MFI Y‐Phase Current MV/MFI B‐Phase Current MV/MFI Neutral Current MV/MFI R‐Y Phase Voltage MV/MFI Y‐B Phase Voltage MV/MFI B‐R Phase Voltage MV/MFI Active Power MV/MFI Active Energy MV/MFI Reactive Power MV/MFI Power Factor MV/MFI Maximum Demand MV/MFI Phase angle 1 MV/MFI Phase angle 2 MV/MFI Phase angle 3 MV/MFI THD Mean Current MV/MFI THD Mean Voltage MV/MFI

Modbus

2.8.1.Comments - Analog signals (Fault Current levels,Disturbance records, Fault graphs for remote diagnosis, etc,)

from Numerical relays needs to be confirmed by vendor before finalize the tender documents.

All the above mentioned signals are compulsory and additional signal (10%) will be considered

during detailed engineering.

Following indications data format should be configured as a DPS (Double point Status) in

Relay(BCPU).

• All Feeders Circuit Breaker ON & Circuit Breaker OFF

• All Feeders BUS Isolators (89A,89B,89L,89T) - ON & OFF

• All Earth Switches ON & OFF

Following command data format should be configured as a DPC (Double point control) in

Relay(BCPU). • All Feeders Circuit Breaker - Open & Close

• All Feeders BUS Isolators (89A,89B,89L,89T) - Open & Close


• All Earth Switches – Open & Close.

3.0 Key Points -

1 All SCADA equipments viz DAU / DCU, MFM, Battery Charger, A-Eberle relays, etc. Should be

powered through auxiliary supply of 48 V DC.

2 Space for Energy Meter – Only Space (Length - 185 mm & Height - 256 mm with CT, PT, Auxiliary Supply terminals & wiring) without cut out is required to install energy meters.

3 Power Supply for Routers/ Gateway (IT Equipments) through an existing battery bank via DC to

DC Converters (Input: 48 VDC/220 VDC, Output: 12 Volt DC) or as per the requirements of

Routers.

4 Any other wiring / cabling if required due to non availability of serial communication

/MODBUS/IEC 61850 protocols (with justified reason) should be hardwired and that is in

Contractor’s scope.

5 Suitable transducers with an output of 4-20 mA have to be installed in the RTCC /Battery

charger if required and the outputs of these transducers should be extended to terminal for

further extension to the RTU.

6 The C & R ,RTCC,Battery Charger Panel should have additional spare contacts (potential free)

for all SCADA signals – Refer Signal List 2.8

7 Warranty (5 Years) for SCADA products - All Supplied SCADA material should cover

warranty for the duration of 5 years & Warranty period will start after successful commissioning of the SCADA equipments at site. If any SCADA materials found faulty

during warranty period should be replaced within two weeks.

8 Training should be provided on configuration, installation, commissioning aspects of

RTU,DCU,BCU and Numerical Relay - BCPU at your training/work center to the BSES SCADA

team (3 to 4 persons approx) & Training Expenses (Air & Local Travel, boarding and

Lodging for 3 to 4 persons) at factory/training center(4 days) comes under Vendor’s scope.

9 FAT expenses for BSES SCADA team (2 Persons) – Air & Local Travels, boarding and

Lodging to be arranged by vendor during FAT inspections.Complete expenditure (Air & Local

Travel, boarding and Lodging) comes under vendor scope.

10 Loose Spares (5%) - loose Spare Materials for following items with below mentioned quantity

to be supplied for emergency back up/maintenance purpose.


• CPU (Main Processor) Card in DCU – 1 No

• CPU in Bay Control Units – 5% of supplied qty.

• Communication Extended Module/Serial Ports for Modbus & IEC-103 protocols– 5%

• DO Contactots – 5% of supplied qty.

• DI/DO/AI/ Cards – 5% of the total IO signals

• PSU Cards in RTU – 5% of supplied qty.

• PSU Cards in Switches – 5% of supplied qty.

• Ethernet Switches – 2 No’s

• LIU Unit – 1 No

• Fiber Optic Patch Cards with Connectors - 10% of total installed cables.

• MFM – 5% of Supplied Qty.

• DC to DC converters if any for RTU Supply – 1 No.

11 Protection devices for all SCADA Equipmentes –

• Surge Protection devices installation between RTU & MFM Serial loops.

• All modules (All Digital, Analog Input modules in BCPU and RTU) and ports (Serial and Ethernet ports) must have in-built or external surge protection devices and optical

isolation.

12 All the above features are indicative only and detailed engineering and deviation will be

analyzed just before actual procurement and with discussion through a supplier/ vendor.

4.0 System Architecture Diagram

The Tentative System Architecture diagram is enclosed for reference.

5.0 DEVIATIONS

Deviation from this specification, if any, shall be clearly brought out in the offer. Unless the

owner explicitly accepts such deviations, it shall be considered that the offer fully complies with

the specification.

85E:5 Technical Specification for

66 kV 3-CORE CABLE

Specification no - SP-EWH2-3C-OO

Preparep by: Checked by : I Approved by: Rev Date

Name Sign I Name I Si9{l7 1)Nal)1e I Sign

~--NI~ r1\. ~~ l\~J/ Supriya f? IMeenakshN .~r \ I K.K.Alla !~\JP o 03.09.2014

L ,

Page I of 19

-

66 kV 3-CORE CABLES– SP-EWH2-3C-00

___________________________________________________________________________________________ Page 2 of 19

1.0 Scope

This specification covers technical requirements of design, manufacture, testing at manufacturer’s works, packing, forwarding, supply and unloading at stores/site, performance of 66 kV 3Cx300 sq. mm cable complete with all accessories for trouble free and efficient operations.

2.0 Applicable Standard

The equipment covered by this specification shall unless otherwise stated, be designed, manufactured and tested in accordance with latest revisions of relevant Indian Standards /IEC and shall conform to the regulations of local statutory authorities. Indian Standards

IS 7098 (Part-3)-1993

Specification for Cross-linked polyethylene insulated PVC sheathed Cables Part: 3 - For working voltages from 66 kV upto and including 220 kV

IS 8130-1984 Specification for Conductor for insulated electric cables & flexible Cords

IS 5831-1984 Specification for PVC insulation and sheath of electric Cables

IS : 3975 -1999 Mild steel wires, formed wires and tapes for Armouring of Cables

IS: 5216 Guide for Safety procedures and practices in electric works

IS: 10418-1982 Specification for Drums for Electric Cables

IEC Standards IEC-60228: 2004 Conductor for insulated cables IEC-60502 (Part-2): 2005

Power cables with extruded insulation and their accessories for rated voltages for rated voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um= 36 kV)

IEC-60811: 1990 Test methods for insulations and sheaths of electric cables and cords. IEC 60840: 2004 Power cables with extruded insulation and their accessories. Test

methods and requirements. 3.0 Cable Design Features

S.NO DESRIPTION REQUIREMENT 3.1 Manufacturing

process The cable shall be manufactured by “Triple head extrusion process”. The conductor screen, Insulation & Insulation screen shall all be extruded in tandem to ensure homogeneity and reduction of voids, in the insulation and the screening system of the cable, whereby enhancing the life of the cable. The cable shall be strictly manufactured by “Dry Cured and Dry-Cooled” process.


___________________________________________________________________________________________ Page 3 of 19

3.2 Conductor Electrolytic grade Aluminum conductor shall H2 grade, class-2 in accordance with IS 8130/IEC 228. The shape of conductor shall be compacted, stranded, and circular.

3.3 Longitudinal water sealing of conductor

Shall be achieved by water swelling yarns/tapes in the interstices of the conductor. The fiber/yarn shall turn into jelly/swell, when in contact with water making the conductor water tight as per IEC 60502-2.

3.4 Semi conducting water blocking tape

Semi-conducting water blocking tapes shall be applied over the conductor, suitable for continuous operating conductor temperature of 90 deg C.

3.5 Conductor Screen

The conductor screen shall consist of extruded semi conducting compound which shall be fully compatible with the conductor and extruded insulation. Outer surface of semiconductor screen shall be super smooth, and firmly bonded to the overlaying insulation. The minimum Thickness of conductor screen shall be 0.8 mm

3.6 Insulation The extruded XLPE insulation shall TREE-RETARDANT and of very high degree of purity with nominal thickness of 11 mm. The minimum thickness at any point shall not be less or more than 10% of the nominal value. Percentage eccentricity of the insulation shall not be more than 10%. The insulation properties shall be stable under Thermal conditions arising out of continuous operation at conductor temperature of 90 deg C rising momentarily to 250 Deg C under short circuit conditions.

3.7 Insulation Screen

The insulation screen shall consist of extruded semi conducting Compound which shall be fully compatible with extruded insulation. Insulation screen shall be firmly bonded to the insulation The minimum Thickness of insulation screen shall be 0.8 mm

3.8 Make of insulation and semi conducting screen

TR-XLPE of Dow or Borealis (any deviation to above shall not be acceptable unless and until it has been specially approved by BSES prior to sourcing of compounds and manufacturing of cable).

3.9 Core The ovality of the core shall not be more than 5%.

3.10 Inner Longitudinal water sealing bedding

Semi-conducting water swellable tapes shall be applied over the extruded semi-conducting core screening. Nominal Thickness of the Swellable Tape = 0.3 mm The swell speed shall be greater 12mm/minute

3.11 Metallic Screen The metallic Screen shall consist of a layer of annealed copper tape of minimum 0.1mm thickness and shall be applied over the


___________________________________________________________________________________________ Page 4 of 19

semi-conducting water-swellable tape with minimum 10% overlap.

3.12 Inner Longitudinal water sealing bedding (2nd layer)

Semi-conducting water swellable tapes shall be applied over the metallic screen again with a minimum overlap of 10 %. Nominal Thickness of the Swellable Tape = 0.3 mm The swell speed shall be greater 12mm/minute

3.13 Core Identification

Cores shall be identified by coloured strips (Red, Yellow, Blue), applied helically / longitudinally over the copper tape. The coloured strips shall carry the name of manufacturer permanently printed at close intervals; this is to provide additional identification of manufacturer of the cable.

3.14 Optical Fiber Cable (as one of the fillers)

30-Fiber optical Fiber cable, with such a construction to facilitate to continuously operate at 80 deg C to be used without any increase in loss beyond permissible limit. The cable manufacture to give confirmation from the optic-fiber manufacturer that the proposed construction is suitable to operate continuously at 80 deg C The OF cable will have:

a) 24 Nos Single Mode fiber as per ITU-T G.657. A1 (low bend sensitive) with 12 Nos per loose tube for SCADA/communication

b) 6 Nos Multi Mode Fiber as per OM-2 (50/125) in a single loose tube for optical-DTS

The manufacturer must have adequate acceptance testing facilities of testing optical fiber cable performance of the complete 3-Core Power Cable post manufacturing. The minimum acceptance test would constitute:

1. Length and Continuity of Fiber inside Power Cable 2. Attenuation at defined wavelengths (Refer Annexure E)

3.15 Fillers Balance fillers used in 3-Core cables shall be of Polyethylene

ST7 grade along with sufficient water blocking yarn to make it water tight construction.

3.16 Laying up of Cores

All the 3-Core, along with Fillers, water-blocking yarn and optical fiber cable shall be laid in the suitable right hand lay.

3.17 Inner Sheath Pressure Extruded PE ST7 confirming to requirements of IEC 60502-2 with latest amendments. The minimum thickness of the inner sheath shall be 1.5 mm. A non-conducting water blocking tape with approx. 10% overlap shall be applied over the inner sheath.


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3.18 Armour The armour shall be of galvanized round steel wires of minimum 4 mm dia complying the requirements of IS 3975:1999 with latest amendments. The armour wires shall be applied with minimum 90% coverage. The joints in the armour round wires shall be made by brazing or welding and the surface irregularities shall be removed. A joint in the wire shall be at least 300 mm from the nearest joint in any other armour wire in the completed cable. The short circuit capacity of armour shall be 26.3 kA for 3 second.

3.19 Binder Tape Rubberized cotton tape shall be wrapped with approx. 10% overlap over armour

3.20 Outer Sheath The outer sheath shall consist of extruded black colored HDPE type ST 7 as per IEC 60502-2 with anti termite protection. The minimum thickness shall be 3 mm at any point. Semi conductive layer either extruded or graphite coating shall be provided over the Outer Sheath.

3.21 Cable Rating The cable size shall be suitable to carry rated load current on 66 kV continuously without exceeding the maximum conductor temperature of 90 deg. C.

3.22 Drum Length 250m ± 5 % (short lengths not acceptable except the last length and minimum acceptable short length shall be 100m). The overall quantity tolerance shall be as purchase order. Manufacturer shall not be allowed to put two cable pieces of different short length in same cable drum.

3.23 Embossing The extruded outer sheath shall be embossed with meter marking at interval of 1 metre. The ”A” end meter marking and “Z” end meter marking and the drum lengths shall be printed on the drum flange along with other markings. The outer sheath shall also be embossed with (min.)

a) Voltage designation b) Type of construction/cable code (i.e. A2XW2Y) c) Number of core and nominal cross sectional area. d) Type of cable “Electric Cable”. e) Manufacturers name & trade mark f) Name of buyer (e.g. BSES) g) Month & year of manufacturing h) Batch no / Lot no. i) Sequential length marking. j) Purchase Order Number and Date

3.24 Joints and

Terminations The 3-Core Joints and Terminations to be used with the cable shall be with proven design and fully type tested as per IS 60840. The Joints and Terminations match or exceed all technical


___________________________________________________________________________________________ Page 6 of 19

performance parameters of the specified cable. The Joints and Terminations would be either Heat Shrink, Cold-Shrink or Pre-moulded type. The Joints and Terminations should have provision for splicing/terminating Optical Fiber Cable and manufacturer to give design for the same along with bid.

4.0 Quality Assurance

4.1 Vendor quality plan To be submitted for purchaser approval 4.2 Inspection points To be mutually identified & agreed in quality plan

5.0 Inspection & testing

5.1 Routine test Each drum length of cable shall be subjected to the following tests

- Measurement of the electrical resistance of the conductor shall be carried out as per the provisions of Clause 10.5 of IEC 60840/ IS 10810 part 5 The measurement shall be made on the conductors of each cable length. The D.C. resistance of the conductor at 20 deg. C shall not exceed the maximum value specified in IEC 60228 / IS 8130.

- High voltage test as per clause 9.3 of IEC-60840/ 20.17 of IS 7098(Part-3):1993

- Partial discharge test shall be carried out as per clause 9.2 of IEC Publication No.60840/20.10 of IS 7098(Part-3):1993

- Measurement of capacitance as per clause 10.10 of IEC60840/ 20.18 of IS 7098(Part-3):1993

- Measurement of length, continuation and attenuation in Optic Fiber as defined in Annexure – E.

- Test on the outer jacket as per Clause 3 of IEC 60229 The cable and the associated accessories like Joints and Terminations of same voltage, design and number of cores shall be of Type Tested from CPRI/ERDA as per IEC 60840:2004 /IS7098-III:1993 with latest amendments . Type test report of not more than five (5) years shall be submitted for the same type, size and rating of the cable offered, along with the bid.

5.2 Type test

All type tests shall be carried out in accordance with Clause 12 of IEC-60840 / Clause 19.1 of IS 7098-III and in accordance with the sequence prescribed therein.


___________________________________________________________________________________________ Page 7 of 19

5.3 Short Circuit Test of Armour

The bidder shall furnish short circuit test report of 26.3 kA for 3 seconds from CPRI/ERDA for the same voltage, size and design of cable. This short circuit test shall be preceded and succeeded by high voltage, Partial Discharge, Armour Resistance and Conductor Resistance Test. Test report shall not be more than five (5) years old.

5.3 Acceptance Tests

Shall be conducted as per IEC: 60840: 2004 / IS: 7098-III: 1993 and approved QA plan for each lot of cable.

5.4 Special Tests The following tests shall be carried out as special tests

Conductor examination as per Clause 10.4 of IEC-60840 for conformance of IEC 60228/IS 8130.

Measurement of thickness of insulation as per Clause 10.6 of IEC- 60840 and Clause 8 of IEC-60811-1-1./ IS 10810 part 6

Measurement of thickness and overall dimensions as per Clause 8 of IEC-60811-1-1./ IS 10810 part 6

Measurement of dimensions of Armour as per Clause 10.7 of IEC-60840/IS 10810 part 36

Measurement of external diameter as per Clause 8.3 of IEC-60811-1-1

Hot set test for XLPE insulation as per Clause 10.9 of IEC-60840/ IS 10810 Part 30

Degree of cross-linking as per ASTM D 2768-01, void and contamination as per 20.1 of IS 7098 (Part-3), abrasion resistance as per BS 7835

Sheath Integrity Test 5.5 Inspection The buyer reserves the right to witness all tests specified on

completed cables

The buyer reserves the right to inspect cables at the Seller’s works at any time prior dispatch, to verify compliance with the specifications.

In-process and final inspection call intimation shall be given in advance to purchaser.

In the event of any discrepancy in the test reports i.e test reports not acceptable or any type tests(including special / assitional tests,if any) not carried out , same shall be carried out without any cost implication to BSES before dispatch of cable.

5.6 Test certificates Three sets of complete test certificates shall be submitted along with the dispatch documents.


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6.0 Drawings, Data & manuals

The seller has to submit: a) Cross sectional drawing of cable. b) Completely filled GTP c) Type test certificates d) Dimensional drawing for pulling eye e) Fault level calculation f) Complete cable catalogue and manual g) Armour Coverage Calculations

6.1 To be submitted along with bid

f) Short Circuit Test Certificate 6.2 Within 15 days, the seller has to submit four sets of above

mentioned drawings along with one soft copy for buyer’s approval.

6.3 Submittals required prior to dispatch

a) Inspection and test reports, carried out in manufacturer’s works (R)

b) Test certificates of all bought out items.

6.4 Drawing and document sizes


6.5 No. of drwgs. / Documents required at different stages

As per Annexure – A

7.0 Shipping, Handling and Site support

7.1 Packing The cable shall be wound on non-returnable steel drums of

suitable size of minimum hub diameter of 15D (where D is the overall diameter of the cable) and packed conforming to international standards. The drum shall be fully enclosed by suitable packing preferably PP sheeting. Cable shall have sea worthy packing in case cables are dispatched by shipping lines.

7.2 Pulling eye & sealing of Cable ends

A cable pulling eye shall be provided at “Z” end of cable on each drum. Suitable fillings/putty shall be used for sealing gap between outer sheath and pulling eye. Heat shrinkable sleeves with the pulling eye shall also be provided. The pulling eye shall be directly connected to the conductor and be capable to withstand a tensile load of 30N / sq mm of conductor area. The “A” end of the cable shall be sealed with heat shrinkable cap. Drawing of the pulling eye shall be submitted along with the bid for review.

7.3 Drum identification label

The following information shall be marked on the drum:

- Drum identification number. - Trade name or trade mark; if any - Name of manufacturer and buyer


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- Nominal sectional area of the conductor of the cable - Type of cable and voltage for which it is suitable - Length of the cable on the drum, with “A” end and “Z” end

markings. - Purchase order number with SAP item code. - Year and month of manufacturing. - Direction of rotation of drum (an arrow) and - Net weight of cable in drum and gross weight of cable with

drum. - Batch no or Lot no. 7.4 Shipping The seller shall give complete shipping information concerning

the gross weight, size of each packing.

7.5 Handling & Storage

Manufacturer instruction shall be followed. Detail handling & storage instruction sheet / manual needs to be furnished before commencement of supply.

7.6 Transit damage

The seller shall be responsible for any transit damage due to improper packing.

8.0 Progress reporting

8.1 Outline

Document To be submitted for purchaser approval for outline of production, inspection, testing, packing, dispatch, documentation programmer.


To be submitted to Purchaser once a month containing a) Progress on material procurement. b) Progress on internal stage inspection c) Reason for any delay in total program d) Details of test failures if any in manufacturing stages e) Progress on final box up. f) Constraints / forward path

9.0 Deviations

9.0 Deviation from

the Specification.

Deviations from this Specification shall be stated in writing with the tender by reference to the Specification clause/GTP/Drawing and a description of the alternative offer. In absence of such a statement, it will be assumed by the Buyer that the Seller complies fully with this specification.


___________________________________________________________________________________________ Page 10 of 19

Annexure – A: Scope of supply 1.0 The scope of supply shall include following 1.1 Design, manufacture, testing at manufacturer works before dispatch, packing, delivery including unloading and stacking at site/store of 38/66kV 3Cx300 sq. mm cable as per BOQ and submission of all documents. 1.2 BOQ as following –

Sr No

Purchaser Equipment Tag No / SAP code

Material/Equipmentdescription

Location Unit Quantity

1 e.g. Delhi km e.g. 10 2 e.g. Goa km e.g. 10 3 4 5 6 7

2.0 Submission of documents

Along with

offer For Approval after award of

contract

Final after approval

Remarks

Detailed dimensional cross-sectional drawing of the cable

3 copies (Typicaldrgs)

4 copies 6 copies + 1 soft copy in CD

Type test certificates.

2 copies (Type Test, Short Circuit Test

Certificate and sample

Routine Test)

6 copies + 1 soft copy in CD

Type test and sample Routine

test reports

Guaranteed technical particulars of each type of cable

3 copies 4 copies 6 copies + 1 soft copy in CD

Dimensional drawing for pulling eye.

3 copies 4 copies 6 copies + 1 soft copy in CD

Rating factors 3 copies 4 copies 6 copies + 1 soft copy in CD

Complete cable catalogue and Manual

1 copy 6 copies + 1 soft copy in CD


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3 Sec rating calculation for Armour

3 copies (Typical)


Armour Coverage Calculations

3 copies (Typical)


List of Sub-Vendors

3 copies (Typical)


Optic Fiber Cable Manufacturer’s declaration for no increase in losses till 80 deg operations

3 copies (Typical)


Data Sheet of Optic Fiber Cables

a) Single Mode Cable (G 657.A1)

b) Multi Mode Cable

3 copies (Typical)


3.0 Delivery schedule 3.1 Delivery period start date - from date of LOI 3.2 Delivery period end date - as agreed with supplier 3.3 Material dispatch clearance - after inspection by purchaser


___________________________________________________________________________________________ Page 12 of 19

Annexure – B: Service Conditions 1.0.0 Delhi Atmospheric conditions a) Average grade atmosphere : Heavily polluted, dry b) Maximum altitude above sea

Level 1000 M

c) Ambient Air temperature Highest 50 deg C, Average 40 deg C d) Minimum ambient air

Temperature Deg C

e) Relative Humidity 90 % Max f) Thermal Resistivity of Soil 150 Deg.C cm/W g) Seismic Zone 4 h) Rainfall 750 mm concentrated in four months


___________________________________________________________________________________________ Page 13 of 19

Annexure – C: Guaranteed Technical Particulars (Data by Supplier)

Sr. Description Unit Data specified by the

purchaser

Data to be filled by the

manufacturer 1 Name of manufacturer 2 Country of manufacturer 3 Type of cable 4 Standard according to which

cable is manufactured

5 Rated voltage kV 38/66 6 Highest system voltage kV 72.5 7 System frequency Hz 50 8 No of phases per circuit Nos 3 9 System earthing Solidly

Grounded

10 Rated short time current of Conductor

kA

11 Rated short time current of Armour

kA 26.3 for 3 sec

12 Rated short time current of metal screen

kA

13 Rated short time current of armour and screen

kA

14 Duration of short circuit current

Sec 1

15

Impulse withstand voltage 1.2/50 micro sec wave

kVp 325

16 Power frequency withstand Voltage

kV(rms) 95 for 30 minutes

17 Conductor a Nominal cross sectional area sqmm 300 b Type class of conductor. Compacted

Stranded Circular

C Material of conductor Aluminum D Flexibility class of conductor Class -2 E Minimum numbers of strands Nos F Diameter of strands before

compaction. (nominal / Minimum)

Mm / mm

G Material of longitudinal water sealing filling of conductor

18 Details of semi conducting tape over the conductor

19 Conductor Screen a Material and type b Minimum thickness mm 0.8 Make and grade of semi

conducting compound.

20 Insulation


___________________________________________________________________________________________ Page 14 of 19

Material of Insulation TR-XLPE Nominal thickness Mm 11 Minimum thickness 9.9 Make and grade of insulation

Compound

Maximum dielectric stress at the conductor surface

kV/mm

21 Insulation screen a Material and type b Minimum thickness mm 0.8 c Make and grade of semi


22 Inner water swellable semi conducting tape

a Nominal thickness mm

0.3

b Minimum swell height in one minute.

mm

12 mm in one Minute

c Overlap % 10 min 23 Min thickness of copper tape mm 0.1 a width of copper

tape mm

b Overlap of copper tape % 10 min 24 outer water swellable

semiconducting tape

a Nominal thickness mm 0.3 b Minimum swell height in one

minute. mm

12 mm in one

Minute

c Overlap % 10 min 25 Nominal diameter over Laying

up mm

26 a Optic Fibers Cable used as per OF Cable specifications defined

I. No. of Single Mode fiber (G 657.A1)

II. No. of Multi Mode – OM-2

Yes/No

No.

No.

26 b No. & Material of balance fillers

No./material / PE ST 7

27 No. of water blocking yarns and denier

No./material

28 Material of the inner sheath PE ST 7 29 Method of Extrusion mm Pressure 30 Minimum thickness of inner

sheath mm 1.5

31 Nominal diameter over inner Sheath

mm

32 Non conducting water blocking tape over inner sheath


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a Nominal thickness mm 0.3 b Overlap % 10 min 33 Armour Nominal Diameter mm 4 No. of wires Armour coverage Area of Armour Short circuit capacity of

Armour kA/3 sec 26.3

Binder tape over Armour RC tape 34 Outer jacket Material and type HDPE type ST 7 Minimum thickness mm 3 Colour Black 35 Semiconducting coating outer

jacket Extruded/Graphite coating

36 AC test voltage at works for insulation.

kV(rms) 95

37 DC test voltage for outer jacket

kV(DC) 25

38 Overall dia of completed single core cable

mm

39 Weight per metre of complete Cable

kg/m

40 Short circuit capacities with maximum conductor temperature of 250Deg C : (conductor temperature of 90 Deg C at the commencement of short circuit) 0.5 second duration 1 second duration 2 second duration 3 second duration

kA

41 Minimum radius of bend round: which cable can be laid a) Direct burial in ground b) In ducts

mm

42 Maximum D.C .resistance of : conductor per KM at 20 deg. C

Ohm/km

0.100

43 Maximum AC resistance of : conductor per KM at 90 deg. C

Ohm

44 Equivalent star reactance per KM: of 3 phase circuit at 50 Hz

Ohm

Maximum electrostatic capacitance : Per KM of cable

pf


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45 Maximum continuous current carrying : Capacity per circuit when laid in ground as per the following parameters -Maximum continuous conductor temperature of 90Deg C -Maximum conductor temperature during short circuit of 250 Deg C -Ground temperature of 30 Deg C -Soil resistivity of 150 DegCcm/ Watt -Depth of laying of 150cm

Amp

46 Maximum continuous current carrying : Capacity per cable when laid in air with ambient temperature of 40DegC and other parameters as per Sl no 49

Amp

47 Rating factors for ambient air temperature attached(Yes/No)

48 Rating factors for ground temperature attached(Yes/No)

49 Rating factors for phase spacing in flat formation attached(Yes/No)

50 Rating factors for grouping of cable laid in ground in horizontal formation attached(Yes/No)

51 Rating factors for grouping of cable laid in ground in tri-foil touching formation attached(Yes/No)

52 Rating factors for thermal resistivity of soil attached(Yes/No)

53 Rating factors for depth of laying attached(Yes/No)

54 Max. power factor of charging KVA of : cable when laid direct in the ground at normal voltage frequency at conductor temperature at 90Deg .C


___________________________________________________________________________________________ Page 17 of 19

55 Max. dielectric power loss of cable per : KM of 3 phase circuit laid direct in ground at normal voltage, frequency and maximum conductor temperature of 90 Deg C

Watt/km

56 Impedance per KM of 3 phase circuit : at 50 C/s and maximum conductor temperature. a) Positive and negative sequence b) Zero sequence

Ohm

57 Standard drum length of cable

Metres

250 +/- 5% (short lengths not acceptable except the last

length

58 The overall quantity tolerance % 59 Cable to be wound on non

returnable steel drum. Yes / no Yes

60 Normal delivery length Metres 61 Cable pulling Eye to be

provided at “Z” end

62 Tensile load withstand capacity for pulling eye

30 N / sqmm

63 Approximate shipping weight for the normal deliver length with the drum size (flange dia. in mm and width in mm):

kg

64 Drum size ( Flange dia X flange width X hub dia)

65 Embossing details on outer jacket

66 Sequential marking at every meter.

Provided

67 Process of cross linking of polyethylene.

68 Maximum Optic Fiber losses i) Each Joint ii) Per km (excluding

Joint)


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Annexure –D: Cross Sectional Drawing (Data by Supplier) Pictorial Label No.

Reference Clause No

Description Nominal Thickness in mm

Nominal Diameter in mm

1 4.2 & 4.3 Compacted, stranded, circular water blocked aluminium conductor

2 4.4 Semi-conducting water blocking tape

3 4.5 Conductor screen 4 4.6 XLPE insulation 5 4.7 Insulation screen 6 4.8 Semiconducting water blocking

tape

7 4.9 Metal screening of a copper tape applied in helical form

8 4.10 Semiconducting water blocking tape

9 4.11 OFC 10 4.12 PE Fillers 11 4.13 Water blocking yarn 12 4.14 PE ST 7 Pressure extruded

inner sheath

13 4.15 Non conducting water blocking tape

14 4.16 G.S Round Wire Armour 15 4.17 RC Tape 16 4.18 HDPE outer jacket

Net weight of cable: …………… kg/m Name of manufacturer: Drawing No and date:


___________________________________________________________________________________________ Page 19 of 19

Annexure –E: Specifications of Optic Fiber A. Single-Mode Fiber (G 657.A1-Low Bend Sensitive Fiber) Attenuation ≤ 0.33 dB/km at 1310 nm

< 0.31 dB/km at 1383 nm or less than attenuation at 1310 nm# ≤ 0.20 dB/km at 1550 nm ≤ 0.21 dB/km at 1625 nm

Mode field diameter 8.8 ± 0.4 μm at 1310 nm

10.3 ± 0.5 μm at 1550 nm Zero dispersion wavelength 1300 nm to 1324 nm Dispersion at 1550 nm ≤ 17.5 ps/nm.km PMD Individual Fiber* ≤ 0.1 ps/√km Cladding diameter 125.0 ± 0.7 μm Core-clad concentricity error ≤ 0.5 μm Cladding non-circularity ≤ 0.7 % Coating diameter (uncoloured) 242 ± 5 μm Coating-cladding concentricity error ≤ 12 μm Zero dispersion slope ≤ 2 0.090 ps/nm .km PMD LDV ≤ 0.06 ps/√km * Individual PMD values may change when cabled # After hydrogen aging according to IEC-60793-2-50 regarding the B1.3 fiber category B. Multi-Mode Fiber (OM -2)

Specification for HT Cable

(38/66kV : Single Core)

Specification no – SP-EWH2-01-00

Prepared by: Reviewed Approved by: Rev Date

Tarun Dey Devendra Sharma Debabrata Guha 00 5-Jan-10

SPECIFICATION FOR HT CABLE

___________________________________________________________________________________________Specification No – SP-EWH2-01-00 Page 2 of 19

Index

1.0.0 Codes & standards ..............................................................................................3

2.0.0 Cable design features........................................................................................3

3.0 Quality assurance ..............................................................................................6

4.0 Inspection & testing...........................................................................................6

5.0.0 Drawings, Data & manuals................................................................................7

6.0.0 Shipping, Handling and Site support...............................................................8

7.0.0 Progress reporting.............................................................................................9

8.0 Deviations.........................................................................................................10

Annexure - A Scope of supply................................................................................11

Annexure – B Service Conditions .........................................................................13

Annexure – C Guaranteed Technical Particulars (Data by Supplier) ...............14

Annexure –D Cross Sectional Drawing (Data by Supplier) .................................19



1.0.0 Codes & standards

Materials and methods used in the manufacture of Cables shall conform to the latest edition of

following –

Indian Standards

IS–8130 Conductor for insulated electric cables & flexible cords

IS-5831 PVC insulation and sheath of electric cables

IS-3975 Mild steel wires strips and tapes for armoring cables

IS-5216 Guide for safety procedures and practices in electrical works

IS-7098 (Part – III) Cross-linked polyethylene insulated thermoplastic sheathed cables specification.

IS – 10810:1984 Methods of test of cables

IEC Standards

IEC-60811 Common test methods for insulating and sheathing materials of electric cables and optical cables

IEC-60228 Conductor for insulated cables

IEC-60840 Power cable with extruded insulation and their accessories for rated voltage above 30kV up to 150kV- Test methods and requirements

2.0.0 Cable design features

(Refer Annexure – “D”)

2.1.0 Manufacturing process The cable shall be manufactured by “Tripple head

extrusion process”. The conductor screen , Insulation &

Insulation screen shall ALL be extruded in SINGLE

POINT AT ONE TIME PROCESS to ensure

homogeneity and reduction of voids, in the insulation

and the screening system of the cable, whereby

enhancing the life of the cable. The cable shall be

strictly manufactured by “DRY CURED” process.

2.2.0 Conductor Electrolytic grade aluminium conductor shall consist of

flexibility class-2 in accordance with IS 8130/IEC 228.

The shape of conductor shall be compacted, stranded,

and circular. Milliken type construction will be preferred

for cable size of 1000 sqmm or greater.



2.3.0 Longitudinal water sealing

of conductor

Shall be achieved by water swelling powder/fibres in the

interstices of the conductor. The powder/fibre/yarn shall

turns into jelly, when in contact with water

2.4.0 Semi conducting separator

tape

Semi-conducting separator tapes shall be applied over

the conductor, suitable for continuous operating

conductor temperature of 90 deg C.

2.5.0 Conductor screen The conductor screen shall consist of extruded semi-

conducting XLPE which shall be fully compatible with

the conductor and extruded insulation. Outer surface of

semiconductor screen shall be supper smoothing,

cylindrical and firmly bonded to the overlaying

insulation.

2.6.0 Insulation The extruded XLPE insulation shall be of very high

degree of purity. The average thickness shall not be

less than nominal value as given in annexure C. The

minimum thickness at any point shall not be less by

more than 10% of the nominal value. Percentage

eccentricity of the insulation shall not be more than

10%.

2.7.0 Insulation Screen The insulation screen shall consist of extruded semi-

conducting XLPE which shall be fully compatible with

extruded insulation. Insulation screen shall be firmly

bonded to the insulation

2.8.0 Make of insulation and

semi conducting screen

DOW – TR XLPE or equivalent of Borealis

(any deviation to above shall not be acceptable unless

and until it has been specially approved by BSES prior

to sourcing of compounds and manufacturing of cable.

2.9.0 Core The ovality of the core shall not be more than 5%.

2.10.0 Inner Longitudinal water

sealing bedding

Semi-conducting water swellable tapes shall be applied

over the extruded semi-conducting core screening.

2.11.0 Metal screening (if

required to meet the short

circuit rating)

The metallic screen shall consists of a layer of copper

wires, followed by a copper tape applied in helical form

2.12.0 Outer Longitudinal water

sealing bedding (when

metallic screening is

Semi-conducting water swellable tapes shall be applied

over the metallic screening.



provided)

2.13.0 Characteristic of water

swellable bedding

a) Nominal thickness = 0.3mm

b) Swell height shall be >= 12mm in one minute.

2.14.0 Metallic sheath The metallic sheath shall consist of EITHER lead alloy

‘E’ seamless sheathing with minimum thickness in

accordance with Table-6 of IS 7098 Part – III (1993) OR

corrugated aluminium sheathing with minimum

thickness of 1.75mm and nominal thickness of 1.8mm,

provided with high-viscosity bitumen-based compound

coating, in conjunction with textile tape as carrier

material for corrosion protection of the outer surface of

corrugated aluminium sheathing. Further the

corrugations shall be filled with compatible filler material

to provide smooth round surface over the aluminium

corrugated sheathing, so as to prevent ingress /

traveling of water along the corrugations.

2.15.0 Outer Jacket The outer jacket shall consist of extruded black colored

HDPE type ST 7 with anti termite protection. The

minimum thickness at any point shall not fall below 85%

of the nominal thickness by more than 0.1mm. Nominal

thickness shall be 4mm.

2.16.0 Semi conductive layer over

the outer jacket

Semi conductive layer shall be either extruded or

graphite coating

2.17.0 Cable Rating The cable size shall be suitable to carry rated load

current on 66KV continuously without exceeding the

maximum conductor temperature of 90 deg. C.

2.18.0 Drum Length 500 Mtr +- 5 % (short lengths not acceptable except the

last length and minimum acceptable short length shall

be 250 mtrs.). The overall quantity tolerance shall be as

purchase order.

Manufacturer shall not be allowed to put two cable

pieces of different short length in same cable drum.

2.19.0 Embossing The extruded outer sheath shall be embossed with

meter marking at interval of 1 metre. The ”A” end meter

marking and “Z” end meter marking and the drum

lengths shall be printed on the drum flange along with



other markings. The outer sheath shall also be

embossed with (min.)

a) Voltage designation

b) Type of construction/cable code (e.g. A2X2Y)

c) Number of core and nominal cross sectional

area.

d) Type of cable “Electric Cable”

e) Manufacturers name & trade mark

f) Name of buyer (e.g. BSES)

g) Month & year of manufacturing

h) Batch no / Lot no.

i) Sequential length marking.

3.0 Quality assurance

3.1.0 Vendor quality plan To be submitted for purchaser approval

3.2.0 Inspection points To be mutually identified & agreed in quality

plan

4.0 Inspection & testing

4.1.0 Routine test Each drum length of cable shall be subjected to the following tests

- Measurement of the electrical resistance of the conductor shall be

carried out as per the provisions of Clause 10.5 of I.E.C.

Publication No.60840 The measurement shall be made on the

conductors of each cable length. The D.C. resistance of the

conductor at 20 deg. C shall not exceed the maximum value

specified in I.E.C. Publication No.60228.

- High voltage test with power frequency alternating voltage applied

between conductor and sheath as per clause 9.3 of IEC-60840

- Partial discharge test shall be carried out as per clause 9.2 of IEC

Publication No.60840.

- Test on outer jacket as per Clause 3 of IEC 60229

- Measurement of capacitance as per clause 10.10 of IEC60840

4.2.0 Type test -The cable shall be of “type tested” quality. Type test report of not



more than five (5) years shall be submitted for the type, size and

rating of the cable offered, along with the bid.

-If the manufacturer’s lab is accredited by govt./authorized body

then it shall be acceptable for type testing.

-All type tests shall be carried out in accordance with Clause 12 of

IEC-60840 and in accordance with the sequence prescribed

therein.

4.3.0 Acceptance

Tests

Shall be conducted as per IEC: 60840 / IS: 7098 (P-3) and

approved QA plan for each lot of cable.

4.4.0 Special Tests The following tests shall be carried out as special tests

- Conductor examination as per Clause 10.4 of IEC-60840.

- Measurement of thickness of insulation as per Clause 10.6 of IEC-

60840 and Clause 8 of IEC-60811-1-1.

- Measurement of thickness and overall dimensions as per Clause

8 of IEC-60811-1-1

- Measurement of thickness of metallic sheath as per Clause 10.7

of IEC-60840

-Measurement of external diameter as per Clause 8.3 of

IEC-60811-1-1

- Hot set test for XLPE insulation as per Clause 10.9 of IEC-60840

4.5.0 Inspection -The buyer reserves the right to witness all tests specified on

completed cables

-The buyer reserves the right to inspect cables at the Seller’s works

at any time prior dispatch, to verify compliance with the

specifications.

-In-process and final inspection call intimation shall be given in

advance to purchaser.

4.6.0 Test certificates Three sets of complete test certificates shall be submitted along

with the dispatch documents.

5.0.0 Drawings, Data & manuals

5.1.0 The seller has to submit:

a) Cross sectional drawing of cable.

b) Completely filled GTP

c) Type test certificates

To be submitted

along with bid

d) Dimensional drawing for pulling eye



e) Fault level calculation

f) Complete cable catalogue and manual

5.2.0 Within 15 days, the seller has to submit four sets of above

mentioned drawings along with one soft copy for buyer’s

approval.

5.3.0 Submittals required

prior to dispatch

a) Inspection and test reports, carried out in manufacturer’s

works (R)

b) Test certificates of all bought out items.

5.4.0 Drawing and

document sizes


5.5.0 No. of drags. /

Documents required

at different stages

As per Annexure - A

6.0.0 Shipping, Handling and Site support

6.1.0 Packing -The cable shall be wound on non-returnable steel

drums of suitable size of minimum hub diameter of 20D

(where D is the overall diameter of the cable) and

packed conforming to international standards. The drum

shall be fully enclosed by continuous metallic cladding.

Cable shall have sea worthy packing in case cables are

dispatched by shipping lines.

6.2.0 Pulling eye & sealing of

Cable ends

-A cable pulling eye shall be provided at “Z” end of

cable on each drum. Suitable fillings/putty shall be used

for sealing gap between outer sheath and pulling eye.

Heat shrinkable sleeves with the pulling eye shall also

be provided. The pulling eye shall be directly

connected to the conductor and be capable to withstand

a tensile load of 30N / sqmm of conductor area. The “A”

end of the cable shall be sealed with filling

material/putty and heat shrinkable cap.

6.3.0 Drum identification label The following information shall be marked on the drum:

- Drum identification number.

- Trade name or trade mark; if any



- Name of manufacturer

- Nominal sectional area of the conductor of the cable

- Type of cable and voltage for which it is suitable

- Length of the cable on the drum, with “A” end and “Z” end markings.

- Purchase order number with SAP item code.

- Year and month of manufacturing.

- Direction of rotation of drum (an arrow) and

- Net weight of cable in drum and gross weight of cable with drum.

- Batch no or Lot no.

6.4.0 Shipping The seller shall give complete shipping information concerning the gross weight, size of each packing.

6.5.0 Handling & Storage Manufacturer instruction shall be followed. Detail handling & storage instruction sheet / manual neds to be furnished before commencement of supply.

6.6.0 Transit damage The seller shall be responsible for any transit damage due to improper packing.

7.0.0 Progress reporting

7.1.0 Outline Document To be submitted for purchaser approval for outline of

production, inspection, testing, packing, dispatch,

documentation programmer.

7.2.0 Detailed Progress report To be submitted to Purchaser once a month containing

a) Progress on material procurement.

b) Progress on internal stage inspection

c) Reason for any delay in total programme.

d) Details of test failures if any in manufacturing stages

e) Progress on final box up.

f) Constraints / forward path



8.0 Deviations

8.0.0 Deviation from the Specification. Deviations from this Specification shall be

stated in writing with the tender by

reference to the Specification

clause/GTP/Drawing and a description of

the alternative offer. In absence of such a

statement, it will be assumed by the Buyer

that the Seller complies fully with this

specification.



Annexure - A Scope of supply

1.0 The scope of supply shall include following 1.1 Design, manufacture, testing at manufacturer works before dispatch, packing, delivery

including unloading and stacking at site/store of 38/66kV single core cable as per BOQ

and submission of all documents.

1.2 BOQ as following -

Sr

No

Purchaser

Equipment Tag

No / SAP code

Material/Equipment

description

Location Unit Quantity

1 e.g. Delhi km e.g. 10

2 e.g. Goa km e.g. 10

3

4

5

6

7


Along with offer For Approval

after award of

contract

Final after

approval

Remarks

Detailed

dimensional

cross-sectional

drawing of the

cable

3 copies (Typical

drgs)

4 copies 6 copies + 1 soft

copy in CD

Type test

certificates.

2 copies (Type

test and sample

Routine Test)

6 copies + 1 soft

copy in CD

Type test and

sample Routine

test reports

Guaranteed

technical

particulars of

each type of

cable

3 copies 4 copies 6 copies + 1 soft

copy in CD



Dimensional

drawing for

pulling eye.

3 copies 4 copies 6 copies + 1 soft

copy in CD

Rating factors 3 copies 4 copies 6 copies + 1 soft

copy in CD

Complete cable

catalogue and

Manual

1 copy 6 copies + 1 soft

copy in CD

1 Sec rating

calculation for

metal sheath

and copper

screen (if

applicable)

3 copies

(Typical)

4 copies 6 copies + 1 soft

copy in CD

3.0 Delivery schedule 3.1 Delivery period start date - from date of LOI

3.2 Delivery period end date - as agreed with supplier

3.3 Material dispatch clearance - after inspection by purchaser



Annexure – B Service Conditions

1.0.0 Mumbai Atmospheric conditions

a) Average grade atmosphere : Heavily polluted , salt Laden, dusty, humid with possibility of condensation

Maximum altitude above sea level

1000 M

b) Ambient Air temperature Highest 45 deg C, Average 35 deg C Minimum ambient air

temperature deg C

c) Relative Humidity 95 % Max d) Thermal Resistivity of Soil 150 Deg.C cm/W e) Seismic Zone 3 f) Rainfall 3000 mm concentrated in four months

2.0.0 Delhi Atmospheric conditions

a) Average grade atmosphere : Heavily polluted, dry Maximum altitude above sea

level 1000 M

b) Ambient Air temperature Highest 50 deg C, Average 40 deg C Minimum ambient air

temperature Deg C

c) Relative Humidity 90 % Max d) Thermal Resistivity of Soil 150 Deg.C cm/W e) Seismic Zone 4 f) Rainfall 750 mm concentrated in four months



Annexure – C Guaranteed Technical Particulars (Data by Supplier)

Sr. Description Unit Data specified

by the purchaser


manufacturer

1 Name of manufacturer 2 Country of manufacturer 3 Type of cable 4 Standard according to which cable

is manufactured

5 Rated voltage kV 38/66 6 Highest system voltage kV 72.5 7 System frequency Hz 50 8 No of phases per circuit Nos 3 9 System earthing Solidly

grounded

10 Rated short time current of conductor

kA

11 Rated short time current of metal sheath (alone)

kA

12 Rated short time current of metal screen (if provided)

kA

13 Rated short time current of metal sheath and screen

kA 19

14 Duration of short circuit current Sec 1 15 Impulse withstand voltage 1.2/50

micro sec wave kVp 325

16 Power frequency withstand voltage

kV(rms) 140

17 Conductor a Nominal cross sectional area sqmm 1000 / 630 b Type class of conductor. Compacted

Stranded Circular

c Material of conductor Aluminum d Flexibility class of conductor Class -2 e Minimum numbers of strands Nos f Diameter of strands before

compaction. (nominal / Minimum) Mm / mm

g Material of longitudinal water sealing filling of conductor

18 Details of semi conducting tape over the conductor

19 Conductor Screen a Material and type b Minimum thickness mm 0.8 c Make and grade of semi




Sr. Description Unit Data specified by the

purchaser


manufacturer 19 Insulation

a Material of Insulation XLPE B Nominal thickness Mm 11 C Minimum thickness 9.9

Make and grade of insulation compound

Maximum dielectric stress at the conductor surface

kV/mm

20 Insulation screen a Material and type b Minimum thickness mm 0.8 c Make and grade of semi


21 Inner water swellable tape a Nominal thickness mm 0.3 a Minimum swell height in one

minute. mm 12 mm in one

minute

22 Copper wire screening and the copper tape (if required to meet the short circuit rating)

a Number of wire Nos

B Diameter of wire mm

c Thickness and width of copper tape

mm / mm

23 outer water swellable tape (if required)

mm

a Nominal thickness mm 0.3 b Minimum swell height in one

minute. mm 12 mm in one

minute

24 Nominal diameter under metal sheath

mm

25 Material of the metal sheath Lead alloy E or

corrugated aluminium(with

corrosion protection & corrugation

filling)

26 Minimum thickness of lead alloy “E” sheath

mm 2.2

27 Minimum thickness of Corrugated Aluminium sheath

mm 1.75

28 Nominal radial clearance allowed under metal sheath ( in case of corrugated aluminium sheathing)

mm As per mfg. stnd.

29 Nominal diameter over metal sheath

mm

Sr. Description Unit Data specified Data to be



by the purchaser

filled by the manufacturer

30 Outer jacket a Material and type HDPE type ST 7 b Minimum thickness mm 3.3 c Nominal thickness mm 4 d Anti termite treated? Yes / No

31 Material of semi-conductive coating/extrusion over the outer jacket

Extruded or

Graphite coating

32 AC test voltage at works for insulation.

KV(rms) 90

33 DC test voltage at works for outer jacket.

KV (DC) 25

41 Overall dia of completed single core cable

mm

42 Weight per metre of complete cable

Kg/m

43 Short circuit capacities with maximum conductor temperature of 250Deg C : (conductor temperature of 90 Deg C at the commencement of short circuit) 0.5 second duration 1 second duration 2 second duration 3 second duration

kA

44 Minimum radius of bend round : which cable can be laid a) Direct burial in ground b) In ducts

mm

45 Maximum D.C .resistance of : conductor per KM at 20 deg. C

Ohm/km 0.0469 for 630 sqmm and 0.0291 for

1000 sqmm Cable.

46 Maximum AC resistance of : conductor per KM at 90 deg. C

Ohm

47 Equivalent star reactance per KM : of 3 phase circuit at 50 Hz

Ohm

48 Maximum electrostatic capacitance : Per KM of cable

pf




by the purchaser


49 Maximum continuous current carrying : Capacity per circuit when laid in ground as per the following parameters (with screens cross bonded) -Maximum continuous conductor temperature of 90Deg C -Maximum conductor temperature during short circuit of 250 Deg C -Ground temperature of 30 DegC -Soil resistivity of 150DegC- cm/Watt -Depth of laying of 150cm a. In tri-foil touching formation b. In flat formation with d+70cm

Amp

50 Maximum continuous current carrying : Capacity per cable when laid in air with ambient temperature of 40DegC and other parameters as per Sl no 49 (with screens cross bonded) a. In tri-foil touching formation b. In flat formation with d+70cm

Amp

51 Rating factors for ambient air temperature attached(Yes/No)

52 Rating factors for ground temperature attached(Yes/No)

53 Rating factors for phase spacing in flat formation attached(Yes/No)

54 Rating factors for grouping of cable laid in ground in horizontal formation attached(Yes/No)

55 Rating factors for grouping of cable laid in ground in tri-foil touching formation attached(Yes/No)

56 Rating factors for thermal resistivity of soil attached(Yes/No)

57 Rating factors for depth of laying attached(Yes/No)

58 Max. power factor of charging KVA of : cable when laid direct in the ground at normal voltage frequency at conductor temperature at 90Deg .C




by the purchaser


59 Max. dielectric power loss of cable per : KM of 3 phase circuit laid direct in ground at normal voltage, frequency and maximum conductor temperature of 90 Deg C

Watt/km

60 Sheath loss of cable per KM of 3 phase : circuit at normal voltage frequency at maximum continuous current rating. a) Laid direct in ground b) Drawn into ducts c) Installed in air

Watt/km

61 Impedance per KM of 3 phase circuit : at 50 C/s and maximum conductor temperature. a) Positive and negative sequence b) Zero sequence

Ohm

62 Standard drum length of cable Metres 500 +/- 5% (short lengths not acceptable except the last

length

63 The overall quantity tolerance %

64 Cable to be wound on non returnable steel drum.

Yes / no Yes

65 Normal delivery length Metres 66 Cable pulling Eye to be provided

at “Z” end

67 Tensile load withstand capacity for pulling eye

30 N / sqmm

68 Approximate shipping weight for the normal deliver length with the drum size (flange dia. in mm and width in mm):

kg

69 Drum size ( Flange dia X flange width X hub dia)

70 Embossing details on outer jacket 71 Sequential marking at every

meter. Provided

72 Process of cross linking of polyethylene.



Annexure –D Cross Sectional Drawing (Data by Supplier)

Pictorial Label No.

Reference Clause No

Description Nominal Thickness

in mm

Nominal Diameter in mm

1 4.2 & 4.3 Compacted, stranded, circular aluminium conductor

2 4.4 Semi-conducting separator tape

3 4.5 Conductor screen 4 4.6 XLPE insulation 5 4.7 Insulation screen 6 4.8 Inner longitudinal water

sealing bedding

7 4.9 Metal screening of copper wire followed by a copper tape applied in helical form (if required)

8 4.10 Outer longitudinal water sealing bedding (if required)

9 4.11 Metallic sheath (Lead Alloy “E” sheath or corrugated aluminium sheathing with coating and filling)

10 4.12 HDPE outer jacket 11 4.13 Semi-conductive

extrusion/Graphite coating

Net weight of cable : …………… kg/m Name of manufacturer: Drawing No and date:

SP-EWHP-01- R4

Page 2 of 42

Index [R4]

Page

Revision Record …………………………… 3 General Specification ……………………… 5 Annexures: Annexure A: ………………………… 18 Scope, Documentation and Delivery Schedule Annexure B: ………………………… 20 General Technical Particulars (GTP) Annexure C: [R4] ………………………… 27 List of R-Infra approved Sub-Vendors Annexure D : [R4] ………………………… 29 Service Conditions Annexure E: ………………………… 30 (Attachments)

a) General Arrangement Drawing for Pulling-eye Assembly

b) General Arrangement Drawing for

End-sealing Cap Annexure F: [R4] ………………………… 33 (Attachment) R-Infra format (typical) for Quality Assurance Plan (QAP) for H. T. Cables Annexure G: [R4] ………………………… 42

Testing and manufacturing process requirements w. r. t. TR- XLPE insulation

SP-EWHP-01- R4

Page 3 of 42

Revision Record Note: Revisions made in R4 are marked by symbol [R4] at the respective text or drawing throughout the Specification. [R4]

Rev. No.

Revision Date

Item/ clause no:

Page No. Nature of Change Approved by

R4 09.03.12 Cl. 1.0.0 ,

5 IS 0462 (Part1)/1983 - added AM

R4 09.03.12 Cl. 1.0.0 ,

5 IEC 332 - added AM

R4 09.03.12 Cl. 2.0.0 , GTP 5.0

5 Cable Code - added

AM

R4 09.03.12 Cl. 2.0.0 , GTP 5.0 (Annexure-B)

5 For 33 kV 3-core Cables only armour strips (not armour wires).

AM

R4 09.03.12 Cl. 2.0.0 5 1c x 630 sq. mm. Cables - added.

AM

R4 09.03.12 Cl. 2.1.1 7 Copper conductor - deleted. AM R4 09.03.12 Cl. 2.1.1 7 Conductor Al grade H4 - deleted AM R4 09.03.12 Cl. 2.1.1,

GTP 8.0 7 “Longitudinal Water Blocking

Arrangement” within conductor - added

AM

R4 09.03.12 Cl. 2.1.3, GTP-10.0

7 Eccentricity check with regard to Insulation - added

AM

R4 09.03.12 Cl. 2.1.4, GTP-11A.0

8 Ovality check on core (over outer semi-con) - added

AM

R4 09.03.12 Cl. 2.1.4A , GTP 28.0

8 For 11 kV Cables also : “Dry-cure process only” (no moisture cure)

AM

R4 09.03.12 Cl. 2.1.6 , GTP 11C

9 Colour strips to carry manufacturer’s name also.

AM

R4 09.03.12 Cl. 2.1.6

9 Copper tape arrangement - added

AM

R4 09.03.12 Cl. 2.1.7

9 Properties of PP filler - added AM

R4 09.03.12 Cl. 2.1.10

9 Zero negative tolerance for diameter of armour wire - added

AM

R4 09.03.12 Cl. 2.1.12 10 Anti-rodent properties for outer sheath - added

AM

R4 09.03.12 Cl. 2.1.12 10 Ovality check over completed cable - added.

AM

R4 09.03.12 Cl. 2.1.12, GTP 15.0

10 FRLS properties for outer sheath, when required - added

AM

R4 09.03.12 Cl. 2.1.12 10-11 Details of Embossing - revised

AM

R4 09.03.12 Cl. 4.0.0 12 R- Infra QAP detail added AM R4 09.03.12 Cl. 4.0.0 12 Strippability Test added in

Routine Test and Acceptance Test.

AM

R4 09.03.12 Cl. 4.0.0 12 Minimum lot size of Cables for AM

SP-EWHP-01- R4

Page 4 of 42

raising Inspection Call - added R4 09.03.12 Cl. 4.0.0 13 Water Penetration Test (WPT)

- added AM

R4 09.03.12 Cl. 4.0.0 13 Make & Grade of critical items used during manufacture to be stated in TC - added

AM

R4 09.03.12 Cl. 5.0.0, GTP 18A.0

14 Cross-sectional drawing - added (required details mentioned)

AM

R4 09.03.12 Cl. 7.0.0 , GTP 18.0

15-16 a) Required Packing details mentioned. b) Drum Identification markings - revised c) M. S. Spindle required for drums - added f) Cable drum handling added

AM

R4 09.03.12 Annexure - A 18 a) Document Submission - revised b) Delivery Schedule - added

AM

R4 09.03.12 Annexure-B (GTP)

20 One consolidated GTP format is prepared, instead of earlier separate GTPs for different types of cables.

AM

R4 09.03.12 Annexure-B (GTP)

20 GTP generally revised as per revised clauses.

AM

R4 09.03.12 Annexure-B GTP 8H.0

21 Longitudinal Water blocking arrangement added

AM

R4 09.03.12 Annexure-B GTP 9.0

21 Conductor Screen thickness revised to 0.5 min.

AM

R4 09.03.12 Annexure-B (GTP) – 11B.0

22 Approval for Pre-slitted w. s. tapes from sub-vendors necessary. - added

AM

R4 09.03.12 Annexure-B GTP – 11D.0

22 Thickness of Copper Tape increased from 0.06 to 0.1 mm

AM

R4 09.03.12 Annexure-B (GTP) - 13.0

23 Inner Sheath – min thickness for 11 kV, 1cx1000 sq.mm. increased from 0.6 to 0.7 mm

AM

R4 09.03.12 Annexure-B (GTP) – 17A.0

24 Overall order tolerance - added AM

R4 09.03.12 Annexure-C , Cl. 2.1.3 , GTP-31.0

27 R-Infra Approved Sub-Vendors List - added

AM

R4 09.03.12 Annexure-D 29 Service Conditions – added.

AM

R4 09.03.12 Annexure-E 31-32 For Pulling-eye Assembly and Sealing-end Cap, new drawings added.

AM

R4 09.03.12 i) Annexure-F (QAP) ii) Cl. 4.0.0 iii) GTP-30.0

34 to 41 QAP format - added. AM

R4 09.03.12 Cl. 2.1.3 GTP 10.0-G

8

21

Introduction of “water-tree retardant” property for XLPE insulation

AM

R4 09.03.12 Annexure-G 42 Introduction of “water-tree retardant” property for XLPE insulation

AM

SP-EWHP-01- R4

Page 5 of 42

General Specification

1.0.0 Codes & Standards

The cables shall be designed, manufactured and tested in accordance with the following National Standards and IEC Standards.

National Standards IS 7098 Part-2 Cross linked polyethylene (XLPE) insulated PVC sheathed cables

for working voltages from 3.3 kV up to and including 33 kV.

IS 5831 : 1984 PVC insulation & sheath of electric cables.

IS 10810 : 1984 Methods of test for cables.

IS 8130 : 1984 Conductors for insulated electric cables and flexible cords.

IS 3975 : 1999 Mild steel wires, formed wires and tapes for armouring of cables.

IS 0462 (Part 1) / 1983 Fictitious Calculation Method for determination of dimensions of protective covering of cables

International Standards IEC 60183 Guide to the selection of high voltage cables IEC 60228 Conductors of insulated cables. Guide to the dimensional limits of

circular conductors.

IEC 60332 - 3 Tests on electric cables under fire conditions.

Part 3: Tests on bunched wires or cables.

IEC 60502 - 2 Power cables for rated voltages from 6 kV (Um = 7.2 kV) up to 30

kV (Um = 36 kV)

IEC 60811 Pts 1 through 5

Common test methods for insulating and sheathing materials of

electric cables.

IEC 885 Pts 1 through 3

Electric test methods for electric cables.

IEC 28 International Standard of Resistance for Copper IEC 332 Test on Electric Cables under fire conditions

2.0.0 Cable Construction Features

This Specification generally covers following types / sizes of XLPE H. T. Cables

used in R-Infra network in Mumbai Discom area, mostly under-ground (buried, with

SP-EWHP-01- R4

Page 6 of 42

chances of flooding by water) or for laying on racks, in ducts, trenches, conduits,

and so on.

Note: (Ref.: Table stating Cable sizes given below.)

Cable Code: [R4] As per IS, cable designations comprise of following codes / options, as applicable

for this Specification:

(N.A. - Not applicable for Specification)

- (with Copper conductor) (N.A.) [R4]

A Aluminium conductor

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

2X XLPE insulation

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

W Steel round Wire armour (N.A.)

W W Double steel round Wire armour (N.A.)

Wa Non-magnetic round Wire armour

F Steel formed wire (strip) armour

FF Double steel formed wire (strip) armour (N.A.)

Fa Non-magnetic formed wire (strip) armour (N.A.)

- (“un-armoured” or without armour) (N.A.)

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

Y PVC outer sheath

Sr. No. Description

Conductor

Material

Cable Code

[R4]

1. 11 kV, 3c x 150 sq. mm. Al A 2X F Y

2. 11 kV, 3c x 300 sq. mm. Al A 2X F Y

3. 33 kV, 3c x 400 sq. mm. Al A 2X F Y

4. 33 kV, 1c x 630 sq. mm. [R4] Al A 2X Wa Y

5. 11 kV, 1c x 1000 sq. mm. Al A 2X Wa Y

6. 33 kV, 1c x 1000 sq. mm Al A 2X Wa Y

SP-EWHP-01- R4

Page 7 of 42

Description of each item mentioned in the Specification (the text, BOQ, GTP or any

site specific requirement) shall be followed, along with IS: 7098 – Part 2.

2.1.1 Conductor a) Electrolytic Grade Stranded Aluminium

Conductor [R4]

b) Grade: H2 as per IS: 8130 / 1984 (For Al) [R4]

c) Stranded, compacted and circular in shape

d) Class 2

e) “Longitudinal Water-Blocking Arrangement” (or

water-tight construction or water barrier

protection) shall be provided within the

Conductor. [R4]

i) As per manufacturer’s procedures, 100 %

water-tight conductor shall be achieved.

iii) Make & Type of materials to be used (i.e.

Water-swellable tapes / yarn / powder,

etc.) shall also be stated in the List of Sub-

Vendors for pre-order approval.

f) All detailed constructional features shall be shown

in the cross-sectional drawing.

2.1.2 Conductor Screen Extruded semi-conducting material.

(Also refer Cl. 2.1.3.)

(Tapes are not acceptable)

2.1.3 Insulation a) Extruded XLPE (Cross-Linked Poly-Ethylene)

Insulation, with water-tree retardant (WTR)

property[R4]

b) The required compound used shall be from R-

Infra-approved sub-vendors and not from any

other (refer Annexure – C). [R4]

c) Uniform thickness of insulation shall be within

the permissible values as per IEC Standards;

SP-EWHP-01- R4

Page 8 of 42

eccentricity check shall be carried out to ensure

this. [R4]

d) Insulation Color : natural

2.1.4 Insulation Screen a) Freely-strippable semi-conducting screen, which

should not require application of heat for its

removal.

(Refer Cl. 2.1.3.)

b) Text “Do not Heat - Freely Strippable” to be

printed on insulation screen (at every 600 mm

interval).

c) Round shape over the outer semi-con shall be

within the permissible limits as per IEC

standards; Ovality check shall be carried out to

ensure this. [R4]

d) Compound used shall be suitable for the

operating temperature of the Cable and shall be

compatible with the insulation used. [R4]

2.1.4A XLPE Process

2.1.4A-1 11 KV Dry Cure process only. [R4]

2.1.4A-2 33 KV Dry Cure process only.

2.1.4A-3 Extrusion [R4]

It is desirable that Conductor Screen, Insulation and

Insulation Screen shall be extruded simultaneously,

in a Single One-Time Process (i.e. as a triple-head

extrusion) to ensure homogeneity of layers over the

conductor, and absence of voids.

However, Tandem Extrusion (1+2) is also acceptable

2.1.4A-4 Make of Compounds for

Insulation and Semi-

conducting

Any deviation from Approved Makes mentioned in

Annexure-C shall not be acceptable, unless the

deviation has been specifically approved by R-Infra,

prior to sourcing the compounds and taking up

manufacturing of cable.

2.1.5 Water-Swellable Tape a) Semi-Conducting Water-Sellable Tape shall be

provided, under the copper tape, on each core.

SP-EWHP-01- R4

Page 9 of 42

b) Nominal thickness : 0.3 mm

c) Weight: 118 gm / sq. m apprx.

d) Swell height: ≥ 12 mm in 1 min.

e) Compatible to strippable / non-strippable semi-

con, over which it is applied.

2.1.6 Core Identification a) For 3-core cables, cores shall be identified by

coloured strips (Red, Yellow, Blue), applied

helically / longitudinally below the copper tape.

The coloured strips shall carry the name of

manufacturer permanently printed at close intervals;

this is to provide additional identification of

manufacturer of the cable. [R4]

2.1.6A Copper Tape Copper Tape shall be applied helically over the layer

formed after application of insulation screen, water-

swellable tape and identification strip. [R4]

2.1.7 Filler a) All interstices, including center interstices shall

be filled by PP filler.

b) PP Filler shall be non-hygroscopic, not having

any effect on other compounds used, stable at

cable temperatures, etc. [R4]

c) PVC filler is not acceptable.

d) Filler is not applicable for single-core cables.

2.1.8 Binder Tape As per manufacturer’s standard

2.1.9 Inner Sheath Extruded Inner Sheath of Black PVC type ST-2

(IS 5831)

2.1.10 Armour a) For 3-core Cables :

Galvanised Steel flat strip armour

b) For 1-core Cables :

Non-magnetic round wire armour

SP-EWHP-01- R4

Page 10 of 42

(hard-drawn aluminium wire)

c) Minimum area of coverage of armouring shall be

90 % (min.). At any time, the gap between any

two adjacent armour strips / wires shall not be

more than the width of strip / diameter of wire.

d) Zero negative tolerance is for :

• Thickness of armour strip

• Diameter of armour wire [R4]

2.1.11 Binder Tape Rubberised cotton tape

2.1.12 Outer Sheath a) Extruded outer sheath of PVC (ST-2 as per IS

5831) with termite-repellant and anti-rodent

properties. [R4]

(Outer Sheath shall be FRLS-type, if chosen by

purchaser.) [R4]

b) Shape of the cable over the outer sheath shall

be circular, when manufactured / completed.

Regular Ovality check shall be carried out at

factory, to detect any abnormality.

Manufacturing quality shall be such that cable

will retain its circular shape, even after it is laid

at site. [R4]

c) The Outer Sheath shall be embossed with

following minimum text : [R4]

1. The voltage designation

2. Type of construction / cable code

(e.g. A2XFY)

3. Manufacturer’s Name and Trade-mark

4. Number of cores and nominal cross-

sectional area of conductor

5. Progressive (sequential) length of cable at

every metre, starting from zero for every

drum.

Colour filled in for the progressive marking,

SP-EWHP-01- R4

Page 11 of 42

shall be with proper contrast in colouring.

6. Name of buyer / purchaser, R-Infra

(Reliance Infrastructure Ltd.)

7. Month & Year of manufacturing

8. IS reference, i.e. IS : 7098

9. Batch No. / Lot No.

(For traceability purpose, in case of any, in

case of any manufacturing defect or

otherwise arising in the cable in future.) 10. Purchase Order Number & date

11. Word ‘ FRLSH ’, in case the cable is of

FRLSH type. [R4]

2.1.13 Pulling-eye Assembly

and

Sealing-end Cap (for Cables)

a) A cable pulling-eye assembly Drg. No.

MISC/E/4-1131/1698 (see Annexure-E) shall be

provided at the loose end (outer end) of the

cable on each drum. Sealing material shall be

filled in inside the spaces / gaps between the

pulling-eye assembly and cable outer sheath.

Further, a heat-shrinkable sleeve shall be

provided over the pulling-eye assembly and

outer sheath of cable.

b) Other end (inner end) of the cable shall be

sealed as per MISC/E/4-1131/1699 (see

Annexure-E.) One PVC cap with Polyurethane

compound shall be provided as primary sealing

and heat-shrink end-cap shall form a secondary

sealing over the PVC cap.

3.0.0 (This number not used.)

4.0.0 Testing & Inspection Tests shall be carried out in accordance with IS 7098

(Part-2).

a) Type Tests 1. Cables must be of type tested quality. Type Test

Reports shall be submitted for the type, size and

SP-EWHP-01- R4

Page 12 of 42

rating of cable offered in the bid.

2. If the manufacturer’s laboratory is accredited by

govt. /authorized body, then it shall be

acceptable for type testing.

3. Type test on one cable drum of each type/rating,

from the first lot, shall be conducted at Govt.-

approved / Internationally accredited labs.

b) R-Infra QAP

(Typical) [R4]

In general, all tests mentioned in the R-Infra QAP

(Characteristics – Typical) mentioned in Annexure-F

shall be included in the Routine Tests, Type Tests

and Acceptance Tests stated above.

c) Routine Tests 1. Measurement of Electrical Resistance

2. HV Test with power frequency AC voltage

3. PD test

4. “Strippability Test” at both the ends of cable for

each drum, to check the freely-strippable

property of the Insulation Screen (outer semi-

con). [R4]

Test results from the above tests must appear in

the documents forwarded by the vendor for

Inspection call / waival.

d) Inspection 1. The Buyer reserves the right to witness all tests

specified on completed cables.

2. The Buyer reserves the right to inspect cables at

Sellers works at any time prior to dispatch, to

verify compliance with the specifications.

3. In-process (stage inspection) and final

inspection call intimation shall be given

sufficiently in advance to the purchaser.

4. Minimum lot size of Cables to be offered for

inspection shall be mutually agreed between

Purchaser and Vendor, before placing the order.

Vendor shall raise inspection call only after a

minimum lot size is ready and with due factory

routine tests already carried out. [R4]

e) Acceptance Tests Acceptance Tests shall be conducted as per Cl. 18.2

SP-EWHP-01- R4

Page 13 of 42

of IS 7098 (Part-2) and the approved Quality

Assurance Plan (QAP) for each lot of cables.

Following tests shall also be carried out during the

Acceptance Tests :

a) “Wafer Boil Test” for checking integrity of semi-

conducting layers.

b) “Void-and-contamination Test” for the Insulation

c) “Strippability Test” at both the ends of cable for

each drum, to check freely-strippable property of

the Insulation Screen (outer semi-con). [R4]

d) “Water Penetration Test (WPT)”, as per

applicable IEC standards, to check adequacy of

water-blocking arrangement provided inside the

conductor. [R4]

Number of times WPT is to be carried out,

during Acceptance Test, shall be mutually

agreed and generally determined as follows :

a) For the order Qty. < 50 kms

: One no. WPT

b) For the order Qty. < 50 kms

: Two times WPT [R4]

f) Test Certificates (TC) Three sets of complete Test Certificates (Routine

tests and Acceptance tests) shall be submitted along

with the delivery of cables.

Soft copy of the TCs shall be separately e-mailed to

the Purchaser. [R4]

Note : [R4]

Make/grades of critical materials (such as, for

conductor screen, insulation, insulation screen, etc.),

actually used during manufacturing of cables for

order-on-hand, shall be clearly stated in the TCs

forwarded by the Manufacturer, enabling references

in future.

5.0.0 Drawing, Data and Manuals

a) Refer Annexure-A regarding Document

Submission.

SP-EWHP-01- R4

Page 14 of 42

b) Cross-Sectional Drawing shall show every

feature of construction, including the thickness /

diameter over every layer. This drawing shall

also state the text to be embossed over the

outer sheath - i.e. type/size, etc. of the cable,

drum no./lot no., sequential marking over every

meter, printing text on outer semi-con (“Do Not

Heat-Freely Strippable”), font sizes to be used,

additional text, if any, etc. Also, drum details,

markings to be made on both sides of the drum,

and so on. [R4]

5.0.1 Documents to be

submitted along with bid

The vendor shall submit :

a) Cross-sectional drawing [R4]

b) GTP (all data to appear)

c) Type Test certificates

d) Dimensional drawing for pulling eye

e) Fault Level Calculation for armour and copper

tape screen

f) Complete Cable Catalogue and Manual

g) Armour Coverage Calculation

5.0.2 Documents after award

of contract

Within 15 days, the seller has to submit four sets of

above-mentioned drawings, along with one soft copy

for buyer’s approval.

5.0.3 Final As-Built Drawings One soft copy of all documents, including type &

routine test certificates.

6.0.0 Drum length & tolerance

Cable length per drum

6.0.1 a) 11 KV, Three core

b) 33 KV, Three core

c) 11 KV, Single core

d) 33 KV, Single core

a) 300 mtr +/- 5 %

b) 200 mtr +/- 5 %

c) 500 mtr +/- 5 %

d) 500 mtr +/- 5 %

6.0.2 Overall tolerance +/- 2 % for the total cable length for the entire order.

SP-EWHP-01- R4

Page 15 of 42

6.0.3 Short length of cables Manufacturer shall take prior approval from

Purchaser for any supply of short length cables.

For 33 KV, 3-core/1-core cables, minimum

acceptable short length cable can be 150 meter and

250 meter respectively. Similarly, for 11 KV cables,

minimum acceptable short length cables can be 250

meter.

In any case, manufacturer shall not put two cable

pieces of different short lengths in same cable drum.

7.0.0 Packing, Shipping, Handling & Storage

a) Packing [R4]

1. Both the ends of the cables shall be properly

sealed to prevent any deterioration of the cable,

due to ingress of water, etc.

2. Cable inner end (starting end) shall project,

outside the completely wound cable, by

sufficient length enabling verify cable details,

including the initial length marking.

3. Similarly, outer end of the cable shall be saddled

/ secured to the drum properly to prevent any

external damage to the end at any time.

4. Before putting on wooden planks, protective

covers (thick plastic sheets, etc.) shall be

secured over the wound cable, to avoid any

abrasion by wooden planks, over the outer

sheath of the cable.

5. After providing the protective covers, the cable

drums shall be finally closed by wooden planks

(with saddles), without leaving any gaps

between the planks; i.e. 100 % covering shall be

SP-EWHP-01- R4

Page 16 of 42

ensured.

b) Drum Identification

Markings:

Direct marking (i.e. text painting through stencils,

etc.) shall be done on the drums, instead of attaching

labels, which may be misplaced/lost over a period of

time. [R4]

1. Drum identification number

2. Cable voltage grade

3. Cable code (e.g. A2XFY, etc.)

4. Number of cores and cross sectional area

5. Cable quantity, i.e. cable length (metre)

6. Purchase order number & date

7. SAP item code

8. Total weight of cable and drum (kg)

9. Manufacturer’s Name

10. Buyer’s name

11. Month & Year of Manufacturing

12. Direction of rotation of drum

13. Cable length final end-markings

(i.e., reading at the inner end and reading at the

outer end, just before packing, shall be marked

on the drum.)

c) Shipping information The seller shall give complete shipping information

concerning the weight, size of each package

d) Transit damage The seller shall be responsible for any transit

damage due to improper packing.

e) Type of Drum Steel / wooden drums, as per relevant IS / IEC.

(Wooden drums shall be with M.S. spindle plate with

nut-bolts)

f) Cable Drum handling The drums shall be with M.S. spindle plate (with nut-

bolts) of adequate size to suit the spindle rods,

normally required for handling the drums, according

to expected weight of the cable drums. [R4]

8.0.0 Quality Assurance Plan (QAP)

8.0.1 Vendor’s QAP Manufacturer shall submit QAP in line with R-Infra

SP-EWHP-01- R4

Page 17 of 42

QAP format (Annexure-F) for purchaser’s approval. [R4]

8.0.2 Inspection Points To be mutually identified and agreed upon in QAP.

9.0.0 Progress Reporting

9.0.1 Outline Document To be submitted for purchaser’s approval for outline

of programmes for production, stage-inspection,

testing, final inspection, packing, dispatch and

documentation.

9.0.2 Detailed Progress Report To be submitted to Purchaser once a month

containing :

i) Progress on material procurement

ii) Progress on fabrication (as applicable)

iii) Progress on assembly (as applicable)

iv) Progress on internal stage-inspection

v) Reason for any delay in total programme

vi) Details of test failures, if any, during

manufacturing stages.

vii) Progress on final box-up Constraints / Forward

Path

10.0.0 Deviation a) Deviations from this specification are only

acceptable, where the Seller has listed in his

quotation the requirements he cannot, or does

not, wish to comply with, and the Buyer has

accepted, in writing, the deviations before the

order is placed.

b) In the absence of any list of deviation, it will be

assumed by the Buyer that the Seller complies

fully with this specification.

SP-EWHP-01- R4

Page 18 of 42

Annexure – A

Scope, Documentation and Delivery schedule 1. Scope

A. Scope Design, manufacture, testing at manufacturer’s works

before dispatch, packing, delivery, unloading, stacking at

stores/site of H.T. Power cables, as per Purchaser’s

BOQ (Bill of Quantity).

B. Delivery Schedule To be filled up on a case-to-case basis.

a) Document Submission Submission of drawings, calculations, catalogues, manuals, test reports shall be as

follows. (Also refer clause 5.0.0 – Drawings, Data and Manuals.)

Legend: GTP : Guaranteed Technical Particulars TTR : Type Test Report RTR : Routine Test Report [R4]

Documents

Along with offer

After award of contract

- for Approval

Final documents

(after Approval)

GTP

3 copies ** 1 soft copy ** 1 soft copy + CD

Drawings 3 copies ** 1 soft copy ** 1 soft copy + CD

Calculations 3 copies ** 1 soft copy ** 1 soft copy + CD

Catalogues & Manual

1 copy each ** 1 soft copy + CD

Test Report 1 copy each of TTR

and sample RTR

** 1 soft copy + CD

** Soft copy and CD shall contain documents duly approved, signed and scanned.

SP-EWHP-01- R4

Page 19 of 42

3. Delivery Schedule [R4]

a) Delivery period Start Date : from date of LOI / LOA

b) Delivery period End Date : as agreed with supplier

c) Material dispatch Clearance : after inspection by purchaser

SP-EWHP-01- R4

Page 20 of 42

Annexure - B

GUARANTEED TECHNICAL PARTICULARS (GTP) [R4]

Note: [R4]

1) For every type / size of cable, every data shall be mentioned.

2) Seller may submit separate GTP for every type / size of cable, as suitable.

3) GTP requirements are generally as per IS : 7098 (Part-II).

4) GTP shall be read in line with purchaser’s Project Site Specific Requirement.

Sr. No.

Description Buyer’s requirement

Unit Seller’s Data

1.0 Purchase Req. No. - 2.0 Guarantee Period (Min.) 60 Months (from date

of commissioning) / 66 Months (from date of receipt at purchaser’s store) whichever is earlier

3.0 Applicable IS / IEC Standard followed by vendor

IS 7098 Part-2 / IEC 60502-2

4.0 Make - 5.0 Type

(as required by purchaser) [R4]

a) 11 kV, 3c x 150 sq. mm. A2XFY b) 11 kV, 3c x 300 sq. mm. A2XFY c) 33 kV, 3c x 400 sq. mm. A2XFY d) 33 kV, 1c x 630 sq. mm. A2XWaY e) 11 kV, 1c x 1000 sq. mm. A2XWaY f) 33 kV, 1c x 1000 sq. mm. A2XWaY 6.0 Voltage Grade a) 11 kV, 3c or 1c 6.35 / 11 kV b) 33 kV, 3c or 1c 19 / 33 kV 7.0 Maximum Conductor

temperature

A Continuous 90 deg. C B Short time 250 deg. C

8.0 Conductor

A Material and Grade As per Cl. 2.1.1 B Size As shown under 5.0

above

SP-EWHP-01- R4

Page 21 of 42

C Wires in each conductor As per Table 2 of IS 8130

Nos.

D Conductor Shape As per Cl. 2.1.1 c E Dia. of wires in each

conductor before compaction Manufacturer

Standard mm

F Diameter over conductor mm G Maximum Conductor

resistance at 20 ° C

a) 11 kV, 3c x 150 sq. mm. 0.2060 ohm/km b) 11 kV, 3c x 300 sq. mm. 0.1000 ohm/km c) 33 kV, 3c x 400 sq. mm. 0.0778 ohm/km d) 33 kV, 1c x 630 sq. mm. 0.0469 ohm/km e) 11 kV, 1c x 1000 sq. mm. 0.0291 ohm/km f) 33 kV, 1c x 1000 sq. mm. 0.0291 ohm/km

H Longitudinal Water Blocking Arrangement within conductor [R4]

Is it provided and shown in the cross-sectional drawing?

(Yes / No)

I Short circuit current-carrying capacity of conductor

kA for 1 sec.

9.0 Conductor Screen

(inner semi-con)

A Material & type As per Cl. 2.1.2 B Thickness (min)

[R4] 0.50 mm

C Diameter over conductor screen

mm

D Make and grade of semi-conducting compound

10.0 Insulation

A Insulation Material As per Cl. 2.1.3 B Nominal thickness

a) 11 kV, 3c or 1c 3.6 mm b) 33 kV, 3c or 1c 8.8 mm

C Minimum thickness a) 11 kV, 3c or 1c 3.14 mm b) 33 kV, 3c or 1c 7.82 mm

D Diameter over Insulation (Approx.)

mm

E Make and grade of Insulation compound

F Eccentricity [R4] As per IEC standards % G Water-tree retardant property Required [R4]

11A. Insulation Screen

(outer semi-con)

SP-EWHP-01- R4

Page 22 of 42

a. i) Thickness of freely strippable Semi conducting screen

0.50

mm

ii) Make and grade of semi-conducting compound

iii) Printing As per Cl. No. 2.1.4 (Yes / No)

iv) Ovality of the core [R4] As per IEC Standards %

b. Diameter over Insulation Screen (apprx.)

mm

11B. Water-Swellable Tape

(if required by Purchaser)

a) Thickness b) Weight c) Swell height d) Compatible to strippable /

non-strippable semi-con, over which it is applied.

e) Make & Grade f) Pre-slitted packed tapes

from sub-vendors approved by R-Infra

[R4]

a) 0.3 mm b) 118 gm / sq. m c) ≥ 12 mm in 1 min. d) Yes / No e) Pl. state f) Yes / No

11C. Cable Core identification

a) By coloured strips over

cores applied helically / longitudinally

b) Manufacturer’s name shall be permanently printed on the strips, at close intervals. [R4]

11D. Copper Tape

i) Dimensions a) Thickness : 0.1 +/- 5 % b) Width : 50 mm C) Overlap: 20% [R4]

Mm

ii) Fault current-carrying capacity of copper tape

Manufacturer’s Standard

(Calculation sheet shall be attached)

… kA for … sec.

11E. Diameter over laid up core

(apprx.) mm

SP-EWHP-01- R4

Page 23 of 42

12.0 Filler (Material and type)

As per Cl. 2.1.7 (Specify no. & size of filler at center & core

interstices)

a) 11 kV, 3c x 150 sq. mm. b) 11 kV, 3c x 300 sq. mm. c) 33 kV, 3c x 400 sq. mm. d) 11 kV or 33 kV, 1core Not applicable 12A.0 Binder Tape over laid-up cores 13.0 Inner Sheath

A Material and type As per Cl. 2.1.9 B Minimum thickness

a) 11 kV, 3c x 150 sq. mm. 0.6 mm b) 11 kV, 3c x 300 sq. mm. 0.7 mm c) 33 kV, 3c x 400 sq. mm. 0.7 mm d) 33 kV, 1c x 630 sq. mm. 0.6 mm e) 11 kV, 1c x 1000 sq. mm. 0.7 [R4] mm f) 33 kV, 1c x 1000 sq. mm. 0.7 mm

C Approx. dia. over inner sheath

mm

14.0 Armour As per

Manufacturer’s Standard and as per

purchaser’s site-specific requirements

A Material a) 11 kV, 3c G. I. Strip No. b) 33 kV, 3c G. I. Strip

[R4] No.

c) 11 kV or 33 kV, 1c non-magnetic wire armour

(Aluminium wire)

No.

B Armour – Wires

a) Diameter of wire b) Number of wires

(min.)

As per Table 4 of IS 7098 Part-2

(zero negative tolerance for diameter)

mm.

no.

SP-EWHP-01- R4

Page 24 of 42

C Armour – GI strips a) Width of strip &

Thickness of strip b) Number of strips

(min.)

4 x 0.8

(zero negative tolerance for thickness)

mm

no.

D Approx. Equivalent Area sq. mm. E Area covered by armour Min. 90 %

Calculation shall be attached.

%

F Dia. over armour - apprx. Mm G Fault current carrying

capacity of armour Calculation sheet shall be attached.

… kA for … sec.

15.0 Outer Sheath

A Material and type As per Cl. 2.2.12 B Thickness (min.) ** As per Table-5 of

IS 7098 Part-2

a) 11 kV, 3c x 150 sq. mm. ** mm b) 11 kV, 3c x 300 sq. mm. ** mm c) 33 kV, 3c x 400 sq. mm. ** mm d) 33 kV, 1c x 630 sq. mm. ** mm

e) 11 kV, 1c x 1000 sq. mm. ** mm f) 33 kV, 1c x 1000 sq. mm. ** mm

C Color Blue D Embossing

(details as per Cl. 2.1.12) Yes / No

E FRLS Properties [R4] As per customer’s requirement

16.0 Approx. overall diameter mm 17.0 Standard drum length

with tolerance

a) 11 kV, 3c x 150 / 300 sq. mm.

300 +/- 5% meters

b) 33 kV, 3c x 400 sq. mm.

200 +/- 5% meters

c) 33 kV, 1c x 630 sq. mm.

500 +/- 5% meters

d) 11 kV or 33 kV, 1c x 1000 sq. mm.

500 +/- 5% meters

17A Overall order tolerance

[R4] + / - 2 % for the total cable length for the

entire order.

18.0 Cable Drum

a. Type of drum Steel / Wooden

SP-EWHP-01- R4

Page 25 of 42

(Specify the relevant IS / IEC followed for

drum design) b. Markings on the drum

(as per Cl. 7.0.0) [R4] On both faces

18A.0 Cross-Sectional Drawing

(ref. Cl. 5.0.0) [R4]

Is drawing submitted, showing every

feature of constructions?

(Yes / No)

19.0 a. Pulling-eye Assembly

(provided at one running end) Refer drawing in Annexure-E [R4]

Is manufacturer’s / Sub-vendor’s

drawing submitted? (Yes / No)

b. Sealing-end Cap

(provided at the other end) Refer drawing in Annexure-E [R4]

Is manufacturer’s / Sub-Vendor’s

drawing submitted? (Yes / No)

20.0 Weights a) Net weight of cable

(apprx.) kg / km

b) Weight of empty drum Kg c) Weight of Cable with drum kg 21.0 Continuous current rating for

standard I. S. condition laid Direct

a) In ground 30° C Amp b) In duct 30° C Amp c) In air 40° C Amp 22.0 (not used) 23.0 Electrical Parameters at

Maximum Operating temperature:

A AC Resistance ohm / km B Reactance at 50 c/s ohm / km C Impedance ohm / km D Zero sequence impedance ohm / km E Positive sequence

impedance ohm / km

F Negative sequence impedance

ohm / km

G Capacitance micro-farad / km

SP-EWHP-01- R4

Page 26 of 42

24.0 Recommended minimum

bending radius --- x O. D. mm

25.0 De-rating factor for following

Ambient Temperatures : Ground / Air

a) At 30° C b) At 35° C c) At 40° C d) At 45° C e) At 50° C 26.0 Group factor for following

numbers of cables laid : Touching Trefoil

a) 3 Nos. b) 4 Nos. c) 5 Nos. d) 6 Nos.

27.0 Recommended pressure for

laying cable using power winch

30 N / mm2 N / sq. mm.

28.0 Process of Cross-linking of

Polyethylene

a) 11 kV, 3c or 1c Dry Cure process only [R4]

b) 33 kV, 3c or 1c Dry Cure process only

29.0 Type test

(TTR - Type Test Report) Is copy of latest valid TTR for respective sizes enclosed? (Yes / No)

30.0 Quality Assurance Plan

(QAP) [R4]

Is QAP Format (Annexure-F), duly filled in and enclosed? (Yes / No)

31.0 List of Sub-Vendors

for construction items (Annexure-C) [R4]

Is this list enclosed for R-Infra approval?

(Yes / No)

SP-EWHP-01- R4

Page 27 of 42

Annexure - C

List of Sub-Vendors

for critical items [R4]

Vendor to state sub-vendors’ names for other items, wherever approved names are not

mentioned, for purchaser’s approval during pre-order / post-order stages.

Ser. No.

Description of Material R-Infra

Approved

@ Sub-Vendors

@ Dow Chemicals , U.S.A.

@ Borealis , Sweden 1. XLPE Compound

@ Hanwha , Seoul , South Korea

@ Dow Chemicals , U.S.A.

@ Borealis , Sweden 2. Semi-Conducting Compound

@ Hanwha , Seoul , South Korea

@ Lantor

@ Geca

@ Freudenberg 3.

Conductor Water-Blocking

tapes / yarn / powder

@ Scapa

@ Lantor

@ Geca

@ Freudenberg

@ Scapa

@ Miracle

4. Water-Swellable Tapes

(Pre-slitted)

@ Tekstilna (Slovenia)

@ Bharat Aluminium Co. Ltd. (BALCO)

@ Hindustan Aluminium Co. Ltd. (HINDALCO)

5. E.C. Grade Aluminium Rod

@ National Aluminium Co. Ltd. (NALCO)

SP-EWHP-01- R4

Page 28 of 42

6. Aluminium Alloy

7. E.C. Grade Copper Rod

8. H.T.G.S. Wire

9. PVC Compound

10. PVC Resin

11. Galvanised Steel Wires /

Strips

12. Copper Tape (for screening)

13. P. P. Fillers

SP-EWHP-01- R4

Page 29 of 42

Annexure - D

Service Conditions [R4] (Atmospheric / Soil conditions at Site)

A. Mumbai a) Average grade atmospheric

condition

Heavily polluted, salt-laden, dusty, humid

with possibility of condensation

b) Average grade soil condition Water-logged

c) Maximum altitude above sea

level

1000 M

d) Ambient Air temperature i) Highest : 45 deg C

ii) Average : 35 deg C

iii) Minimum : 15 deg C

e) Relative Humidity 100 % Max

f) Thermal Resistivity of Soil 150 deg. C . cm / W max.

g) Seismic Zone 3

h) Rainfall 3000 mm concentrated in four months

B. Delhi a) Average grade atmospheric

condition

Heavily polluted, dry

b) Average grade soil condition

c) Maximum altitude above sea

level

1000 M

d) Air temperature Ambient i) Highest : 50 deg C

ii) Average : 40 deg C

iii) Minimum : 0 deg C

e) Relative Humidity 100 % max

f) Thermal Resistivity of Soil 150 deg. C . cm / W max.

g) Seismic Zone 4


SP-EWHP-01- R4

Page 30 of 42

Annexure E

1. General Arrangement Drawing for Cable Pulling Eye [R4]

2. General Arrangement Drawing for End-sealing Cap [R4]

Both the above drawings are given on next pages.

Ø130

Ø90

PULLIN

G B

LOCK H

OU

SING

4

THR

EAD

30°

Ø90

30°

53

Ø90

15

15

SO

CK

ET FIXIN

G BLO

CK3

Thread

Ø8

15

LOC

KIN

G SCREW

10(Suitably lon

g to fix CAP (2)

with socket fixin

g block (3)

15

'A'

Ø8

Weldin

g tack(Typical)

FIXED

PART

RO

TATIN

G PAR

TTH

RO

UG

H 360°

THR

EAD

CAP

2PU

LLING

EYE1

Ø110

THR

EADIN

SID

E

THR

EADIN

SID

E

3045

50Ø

31

Ø25

10

Ø16

'A'

'A'

CO

ND

UC

TOR SO

CKET5

(for crimpin

g on conductor)

'B'

'B'

VIEW

-AV

IEW-B

THR

EADM

16

Ø90

Weldin

g tack(Typical)

THIS PA

RT (SPH

ERE) W

ELD

EDTO

PULLIN

G E

YE SHALL

SW

IVEL FR

EE A

T ANY AN

GLE.

PULLIN

G EYE

OPTIO

NA

L AR

RANG

EMEN

T

ThreadO

UTSID

E

NO

.D

ISCR

IPTION

QTY.

MATER

IAL

1 2 3 4 5 6 7 8 9

PULLIN

G EYE

SPR

ING

. WAS

HER

PULLIN

G B

LOCK

HO

USIN

G

SO

CK

ET FIXIN

G BLO

CK

PLAIN

WAS

HER

CO

ND

UC

TOR

SOCKET

NU

T

LOC

K N

UT

LOC

KIN

G SCREW

1 311 33 3 3 2M

.S.Z

inc-Plated

M.S

.Zinc-Plated

M.S

.Zinc-Plated

M.S

.Zinc-Plated

M.S

.Zinc-Plated

M.S

.Zinc-Plated

M.S

.Zinc-Plated

M.S

.Zinc-Plated

AL.

All D

imensions are in m

m, unless otherw

ise stated.This draw

ing is typical / indicative.Separate dim

ensioned drawing for cable

pulling eye assembly, suitable for required size &

rating of cables, shall besubm

itted for approval,prior to manufacturing.

After fixing cable pulling eye, P.U

.(Poly-Urethane) C

ompound shall be

poured to occupy inner spaces to avoid ingress of Water / M

oisture.A

fter P.U.C

ompound oozes/flow

s out from the cable side,the sam

e edgeshall be sealed w

ith suitable sleeve/Tape.

NO

TE:1)2)

CAB

LE PULLIN

G EYE A

SSEM

BLY

MIS

C/E/4-1133/1699

3)4)

10

CAP

1M

.S.Z

inc-Plated

C A

B L E

CRIM

PING CO

ND

UC

TOR

CO

ND

UC

TOR

4

5

32

76

98

1

10H

ole forpouring P.U

.Com

pound

2Nos.Ø

8holeS

tanderdThreaded forlocking M

8 screw

15

'A'

SEC

TION

AL VIEW

15

Ø60

Apprx.

Exploded View

Final Assem

bly

This space sh

all be filled with P.U

.Coum

pound

Ø16

Ø8

Hole to let air out

APPR

X.90A

PPRX.30

2040

260

Ø118

125

6

Ø102

CO

ND

UCTO

RSO

CKET

CAP

Ø48

APPRX.

3N

OS-Ø

18 H

OLES

60

(Made of apprx.Ø

12mm

rod)

To accomm

odate M8 screw

no th

reading required

CAP

RO

TATIN

G PAR

TTH

RO

UG

H 360°

(TYPICAL)

SU

ITABLE FO

R M16 BO

LT

Hole to let air out

20.0

3.030.0

30.0

15.0

Ø102

For cable size 33kV, 3/C X 400sq m

m A

l XLPE.D

iameter over conductor : 23.8m

m apprx.

Overall diam

eter : 108±3m

m apprx.

Pulling force applicable on the cable : 30 N/sq m

mPulling eye shall w

ithstand total force of : 36000N+

Safety m

argin

EXAM

PLE:1)2)

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRO

DU

CED

BY

AN

AU

TOD

ESK

ED

UC

ATI

ON

AL

PRO

DU

CT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRO

DU

CED

BY A

N A

UTO

DESK

EDU

CA

TION

AL PR

OD

UC

T

SP-EWHP-01- R4

Page 33 of 42

Annexure- F

QAP Format (Quality Assurance Plan) For H. T. Cables (Typical) (Page 1 to 10) [R4]

Typical Characteristics are mentioned in the above QAP format, which is appearing on the next pages. Vendor shall submit the QAP, duly filled in, in accordance with IS / IEC standards and manufacturer’s standards/procedures, for Purchaser’s approval, during pre-order / post-order stages.

QUALITY ASSURANCE PLAN (QAP) FOR H. T. CABLES 09.03.2012 (Typical Format)

Legend : SV : Sub-Vendor of Cable Manufacturer, MFR : Cable Manufacturer, R-Infra : Reliance Infra-Structure Ltd., PS : Purchase Specification of Cable Vendor, R-Infra Spec. - R-Infra Specification P - Perform , V - Verify , W - Witness

SV MFR R-Infra

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

A. RAW MATERIALS

a) Tensile strength kg P P/V V/Wb) Resistivity at 20 Deg C ohm-

mm2/kmP P/V V/W

c) Diameter mm P P/V V/Wd) Chemical composition P V Ve) Surface finish -- P P V/Wf) Purity of Aluminium / Copper One sample

per POP P V/W

a) Tensile Strength N/sq.mm. P P/V Vb) Elongation at break % P P/V Vc) Thermal stability min. P P/V Vd) Additional test

(for FRLS Sheathing compound only)

i) Oxygen Index test P P/V Vii) Temperature Index test P P/V Viii) Smoke generation test P P/V Viv) Acid gas generation test P P/V V

a) Packing P V Vb) Tensile Strength N/sq.mm. P P/V Vc) Elongation at break % P P/V Vd) Hot set test % P P/V Ve) Volume Resistivity ohm-cm P P/V Vf) Cure Curve (Max. Torque) lb-in - P Vg) Density g/cc P P/V V

a) Packing P V Vb) Volume Resistivity P P/V Vc) Tensile Strength N/sq.mm. P P/V Vd) Elongation at break % P P/V Ve) Cure Curve (Max. Torque) lb-in - P Vf) Density g/cc P P/V Vg) Firmly bonded over conductor P P/V Vh) Easly strippable over XLPE

insulationP P/V V

a) Thickness & width mm x mm P P/V Vb) Tensile Strength N/sq.mm. P P/V Vc) Elongation at break % P P/V Vd) Resistivity ohm-mm2/km P P/V V

Remarks

1 Aluminium / Copper Rod

QUANTUM OF CHECK

ACCEPTANCE NORMS

FORMAT OF RECORD

AGENCYSr. No.

COMPONENT CLASS

2 PVC Compound

3 XLPE Compound

5 Copper Tape

4 Semi-conducting Compound

Measuring Equipment / Technique

REFERENCE DOCUMENT /

TEST

CHARACTERISTICS & OPERATIONS

UNIT TYPE OF CHECK

Page 1 of 8



SV MFR R-Infra

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

RemarksQUANTUM OF CHECK

ACCEPTANCE NORMS

FORMAT OF RECORD

AGENCYSr. No.

COMPONENT CLASS Measuring Equipment / Technique


TEST


UNIT TYPE OF CHECK

a) Dimensions mm x mm P P/V Vb) Surface condition/finish -- P P/V Vc) Tensile Strength N/sq.mm. P P/V Vd) Elongation at break % P P/V Ve) Torsion test for round wire P P/V Vf) Wrapping test P P/V Vg) Mass of zinc coating g/sq.m. P P/V Vh) Uniformity of zinc coating dips P P/V Vi) Adhesion test P P/V Vj) Resistivity test ohm-mm2/km P P/V V

a) Dimensions mm x mm P P/V Vb) Swelling height mm P P/V Vc) Resistivity P P/V Vd) Mass g/sq.m. P P/V V

a) Dimension mm As per IS - P P Vb) Finish & workman ship -- - P P V

a) Dimensions & Material mm R-Infra approved drawing

- P P V

b) Finish & workman ship -- - P P V c) Tension test on pulling eye N/sq.mm. - P P V

10 Binder Tape Dimensions & material mm - P P V

11 Poly-propylene Net Filler

Size - P P V

a) Bore diameter mm R-Infra approved drawing

- - P V

b) Length of end cap mm R-Infra approved drawing

- - P V

c) hot melt adhesive

B. IN-PROCESS INSPECTION

a) Diameter mm - P V/Wb) Surface finish -- - P V/Wc) Tensile test (for Al) N/sq.mm. IS: 8130/84 IS: 8130/84 - P V/Wd) Elongation test (for Cu) IS: 8130/84 IS: 8130/84 - P V/We) Wrapping test (for Al) IS: 8130/84 IS: 8130/84 - P V/Wf) D.C. Resistance at 20 deg C ohm-cm P V/W

a) No. of wires/strands no. - P Vb) Lay length & Lay direction mm - P Vc) Dia of conductor mm - P Vd) Surface finish -- - P Ve) Mass of conductor kg IS 8130/84 - P V

2

12 Heat-shrinkable EndCap

Stranding

1 Wire Drawing

9 Cable Pulling Eye

R-Infra approved drawing

6

7 Water Swellable Tape(Non-Woven)

8 Steel / Wooden Drum

Armour wires/strips (Galvanised Steel)

Page 2 of 8



SV MFR R-Infra

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


ACCEPTANCE NORMS

FORMAT OF RECORD

AGENCYSr. No.



TEST


UNIT TYPE OF CHECK

a) Compound Make/Grade -- - - P Vb) i) Thickness of Conductor

Screen ii) Thickness of Insulation iii) Thickness of Insulation Screen

mm IS 7098 (Part 2) / 85

IS 7098 (Part 2) / 85

- P V

c) Surface finish -- - P Vd) Printing on outer semi-conducting

layer- P V

e) Tensile Strength IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V

f) Elongation at break IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V

g) Hot set test % IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V

h) Eccentricity of insulation % - P Vi) Core diameter

and Ovality check on coremm - P V

j) Void & contamination test for insulation (Silicon Oil test)

no. - P V/W

k) Condition of Triple Extrude - P V/Wl) CCV tube pressure (N2) and

temperaturebars & deg. C

- P V/W

m) Temperature of Extruder (65 mm, 80 mm, 150 mm)

deg C - P V/W

n) Haul off / Line Speed m/min - P V/Wo) Dimensions and Condition of dies

& nipplemm - P V/W

p) Freely strippable insulation screen (Strippability Test)

IS:7098/3, 93 Cl. No. 20

IS:7098/3, 93 Cl. No. 20

- P V/W

q) Water boil test for extruded semi-conducting layers

BIS draft Specn

BIS draft Specn - P V/W

r) Longitudinal Water-Blocking Test IEC 60502-2 IEC 60502-2 - P V/W

a) Dimensions (thickness x width) mm x mm - P Vb) Tape Application (Overlap) % - P Vc) Lay direction --

a) Diameter under copper tape mm - P Vb) Dimensions (thickness x wid mm x mm - P Vc) Number of tapes - P Vd) Tape application (Overlap) % - P Ve) Diameter over copper tape mm - P V

a) Identification of cores -- - P Vb) Direction of lay & core sequence Measuring

tapeIS 7098(Part

2)/85IS 7098(Part

2)/85- P V

c) Lay length Scale - P Vd) Shape of laid up assembly -- - P Ve) P. P. Filler size mm - P Vf) Diameter over Lay-up mm - P V

“DO NOT HEAT, FREELY STRIPPABLE”

6 Laying up

5 Copper Tape- taping

4 Water Swellable Semi-conducting

3 Core Extrusion (CCV)

Conductor Screen

+

Insulation(XLPE with water-tree retardant property)

+

Insulation Screen

Page 3 of 8



SV MFR R-Infra

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


ACCEPTANCE NORMS

FORMAT OF RECORD

AGENCYSr. No.



TEST


UNIT TYPE OF CHECK

a) Material & type -- - P Vb) Thickness mm IS 7098(Part

2) / 85IS 7098(Part 2) /

85- P V

c) Surface finish -- - P Vd) Colour of inner sheath - P Ve) Diameter over Inner Sheath mm - P V

a) Dimension of wires/strips mm - P Vb) No. of wires/strip no. - P Vc) Armour coverage % IS 7098(Part

2)/85IS 7098(Part

2)/85- P V

d) Direction of lay IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V

e) Lay length/Gear setting mm - P Vf) Surface finish -- - P Vg) Diameter over Armour mm - P Vh) Rubberised cotton tape over

armour

a) Material & type - - P Vb) Anti termite additives - P Vc) Thickness mm - P Vd) Overall diameter of the Cable mm - P Ve) Surface finish & colour of sheath -- - P Vf) Cable length verification - P Vg) Embossing / Printing / Sequential

Marking- P V

a) Cable appearance -- - P Vb) Ovality check over completed

cable- P V

c) Drum appearance,including fixing of M. S. Spindle Plates

-- - P V

d) Winding -- - P Ve) Packing -- - P Vf) Embossing / Printing -- - P Vg) Surface finish -- - P V

C. TESTING & INSPECTION

Type Tests at Vendor's works

a) Tests on conductor One samplei) Annealing test for copper IS 8130/84 IS 8130/84 - P Vii) Tensile test for aluminium N/mm2 IS 8130/84 IS 8130/84 - P Viii) Wrapping test for aluminium IS 8130/84 IS 8130/84 - P Viv) Conductor resistance test ohm/km IS 8130/84 IS 8130/84 - P V/W

8 Armouring

7 Inner Sheath

9 Outer Sheath

As per R-Infra’s approved GTP/Cross-sectional drawing

1. Type Tests

10 Cable Winding over the drum

Page 4 of 8



SV MFR R-Infra

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


ACCEPTANCE NORMS

FORMAT OF RECORD

AGENCYSr. No.



TEST


UNIT TYPE OF CHECK

b) Tests on armouring wires/stripsOne sample

i) Dimensions of wire/strip mm - P V/Wii) Tensile strength & Elongation at

breakN/mm2 IS 3975 IS 3975 - P V/W

iii) Torsion test for round wire IS 3975 IS 3975 - P V/Wiv) Winding test for strip

(Wrapping Test for Al wires/formed wires only)

IS 3975 IS 3975 - P V/W

v) Uniformity of zinc coating(for GS)

dips IS 3975 IS 3975 - P V/W

vi) Mass of zinc coating(for GS)

g/mm2 IS 3975 IS 3975 - P V/W

vii) Adhesion Test IS IS - P V/Wviii) Resistivity of wire/strip ohm-cm IS 3975 IS 3975 - P V/W

c) Test for thickness of insulation & sheath

mm One sample - P V/W

d) Physical tests on insulation One sample i) Tensile strength & Elongation test

(before and after ageing)N/mm2, % IS 7098(Part

2)/85IS 7098(Part

2)/85- P V/W

ii) Ageing in air oven IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

iii) Hot set test % IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

iv) Shrinkage test IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

v) Water absorption test (gravimetric) IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

vi) Eccentricity test - P V/W

e) Physical tests on outer sheath One samplei) Tensile strength & Elongation test

at break(before and after ageing)

IS 5831/84 IS 5831/84 - P V/W

ii) Ageing in air oven IS 5831/84 IS 5831/84 - P V/Wiii) Shrinkage test % IS 5831/84 IS 5831/84 - P V/Wiv) Hot deformation test IS 5831/84 IS 5831/84 - P V/Wv) Loss of mass test in air oven IS 5831/84 IS 5831/84 - P V/Wvi) Heat shock test IS 5831/84 IS 5831/84 - P V/Wvii) Thermal stability test deg C,

timeIS 5831/84 IS 5831/84 - P V/W

viii) Cold Bend Test IS 5831/84 IS 5831/84 - P V/Wix) Cold Impact Test IS 5831/84 IS 5831/84 - P V/W

IS 7098(Part 2)/85

IS 3975, IS 10810 Pt. 36

Page 5 of 8



SV MFR R-Infra

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


ACCEPTANCE NORMS

FORMAT OF RECORD

AGENCYSr. No.



TEST


UNIT TYPE OF CHECK

f) Electrical Tests One samplei) Partial discharge test pC IS 7098(Part

2)/85IS 7098(Part

2)/85- P V/W

ii) Bending test IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

iii) Partial discharge test pC IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

iv) Dielectric power factor test (as a function of voltage)

IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

v) Dielectric power factor test (as a function of temperature)

IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

vi) Heating cycle test deg C, hrs., nos.

IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

vii) Dielectric power factor as a function of voltage

IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

viii) Partial discharge test pC IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

ix) Impulse withstand test IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

x) High voltage test kV, min. IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

g) Insulation Resistance test (Volume Resistivity test)

ohm-cm One sample IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

h) Flammability Test One sample IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

i) Water Penetration Test (WPT)on core(Longitudinal Water-Blocking test)

One sample IEC 60502-2 IEC 60502-2 - P V/W

j) Freely strippable insulation screen (Strippability Test)

- P V/W

k) Ovality check on core - P V/Wl) Ovality check on completed Cable - P V/W

m) Check on fixing of M.S. Spindle Plates

- P V/W

o) Additional tests on FRLS-type cables only

1) Tests on FRLS outer sheath One samplei) Oxygen Index test - P Vii) Temperature Index test - P Viii) Acid gas generation test - P Viv) Smoke density test - P V

2) Flammability test on a piece of completely ready FRLS cable

One sample IS 7098(Part 2)/85 /

IEC 332 (Part 3- Category

B)

IS 7098(Part 2)/85

- P V/W

Page 6 of 8



SV MFR R-Infra

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


ACCEPTANCE NORMS

FORMAT OF RECORD

AGENCYSr. No.



TEST


UNIT TYPE OF CHECK

a) High Voltage kV, min. 100 % IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V

b) Conductor Resistance ohm/km 100 % IS 8130/84 IS 8130/84 - P Vc) Partial Discharge pC 100 % IS 7098(Part

2)/85IS 7098(Part

2)/85- P V

d) Freely strippable insulation screen(Strippability Test)

- P V

a) Annealing test for copper IS 8130/84 IS 8130/84 - P Vb) Tensile test for aluminium IS 8130/84 IS 8130/84 - P Vc) Wrapping test for aluminium IS 8130/84 IS 8130/84 - P Vd) Conductor resistance test ohm/km IS 8130/84 IS 8130/84 - P We) Test for thickness of insulation &

sheathIS 7098(Part

2)/85IS 7098(Part

2)/85- P W

f) Eccentricity test on insulationg) Hot set test for insulation % IS 7098(Part

2)/85IS 7098(Part

2)/85- P W

h) Tensile strength & Elongation at break of insulation & outer sheath

N/mm2, % - P W

i) Partial discharge test pC IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P W

j) High voltage test kV, min. IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P W

k) Insulation resistance (Volume resistivity) test

ohm-cm IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P W

l) Tests for dimension and number of armour wires/strips

mm - P W

m) i) Test for anti-termite property of outer sheath

- P W

ii) Test for anti-rodent property of outer sheath

- P W

n) Winding of cable on drumTo check :i) cable appearanceii) drum appearanceiii) cable windingiv) packingv) embossing / printingvi) length verificationvii) mass of cableviii) ovality check on completed cablex) Fixing of M. S. Plates

One drum from offered lot

- P W

Routin Tests

Appendix A to IS 7098(Part 2)/85

Appendix A to IS7098(Part 2)/85

IS 3975, IS 10810 Pt. 36

IS 7098 (Part 2 ) / 85 & IS 5831/84 (Type ST2)

3. Acceptance Tests

2.

Page 7 of 8



SV MFR R-Infra

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


ACCEPTANCE NORMS

FORMAT OF RECORD

AGENCYSr. No.



TEST


UNIT TYPE OF CHECK

o) Water Boil test to check the integrity of semiconducting layer

- P W

p) Void and Contamination test for insulation

- P W

q) Swell Height of water-swellable tape

- P W

r) Lay Ratio of armour - P Ws) Mass of Zinc coating for armour - P Wt) Uniformity of Zinc coating - P Wu) Printing over semicon - P Wv) Water Penetration Test (WPT)

on core (i.e. Longitudinal Water-Blocking Test)

IEC 60502-2 IEC 60502-2 - P W

w) Freely strippable insulation screen(Strippability Test)

- P W

x) Ovality check on core - P W

y) Additional tests for FRLS cables1) Tests on FRLS sheath

i) Oxygen Index test - P Wii) Temperature Index test - P Wiii) Acid gas generation test - P Wiv) Smoke density test - P W

2) Flammability test on finished cable - P W

D. PACKING & MARKINGS

a) Cable end sealing 100 % IS 7098(Part 2)/85

IS 7098(Part 2)/85

- P V/W

b) Pulling eye at leading end 100 % - P V/Wc) Stencilling / Marking on drum 100 % IS 7098(Part

2):85IS 7098(Part

2):85- P V

Note :

1. Checks specified above for Raw Material, In-Process and Final Inspection shall be as relevant to the specific cable construction.2. Number of samples shall be selected as per Factory Standard/Agreement wherever ‘sample’ is indicated for extent of check.3. Plant standards shall be followed in case Technical Data Sheet does not include requirements for characteristics to be checked.4. R-Infra's may witness Raw materials and In process Inspections, in addition to Type/Routine/Acceptance tests, at any time/stage of manufacturing.5. R-Infra’s Inspector shall randomly select a cable drum for type testing at vendor's premises / CPRI / ERDA among the lot offered for inspection.6. For each of the offered lot for inspection, R-Infra may randomly select one cable drum for testing of end cap “Destructive testing” to verify adhesion of sealing cap to cable outer sheath. Similarly, pulling eye shall be tested with 30N/mm2 pressure.

Appendix A to IS 7098(Part 2)/85

IS 3975, IS 10810 Pt. 36 & IS 3975, IS 10810 Pt. 36

1 Packing & Marking

Page 8 of 8

SP-EWHP-01- R4

Page 42 of 42

Annexure- G

Testing and manufacturing process requirements w. r. t. TR- XLPE insulation All cables made with TR-XLPE Insulation should be tested and/or certified to meet the following performance parameters as per ANSI /ICEA S-94-649 after one year AWTT. Property Units Requirements Values Min. Avg. Electrical Breakdown Strength(qual. test)

Kv/mm > 25

Impulse Strength Kv/mm > 83 Water Tree Length mm 0.25 Max. Bowtie Tree Density

(Number per 16.4 cu. cm)

Maximum 15 (0.12-0.25 mm range)

Manufacturing processes to produce high-quality cables with the following characteristics: • Cure consistency with hot set/creep less than 100% • No voids larger than 75 microns per 16.4 cubic cm • No ambers larger than 250 microns per 16.4 cubic cm • No contaminants larger than 125 microns and less than 5 between 50-125 microns per

cubic 16.4 cubic cm tested. • Neutral indent on cable is less than 375 microns • Cable insulation concentricity greater than 90% tested • No protrusions greater than 75 microns at the conductor shield and 125 microns at the

insulation shield

SP-LALU-01-R0

Page 2 of 18

Index

1.0 General Specification…………………………………………………………………. 03-08 2.0 Annexure – A : Scope & Documentation………………………………………… 09-10 3.0 Annexure – B : Ambient Conditions…………………………………………….....11-11 4.0 Annexure – C1 : Guaranteed Tech. Particulars for 66KV Lightning Arrester......12-14 5.0 Annexure – C2 : Guaranteed Tech. Particulars for 33KV Lightning Arrester….. 15-17 6.0 Annexure – D : Recommended spares (Data by supplier)……………………18-18

SP-LALU-01-R0

Page 3 of 18

General Specification 1.0.0 Codes & Standards

Materials, equipment and methods used in the manufacture of Lightning Arresters

shall conform to the latest edition of following –

National Standards

Standard Code Standard Description Indian Electricity Rules

Indian electricity act

CBIP manual

IS : 3070 – Part 3 Lightning Arresters for Alternating Current Systems

IS : 2071 - Part I Method of high voltage testing

IS : 2629 - 1985 Recommended Practice for Hot-Dip Galvanizing of Iron and Steel

IS : 5621 - 1980 Hollow insulators for use in electrical equipment

IS : 6639 - 1972 Specification for Hexagon Bolts for Steel Structures

International Standards

Standard Code Standard Description IEC 60099-4-2001 Metal-Oxide Surge Arresters without gaps for AC Systems

Important Note : In the event of direct conflict between various order documents, the precedence of authority of documents shall be as follows – i. Specification including applicable codes, standards ii. Guaranteed Technical Particulars (GTP) iii. Approved Vendor Drawings

SP-LALU-01-R0

Page 4 of 18

Sr. No.

Description Requirement / Rating

2.0.0 Design Features

Common for both 66KV and 33 KV Lightning Arresters

2.1.0 Application To be used for protection of transformers, circuit breakers and other sub-station equipment against lightning and switching surges.

2.2.0 Type of Lightning Arrester

Gap-less metal oxide type (ZnO Type).

2.3.0 Pressure relief device

Pressure relief device of class 40 KA shall be provided.

2.4.0 Accessories Refer Annexure-A : Scope of Supply.

2.5.0 Mounting LA mounting vertically on steel structures with insulating bases. Surge counters in weather proof enclosures suitable for mounting on structure of lightning arrester.

2.6.0 Line side Terminal Connectors

Suitable for ACSR Zebra/ Goat conductor (Refer GTP)

2.7.0 Ground Terminal Connectors

Suitable for 50x6 mm GS flat

2.8.0 Surge Counter Non-resettable type 2.9.0 Name plate

Marking Following minimum information must be marked – i) Name of the manufacturer ii) Type and serial No. iii) Model No. iv) Rated voltage v) Max. continuous Operating Voltage vi) Nominal discharge current vii) Pr. Relief Class viii) Identification mark on each separately housed unit to

enable it to be replaced in correct position after the multiunit arrester has been dismantled.

3.0.0

Approved Make of Components

Common for both 66KV and 33 KV Lightning Arresters

3.1.0 Insulators JSI / WSI/ BHEL/ Modern/ Saravana

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Sr. No.


4.0.0 Testing & Inspection 4.1.0 Internal Test Manufacturer shall carry out comprehensive inspection

and testing during manufacture of the equipment.

4.2.0 Type test The product must be of type tested quality. Type test reports shall be submitted for the type, size & rating of equipment offered along with bid. If the manufacturer’s lab is accredited by govt./ authorised body then it shall be acceptable for type testing.

4.3.0 Routine test As per relevant IS / IEC.

4.4.0 Acceptance test As per relevant IS / IEC.

4.5.0 Test Witness 4.5.1

The Buyer reserves the right to witness all tests specified on completed product.

4.5.2 The Buyer reserves the right to inspect the product at the Sellers works at any time prior to dispatch, to verify compliance with the specifications.

4.5.3 In-process and final inspection call intimation shall be given in advance to purchaser.

4.6.0 Tests on fitting and Accessories

As per Manufacturer’s Standards and relevant IS / IEC.

5.0.0 Drawing, Data &

Manuals

5.1.0 To be submitted along with bid

The seller has to submit :

i) Tentative GA / cross sectional drawing of product showing all the views / sections.

ii) Detailed reference list of customers already using the offered product during the last 5 years with particular emphasis on units of similar design and rating.

iii) Completely filled GTP

iv) Deviations from this specification. Only deviations approved in writing before award of contract shall be accepted.

v) Details of manufacturer's quality assurance standards and program and ISO 9000 series or equivalent national certification.

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Sr. No.


vi) Type test reports shall be submitted for the type, size & rating of product / equipment offered along with bid. In case the type test report for identical product is not available then type test report of nearby size/ rating shall be submitted for review. They shall be considered valid for 5 years from date of test performed on product /equipment.

vii) Complete product catalogue and Manual along with the bid.

viii) Recommended spare parts and consumable items for five years of operation with prices and spare parts catalogue with price list for future requirements

ix) Bill of material with make, model & quantity of items. 5.2.0 To be submitted after

award of contract The seller has to submit : for buyer’s Approval (A) / Reference (R)

i) Program for production and testing (A) ii) Guaranteed Technical Particulars (A) iii) Calculations to substantiate choice of electrical, structural,

mechanical component size / ratings (A)

iv) a) Detailed dimension drawing for all components, geb) Drawings of major components (A) c) Rating and diagram plate (R)

v) Detailed loading drawing to enable the buyer to design and construct foundations (as applicable) (R)

vi) Transport / Shipping dimensions with weights (R) vii) Detailed Bill of Materials for all fittings and

accessories with their make, model & tag no. etc. (A)

viii) Detailed installation and commissioning instructions (R) ix) Quality plan (A)

5.3.0 Submittals required prior

to dispatch The seller has to submit :

i) Inspection and test reports, carried out in manufacturer’s works (R)

ii) Test certificates of all bought out items iii) Operation and maintenance Instruction as well as trouble

shooting charts/ manuals 5.4.0 Drawing and document

sizes Standard size paper A0, A1, A2, A3, A4

5.5.0 No of drgs. / Documents required at different stages

As per Annexure- A

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Sr. No.


6.0.0 Packing 6.1.0 Packing

Protection Against corrosion, dampness, heavy rains, breakage and vibration

6.2.0 Packing for accessories and spares

Robust wooden non returnable packing case with all the above protection & identification Label

6.3.0 Packing Identification Label

In each packing case, following details are required :

i) Individual serial number ii) Purchaser's name iii) PO number (along with SAP item code, if any) & date iv) Equipment Tag no. (if any) v) Destination vi) Manufacturer / Supplier's name vii) Address of Manufacturer / Supplier / it’s agent viii) Description and Quantity ix) Country of origin x) Month & year of Manufacturing xi) Case measurements xii) Gross and net weights in kilograms xiii) All necessary slinging and stacking instructions 7.0.0 Shipping,

Handling & Storage

7.1.0 Shipping Information

The seller shall give complete shipping information concerning weight, size etc. of each package.

7.2.0 Shipping Constraints

The seller shall ascertain at an early date before the commencement of manufacture, any transport limitations such as weights, dimensions, road culverts, overhead lines, free access etc. from the manufacturing plant to the project site. Bidder shall furnish the confirmation that the proposed packages can be safely transported, as normal or oversize packages, upto the site. Any modifications required in the infrastructure and cost thereof in this connection shall be brought to the notice of the Purchaser.

7.3.0 Transit Damage The seller shall be responsible for any transit damage due to improper packing.

7.4.0 Handling & Storage

Manufacturer’s instructions shall be followed. Detail handling & storage instruction sheet / manual needs to be furnished before commencement of supply.

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Sr. No.


8.0.0 Quality Assurance

8.1.0 Vendor quality plan

To be submitted for purchaser approval

8.2.0 Inspection points To be mutually identified & agreed in quality plan

9.0.0 Progress

Reporting

9.1.0 Outline Document

To be submitted for purchaser approval for outline of production, inspection, testing, inspection, packing, dispatch, documentation program

9.2.0 Detailed Progress report

To be submitted to Purchaser once a month containing

i) Progress on material procurement ii) Progress on fabrication (As applicable) iii) Progress on assembly (As applicable)

iv) Progress on internal stage inspection v) Reason for any delay in total program

vi) Details of test failures if any in manufacturing stages

vii) Progress on final box up viii) Constraints / Forward path

10.0.0 Deviations i) Deviations from this Specification are only acceptable where the

Seller has listed in his quotation the requirements he can’t or does not wish to comply with and the buyer has accepted in writing the deviations before the order is placed.

ii) In the absence of a list of deviations, it will be assumed by the Buyer that the Seller complies fully with this specification.

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Annexure – A

1.0 Scope

Sr. No.


1.0.0 Scope 1.1.0 Main Equipment Design, manufacture, assembly & testing at manufacturer’s works

before dispatch, packing & delivery of Lightning Arresters rated up to 66 kV.

1.2.0 Accessories

i) Supporting insulators for LA. ii) Line terminal connectors.

iii) Surge counter with leakage current ammeter.

iv) Grounding terminal bracket

v) Necessary flanges alongwith all stainless steel hardware like nut bolts/ washers etc. for mounting of LA & surge Counter

vi) Suitably sized Cu flat or insulated copper cable for connection between LA and surge counter

vii) Any other item necessary or usual for efficient performance and satisfactory maintenance under the various operating and atmospheric conditions

1.3.0 Documentation Submission of all drawings & documents pertaining to the equipment.

1.4.0 Site Supervision Supervision of testing & commissioning of equipment at site. 1.5.0 Bill of Materials Complete bill of materials shall be submitted in the following

format. Sr. No.

Purchaser Equipment Tag No. / Sap Code

Equipment Description

Location / Substation Name

Unit Quantity

e.g. Santacruz

Nos. e.g. 1

e.g. Alaknanda

Nos. e.g. 6

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2.0.0 Document Submission Submission of drawings, calculations, catalogues, manuals, test reports shall be as follows :

Item Description

Along with offer

For Approval after award of contract


Remarks

Drawings 3 copies (Typical drgs)

4 copies + 1 Soft Copy


See Clause 5.0.0 for various drawings required

Calculations 3 copies (Typical)



See Clause 5.0.0 for details

Catalogues 1 copy 6 copies + 1 soft copy in CD

Instruction manual


Test Report 2 copies 6 copies + 1 soft copy in CD

Type test and routine test reports

3.0.0 Delivery Schedule

Sr. No.


i) Delivery period start date

From date of purchase order

ii) Delivery period end date

As agreed with supplier

iii) Material dispatch clearance

After inspection by purchaser

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Annexure – B Ambient Conditions : A) Mumbai a) Average grade

atmosphere Heavily polluted , salt Laden, dusty, humid with possibility of condensation

b) Maximum altitude above sea level

1000 M

c) Ambient Air temperature

Highest 45 deg C, Average 35 deg C

d) Minimum ambient air temperature

20 deg C

e) Relative Humidity 100 % Max f) Thermal Resistivity of

Soil 150 Deg. C cm/W

g) Seismic Zone 3 h) Rainfall 3000 mm concentrated in four months

B) Delhi a) Average grade

atmosphere Heavily polluted, dry


1000 M

c) Ambient Air temperature

Highest 50 deg C, Average 40 deg C

d) Minimum ambient air temperature

0 Deg C

e) Relative Humidity 100 % Max f) Thermal Resistivity of

Soil 150 Deg. C cm/W

g) Seismic Zone 4 h) Rainfall 750 mm concentrated in four months

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Annexure – C1 Guaranteed Tech. Particulars for 66KV Lightning Arrester

Sr. No.

Description Data By Purchaser Data by Supplier

1 Name of manufacturer 2 Type Gapless, ZnO type,

single pole, heavy duty, station class, pedestal mounted

3 Model 4 No. of units. 5 Installation Outdoor

6 Application Protection of Transformers, circuit breakers, lines and other outdoor S/S equipment.

7 LA connection to system Phase to earth

8 Type of Conductor ACSR Zebra / Goat 9 Construction Single Phase

10 Rated voltage of arrester (KVrms) 60 KV 11 Nominal discharge current (Amps)

(8x20 micro sec. wave) peak value 10KA

12 System Particulars i) Highest System Voltage 72.5 KV

ii) Frequency 50HZ ± 5% iii) System neutral Solidly earthed

Max. value of temporary over voltage & its max. duration

- Insulation level of equipment to be protected

325 KVp

iv)

- System short circuit level 31.5KA for 3 seconds. 13 Maximum continuous operating

voltage (MCOV) 52KV

14 Impulse withstand current 100KAp

15 Long Duration discharge class 3 16 Minimum single impulse energy

capability

17 Maximum residual voltage at switching impulse current of 1KAp (30/60 micro sec. wave)

136 KVp

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Sr. No.


18 Max. residual voltage (1x20 micro sec. wave)

i) At 05 KAp ii) At 10 KAp iii) At 20 KAp 19 Minimum creepage distance

31 mm/KV

20 Pressure relief class 40KA 21 Reference current (mA)

22 Leakage current at COV (mA) Resistive Capacitive

23 Dry and wet power frequency withstand voltage of arrester insulation (KVrms)

24 Virtual steepness for front of wave for above (KV/micro sec.)

25 Ratio of system voltage withstand level to protection level of surge arrester

26 High current impulse withstand 4/10 micro second peak value (KV)

27 Long duration current Impulse i) Current peak. ii) Virtual duration. 28 Temporary Over Voltage Capacity

(KVp)

i) At 0.1 Sec. ii) At 1.0 Sec. iii) At 10.0 Sec. iv) At 100.0 Sec. 29 Weight of complete unit (Kg) 30 Height of complete unit from base to

the line side (mm)

31 Minimum recommended spacing between arresters Centro to Centro (mm)

32 Clearance required from ground equipment at various heights of arresters unit (mm)

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Sr. No.


33 Earthing arrangement provided for earthing side of arresters.

34 Mounting flanges dimensional details.

35 Type and range of milli-ampere meter.

36 Type and specifications of the surge connecters.

37 Surge counter min. current for recording a lightning stroke

200 Amp

38 Surge counter max. disch. Current withstand

100KA peak for 4/10 wave shape.

39 Range of continuous leakage current at rated voltage with variation due to change in temperature & frequency

40 Size and length of flexible Cu cable for connection between LA & surge counter

41 Voltage time curve for thermal stability of LA after a stroke

To be provided

42 Paint shade of surge counter housing

Polyurethane, 692 of IS-5

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Annexure – C2 Guaranteed Tech. Particulars for 33KV Lightning Arrester

Sr. No.


1 Name of manufacturer 2 Type Gapless, ZnO type,

single pole, heavy duty, station class, pedestal mounted

3 Model 4 No. of units. 5 Installation Outdoor

6 Application Protection of Transformers, circuit breakers, lines and other outdoor S/S equipment.

7 LA connection to system Phase to earth

8 Type of Conductor ACSR Zebra / Goat 9 Construction Single Phase

10 Rated voltage of arrester (KVrms) 30 KV 11 Nominal discharge current (Amps)

(8x20 micro sec. wave) peak value 10KA

12 System Particulars i) Highest System Voltage 36 KV

ii) Frequency 50HZ ± 5% iii) System neutral Solidly earthed

Max. value of temporary over voltage & its max. duration

- Insulation level of equipment to be protected

170 KVp

iv)

- System short circuit level 26.3KA for 3 seconds. 13 Maximum continuous operating

voltage (MCOV) 25KV

14 Impulse withstand current 100KAp

15 Long Duration discharge class 3 16 Minimum single impulse energy

capability

17 Maximum residual voltage at switching impulse current of 1KAp (30/60 micro sec. wave)

70 KVp

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Sr. No.


18 Max. residual voltage (1x20 micro sec. wave)

i) At 05 KAp ii) At 10 KAp iii) At 20 KAp 19 Minimum creepage distance

31 mm/KV

20 Pressure relief class 40KA 21 Reference current (mA)

22 Leakage current at COV (mA) Resistive Capacitive

23 Dry and wet power frequency withstand voltage of arrester insulation (KVrms)

24 Virtual steepness for front of wave for above (KV/micro sec.)

25 Ratio of system voltage withstand level to protection level of surge arrester

26 High current impulse withstand 4/10 micro second peak value (KV)

27 Long duration current Impulse i) Current peak. ii) Virtual duration. 28 Temporary Over Voltage Capacity

(KVp)

i) At 0.1 Sec. ii) At 1.0 Sec. iii) At 10.0 Sec. iv) At 100.0 Sec. 29 Weight of complete unit (Kg) 30 Height of complete unit from base to

the line side (mm)

31 Minimum recommended spacing between arresters Centro to Centro (mm)

32 Clearance required from ground equipment at various heights of arresters unit (mm)

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Sr. No.


33 Earthing arrangement provided for earthing side of arresters.

34 Mounting flanges dimensional details.

35 Type and range of milli-ampere meter.

36 Type and specifications of the surge connecters.

37 Surge counter min. current for recording a lightning stroke

200 Amp

38 Surge counter max. disch. Current withstand

100KA peak for 4/10 wave shape.

39 Range of continuous leakage current at rated voltage with variation due to change in temperature & frequency

40 Size and length of flexible Cu cable for connection between LA & surge counter

41 Voltage time curve for thermal stability of LA after a stroke

To be provided

42 Paint shade of surge counter housing

Polyurethane, 692 of IS-5

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Annexure – D

Recommended spares (Data by supplier) List of recommended spares shall be submitted as follows – Sr. No.

Description of spare part Unit Quantity

1 Nos. 2 Nos. 3 4 5 6

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Index

General Specification ........................................................................................................................ 3

1.0.0 Codes & standards ............................................................................................................ 3

2.0.0 Circuit Breaker design features ....................................................................................... 4

3.0.0 Quality assurance............................................................................................................ 11

4.0.0 Testing & Inspection ....................................................................................................... 12

5.0.0 Drawings, Data & manuals ............................................................................................. 13

6.0.0 Packing, Shipping, Handling & Storage........................................................................ 15

7.0.0 Progress reporting .......................................................................................................... 16

8.0.0 Deviations ......................................................................................................................... 16

Annexure - A Scope of supply .................................................................................................. 17

Annexure – B Service Conditions ............................................................................................. 19

Annexure - C Guaranteed Technical Particulars (33kV Circuit Breaker)............................. 20

Annexure - D Guaranteed Technical Particulars (66kV Circuit Breaker)............................. 31

Annexure - E Recommended spares (Data by supplier) ....................................................... 43

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General Specification 1.0.0 Codes & standards

The circuit breakers shall be designed, manufactured and tested in accordance with the

latest applicable Indian Standard, IEC standard and CBIP manuals as listed below-

National Standards

Indian Electricity Rules


CBIP manual

IS-2516 Specification for circuit. Breaker.

IS-13118-1991 Specification for high voltage alternating current circuit-

breaker

IS-335-1995 Insulating oil for Transformer & Switchgear.

IS-2090-1973 Bushing for alternating voltage above 1000 volts.

IS-731-1971 Insulator for Overhead lines.

IS -996-1979 Single phase small AC and Universal Electric Motors.

IS-7572-1974 Guide for testing single phase AC and Universal motors.

IS 4237-1967 General Requirement for switchgear for voltage not

exceeding 1Kv.

IS-2147-1962 degree of protection provided by enclosure for low-

voltage switchgear control gear.

IS-1554 Part-I 1988 PVC insulated cables up to & including 1100 volts.

IS-2208 HRC Cartridge fuses links up to 650 volts.

IS-375 Outdoor switchgear & control gear matching with latest

IS/IEC requirement

IS-2544 Porcelain Post Insulator

IS-5621 Hollow insulators for use in electrical equipment

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International Standards

IEC-56 Specification for high voltage alternating current circuit-

breaker

IEC- 62271 – 100 High Voltage alternating Current Circuit Breaker

IEC-60694 Common specification for high voltage switchgear and

control gear standards

IEC-376 SF6 Gas

2.0.0 Circuit Breaker design features 2.1.0 Contacts

2.1.1 Making & Breaking

Contacts

Hermetically sealed, free from atmospheric

effects , adjustable to allow for wear and shall

have a minimum number of moveable parts

and adjustments to accomplish these results.

2.1.2 Arcing Contacts First to close and last to open

2.1.3 Main Contacts First to open and last to close.

2.1.4 Material of tips of contact Silver-plated and have tungsten alloy tipping.

2.2.0 Sulphur Hexa Fluoride Gas

(SF6 Gas)

SF6 gas shall comply with IEC 376 , suitable

in all respect for use in the switchgear under

all the operating conditions.

2.3.0 Operating Mechanism a) Suitable for high speed re-closing, anti-

pumping and trip free (as per IEC definition)

electrically or mechanically under every

method of closing (except during closing for

maintenance).

b) The operating mechanism shall be such

that the failure of any auxiliary spring will not

prevent tripping.

2.4.0 Indicators Electrical indicator as well as mechanical

indicator shall be provided for

a) Open and close position indication of

breaker.

b) Spring Charged indication

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c) Local / Remote indication

These indications shall be located in a

position where it will be visible to a man

standing on the ground with the

mechanism housing closed.

An operation counter shall also be

provided with each breaker.

SF6 gas density monitor shall be provided at

1.5 metre from ground level, tubing between

gauge & breaker shall be stainless steel.

2.5.0 Closing Coil Closing coil shall operate correctly at all

values of voltage between 85% and 110% of

the rated voltage.

2.6.0 Tripping Coil a) Shunt trip shall operate correctly at all

values of supply voltage between 70% and

110% of rated voltage.

b) Trip coil shall be suitable for trip circuit

supervision, the relay for monitoring which will

be provided by the purchaser and mounted on

control panel.

2.7.0 Remote / Local Closing &

Tripping

a) Operating mechanism shall normally be

operated by remote electrical control.

Electrical tripping shall be performed by

shunt trip coils.

b) A conveniently located manual tripping

lever or button shall also be provided for

local tripping of the breaker and

simultaneously opening the re-closing

circuit. It shall be possible to trip the

breaker in the event of auxiliary supply

failure.

2.8.0 Manual Spring Charging For spring charged mechanism a local manual

closing device which can easily be operated

by one man standing on the ground shall also

be provided for maintenance purpose and

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direction of motion of handle shall be clearly

marked.

2.9.0 Spring Operated

Mechanism

a) Complete with motor, opening spring and

closing spring with limit switch for

automatic charging and all other necessary

accessories to make the mechanism a

complete operating unit

b) One close-open operation shall be possible

after failure of power supply to motor

c) Closing action of the circuit breaker shall

compress the opening spring ready for

tripping.

2.10.0 Motors Motors shall be ‘Universal type’ capable of

satisfactory operation for the application and

duty as required by the driven equipment.

Motor shall be rated for 240 Volts AC.

2.10.1 Duty Requirement Motors shall be capable of giving rated output

without reduction in the expected life span

when operated continuously in the system.

2.10.2 Supply Voltage Variation ± 10%

2.10.3 Frequency variation ± 5%

2.10.4 Combined voltage &

frequency

± 10%

2.11.0 Interlocks Necessary interlocks to prevent the closing or

opening of the breaker under low SF6

pressure & devices for initiating alarm shall be

provided

2.12.0 Control Cabinets Operating mechanism and all accessories

shall be enclosed in a control cabinet. A

common marshalling box for the three poles of

the breaker shall be provided.

2.12.1 Enclosure Control cabinet enclosure shall be sheet steel

enclosed, dust, weather and vermin proof with

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a degree of protection as mentioned in

Annexure-B.

2.12.2 Mounting Control cabinets shall be suitable for mounting

on the breaker structure at sufficient height for

easy operation.

2.12.3 Doors & Locks Control, cabinets shall be provided with double

hinged doors with padlocking arrangement. All

doors, removable covers and plates shall be

gasketed all around with neoprene gaskets.

2.12.4 Control cables Control cable entries shall be from bottom.

Suitable removable, undrilled cable gland

plate shall be provided on the cabinet for this

purpose.

2.12.5 Heaters Suitable heaters with auto control for ON/OFF

at preset temp. shall be mounted in the

cabinet to prevent condensation. ON/OFF

switch and fuse shall also be provided. Heater

shall be suitable for 240 V AC supply voltage

2.12.6 Terminals a) Terminal blocks shall be 650 V grade 10

Amps rating, complete with insulated

barriers stud type terminals, washers, nuts

and lock nuts and identification strips.

Separate stud shall be provided for

incoming and outgoing, wires. Marking of

terminal strips shall correspond to wire

number on diagrams.

b) Terminal blocks shall be fully enclosed with

easily removable covers and made of

moulded non-inflammable plastic material.

The terminal blocks shall have marking

strips and all terminals shall be clearly

marked with identification numbers or

letters to facilitate connections to the

external wiring

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c) 20 percent spare terminal blocks shall be

provided for purchasers use in addition to

those already provided for interlocks

2.12.7 Illumination A suitable switch to operate on opening of the

door shall be provide to illuminate the interior

of the control cabinet

2.12.8 Control Cubicle Wiring All wiring shall be carried out with 650 Volt

grade Single core stranded, flexible copper

conductor wire with PVC insulation and shall

be vermin and rodent proof. The size of

control wire shall be 1.5 sqmm.

2.12.9 Lugs Wire terminations shall be made with

solderless crimping type of tinned copper lugs.

All lugs shall be pre insulated type.

2.12.10 Sleeves Insulated sleeves shall be provided at all the

wire ends and shall fit tightly on the wires and

shall not fall off when the wire is disconnected

from terminal blocks. The wire numbers on the

wiring diagram shall be in accordance with IS:

375 or to the international Standard

2.12.11 Push Button a) Close/Trip push buttons shall be

momentary contact type. The color of the

push button shall be subject to approval of

the Purchaser. Each push Button shall be

provided with integral inscription plates

engraved with their function.

b) All push buttons shall have two normally

open and two normally open and two c

normally closed contacts. The contact shall

be able to make and carry 5 Amps at

220V/110V/50V DC and shall be capable

of breaking 1 Amp. Inductive load

2.12.12 Switches All control switches shall be of rotary switch

type and toggle/piano switches shall not be

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accepted. All control switches shall be rated

for 220V/110V/50V DC

2.12.13 MCB 220V/110V/50V DC, 16A DP MCB shall be

used for control circuit and 240V AC, 10A SPN

MCB shall be used for motor and heater

circuit.

2.12.14 Earthing a) All metal parts not intended for carrying

current shall be made of stainless steel and

connected to duplicate earthing system and

suitable terminals shall be provided on each

equipment or part of equipment in conformity

with the I.E. Rules and relevant ISS.

b) The earth continuity conductor shall have

sufficient cross-sectional area so as afford a

low resistance path for the full fault current

corresponding to the Circuit breaker rating

c) The size of earth continuity conductor shall

be as large as possible to reduce the potential

rise to minimum of the metal frame of the

circuit breaker and in no case, more than 10

V.

d) The size of earth conductor shall also be

adequate, so as to restrict the temperature

rise to the limit without causing any damage to

the earth connection while short circuit current

flows through it for the short time rating of the

equipment

e) No riveted joints in current conducting path

shall be permitted. Only bolted joints with

proper size of nuts & bolts with Plain/spring

washer and also locking washer is permitted.

The nuts & bolts shall made of stainless steel

only.

2.13.0 Caution/Danger Plate Caution name plate shall be provided at all

points where terminals are likely to remain live

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and isolation is possibly only at remote end

2.14.0 Safety Interlocks Suitable provision for safety electrical

interlocks shall be made as per advise of the

purchaser

2.15.0 Bushings Porcelain used in bushing manufacture shall

be homogenous, free from laminations,

cavities and other flaws or imperfections that

might affect the mechanical or di-electric

quality and shall be thoroughly vitrified tough

and impervious to moisture

2.15.1 Colour & Glazing of

Bushing

Glazing of the porcelain shall be of uniform

brown colour free from blisters, burns and

similar other defects.

2.16.0 Galvanization All iron parts shall be hot-dip galvanized

2.17.0 Nuts & Bolts Nuts & Bolts shall be of stainless steel only

2.18.0 Joints All joints shall be airtight. Surfaces of the joints

shall be tarred up, porcelain parts by grinding

and metal part of machining.

2.19.0 Creepage distance The Creepage distance of the bushing shall in

no case be less than 31mm/KV. Suitable for

heavily polluted atmosphere

2.20.0 Duty Requirement of

Circuit Breaker

a) The circuit breakers shall be totally re strike

free under all duty conditions as per

specification in Annexure-B

b) The circuit breakers shall meet the above

duty requirements in case of application on

U/G cable circuits as well as on power

transformer

c) The circuit breaker shall be capable of

Breaking the steady and transient

magnetizing current corresponding to

transformers Breaking line charging

currents as per IS 2165 (Part-II Sec.2) with

a temporary over voltage of 3.5 PU without

the use of opening resistors.

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d) Breaking 25% of the rated fault current at

twice rated voltage under phase

oppositions conditions as per IS: 9135

1979

2.21.0 Transient recovery voltage The rated transient recovery voltage for

terminal fault and short line faults shall be as

per IS: 2165.

2.22.0 Temperature rise The temperature rise and the maximum

temperature on any part of the equipment

when in service at site under continuous full

load condition and exposed continuously in

the direct rays of the sun shall not exceed the

permissible limits as per table-4 of IEC

publication No. 56-2 and IS: 2516 when the

standard specifies the limit of temperature

rise. This shall not be exceeded when

corrected for the difference between the

ambient temperature at site and the ambient

temperature specified in the relevant

specification. The correction proposed shall be

stated in the tender and shall be subjected to

the approval of the purchaser

2.23.0 Painting Polyurethane based paints shall be used. The

color for the finishing paint shall be light gray

as per shade No. 692 of IS-5.

2.24.0 Line side terminal

connector

Al-alloy terminal connectors shall suitable for

single/twin ACSR conductor as specified in

Annexure-C.

3.0.0 Quality assurance 3.1.0 Vendor quality plan To be submitted for purchaser approval

3.2.0 Inspection points To be mutually identified & agreed in

quality plan

SP-CBLU-01-R0

Page 12 of 43

4.0.0 Testing & Inspection 4.1.0 Tests Test shall be carried out in accordance

with IS-13118 / IEC-56 / IEC-60694 /

IEC-62271-100

4.1.1 Type Tests a) Circuit breakers must be of type tested

quality.

b) Incase, the product is never type

tested earlier, seller has to conduct the

type tests from Govt. recognized /

Internationally accredited test Labs at

their own cost, before commencement

of supply.

c) If the manufacturer’s lab is accredited

by govt. /authorised body then it shall

be acceptable for type testing.

4.1.2 Routine test Test shall be carried out in accordance

with IS-13118 / IEC-56 / IEC-60694 / IEC-

62271-100

4.1.3 Acceptance Test Test shall be carried out in accordance

with IS-13118 / IEC-56 / IEC-60694 / IEC-

62271-100

4.2.0 Tests on fitting and Accessories As per Manufacturer’s Standards

4.3.0 Inspection and Testing a) The Buyer reserves the right to witness

all tests specified on completed

product.

b) The Buyer reserves the right to inspect

the product at the Sellers works at any

time prior to dispatch, to verify

compliance with the specifications.

c) In-process and final inspection call

intimation shall be given in advance to

purchaser.

SP-CBLU-01-R0

Page 13 of 43

5.0.0 Drawings, Data & manuals 5.1.0 To be submitted along with bid The seller has to submit :

a-1: Complete assembly drawing of the

outdoor type circuit breaker showing plan,

elevation and typical sectional view giving

complete dimensions.

a-2: Assembly drawings and weight of

main component parts

a-3: Drawings showing the loads for

foundations

a-4: Schematic control and wiring diagram

in accordance with National / International

practice

a-5: Structural drawing and the breaker

mounting arrangement

a-6: Rating Plate diagram

a-7: Drawings of terminal connectors

b) Detailed reference list of customers

already using the offered product during the

last 5 years with similar design and rating.

c) Completely filled GTP

d) Deviations from this specification. Only

deviations approved in writing before

award of contract shall be accepted.

e) Details of manufacturer's quality

assurance standards and programme and

ISO 9000 series or equivalent national

certification.

f) Type test reports shall be submitted for

the type, size & rating of product /

equipment offered along with bid. They

shall be considered valid for 5 years from

date of test performed on product

/equipment.

SP-CBLU-01-R0

Page 14 of 43

g) Complete product catalogue and

Manual along with the bid.

h) Recommended spare parts and

consumable items for five years of operation

with prices and spare parts catalogue with

price list for future requirements

5.2.0 After award of contract, seller has to

submit mentioned drawings for

buyer’s Approval (A) / Reference

(R)

a) Programme for production and testing (A)

b) Guaranteed Technical Particulars (A)

c) Calculations to substantiate choice of

electrical, structural, mechanical component

size / ratings (A)

e-1: General arrangement drawing of the

circuit breaker (A).

e-2: Schematic wiring diagram of the circuit

breaker external wiring termination

along with terminal and wiring

numbers for the various equipment

controlled from the control panel etc

(A)

e-3: Foundation drawings of circuit breaker

with size & nos of foundation bolts (A)

e-4: Structural erection drawings (A)

e-5: Terminal connector drawings. (A)

e-6: Detailed loading drawing to enable

the buyer to design and construct

foundations (as applicable) (R)

e-7: General arrangement drawing of

control cabinet (A)

f) detailed installation and commissioning

instructions (R)

g) quality plan

SP-CBLU-01-R0

Page 15 of 43

5.3.0 Submittals required prior to

dispatch

a) Inspection and test reports, carried out

in manufacturer’s works (R)

b) Test certificates of all bought out items

c) Operation and maintenance Instruction as

well as trouble shooting charts/ manuals

5.4.0 Drawing and document sizes Standard size paper A0, A1, A2, A3, A4

5.5.0 No of drgs. / Documents required at

different stages

As per Annexure- A

6.0.0 Packing, Shipping, Handling & Storage 6.1.1 Packing Protection Against corrosion, dampness, heavy

rains, breakage and vibration

6.1.2 Packing for accessories and spares Robust wooden non returnable packing

case with all the above protection &

identification Label

6.1.3 Packing Identification Label In each packing case, following details

are required :

a) Individual serial number

b) Purchaser's name

c) PO number (along with SAP item code,

if any) & date

d) Equipment Tag no. (if any)

e) Destination

f) Manufacturer / Supplier's name

g) Address of Manufacturer / Supplier /

it’s agent

h) Description and Quantity

i) Country of origin

j) Month & year of Manufacturing

k) Case measurements

l) Gross and net weights in kilograms

m) All necessary slinging and stacking

instructions

6.2.0 Shipping a) Bidder shall furnish the confirmation that the proposed packages can be delivered safely upto the site.

SP-CBLU-01-R0

Page 16 of 43

b) The seller shall be responsible for all

transit damage due to improper packing.

6.3.0 Handling & Storage Manufacturer instruction shall be

followed. Detail handling & storage

instruction sheet / manual needs to be

furnished before commencement of

supply.

7.0.0 Progress reporting 7.1.0 Outline Document To be submitted for purchaser approval

for outline of production, inspection,

testing, packing, dispatch, documentation

programme

7.2.0 Detailed Progress report To be submitted to Purchaser once a

month containing

a) Progress on material procurement

b) Progress on fabrication (As applicable)

c) Progress on assembly (As applicable)

d) Progress on internal stage inspection

e) Reason for any delay in total

programme

f) Details of test failures if any in

manufacturing stages

g) Progress on final box up

h) Constraints / forward path

8.0.0 Deviations 8.0.0 Deviation from the Specification Deviations from this Specification shall

be stated in writing with the tender by

reference to the Specification

clause/GTP/Drawing and a description of

the alternative offer. In absence of such a

statement, it will be assumed by the

Buyer that the Seller complies fully with

this specification.

SP-CBLU-01-R0

Page 17 of 43

Annexure - A Scope of supply 1.0 The scope of supply shall include following 1.1 Design, manufacture, testing at manufacturer works before dispatch, packing,

delivery of Circuit Breaker as per BOQ and submission of all documents.

1.2 Supply of SF6 Gas cylinder for first filling.

1.3 Gas filling equipment with valves and tubing

1.4 Terminal connector

1.5 Hot-dip galvanized supporting structure along with foundation bolts.

1.6 Supervision of testing & commissioning of Circuit Breaker at site

1.7 BOQ as following -

Sr

No

Purchaser

Equipment Tag

No / SAP code

Equipment

Description

Location /

Substation name

Unit Quantity

1 e.g. Santacruz No e.g. 1

2 e.g. Alaknanda No e.g. 1

3

4

5

6

7


Submission of of drawings , calculations, catalogues, manuals, test reports shall be as

follows-

Along with offer For Approval

after award of

contract

Final after

approval

Remarks

Drawings 3 copies

(Typical drgs)

4 copies 6 copies + 1

soft copy in CD

See Clause 5.0

for various

drawings

required

Calculations 3 copies

(Typical)

4 copies 6 copies + 1

soft copy in CD

See Clause 5.0

for details

SP-CBLU-01-R0

Page 18 of 43

Catalogues 1 copy 6 copies + 1

soft copy in CD

Instruction

manual for the

circuit breaker

1 copy 6 copies + 1

soft copy in CD

Test Report 2 copies 6 copies + 1

soft copy in CD

Type test and

sample routine

test reports

Delivery schedule 2.1 Delivery period start date - from date of purchase order


2.3 Material dispatch clearance - after inspection by purchaser and

written dispatch clearances for

purchaser

SP-CBLU-01-R0

Page 19 of 43

Annexure – B Service Conditions

1.0.0 Mumbai Atmospheric

conditions

a) Average grade atmosphere : Heavily polluted , salt Laden, dusty, humid with

possibility of condensation

b) Maximum altitude above sea

level

1000 M

c) Ambient Air temperature Highest 45 deg C, Average 35 deg C

d) Minimum ambient air

temperature

20 deg C


f) Thermal Resistivity of Soil 150 Deg.C cm/W

g) Seismic Zone 3


2.0.0 Delhi Atmospheric conditions

a) Average grade atmosphere : Heavily polluted, dry

b) Maximum altitude above sea

level

1000 M

c) Ambient Air temperature Highest 50 deg C, Average 40 deg C

d) Minimum ambient air

temperature

0 Deg C


f) Thermal Resistivity of Soil 150 Deg.C cm/W

g) Seismic Zone 4


SP-CBLU-01-R0

Page 20 of 43

Annexure - C Guaranteed Technical Particulars (33kV Circuit Breaker) Sr. No. Description Data By Purchaser Data By Supplier

1.0 Name of manufacturer

2.0 Manufacturer’s type and

designation

3.0 Governing standard As per Clause 1.0.0 0f the

specification

4.0 Type of circuit breaker Vacuum

5.0 Installation Outdoor

6.0 No. of phase & no. of

pole

3 (Three), 3 (Three)

7.0 Rated voltage (kV) 33kV

8.0 Highest system voltage

(kV)

36kV

9.0 System Neutral Solidly earthed

10.0 Rated insulation level 170kVp

11.0 Frequency (Hz) 50Hz

12.0 Class

13.0 Normal current rating

(amps)

13.1 Under standard

conditions

1250A

13.2 Under site conditions

overload rating

a) 1 Hour

b) 3 Hour

13.3 Derating factor, if any, for

site condition

13.4 Temperature rise at

150% rating for 3 Hours

14.0 Short time current rating

(kA)

(a) For 1 Second

(b) For 3 Second

25kA

SP-CBLU-01-R0

Page 21 of 43

Sr. No. Description Data By Purchaser Data By Supplier

15.0 Maximum temperature

rise over highest ambient

( refer annexure-B ) due

to rated current in main

contacts, measured after

breaking test.

40 deg C

16.0 Rated short circuit

breaking current

16.1 Rated short circuit current

(Ac component)

16.2 Percentage DC

component at KV

16.3 Asymmetrical breaking

Current (including DC

Component)

16.4 Making capacity (KA

peak) – at KV

17.0 Rated operating

sequence

O-0.3Sec.-CO-3Min.-CO

18.0 Total break time (Milli-

seconds) :

18.1 For interruption of 10% of

the rated capacity

60ms (max)


the rated capacity

60ms (max)


the rated capacity

60ms (max)

18.4 For interruption of the full

rated capacity

60ms (max)

19.0 Arcing time (Milli-

seconds)

20.0 Opening time (Milli-

seconds)

SP-CBLU-01-R0

Page 22 of 43


21.0 Break time (Milli-seconds)

22.0 Closing time (Milli-

seconds)

60ms (max)

23.0 Minimum re-closing time

at rated interrupted

capacity from the instant

of the trip coil

energisation (Milli-

seconds)

24.0 Minimum dead time for

24.1 3 phase re-closing

(Milli-seconds)

24.2 Limit of adjustment of

dead time for 3- phase re-

closing.

25.0 Data on re-striking

voltage for 100%, 50% or

30% rated capacity

100% 50% 30%

25.1 Phase factor

25.2 Amplitude factor

25.3 Natural frequency (Hz)

25.4 Rate of rise of re-striking

voltage (V/micro sec.)

26.0 Rated out-of phase

breaking current

27.0 Rated line charging

breaking current

28.0 Maximum line charging current breaking capacity and corresponding over-voltage recorded in test:

a) On supply side

b) On line side

SP-CBLU-01-R0

Page 23 of 43


29.0 Maximum cable charging

current :

breaking capacity and

corresponding over-

voltage recorded in test:

a) On supply side.

b) On line side

30.0 Rated single capacitor

bank :

30.1 Capacity in rush current

handling, capability

30.2 Capacitive breaking

current Capability.

31.0 Rated small inductive

breaking current and the

corresponding over

voltage

32.0 First pole to clear factor 1.5

33.0 Rated transient recovery

voltage for terminal faults

34.0 Rated characters for

short line faults is rate of

rise.

30.0 Rated short circuit

breaking current

35.0 Dry 1-minute power

frequency test withstand

voltage, for complete

circuit breaker

35.1 Between line terminal and

grounded parts (KV rms)

80kV (rms)

SP-CBLU-01-R0

Page 24 of 43


35.2 Between terminals with

breaker contact open (KV

rms)

80kV (rms)

36.0 Wet 1-minute power


voltage :



75kV (rms)


breakers contacts open

(KV rms)

75kV (rms)

36.3 Between poles

37.0 1.2/50 microsecond wave

impulse with stand test

voltage for complete

circuit breaker:


ground (KV peak)

200kVp

37.2 Between terminal with

circuit breaker contacts

open.

200kVp

37.3 Between Poles

38.0 Minimum Clearance in

air.

38.1 Between phases (mm).

320mm (min)

38.2 Live parts and earth

(mm).

320mm (min)

38.3 Live parts to ground level

(mm).

3700mm (min)

SP-CBLU-01-R0

Page 25 of 43


39.0 Number of operation

possible without

maintenance.

39.1 At full rated interrupting

capacity

35.2 At 150% of rated current.

39.3 At 100% of rated current


40.0 Supporting Insulator

40.1 Make and type.

40.2 Insulation class A

40.3 Weight.

40.4 Transport dimensions.

40.5 Visible corona discharge

voltage

40.6 Dry-1 minute power

frequency flashover

voltage.

70kV rms

40.7 Wet-1-minute power

frequency lashover

voltage.

70kV rms

40.8 1.2/50 microsecond

impulse flashover

voltage.

170kVp

SP-CBLU-01-R0

Page 26 of 43


40.9 Creepage distance to

ground (mm)

a) Total

b) Protected

31mm/kV

41.0 No. of breaks per pole

1 (one)

42.0 Total length or breaks per

phase (mm)

43.0 Type of main contacts

44.0 Material of main contacts Silver plated copper

45.0 Whether main contacts

silver plated (Yes/No.)

Thickness of silver

coating on main contacts

(mm).

15 +/- 5 microns (min)

46.0 Contact pressure on

arcing contacts (kg/m2).

47.0 Type of arcing contacts

48.0 Contact pressure on main

contact (kg/m2).

49.0 Type of auxiliary

switches.

50.0 Whether all contacts

silver plated (Yes/No)

51.0 No. of auxiliary switch

contacts operating with all

three poles of breaker

51.1 Which are closed when

breaker is closed.

SP-CBLU-01-R0

Page 27 of 43


51.2 Which are open when

breaker is closed

51.3 Those adjustable with

respect to the position of

main contacts

52.0 No. of spare auxiliary

switch contacts operation

with all three poles of

breaker:


breaker is closed

6 (six)


breaker is closed

6 (six)



main contacts

53.0 Total number of terminal

block

54.0 Number of spare terminal

Block:

20%

55.0 Mounting flange details:

(a)Opening.

(b)Closing.

56.0 Tripping and closing

circuit voltage (V).

50V/110V/220V DC

57.0 Power required for trip

coil

58.0 Power required for

closing coil.

59.0 Rated voltage for spring

charging motor

240V AC

60.0 Rated voltage of space

heater and socket

240V AC

SP-CBLU-01-R0

Page 28 of 43


61.0 Contingencies for which

alarm provided

62.0 Design data for

supporting structure.

63.0 Weight of supporting

steel structure for

breaker.

64.0 Descriptive leaflets

enclosed (Yes/No)

65.0 Operating Mechanism

65.1 Type of operating

mechanism offered

65.2 Manufacturer’s type

designation

65.3 Material of control cabinet

enclosure

65.4 Thickness of sheet metal

enclosure

3.0mm for bottom and

2.5mm elsewhere.

65.5 Painting & colour shade Polyurethane paint, 692 of

IS-5

65.6 Enclosure protection IP 55

65.7 Pad locking facility

provided (Yes/No)

65.8 Wring

a) Control wire size

b) Insulation

c) Colour

1.5 Sqmm

650V

Grey for control, Black for

AC and Green for earth

SP-CBLU-01-R0

Page 29 of 43


65.9 Normal power consumption at rated voltage (Watt)

65.10 Normal power of spring

charging motor

65.11 Number of close/open

operation possible after

failure of AC supply to

motor

65.12 Time required to charge

the closing spring

65.13 Whether indication of

spring charged condition

provided in central control

cabinet (Yes/No)

Yes

65.14 Dimension of the control

cabinets.

65.15 Weight of control cabinet

66.0 Details of safety interlock

provided

67.0 Whether supporting structure for circuit breaker provided (Yes/No)

Yes

67.1 Thickness of galvanizing

(mm)

67.2 Size of foundation bolts

68.0 Material of nuts & bolts Stainless steel

69.0 Weight of 3-phase breaker complete with operating mechanism, insulating support frame work, etc.

SP-CBLU-01-R0

Page 30 of 43


70.0 Impact loading for

foundation design to

include load plus impact

value on opening at

maximum interrupting

ratings in terms of

equivalent of static load.

71.0 Weight of heaviest

package

SP-CBLU-01-R0

Page 31 of 43

Annexure - D Guaranteed Technical Particulars (66kV Circuit Breaker) Sr. No.

Description Data By Purchaser Data By Supplier

1.0 Name of manufacturer

2.0 Manufacturer’s type and

designation

3.0 Governing standard As per Clause 1.0.0 0f

the specification

4.0 Type of circuit breaker SF6

5.0 Installation Outdoor

6.0 No. of phase & no. of pole 3 (Three), 3 (Three)

7.0 Rated voltage (kV) 66 kV

8.0 Highest system voltage

(kV)

72.5 kV

9.0 System Neutral Solidly earthed

10.0 Rated insulation level 325kVp

11.0 Frequency (Hz) 50Hz

12.0 Class

13.0 Normal current rating

(amps)

13.1 Under standard conditions 2000A

13.2 Under site conditions

overload rating

c) 1 Hour

d) 3 Hour

13.3 Derating factor, if any, for

site condition

13.4 Temperature rise at 150%

rating for 3 Hours

14.0 Short time current rating

(kA)

(a) For 1 Second

(b) For 3 Second

31.5kA

SP-CBLU-01-R0

Page 32 of 43

Sr. No.


15.0 Maximum temperature rise

over highest ambient ( refer

annexure-B ) due to rated

current in main contacts,

measured after breaking

test.

40 deg C

16.0 Rated short circuit breaking

current

16.1 Rated short circuit current

(Ac component)

16.2 Percentage DC component

at KV

16.3 Asymmetrical breaking

Current (including DC

Component)

16.4 Making capacity (KA peak)

– at KV

17.0 Rated operating sequence O-0.3Sec.-CO-3Min.-CO

18.0 Total break time (Milli-

seconds) :


the rated capacity

60ms (max)


the rated capacity

60ms (max)


the rated capacity

60ms (max)

18.4 For interruption of the full

rated capacity

60ms (max)

19.0 Arcing time (Milli-seconds)

20.0 Opening time (Milli-

seconds)

21.0 Break time (Milli-seconds)

SP-CBLU-01-R0

Page 33 of 43

Sr. No.


22.0 Closing time (Milli-seconds) 60ms (max)

23.0 Minimum re-closing time at

rated interrupted capacity

from the instant of the trip

coil energisation (Milli-

seconds)

24.0 Minimum dead time for

24.1 3 phase re-closing

(Milli-seconds)

24.2 Limit of adjustment of dead

time for 3- phase re-

closing.

25.0 Data on re-striking voltage

for 100%, 50% or 30%

rated capacity

100% 50% 30%

25.1 Phase factor

25.2 Amplitude factor

25.3 Natural frequency (Hz)

25.4 Rate of rise of re-striking

voltage (V/micro sec.)

26.0 Rated out-of phase

breaking current

27.0 Rated line charging

breaking current

28.0 Maximum line charging

current :

breaking capacity and

corresponding over-voltage

recorded in test:

c) On supply side

d) On line side

SP-CBLU-01-R0

Page 34 of 43

Sr. No.


29.0 Maximum cable charging

current breaking capacity

and corresponding over-

voltage recorded in test:

a) On supply side.

b) On line side

30.0 Rated single capacitor

bank :

30.1 Capacity in rush current

handling, capability

30.2 Capacitive breaking current

Capability.

31.0 Rated small inductive

breaking current and the

corresponding over voltage

32.0 First pole to clear factor 1.5

33.0 Rated transient recovery

voltage for terminal faults

34.0 Rated characters for short

line faults is rate of rise.

30.0 Rated short circuit breaking

current

35.0 Dry 1-minute power


voltage, for complete circuit

breaker



140kV (rms)


breaker contact open (KV

rms)

140kV (rms)

SP-CBLU-01-R0

Page 35 of 43

Sr. No.


36.0 Wet 1-minute power


voltage :



140kV (rms)


breakers contacts open

(KV rms)

140kV (rms)

36.3 Between poles

37.0 1.2/50 microsecond wave

impulse with stand test

voltage for complete circuit

breaker:


ground (KV peak)

325kVp

37.2 Between terminal with

circuit breaker contacts

open.

325kVp

37.3 Between Poles

38.0 Minimum Clearance in air.

38.1 Between phases (mm).

630mm (min)

38.2 Live parts and earth (mm). 630mm (min)

38.3 Live parts to ground level

(mm).

4000mm (min)

39.0 Number of operation

possible without

maintenance.

SP-CBLU-01-R0

Page 36 of 43

Sr. No.


39.1 At full rated interrupting

capacity


39.3 At 100% of rated current


40.0 Supporting Insulator

40.1 Make and type.

40.2 Insulation class A

40.3 Weight.

40.4 Transport dimensions.

40.5 Visible corona discharge

voltage

40.6 Dry-1 minute power

frequency flashover

voltage.

140kV rms

40.7 Wet-1-minute power

frequency lashover

voltage.

140kV rms

40.8 1.2/50 microsecond

impulse flashover voltage.

325kVp

40.9 Creepage distance to

ground (mm)

c) Total

d) Protected

31mm/kV

SP-CBLU-01-R0

Page 37 of 43

Sr. No.


41.0 No. of breaks per pole

1 (one)

42.0 Total length or breaks per

phase (mm)

43.0 Type of main contacts

44.0 Material of main contacts Silver plated copper

45.0 Whether main contacts

silver plated (Yes/No.)

Thickness of silver coating

on main contacts (mm).

15 +/- 5 microns (min)

46.0 Contact pressure on arcing

contacts (kg/m2).

47.0 Type of arcing contacts

48.0 Contact pressure on main

contact (kg/m2).

49.0 Type of auxiliary switches.

50.0 Whether all contacts silver

plated (Yes/No)

51.0 No. of auxiliary switch

contacts operating with all

three poles of breaker


breaker is closed.


breaker is closed



main contacts

SP-CBLU-01-R0

Page 38 of 43

Sr. No.


52.0 No. of spare auxiliary

switch contacts operation

with all three poles of

breaker:


breaker is closed

6 (six)


breaker is closed

6 (six)



main contacts

53.0 Total number of terminal

block

54.0 Number of spare terminal

Block:

20%

55.0 Mounting flange details:

(a)Opening.

(b)Closing.

56.0 Tripping and closing circuit

voltage (V).

50V/110V/220V DC

57.0 Power required for trip coil

58.0 Power required for closing

coil.

59.0 Rated voltage for spring

charging motor

240V AC

60.0 Rated voltage of space

heater and socket

240V AC

61.0 Contingencies for which

alarm provided

62.0 Design data for supporting

structure.

SP-CBLU-01-R0

Page 39 of 43

Sr. No.


63.0 Weight of supporting steel

structure for breaker.

64.0 Descriptive leaflets

enclosed (Yes/No)

65.0 For SF6 gas circuit breaker

65.1 Rated pressure of SF-6

Gas in the gas cylinder

(kg./sq cm.).

65.2 Quantity of SF-6 gas

required per single pole

unit (kg.)


required cylinder (kg.)

65.4 Weight of empty cylinder

(kg).

65.5 Quantity of absorbent

required per pole (kg).

65.6 Recommended interval for

renewal of absorbent in

case of outdoor circuit

breakers operating in

tropical conditions.

65.7 Chemical composition of

the absorbent

65.8 Quantity of absorbent

covered in the scope of

supply. (including spare

qty. ) (kg).

65.9 Limit of gas pressure for

proper operation of circuit

breaker.

SP-CBLU-01-R0

Page 40 of 43

Sr. No.


65.10 Pressure and temperature

at which the temperature

compensated gas pressure

switch will:

a) Give alarm.

b) Cut off.

65.11 Name of SF-6 supplier and

country of origin.


supplied for:

a) Actual use in

breaker (kg).

b) As spare (kg).

65.13 Chemical composition of

gas:

a) Qty. of air by

weight (ppm).

b) Qty. of H20 by

weight (ppm).

c) Qty. of CF4 by

weight (ppm).

66.0 Operating Mechanism

66.1 Type of operating

mechanism offered

66.2 Manufacturer’s type

designation

66.3 Material of control cabinet

enclosure

66.4 Thickness of sheet metal

enclosure

3.0mm for bottom and

2.5mm elsewhere.

66.5 Painting & colour shade Polyurethane paint, 692

of IS-5

SP-CBLU-01-R0

Page 41 of 43

Sr. No.


66.6 Enclosure protection IP 55

66.7 Pad locking facility

provided (Yes/No)

66.8 Wring

a) Control wire size

b) Insulation

c) Colour

1.5 Sqmm

650V

Grey for control, Black

for AC and Green for

earth

66.9 Normal power consumption

at rated voltage (Watt)

66.10 Normal power of spring

charging motor

66.11 Number of close/open

operation possible after

failure of AC supply to

motor

66.12 Time required to charge

the closing spring

66.13 Whether indication of

spring charged condition

provided in central control

cabinet (Yes/No)

66.14 Dimension of the control

cabinets.

66.15 Weight of control cabinet

SP-CBLU-01-R0

Page 42 of 43

Sr. No.


67.0 Details of safety interlock

provided

68.0 Whether supporting

structure for circuit breaker

provided (Yes/No)

68.1 Thickness of galvanizing

(mm)

68.2 Size of foundation bolts

69.0 Material of nuts & bolts Stainless steel

70.0 Weight of 3-phase breaker

complete with operating

mechanism, insulating

support frame work, etc.

71.0 Impact loading for

foundation design to

include load plus impact

value on opening at

maximum interrupting

ratings in terms of

equivalent of static load.

72.0 Weight of heaviest

package

SP-CBLU-01-R0

Page 43 of 43

Annexure - E Recommended spares (Data by supplier)

List of recommended spares as following –

Sr No Description of spare part Unit Quantity

1 No

2 No

3

4

5

6

, - ,~--------- ~,------

8SE Specification for

OUTDOOR CURRENT TI~ANSF()I{MI'~I{

(33 & 66KV)

Specification no. SP-CTLU-01-R1

I , , I I -~--- --~

Rev I Date Prepared by'

00 I 29 -Jan-OS

01 I 16-JLlly 14

\ \ " ~-!," 'J

\-

K.K.Alla

Page 1 of 23

os

Tanu

NarnelSign

SP-CTLU-01-R1

Page 2 of 23

Record of Revision Sl. no.

Revision no.

Clause No.

Nature of change Approved by

1. R1 2.2 All ferrous parts, CT tank and other metallic parts exposed to atmosphere shall be hot dip galvanised with galvanising thickness of 610gm/sqmm minimum.

MDB/KKA

2. R1 3.0.0 ABIL and IEC included in approved makes of insulators

MDB/KKA

3. R1 6.1.1 Type Test to be conducted from CPRI/ERDA

MDB/KKA

4. R1 Annexure C, 10.4

Accuracy class of metering core shall be 0.2s

MDB/KKA


Knee point voltage & corresponding exciting current (project specific) shall be greater than or equal to 40 (RCT+8)

MDB/KKA


Magnetizing current at Vk/2 (project specific) shall be less than or equal to 30 mA

MDB/KKA

SP-CTLU-01-R1

Page 3 of 23

Index

General Specification .........................................................................................................3 1.0 Codes & standards .......................................................................................................3 2.0 Current transformer design features ...........................................................................3 3.0 Approved make of components ..................................................................................5 4.0 Name Plate and Terminal Marking ...............................................................................5 5.0 Quality assurance.........................................................................................................5 6.0 Testing & Inspection ....................................................................................................6 7.0 Drawings, Data & manuals ...........................................................................................7 8.0 Packing, Shipping, Handling & Storage ......................................................................8 9.0 Progress reporting .......................................................................................................9 10.0 Deviations .................................................................................................................10 Annexure – A Scope of supply ......................................................................................11 Annexure – B Service Conditions .................................................................................13 Annexure- C1 Guaranteed Technical Particulars (33kV, 800-400/1/1/1/1A) .................14 Annexure – C2 Guaranteed Technical Particulars (33kV, 2000-1000/1/1/1/1A) ...........16 Annexure – D1 Guaranteed Technical Particulars (66kV, 400-200/1/1/1/1A) ...............18 Annexure – D2 Guaranteed Technical Particulars (66kV, 800-400/1/1/1/1A) ...............20 Annexure – D3 Guaranteed Technical Particulars (66kV, 1600-800/1/1/1/1A) .............20 Annexure – E Recommended spares (Data by supplier) .............................................22

SP-CTLU-01-R1

Page 4 of 23

1.0 CODES & STANDARDS: The current transformer shall be designed, manufactured and tested in accordance with the latest applicable Indian Standard, IEC standard and CBIP manuals as listed below – National Standard Standard Code Standard DescriptionIndian electricity act CBIP manual IS- 335 New insulating oil IS-2705 (Part I to V) Specification for current transformer. IS-4201 Application guide for current transformer. IS-2099 High voltage porcelain bushings IS-731 Insulator for O/H power line IS-335 New insulating oil for transformer and switchgear. IS-9676 Reference ambient temperature of electrical equipment IS-5561 Specification of electric power connectors IS-9676 Summation current transformer IS-4201 Application guide for current transformer IS-2099 High voltage porcelain bushings IS-5621 Hollow insulator for use in electrical equipment International Standard Standard Code Standard DescriptionIEC: 137 Bushing for alternating current above 1000V IEC: 185 Specification for current transformers IEC: 439 Specification for Terminal box / Marshalling box

2.0 DESIGN FEATURES Description Requirement / Rating

2.1 Type Shall be dead tank type; oil immersed, self-cooled outdoor type or Polycrete.

2.2 Construction

a) Oil immersed CT shall be hermetically sealed to eliminate breathing and to prevent air and moisture. The core and winding shall be provided in porcelain bushing. Provision for oil expansion without breathing to be provided (diaphragm or bellow as per manufacturer design) .

b) All ferrous parts, CT tank and other metallic parts exposed to atmosphere shall be hot dip galvanized.

c) Galvanising thickness shall be 610gm/sqmm minimum

2.3 Core

The core shall be of high-grade non-ageing, electrical silicon laminated steel of low hysteresis loss and high permeability to ensure high accuracy at both normal and over current conditions. The saturation factor of the core shall be low enough not to cause any damage to measuring instruments in the event of maximum short circuit current.

2.4 Winding The winding shall be suitable for simultaneous 100% full load continuous rating. The winding shall be capable of desired output as per specified limit.

2.5 Insulation The current transformer shall withstand satisfactorily the dielectric test voltage corresponding to basic insulation level

SP-CTLU-01-R1

Page 5 of 23

specified.

2.6 Insulation Oil

The quantity of insulating oil in each current transformer shall be best available and the complete specification of the oil shall be furnished with the tender. The current transformer offered shall be hermetically sealed completely filled with insulating oil with provision to replace the oil. Oil level indication shall be provided.

2.7 Bushing

Porcelain used in bushing manufacture shall be homogenous, free from laminations, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality. Glazing of the porcelain shall be uniform brown color free blisters, burns and similar defects. The bushing shall be designated to have ample insulation, mechanical strength and rigidity.

2.8 Creepage distance Not less than 31mm /KV 2.9 Terminal Connectors

2.9.1 Primary The current transformers offered shall be supplied with Aluminum- alloy terminal connector with bimetallic sleeve, suitable for connection with single/double ACSR conductor.

2.9.2 Secondary

All the secondary terminals shall be bought in IP55 box with brass/ copper stud type terminals. The secondary terminals shall be shorted by brass/copper links before dispatch. Terminal box to be provided with earthing stud Box shall be of adequate size with proper clearance between the terminals for ease of working and maintenance. Gasket for Box shall be Neoprene.

2.10 Terminal Marking Terminal marking shall be as per IS 2705

3.0 APPROVED MAKE OF COMPONENTS 3.1.0 Insulator JSI/WSI/Modern/Saravana/BHEL/ABIL/IEC 3.2.0 Terminals Connectwell / Elmex

4.0 NAME PLATE & TERMINAL MARKING 4.1.0 Name Plate 4.1.1 Material Anodized Aluminium 16SWG 4.1.2 Background SATIN SILVER

4.1.3 Letters, diagram & border Black

4.1.4 Process Etching

4.1.5 Name plate details

Manufacturer name & address, year of manufacturer, Serial number and type designation, Rated Primary & secondary current, rated frequency, rated output and accuracy class, Highest system voltage, Rated Insulation level, Rated short-time thermal current or short time factor with rated time, Rated dynamic current, Reference Standard.

4.2.0 Danger plate on front & rear side Not required

5.0 QUALITY ASSURANCE

5.1.0 Vendor quality plan To be submitted for purchaser approval 5.2.0 Inspection points To be mutually identified & agreed in

quality plan

SP-CTLU-01-R1

Page 6 of 23

SP-CTLU-01-R1

Page 7 of 23

6.0 INSPECTION & TESTING

6.1.0 Test Test shall be carried out in accordance with IS-2705 / IEC-185

6.1.1 Type test

a) Following type test shall be carried out on current transformer- - Short-time current test - Temperature-rise test - Lightning impulse test - HV power frequency wet withstand voltage test on CT - Determination of errors b) Current transformer must be of type tested from CPRI/ERDA and reports hall be submitted. c) In case the product is never type tested earlier, seller has to conduct the type tests from CPRI/ERDA at their own cost, before commencement of supply.

6.1.2 Routine test Test shall be carried out in accordance with IS-2705 / IEC-185

6.1.3 Acceptance test Test shall be carried out in accordance with IS-2705 / IEC-185

6.2.0 Test on fitting and accessories As per manufacturer’s standard

6.3.0 Inspection and Testing a) The buyer reserves the right to witness all tests specified on completed product

b) The buyer reserves the right to inspect the product at the seller’s works at any time prior to dispatch, to verify compliance with the specifications.

c) In-process and final inspection call intimation shall be given, 10 days in advance to Purchaser.

7.0 DRAWINGS, DATA & MANUALS

7.1.0

To be submitted along with bid The seller has to be submit : a-1) Complete assembly, GA drawing outdoor current transformer showing plan, elevation and typical section view. a-2) Typical connection diagram and winding connection of current transformer. a-3) Secondary box details a-4) Structural drawing for CT mounting arrangement a-5) Rating plate diagram a-6) Drawings of terminal connectors b) Detailed reference list of customers

already using the offered product during the last 5 years with similar design and rating.

c) Completely filled GTP d) Deviations from this specification. Only

deviations approved in writing before award of contract shall be accepted.

e) Details of manufacturer’s quality assurance standards and program and ISO 9000 series or equivalent national

SP-CTLU-01-R1

Page 8 of 23

certification f) Type test report shall be submitted for

the type, size & rating of product / equipment offered along with bid. They shall be considered valid for 5 years from date of test performed on product / equipment.

g) Complete product catalogue and manual along with the bid.

h) Recommended spare parts and consumable items for 5 years of operation with prices and spare parts catalogue with list for future requirements.

7.2.0 After award of contract, seller has to submit mentioned drawings for buyer’s Approval (A ) / Reference (R)

a) Programme for production and testing (A)

b) Guaranteed Techinal Particulars (A) c) Calculations to substantiate choice of

electrical , mechanical component size / ratings (A)

d-1) General arrangement drawing of the current transformer (A) d-2) Typical connection diagram and winding connection of current Transformer (A). d-5) Terminal connector drawings (A) d-7) General arrangement drawing secondary terminal box (A) e) Detailed installation and commissioning

instructions ( R) f) Quality plan

7.3.0 Submittals required prior to dispatch

a) Inspection and test reports, carried out in manufacturer’s work (R )

b) Test certificates of all bought out items c) Operation and maintenance instruction

as well as trouble shooting charts / manuals.

7.4.0 Drawing and document sizes Standard size paper A0, A1 , A2, A3, A4 7.5.0 No of drgs./Documents required at

different stages As per Annexure A

8.0 PACKING , SHIPPING, HANDLING AND STORAGE

8.0.0 Packing 8.1.1 Packing protection Against corrosion , dampness, heavy rains, breakage and

vibration 8.1.2 Packing for accessories

and spares Robust wooden non returnable packing case with all the above protection and identification labels.

SP-CTLU-01-R1

Page 9 of 23

8.1.3 Packing identification label

In each packing case, following details are required : a) Individual serial number b) Purchaser’s name c) PO number (along with SAP item code , if any) &

date d) Equipment Tag no. (if any) e) Destination f) Manufacturer / Supplier’s name g) Address of manufacturer’s / supplier’s its agent h) Description and quantity i) Country of origin j) Month and year of manufacturing k) Case measurements l) Gross and net weight in kilograms m) All necessary slinging and stacking instructions.

8.1.4 Shipping a) The bidder shall furnish the confirmation that the proposed packages can be delivered safely upto the site.

b) The seller shall be responsible for all transit damage due to improper packing.

8.1.5 Handling and Storage Manufacturer instruction shall be followed. Detail handling & storage instruction sheet / manual need to be furnished before commencement of supply.

9.0.0 PROGRESS REPORTING

9.1.0

Outline Document To be submitted for purchase approval for outline of production, inspection, testing, inspection, packing, dispatch, documentation programme.

9.2.0 Detailed Progress Report To be submitted to purchaser once a month containing

a) Progress on material procurement b) Progress on fabrication (As applicable) c) Progress on assemble (As applicable) d) Progress on internal stage inspection e) Reason for any delay in total

programme f) Details of test failures if any in

manufacturing stages g) Progress on final box up constraints /

forward path

SP-CTLU-01-R1

Page 10 of 23

10.0.0 DEVIATIONS

10.0.0 Deviation from the specification Deviation from the specification shall be started in writing with the tender by reference to the specification clause/GTP/Drawing and a description of the alternative offer. In absence of such a statement. It will be assumed by the Buyer that the seller complies fully with this specification.

SP-CTLU-01-R1

Page 11 of 23

Annexure – A Scope of supply

1.0 The scope of supply shall include following 1.1 Design, manufacture, assembly, testing at manufacturer’s works before dispatch,

packing, delivery and submission of all documentation of outdoor current transformer. 1.2 Terminal connector. 1.3 Supervision of testing & commissioning of current transformer at site 1.4 BOQ as following –

Sr no. Purchaser Equipment Tag No / SAP code


Location Substation name

Unit Quantity

1 2 3 4 5 6 7

2.0 Submission of documents Submission of drawing, calculations, manual , catalogues, test report shall be as follows

Along with offer For Approval after award of contract


Remarks

Drawing 3 copies (Typical drgs)


See clause 5.0 for various drawing required



See clause 5.0 for details


Instruction manual for the transformer


Test Report 2 copy 6 copies + 1 soft copy in CD

Type test and sample routine test reports

3.0 Delivery schedule

3.1 Delivery period start date - from date of purchase order


3.3 Material dispatch clearance - after inspection by purchaser and written

dispatch clearances for purchaser

SP-CTLU-01-R1

Page 12 of 23

Annexure – B SERVICE CONDITIONS

1.0.0 Delhi Atmospheric conditions a) Average grade atmosphere Heavy polluted , dry b) Maximum altitude above see

level 1000 M

c) Ambient Air temperature Highest 50 deg C, Average 40 deg C d) Maximum ambient air

temperature 0 deg C

e) Relative Humidity 100 % Max f) Thermal Resistivity of Soil 150 deg. C cm/W g) Seismic Zone 4 h) Rainfall 750 mm concentrated in four months

SP-CTLU-01-R1

Page 13 of 23

Annexure – C1: Guaranteed Technical Particulars (33KV , 800-400/1/1/1/1A)

Description Data By Purchaser Data By Supplier 1 Name of Manufacturer 2 Address and contact details 3 Type 4 Rated Nominal Voltage 33 kV 5 Highest System Voltage 36 kV 6 Rated Frequency 50 Hz 7 Rated Primary Current 800 - 400 A 8 Rated Secondary current 1A 9 Number of cores

10.0 Core-1 Core-2

Core-3

Core-4

10.1 Secondary Current 1A 1A 1A 1A

10.2 Purpose /Application

Met

erin

g

Pro

tect

ion

(O/C

& E

/F)

Pro

tect

ion

(B

us B

ar)

Pro

tect

ion

(Spa

re)

10.3 Rated output (project specific) 30 VA 30 VA

10.4 Class of accuracy 0.2s 5P PS PS

10.5 Instrument security factor ≤ 5 10.6 Accuracy limit factor 20

10.7 Knee point voltage & corresponding exciting current (project specific)

≥

40 (R

CT+

8)

≥

40

(RC

T+8)

10.8 Magnetizing current at Vk/2 (project specific) ≤30

mA ≤30 mA

10.9 Resistance of the secondary winding at 75 deg C

10.10 Secondary limiting voltage

11 Short time thermal rating of primary

11.1 One Seconds 11.2 Three seconds 26.3 kA

12 Rated dynamic current of primary

13 Rated continuous thermal current

14 Temp rise at an ambient of 50 deg C

14.1 Winding 14.2 Oil at the top

14.3 Exposed current carrying parts

15 One minute power frequency dry withstand voltage (KV rms)

70 kV rms

SP-CTLU-01-R1

Page 14 of 23

16 One minute power frequency wet withstand voltage (KV rms)

70 kV rms

17 1.2/50 microsecond impulse withstand test voltage KV peak

170 kVp

18 Minimum creepage distance in mm 31 mm/kV

19 Protective creepage distance in mm

20 Magnetization curve of CT core

21 Variations in ratio and phase angle error due to variation in

21.1 Voltage by 1 Volt 21.2 Frequency by 1Hz

22 Current density in primary winding

23 Weight of oil 24 Total weight 25 Mounting details 26 Overall dimensions 27 Terminal Connector

SP-CTLU-01-R1

Page 15 of 23

Annexure – C2: Guaranteed Technical Particulars (33KV, 2000-1000/1/1/1/1A)


1 Name of Manufacturer 2 Address and contact details 3 Type 4 Rated Nominal Voltage 33kV 5 Highest System Voltage 36 kV 6 Rated Frequency 50 Hz 7 Rated Primary Current 2000-1000 A 8 Rated Secondary current 1A 9 Number of cores

10.0 Core-1 Core-2

Core-3

Core-4



Met

erin

g

Pro

tect

ion

(O/C

& E

/F)

Pro

tect

ion

(B

us B

ar)

Pro

tect

ion

(Spa

re)





≥ 40

(R

CT+

8)

≥ 40

(R

CT+

8)

10.8 Magnetizing current at Vk/2

(project specific) ≤30 mA

≤30 mA




11.1 One Seconds 11.2 Three seconds 26.3kA







70 kV rms

SP-CTLU-01-R1

Page 16 of 23


70 kV rms


170 kVp








SP-CTLU-01-R1

Page 17 of 23

Annexure – D1 : Guaranteed Technical Particulars (66KV , 400-200/1/1/1/1A)

Description Data By Purchaser Data By Supplier 1 Name of Manufacturer 2 Address and contact details 3 Type 4 Rated Nominal Voltage 66kV 5 Highest System Voltage 72.5 kV 6 Rated Frequency 50 Hz 7 Rated Primary Current 400-200 A 8 Rated Secondary current 1A 9 Number of cores

10.0 Core-1 Core-2

Core-3

Core-4



Met

erin

g

Pro

tect

ion

(O/C

& E

/F)

Pro

tect

ion

(B

us B

ar)

Pro

tect

ion

(Spa

re)





≥ 40

(R

CT+

8)

≥ 40

(R

CT+

8)


mA ≤30 mA











140 kV rms

SP-CTLU-01-R1

Page 18 of 23


140 kV rms


325 kVp








SP-CTLU-01-R1

Page 19 of 23

Annexure – D2: Guaranteed Technical Particulars (66KV, 800-400/1/1/1/1A)

Description Data By Purchaser Data By Supplier 1 Name of Manufacturer 2 Address and contact details 3 Type 4 Rated Nominal Voltage 66kV 5 Highest System Voltage 72.5 kV 6 Rated Frequency 50 Hz 7 Rated Primary Current 800-400 A 8 Rated Secondary current 1A 9 Number of cores

10.0 Core-1 Core-2

Core-3

Core-4



Met

erin

g

Pro

tect

ion

(O/C

& E

/F)

Pro

tect

ion

(B

us B

ar)

Pro

tect

ion

(Spa

re)





≥ 40

(R

CT+

8)

≥ 40

(R

CT+

8)


mA ≤30 mA











140 kV rms

SP-CTLU-01-R1

Page 20 of 23


140 kV rms


325 kVp








SP-CTLU-01-R1

Page 21 of 23

Annexure – D3: Guaranteed Technical Particulars (66KV, 1600-800/1/1/1/1A)


1 Name of Manufacturer

2 Address and contact details

3 Type 4 Rated Nominal Voltage 66 kV 5 Highest System Voltage 72.5 kV 6 Rated Frequency 50 Hz 7 Rated Primary Current 1600-800 A 8 Rated Secondary current 1A 9 Number of cores

10.0 Core-1 Core-2

Core-3

Core-4



Met

erin

g

Pro

tect

ion

(O/C

& E

/F)

Pro

tect

ion

(B

us B

ar)

Pro

tect

ion

(Spa

re)





≥ 40

(R

CT+

8)

≥ 40

(R

CT+

8)

10.8 Magnetizing current at

Vk/2 (project specific) ≤30 mA

≤30 mA




11.1 One Seconds 11.2 Three seconds 31.5 kA






SP-CTLU-01-R1

Page 22 of 23


140 kV rms


140 kV rms


325 kVp








SP-CTLU-01-R1

Page 23 of 23

Annexure –D Recommended spares (Data by Supplier) List of recommended spares as following – Sr. No. Description of spare part Unit Quality

1 2 3 4 5 6

SP-ISLU-01-R0

Page 2 of 21

Index

1.0 General Specification…………………………………………………………………. 03-11 2.0 Annexure – A : Scope & Documentation………………………………………… 12-13 3.0 Annexure – B : Ambient Conditions……………………………………………..... 14-14 4.0 Annexure – C1 : Guaranteed Tech. Particulars for 66KV Disconnecting Switch... 15-17 5.0 Annexure – C2 : Guaranteed Tech. Particulars for 33KV Disconnecting Switch… 18-20 6.0 Annexure – D : Recommended spares (Data by supplier)…………………….. 21-21

SP-ISLU-01-R0

Page 3 of 21

General Specification 1.0.0 Codes & Standards

Materials, equipment and methods used in the manufacture of outdoor disconnecting

switch shall conform to the latest edition of following –

National Standards

Standard Code Standard Description Indian Electricity Rules


CBIP manual

IS : 9921 - Part I to V Specification for Alternating Current Disconnectors (Isolators) and Earthing Switches

IS : 0996 -1979 Single phase small AC and Universal Electric Motors. IS : 7572 -1974 Guide for testing single phase AC and Universal motors.

IS : 4237 -1967

General Requirement for switchgear for voltage not exceeding 1.1 kV.

IS : 2147 -1962

Degree of protection provided by enclosure for low-voltage switchgear control gear

IS : 2544 Porcelain Post Insulator

IS : 2629 -1985 Recommended Practice for Hot-Dip Galvanizing of Iron and Steel

IS : 6639 - 1972 Specification for Hexagon Bolts for Steel Structures

Important Note : In the event of direct conflict between various order documents, the precedence of authority of documents shall be as follows – i. Specification including applicable codes, standards ii. Guaranteed Technical Particulars (GTP) iii. Approved Vendor Drawings

SP-ISLU-01-R0

Page 4 of 21

Sr. No.


2.0.0 Design Features

Common for both 66KV and 33 KV equipment

2.1.0 Disconnect Switch Type & Mechanism

Motor operated, central rotating double break with turn and twist mechanism, triple pole, outdoor type for installation and operation in horizontal plane for 66KV & in vertical plane for 33 kv with or without earth switches, as required complete in all respects.

i) Motor assembly Suitable for 3 phase 415V, 50 Hz. Provided with a quick electro-mechanical brake on high speed shaft for rapid braking.

2.2.0 Earth Switch Mechanism

Manually operated

2.3.0 Disconnector Switch Controls

i) Remote electrical control

Required

ii) Local Manual control

Required

iii) Local electrical control

Required from integral Local Control Cabinet

2.4.0 Interlock with circuit breakers

Electrical interlock suitable for 220 V / 50 V DC

2.5.0 Interlock with Earth Switch

Mechanical & Electrical interlock

2.6.0 Padlock for Earth Switch

Padlock & keys for both positions i.e. when earth switch is grounded and when earth switch is un-grounded

2.7.0 Fixed Contacts i) Type of contacts Spring loaded with smooth surface, silver plated ii) Current carrying

castings Non corrodible, non ferrous material

iii) Current carrying Springs

Made of non aging, non magnetic stainless steel with life long spring action strength

2.8.0 Insulators i) Construction Comprising of cylindrical solid core post insulators. The

porcelain used in the insulators shall be homogeneous, free from laminations, cavities or any other defect which may affect its mechanical and dielectric qualities and shall be thoroughly vitrified, tough and impervious to moisture. The glazing of the porcelain shall be of uniform brown colour, free from blisters, burrs and other defects.

ii) Fasteners All metal caps, jointing flanges, bolts and nuts shall be made of high grade cast iron or malleable steel casting, machine faced and hot-dip galvanised.

SP-ISLU-01-R0

Page 5 of 21

Sr. No.


2.9.0 Moving Contacts

i) Type of contacts High pressure relieving copper contacts, silver plated ii) Wiping Action Required during opening & closing. Shall be adequate to

remove any oxide film formed without causing scouring or abrasion on the contact surfaces.

2.10.0 Current carrying Springs

Made of non aging, non magnetic stainless steel with life long spring action strength

2.11.0 Fault Current rating Earth switch shall be able to carry same Fault Current as assigned to the disconnecting switch.

2.12.0 Disconnecting Switch contacts movement

90 deg from full open to full close in order to ensure a distinct break ands clear visibility.

2.13.0 Corona Effect Shall be free from visible corona discharge in both open & close positions at visible discharge test voltages.

2.14.0 Control cabinet i) Enclosure Weather-proof, water-shedding, corrosion-proof IP-55 steel

cabinet ii) Cabinet Door Gasketed, hinged access door shall have a mechanical

indicator fitted to clearly indicate fully opened and fully closed positions of the disconnection switch.

iii) Wiring Control wiring shall be done using 1.1KV grade 2.5 sq.mm stranded copper conductor, PVC insulated, cables laid in GI conduits.

iv) Locking arrangement

Padlocking arrangement to be provided.

v) Incomer A local TPN MCB to be provided in cabinet at power supply incoming point.

vi) Outgoing Control Wiring

All outgoing control wiring shall terminate on terminal blocks, inside the cabinet so as to have maximum access to all conductor terminals.

vii) Aux. Contacts All auxiliary contacts of the disconnection switch and earthing switches shall be supplied duly wired up to the terminal blocks.

viii) Terminals Stud type terminals with at least twenty (20) percent spare terminals shall be provided over and above the number actually required.

ix) Paint Shade Polyurethane Paint Shade no. 692 of IS-5. x) Local Controls A local/ remote changeover switch shall be fitted inside the

cabinet together with open/ close push buttons for local control.

SP-ISLU-01-R0

Page 6 of 21

Sr. No.


xi) Cabinet accessories

Cabinet illumination incandescent lamp with ON/OFF switch, 5/15A single phase 3 pin socket with switch & fuse, 240V AC space heater with switch & thermostat etc.

2.15.0 Manual Operation Manual operation of disconnection switch by means of crank handle disconnecting power supply to the 3-pole operating mechanism on insertion into its socket. The height of socket shall be about 1.2 metre above the finished ground level of the substation.

2.16.0 Disconnection switches with Earth switch

Switch shall have three (3) grounding blades forming integral part of the isolator. These blades shall be capable of being fitted on either side of the brakes. Flexible heavily tinned copper braids of adequate cross-sectional area with connector suitable for the specified short circuit current shall be provided on the hinged end of the grounding blade for connection to the station grounding grid.

2.17.0 Grounding Blades Operation

Manually operated and interlocked with disconnection switch so that the grounding blades can be closed only when the disconnection switch is open.

2.18.0 Pivot bearings Shall be maintenance-free and corrosion resistant. Double tapered-roller bearings located 150 mm apart suitable for ensuring smooth and dependable operation of the disconnection switch shall be located at the base of the supporting insulators. The earthing switch shaft shall also be provided with necessary bearings. The bearings shall be suitable for effective operation of disconnection switch and earthing switches even after long periods of their remaining in closed/ open position.

2.19.0 Disconnection Switch Poles & base

Each pole of the disconnection switch shall be provided with a complete galvanized steel base designed for mounting on a supporting structure/ gantry. The base shall be rigid and self-supporting and shall require no guying or cross bracing between phases. The group operated isolators shall have a common supporting structure for all the three (3) poles.

2.20.0 Grounding Pads Each pole of disconnection switch shall be provided with two (2) grounding pads of non-corrodible material brazed to the channel base at opposite ends. Flexible tinned copper (15-25 microns) connectors shall be provided for a) Connection of earthing pad of each pole, b) Operating handle, c) Earthing switches.

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Sr. No.


2.21.0 Counter-Balancing Springs/ Weights

Springs/ weights of non-rusting alloy composition shall be provided for counter-balancing the earthing switch blades to prevent impact at the end of travel both on opening and closing of the earthing switch.

2.22.0 Name Plates Corrosion-proof nameplates giving all the relevant mandatory as well as optional information as stipulated in IS shall be provided on disconnection switches, earthing switches and operating devices as per the Purchaser's/ Consulting Engineer's approval.

3.0.0

Approved Make of Components

Common for both 66KV and 33 KV outdoor disconnecting switch

3.1.0 Motors ABB / Siemens / Crompton

3.2.0 Insulators JSI / WSI / Modern / Saravana / BHEL

3.3.0 Switch Kaycee / L&T (Salzer)

3.4.0 HRC Fuse Links Alstom / Siemens / L&T

3.5.0 AC Contactors &

O/L Relay

L&T / Siemens / Schneider

3.6.0 Terminals Connectwell / Elmex

3.7.0 Push buttons /

Actuator

L&T / Teknic / Siemens

3.8.0 MCB Merlin Gerin / Siemens / Schneider

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Sr. No.


4.0.0 Testing & Inspection 4.1.0 Internal Test Manufacturer shall carry out comprehensive inspection

and testing during manufacture of the equipment.

4.2.0 Type test The product must be of type tested quality. Type test reports shall be submitted for the type, size & rating of equipment offered along with bid. If the manufacturer’s lab is accredited by govt./ authorised body then it shall be acceptable for type testing.

4.3.0 Routine test As per relevant IS / IEC.

4.4.0 Acceptance test As per relevant IS / IEC.

4.5.0 Test Witness 4.5.1

The Buyer reserves the right to witness all tests specified on completed product.

4.5.2 The Buyer reserves the right to inspect the product at the Sellers works at any time prior to dispatch, to verify compliance with the specifications.

4.4.3 In-process and final inspection call intimation shall be given in advance to purchaser.

4.6.0 Tests on fitting and Accessories

As per Manufacturer’s Standards and relevant IS / IEC.

5.0.0 Drawing, Data &

Manuals

5.1.0 To be submitted along with bid

The seller has to submit :

i) Tentative GA / cross sectional drawing of product showing all the views / sections.

ii) Detailed reference list of customers already using the offered product during the last 5 years with particular emphasis on units of similar design and rating.

iii) Completely filled GTP iv) Deviations from this specification. Only deviations

approved in writing before award of contract shall be accepted.

v) Details of manufacturer's quality assurance standards and program and ISO 9000 series or equivalent national certification.

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Sr. No.


vi) Type test reports shall be submitted for the type, size & rating of product / equipment offered along with bid. In case the type test report for identical product is not available then type test report of nearby size/ rating shall be submitted for review. They shall be considered valid for 5 years from date of test performed on product /equipment.

vii) Complete product catalogue and Manual along with the bid.

viii) Recommended spare parts and consumable items for five years of operation with prices and spare parts catalogue with price list for future requirements.

ix) Bill of material with make, model & quantity of items.

5.2.0 To be submitted after award of contract

The seller has to submit : for buyer’s Approval (A) / Reference (R)

i) Program for production and testing (A) ii) Guaranteed Technical Particulars (A) iii) Calculations to substantiate choice of electrical, structural,

mechanical component size / ratings (A)

iv) a) Detailed dimension drawing for all components, generab) Drawings of major components (A) c) Rating and diagram plate (R)

v) Detailed loading drawing to enable the buyer to design and construct foundations (as applicable) (R)

vi) Transport / Shipping dimensions with weights (R) vii) Detailed Bill of Materials for all fittings and accessories

with their make, model & tag no. etc. (A)

viii) Detailed installation and commissioning instructions (R) ix) Quality plan (A)

5.3.0 Submittals required prior

to dispatch The seller has to submit :

i) Inspection and test reports, carried out in manufacturer’s works (R)

ii) Test certificates of all bought out items iii) Operation and maintenance Instruction as well as trouble

shooting charts/ manuals

5.4.0 Drawing and document sizes


5.5.0 No of drgs. / Documents required at different stages

As per Annexure- A

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Sr. No.


6.0.0 Packing 6.1.0 Packing

Protection Against corrosion, dampness, heavy rains, breakage and vibration

6.2.0 Packing for accessories and spares

Robust wooden non returnable packing case with all the above protection & identification Label

6.3.0 Packing Identification Label

In each packing case, following details are required :

i) Individual serial number ii) Purchaser's name iii) PO number (along with SAP item code, if any) & date iv) Equipment Tag no. (if any) v) Destination vi) Manufacturer / Supplier's name vii) Address of Manufacturer / Supplier / it’s agent viii) Description and Quantity ix) Country of origin x) Month & year of Manufacturing xi) Case measurements xii) Gross and net weights in kilograms xiii) All necessary slinging and stacking instructions 7.0.0 Shipping,

Handling & Storage

7.1.0 Shipping Information

The seller shall give complete shipping information concerning weight, size etc. of each package.

7.2.0 Shipping Constraints

The seller shall ascertain at an early date before the commencement of manufacture, any transport limitations such as weights, dimensions, road culverts, overhead lines, free access etc. from the manufacturing plant to the project site. Bidder shall furnish the confirmation that the proposed packages can be safely transported, as normal or oversize packages, upto the site. Any modifications required in the infrastructure and cost thereof in this connection shall be brought to the notice of the Purchaser.

7.3.0 Transit Damage The seller shall be responsible for any transit damage due to improper packing.

7.4.0 Handling & Storage

Manufacturer’s instructions shall be followed. Detail handling & storage instruction sheet / manual needs to be furnished before commencement of supply.

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Sr. No.


8.0.0 Quality Assurance

8.1.0 Vendor quality plan

To be submitted for purchaser approval

8.2.0 Inspection points To be mutually identified & agreed in quality plan

9.0.0 Progress

Reporting

9.1.0 Outline Document

To be submitted for purchaser approval for outline of production, inspection, testing, inspection, packing, dispatch, documentation program

9.2.0 Detailed Progress report

To be submitted to Purchaser once a month containing

i) Progress on material procurement ii) Progress on fabrication (As applicable) iii) Progress on assembly (As applicable)

iv) Progress on internal stage inspection v) Reason for any delay in total program

vi) Details of test failures if any in manufacturing stages

vii) Progress on final box up viii) Constraints / Forward path

10.0.0 Deviations i) Deviations from this Specification are only acceptable where the

Seller has listed in his quotation the requirements he can’t or does not wish to comply with and the buyer has accepted in writing the deviations before the order is placed.

ii) In the absence of a list of deviations, it will be assumed by the Buyer that the Seller complies fully with this specification.

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Annexure – A

1.0 Scope

Sr. No.


1.0.0 Scope 1.1.0 Main Equipment Design, manufacture, assembly & testing at manufacturer’s works

before dispatch, packing & delivery of outdoor disconnecting switch rated up to 66 kV.

1.2.0 Accessories

i) Clamps & terminal connectors. ii) Stainless steel hardware like nut bolts/ washers etc. for fixing of

all equipment / accessories in the scope of the bidder with supporting structure.

iii) Any other item necessary or usual for efficient performance and satisfactory maintenance under the various operating and atmospheric conditions

1.3.0 Documentation Submission of all drawings & documents pertaining to the equipment.

1.4.0 Site Supervision Supervision of testing & commissioning of equipment at site. 1.5.0 Bill of Materials Complete bill of materials shall be submitted in the following

format.

Sr. No.

Purchaser Equipment Tag No. / Sap Code


Location / Substation Name

Unit Quantity

e.g. Santacruz

Nos. e.g. 1

e.g. Alaknanda

Nos. e.g. 6

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2.0.0 Document Submission Submission of drawings, calculations, catalogues, manuals, test reports shall be as follows :

Along with offer



Remarks

Drawings 3 copies (Typical drgs)



See Clause 5.0.0 for various drawings required




See Clause 5.0.0 for details


Instruction manual


Test Report 2 copies 6 copies + 1 soft copy in CD

Type test and routine test reports

3.0.0 Delivery Schedule

Sr. No.


i) Delivery period start date

From date of purchase order

ii) Delivery period end date

As agreed with supplier

iii) Material dispatch clearance

After inspection by purchaser

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Annexure – B

Ambient Conditions : A) Mumbai a) Average grade

atmosphere Heavily polluted , salt Laden, dusty, humid with possibility of condensation


1000 M


temperature 20 deg C

e) Relative Humidity 100 % Max f) Thermal Resistivity of Soil 150 Deg. C cm/W g) Seismic Zone 3 h) Rainfall 3000 mm concentrated in four months

B) Delhi a) Average grade

atmosphere Heavily polluted, dry


1000 M


temperature 0 Deg C

e) Relative Humidity 100 % Max f) Thermal Resistivity of Soil 150 Deg. C cm/W g) Seismic Zone 4 h) Rainfall 750 mm concentrated in four months

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Annexure – C1

Guaranteed Tech. Particulars for 66KV Outdoor Disconnecting Switch

Sr. No.


1 Name of manufacturer 2 Type Motor operated,

central rotating double break with turn & twist mechanism.

3 Model 4 No. of units. 5 Installation Outdoor horizontal

6 System Particulars i) Highest System Voltage 72.5 kV ii) Rated frequency 50 Hz ± 5% iii) System Neutral Solidly Earthed 7 Rated Insulation Data

7.1 1.2/50 µs lighting impulse withstand voltage (Positive and negative polarity)

i) To earth 325 kV ii) Across the isolating distance 375 kV

7.2 Rated One minute power frequency withstand voltage

i) To earth 140 kV ii) Across the isolating distance 160 kV 8 Main Switch Current Capacity i) Rated normal current 800 A / 1250 A ii) Rated Short time withstand Current 31.5 kA for 3 Sec. iii) Rated peak withstand current 2.5 times of short time

withstand current

iv) Maximum magnetizing current (Make/ break capacity)

6 - 8 Amps.

9 Earthing switch current capacity i) Rated Short time withstand Current 31.5 kA for 3 Sec. ii) Rated peak withstand current 2.5 times of short time

withstand current

iii) Making capacity for discharging line charge

10 Minimum clearances i) In air between live parts and earth 630 mm ii) In air between Phase to phase 630 mm iii) Minimum ground clearance 4000 mm

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Sr. No.


11 Phase spacing 2000 mm (Project Specific)

12 No. of breaks per circuit pole Two for double break

13 Nos. of insulators pedestal Three stacks per phase of heavy duty post type insulators

14 Main Switch Contacts i) Type of Contact High pressure

relieving copper contacts (rotating blade features of twist mechanism). The moving arm enters the fixed female contact assembly developing high pressure.

ii) Material for rotating blade Electrolytic tinned copper

iii) Material of contact Silver plated electrolytic copper.

15 Earth Switch Contacts i) Type of Contact of Earth switch High pressure

banging type

ii) Material for earth switch blade Electrolytic tinned copper

iii) Material of earth switch contact Silver plated electrolytic copper.

16 Thickness of Silver Coating 15 - 25 microns. 17 Maximum current density 1.5 A /sq mm 18 Type of bearing for rotating insulator

stocks

19 Number of auxiliary contacts i) Isolator operating mechanism 10 NO + 10 NC ii) Earthing Device 4 No + 4 NC 20 Temperature rise As per IS 9921 21 Control supply voltage 220 V / 110 V / 50 V

DC

22 AC Aux. Supply (4 wire) 415 V ± 10%

23 Inter Locking arrangement Electrical and mechanical

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Sr. No.


24 Terminal connectors Suitable for twin ACSR Zebra conductor

25 Minimum creepage distance of insulator

26 Type of control for i) Disconnection switch Motorised with

Manual Facility

ii) Earthing switch Manual 27 Locking arrangement 28 Rated mechanical terminal loads in

addition to wind load acting on the equipment and short-circuit forces

29 Total operating time of disconnection switch including that of its operating mechanism

30 Weight of Isolators 31 Post insulators i) Make & type

ii) Height iii) Voltage level iv) Cantilever Strength v) Torsinal Strength vi) Creepage Distance Min 31mm/KV vii) Basic insulation level (1 min. power

frequency flashover voltage)

a) Dry 140 KV rms b) Wet 140 KV rms

viii) Visible corona discharge voltage ix) 1.2/50 micro second impulse

flashover voltage 325 KVp

x) Insulation class A 32 Drive Motor i) Make ii) KW Rating / rpm iii) Rated current iv) Frame size v) Rated Voltage 415 V AC vi) Degree of Protection IP-55 vii) Insulation Class B/F viii) Duty

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Annexure – C2

Guaranteed Tech. Particulars for 33KV Outdoor Disconnecting Switch

Sr. No.


1 Name of manufacturer 2 Type Motor operated,

central rotating double break with turn & twist mechanism.

3 Model 4 No. of units. 5 Installation Outdoor Vertical

6 System Particulars i) Highest System Voltage 36 kV ii) Rated frequency 50 Hz ± 5% iii) System Neutral Solidly Earthed 7 Rated Insulation Data

7.1 1.2/50 µs lighting impulse withstand voltage (Positive and negative polarity)

i) To earth 145 kV ii) Across the isolating distance 165 kV

7.2 Rated One minute power frequency withstand voltage

i) To earth 70 kV ii) Across the isolating distance 80 kV 8 Main Switch Current Capacity i) Rated normal current 1250 A ii) Rated Short time withstand Current 26.3 kA for 3 Sec. iii) Rated peak withstand current 2.5 times of short time

withstand current

iv) Maximum magnetizing current (Make/ break capacity)

6 - 8 Amps.

9 Earthing switch current capacity i) Rated Short time withstand Current 26.3 kA for 3 Sec. ii) Rated peak withstand current 2.5 times of short time

withstand current

iii) Making capacity for discharging line charge

10 Minimum clearance i) In air between live part and earth 320 mm ii) In air between Phase to phase 320 mm iii) Minimum ground clearance 3700 mm

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Sr. No.


11 Phase spacing 1500 mm (Project Specific)

12 No. of breaks per circuit pole Two for double break 13 Nos. of insulators pedestal Three stacks / phase

of heavy duty post type insulators

14 Main Switch Contacts i) Type of Contact High pressure

relieving copper contacts (rotating blade features of twist mechanism). The moving arm enters the fixed female contact assembly developing high pressure.

ii) Material for rotating blade Electrolytic tinned copper

iii) Material of contact Silver plated electrolytic copper.

15 Earth Switch Contacts i) Type of Contact of Earth switch High pressure

banging type

ii) Material for earth switch blade Electrolytic tinned copper

iii) Material of earth switch contact Silver plated electrolytic copper.

16 Thickness of Silver Coating 15 - 25 microns. 17 Maximum current density 1.5 A /sq mm 18 Type of bearing for rotating insulator

stocks

19 Number of auxiliary contacts i) Isolator operating mechanism 10 NO + 10 NC ii) Earthing Device 4 No + 4 NC 20 Temperature rise As per IS 9921 21 Control supply voltage 220 V / 110 V / 50 V

DC

22 AC Aux. Supply (4 wire) 415 V ± 10%

23 Inter Locking arrangement Electrical and mechanical

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Sr. No.


24 Terminal connectors Suitable for twin ACSR Zebra conductor

25 Minimum creepage distance of insulator

26 Type of control for i) Disconnection switch Motorised with

Manual Facility

ii) Earthing switch Manual 27 Locking arrangement 28 Rated mechanical terminal loads in

addition to wind load acting on the equipment and short-circuit forces

29 Total operating time of disconnection switch including that of its operating mechanism

30 Weight of Isolators 31 Post insulators i) Make & type ii) Height iii) Voltage level iv) Cantilever Strength v) Torsinal Strength vi) Creepage Distance Min 31mm/KV vii) Basic insulation level (1 min. power

frequency flashover voltage)

a) Dry 70 KV rms b) Wet 70 KV rms

viii) Visible corona discharge voltage ix) 1.2/50 micro second impulse

flashover voltage 145 KVp

x) Insulation class A 32 Drive Motor i) Make ii) KW Rating / rpm iii) Rated current iv) Frame size v) Rated Voltage 415 V AC vi) Degree of Protection IP-55 vii) Insulation Class B/F viii) Duty

SP-ISLU-01-R0

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Annexure – D

Recommended spares (Data by supplier) List of recommended spares shall be submitted as follows – Sr. No.

Description of spare part Unit Quantity

1 Nos. 2 Nos. 3 4 5 6

II I ! I f

I !

, '

ISpecification for I

! !OUTDOO)~

POTENTIAL TRANSFO){MEI{

(33 & 66KV)

Specification no. SP-PTLU-01-R1

- -.- --_._- -<

Rev DatEPrepared by' Checked by , Approved by -__0____ --1

S' ~Name Sign Name SignV'Nametg n .. / --- -j

29 -"I, jI' \l:OS l 16-Ju1Y 14K.K.Alla 01 ITanu Meenakshl\ ~7~~t \1 • I j

;,,'W DG 00• HPB

.. I-\

Page 1 or 18

SP-PTLU-01-R1

Page 2 of 18

Record of Revision Sl. no.

Revision no.

Clause No.

Nature of change Approved by

1. R1 2.3.2 Material of tank construction shall be hot dip galvanized with minimum thickness of 610gm/sq mm

MDB/KKA

2. R1 3.0.0 ABIL & IEC included in approved makes of insulators

MDB/KKA

3. R1 6.1.1 Type Test to be conducted from CPRI/ERDA

MDB/KKA


Accuracy class of metering core shall be 0.2

MDB/KKA

SP-PTLU-01-R1

Page 3 of 18

Index

General Specification...................................................................................................3 1.0.0 Codes & Standards...........................................................................................3

2.0.0 Major Design Criteria & Parameters of the PT..................................................3 . 3.0.0 Fittings and Accessories on Potential Transformer .......................................5 4.0.0 Approved make of components .......................................................................5 5.0.0 Quality assurance ..............................................................................................5 6.0.0 Progress Reporting ...........................................................................................6 7.0.0 Drawing, Data & manuals..................................................................................6 8.0.0 Inspection & testing ..........................................................................................8 9.0.0 Packing, Shipping, Handling and Storage .....................................................10 10.0.0 Deviations........................................................................................................11 Annexure - A Scope of supply ................................................................................12 Annexure – B Service Conditions ...........................................................................14 Annexure – C1 Guaranteed Technical particulars for 66KV PT............................15 Annexure – C2 Guaranteed Technical particulars for 33KV PT............................18 Annexure - D Recommended spares (Data by supplier)........................................21

SP-PTLU-01-R1

Page 4 of 18

General Specification 1.0 CODES & STANDARDS:

Materials, equipment and methods used in the manufacture of Potential Transformer shall conform to the latest edition of following – National Standard Standard Code Standard Description IS-3156 (Part I to IV) Specification for Voltage transformer.

IS-4146 Application guide for voltage transformer. IS-2099 High voltage porcelain bushings IS-731 Insulator for O/H power line IS-335 New insulating oil for transformer and switchgear. IS-9676 Reference ambient temperature of electrical equipment IS-5561 Specification of electric power connectors IS-5621 Hollow insulator for use in electrical equipments IS-3156 (Part I to IV) Specification for Voltage transformer. IS-4146 Application guide for voltage transformer. IS-2099 High voltage porcelain bushings IS-731 Insulator for O/H power line Indian Electricity Rules Indian electricity act CBIP manual

2.0 MAJOR DESIGN CRITERIA & PARAMETERS OF THE PT Description Requirement / Rating

2.1.0 System 66KV 33KV 2.1.1 Voltage 66KV ± 10% 33KV ± 10% 2.1.2 Frequency 50HZ ± 5% 50HZ ± 5% 2.1.3 Fault level 31.5KA for 3secs. 26.3KA for 3secs. 2.1.4 Earthing Solidly grounded

2.2.1 Type Single phase, outdoor, dead tank type, oil immersed, self cooled type.

2.2.2 Construction feature Oil immersed PT shall be hermetically sealed to eliminate breathing and to prevent ingress of air and moisture.

2.3.0 Major Parts 2.3.1 Tank

2.3.2 Material of Construction Tank shall be of MS with Hot Dip Galvanized Steel. Galvanizing thickness shall be 610gm/sqmm.

2.3.3 Tank Feature The tank shall be provided with oil draining

SP-PTLU-01-R1

Page 5 of 18

plug, Oil level gauge glass.

2.3.4 Oil Expansion Stainless steel bellow or diaphragm shall be provided to take care of oil expansion

2.3.5 Core High grade, non ageing, low loss, high permeability, cold rolled grain oriented silicon steel lamination.

2.4.0 Winding 2.4.1 Material Electrolytic Copper

2.4.2 Winding Insulating material Class A, non catalytic, inert to transformer oil, free from compounds liable to ooze out, shrink or collapse.

2.4.3 Winding Insulation Uniform

2.4.4 Design features Winding shall be capable of desired output as per specified limits without exceeding permissible temperature rise.

2.5.0 Insulating oil

2.5.1 Type

Class 1 new mineral insulating oil as per IS 335, shall be certified not to contain PCBs. Anti oxidant inhibitor if recommended shall be subject to Purchaser’s approval.

2.6.0 Bushings and Terminations 2.6.1 Type Porcelain bushing

2.6.2 Termination on HV side bushing

The HV Terminal shall be of copper. Termination shall be by bimetallic of Aluminum alloy grade A6 suitable for Twin Zebra ACSR conductor..

2.6.3 Termination of LV side

The secondary terminals shall be provided in IP55 Box with Brass/copper stud type terminals accessible from front with removable cover. Box shall be of adequate size with proper clearance between the terminals for ease of working and maintenance. Gasket for Box shall be Neoprene.

2.6.4 Termination of Earth terminal of HV winding

The earth terminal of HV winding shall be bought out in secondary Terminal box by bushing. This shall be connected with body earth terminal with flexible copper lead through a link.

2.6.5 Terminal marking Terminals shall be marked as per IS 3156

2.7.1 Minimum creepage distance of bushing 31 mm/KV

2.8.1 Protected creepage distance At least 50 % of total creepage distance

2.9.1 Over Voltage factor 1.2 times for continuous rating and 1.5 times for 30 seconds.

2.10.1 Atmospheric protection for clamp and fitting of iron and steel Hot dip galvanizing as per IS 2633

2.10.2 Gland Plate Min. 3 mm thick detachable with three knockout holes of 3/4 inch.

2.10.3 Cable entry Bottom for all cables

2.11.1 Earthing The PT assembly comprising of the chasis, frame work and fixed parts of metal casing

SP-PTLU-01-R1

Page 6 of 18

shall be provided with two separate body earthing terminals.

3.0 FITTINGS & ACCESSORIES ON POTENTIAL TRANSFORMER 3.1.0 Rating and Diagram Plate Required 3.1.1 Material Anodized Aluminum 16SWG 3.1.2 Background SATIN SILVER 3.1.3 Letters, diagram & border Black 3.1.4 Process Etching 3.2.5 Name plate details Required 3.3.6 Terminal marking of Primary and

secondary terminals. Required

3.4.0 Drain Plug on tank Base Required

4.0 APPROVED MAKE OF COMPONENTS

4.1.0 Insulator JSI/WSI/Modern/Saravana/BHEL/ABIL

5.0 QUALITY ASSURANCE

5.1 Vendor quality plan To be submitted for purchaser approval. 5.2 Inspection point To be mutually identified and agreed in

quality plan.

6.0 PROGRESS REPORTING 6.1

Out Line Document To be submitted for purchase approval for outline of production, inspection, testing, inspection, packing, dispatch, documentation programme.

6.2 Detailed Progress Report To be submitted to purchaser once a month containing

i) Progress on material procurement ii) Progress on fabrication (As applicable) iii) Progress on assemble (As applicable) iv) Progress on internal stage inspection v) Reason for any delay in total

programme vi) Details of test failures if any in

manufacturing stages vii) Progress on final box up constraints /

SP-PTLU-01-R1

Page 7 of 18

Forward path

7.0 DRAWING, DATA & MANUALS 7.1.0

To be submitted along with bid Seller has to be submitted : i) Tentative GA /cross sectional

drawing of product showing all the views / sections

ii) Detailed reference list of customers already using the offered product during the last 5 years with particular emphasis on units of similar design and rating

iii) Completely filled GTP iv) Deviations from this specification.

Only deviations approved in writing before award of contract shall be accepted.

v) Details of manufacturer’s quality assurance standards and programme and ISO 9000 series or equivalent national certification

vi) Type test report shall be submitted for the type , size & rating of product / equipment offered along with bid in case the type test report for identical product is not available then type report of higher size / rating shall be submitted for review. They shall be considered valid 5 years from date of test.

vii) Complete product catalogue and manual along with the bid.

viii) Recommended spare parts and consumables items for 5 years of operation with prices and spare parts catalogue with list for future requirements.

7.2.0 After award of contract, seller has to submit mentioned drawings for buyer’s Approval (A ) / Reference (R)

i) Programme for production and testing (A)

ii) Guaranteed Techinal Particulars (A) iii) Calculations to substantiate choice of

electrical , structural , mechanical

SP-PTLU-01-R1

Page 8 of 18

component size / ratings (A) iv) Detailed dimensional drawing for all

components, general arrangement drawing showing detailed component layout and the detailed schematic and wiring drawings for all components (like marshalling box)

v) Terminal arrangement & cable box details etc. (as applicable) (A)

vi) Drawing for major components (A) vii) Rating & Diagram plate (A) viii) Detailed loading drawing to enable

the buyer to design and construct foundations (as applicable ) (R)

ix) Transport / Shipping dimensions with weights, wheel base details, untanking height etc. (As applicable ) (R)

x) List of makes of all fittings and accessories (A)

xi) Detailed installation and commissioning instructions ( R)

xii) Quality plan 7.3.0 Submittals required prior to

dispatch i) Inspection and test reports, carried

out in manufacturer’s work (R ) ii) Test certificates of all bought out

items iii) Operation and maintenance

instruction as well as trouble shooting chart / manuals.

iv) 7.4.0 Drawing and document size Standard size paper A0, A1 , A2, A3, A4 7.5.0 No of drgs./Documents required at

diffderent stages As per Annexure A scope of supply

8.0 INSPECTION & TESTING

8.1.0 Inspection and Testing during manufacture

8.2.0 Tank

i) Checking of dimensions as per approved drawing. ii) Checking for leakage by pressure testing. iii) Thickness of Galvanization shall be 610gm/ sq

mm

8.3.0 Porcelain i) Check dimension. ii) Check finish of sealing surface. iii) Check creepage distance.

SP-PTLU-01-R1

Page 9 of 18

iv) Check for routine electrical test. v) Check for porosity and temperature cycle test.

8.4.0 Insulating Materials i) Sample check for physical properties of materials. ii) Check for dielectric strength. iii) Visual and dimensional checks.

8.5.0 Copper conductor

i) Check for dimension. ii) Check for elongation. iii) Check for unidirectional scrap. iv) Check for heat shock.

8.6.0 Oil

i) Check for break down voltage. ii) Check for density. iii) Check for flash point. iv) Check for moisture content. v) Check for neutralization value. vi) Check for inter facial tension at 27 Deg c. vii) Check for sludge content. viii) Check for specific resistance. ix) Check for pour point.

8.7.0 Secondary terminals i) Check for one min AC Test 8.8.0 Routine tests Tests shall be carried out in accordance with IS 3156

8.9.0 Type Tests a) On one PT of each rating and type tested from

CPRI/ERDA b) All the test as per IS 3156

c) In case the product is never type tested earlier,

seller has to conduct the type tests from CPRI/ERDA test labs on BSES order at their own cost, before commencement of supply.

8.10.0 Acceptance test

To be performed in presence of Purchaser at manufacturer works:-

i) Physical inspection of dimensions and BOM. ii) Verification of terminal marking and polarity. iii) Power frequency dry withstand tests on primary

winding. iv) Power frequency dry withstand tests on secondary

winding. v) Partial discharge test ( this shall be only for future

reference) vi) Determination of ratio and phase angle errors

according to the appropriate designation or accuracy class.

9.0 PACKING , SHIPPING, HANDLING AND STORAGE 9.0.0 Packing 9.1.1 Packing protection Against corrosion , dampness, heavy rains, breakage and

vibration 9.1.2 Packing for accessories

and spares Robust wooden non returnable packing case with all the above protection and identification labels.

9.1.3 Packing identification label

In each packing case, following details are required : i) Individual serial number

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ii) Purchaser’s name iii) PO number (along with SAP item code , if any) &

date iv) Equipment Tag no. (if any) v) Destination vi) Manufacturer / Supplier’s name vii) Address of manufacturer’s / supplier’s its agent viii) Description and quantity ix) Country of origin x) Month and year of manufacturing xi) Case measurement xii) Gross and net weight in kilograms xiii) All necessary slinging and stacking instructions.

9.1.4 Shipping i) The bidder shall ascertain at an early date and definitely before the commencement of manufacture, any transport limitations such as weights, dimensions, road culverts, overhead lines, free access etc. from the manufacturing plant to the project site, and furnish to the purchaser confirmation that the proposed packages can be safely transported, as normal or oversize packages, upto the plant site. Any modification required in the infrastructure and cost thereof in this connection shall be brought to the notice of the Purchaser.

ii) The seller shall be responsible for all transit damage due to improper packing.

9.1.5 Handling and Storage Manufacturer instruction shall be followed. Detail handling & storage instruction sheet / manual need to be furnished before commencement of supply.

10.0 DEVIATIONS Deviation from this specification shall be started in writing with the tender by reference to the specification clause/ DTP/Drawing and a description of the alternative offer. In absence of such a statement, it will be assured by the Buyer that the seller complies fully with this specification.

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Annexure –A Scope of supply 1.0 The scope of supply shall include following 1.1 Design, manufacture, assembly, testing at storages of manufacturing as per C l. 12 of this

specification, final testing at manufacturer works on completely assembled transformer before dispatch, packing delivery and submission of all documentation for the Power transformer with all accessories as below

Sr. No. Description Scope of Supply

1.0 Fully assembled PT with all major parts like Tank, bushing, Primary terminal with connector and secondary terminal box.

YES

1.1 Galvanised steel structure for PT NO 1.2 Fixing Bolts for PT YES1.3 Routine testing as per this specification YES1.4 Type testing as per this specification YES1.5 Submission of Documentation as detailed below YES

1.2 Supervision of testing & commissioning of PT as site 1.3 BOQ as following-

Sr. No. Purchaser Equipment Tag No. / SAP code

Location / Substation name

Unit Quantity

1 e.g. Santacruz No e.g. 1 2 e.g. Alaknanda No e.g. 1 3 4 5

2.0 Submission of documents Submission of drawing, calculations, manual, catalogues, test report shall be as follows

Along with offer For Approval after award of contract


Remarks

Drawing 3 copies (Typical drgs)


See clause 5.0 for various drawing required



See clause 5.0 for details


Instruction manual for the transformer


Test Report 2 copy 6 copies + 1 soft copy in CD

Type test and sample routine test reports

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3.0 Delivery Schedule 3.1 Delivery Period start date - from data of purchase order 3.2 Delivery Period end date - as agreed with supplier 3.3 Material dispatch clearance - after inspection by purchaser and written dispatch clearance for purchaser

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Annexure – B SERVICE CONDITIONS

1.0.0 Mumbai Atmospheric conditions a) Average grade atmosphere Heavy polluted , salt Laden, dusty, humid

with possibility of condensation Maximum altitude above see level 1000 M b) Ambient Air temperature Highest 45 deg C, Average 35 deg C Maximum ambient air temperature 20 deg C c) Relative Humidity 100 % Max d) Thermal Resistivity of Soil 150 deg. C cm/W e) Seismic Zone 3 as per IS 1893 f) Rainfall 3000 mm concentrated in four months

2.0.0 Delhi Atmospheric conditions a) Average grade atmosphere Heavy polluted , dry Maximum altitude above see level 1000 M b) Ambient Air temperature Highest 50 deg C, Average 40 deg C Maximum ambient air temperature 0 deg C c) Relative Humidity 100 % Max d) Thermal Resistivity of Soil 150 deg. C cm/W e) Seismic Zone 4 as per IS 1893 f) Rainfall 750 mm concentrated in four months g) Wind Pressure 195 Kg/m2 up to 90 M elevation as per IS

875-1975

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Annexure C1 GURANTEED TECHNICAL PARTICULARS FOR 66 KV PT


1.0 Location of Equipment Project specific to be filled up

2.0 Name of Manufacturer 3.0 Address & Contact details

4.0 Type

Single phase, outdoor, dead tank type, oil immersed, self-cooled hermetically sealed type.

5.0 Manufacturer Model No

6.0 Reference design ambient temperature 50 Deg C

7.0 Reference Standard IS: 3156 (Part1 to 4) 8.0 Nominal system voltage 66KV 9.0 Highest system voltage 72.5KV 10.0 Basic Insulation level 325KVp 11.0 Power frequency voltage 140KV 12.0 Type of cooling ONAN 13.0 Rated frequency (Hz) 50 Hz 14.0 Insulation Class A 15.0 Rated Primary voltage 66KV / √3 16.0 Rated secondary voltage 110V / √3 17.0 Number of secondary cores Two 18.0 CORE Specifications 18.1 Core - 1 18.2 Purpose Metering 18.3 Rated Output 50 VA 18.4 Class of accuracy 0.2 18.5 Ratio error As per IS 18.6 Phase angle error As per IS 19.0 Core - 2 19.1 Purpose Protection 19.2 Rated Output 50 VA 19.3 Class of accuracy 3P 19.4 Ratio error As per IS 19.5 Phase angle error As per IS 20.0 Rated over voltage factor 20.1 - Continuous 1.2 times 20.2 - 30 Seconds 1.5 times

21.0

Temperature rise above an ambient of 50Deg C at 1.2 times voltage factor for 30 seconds rating

21.1 - For Winding 50 Deg C 21.2 - For Oil 40 Deg C

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22.0



23.0 One minute power frequency dry withstand voltage for 66 kV PT (KV rms)

24.0 One minute power frequency wet withstand voltage for 66 kV PT (KV rms)

25.0 1.2/50 microsecond impulse withstand test voltage for 66 KV PT (KV rms)

325 KVp

26.0 One minute Power frequency withstand voltage on secondary winding

3KV

27.0 Minimum creepage distance in mm for 66KV PT 2250 mm

28.0 Protective creepage distance in mm for 66KV PT 1125 mm

29.0 Partial discharge test, whether will be carried out Yes / No

30.0 Weight of core 31.0 Weight of oil 32.0 Total weight 33.0 Mounting details 34.0 Overall dimensions

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Annexure C2 GUARANTEED TECHNICAL PARTICULARS FOR 33 KV PT


1.0 Location of Equipment Project specific to be filled up

2.0 Name of Manufacturer 3.0 Address & Contact details

4.0 Type

Single phase, outdoor, dead tank type, oil immersed, self-cooled hermetically sealed type.

5.0 Manufacturer Model No

6.0 Reference design ambient temperature 50 Deg C

7.0 Reference Standard IS: 3156 (Part1 to 4) 8.0 Nominal system voltage 33KV 9.0 Highest system voltage 36KV 10.0 Basic Insulation level 170KVp 11.0 Power frequency voltage 70KV 12.0 Type of cooling ONAN 13.0 Rated frequency (Hz) 50 Hz 14.0 Insulation Class A 15.0 Rated Primary voltage 33KV / √3 16.0 Rated secondary voltage 110V / √3 17.0 Number of secondary cores Two 18.0 CORE Specifications 18.1 Core - 1 18.2 Purpose Metering 18.3 Rated Output 50 VA 18.4 Class of accuracy 0.2 18.5 Ratio error As per IS 18.6 Phase angle error As per IS 19.0 Core - 2 19.1 Purpose Protection 19.2 Rated Output 50 VA 19.3 Class of accuracy 3P 19.4 Ratio error As per IS 19.5 Phase angle error As per IS 20.0 Rated over voltage factor 20.1 - Continuous 1.2 times 20.2 - 30 Seconds 1.5 times

21.0



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22.0



23.0 One minute power frequency dry withstand voltage for 66 kV PT (KV rms)

24.0 One minute power frequency wet withstand voltage for 66 kV PT (KV rms)

25.0 1.2/50 microsecond impulse withstand test voltage for 66 KV PT (KV rms)

170 KVp

26.0 One minute Power frequency withstand voltage on secondary winding

3KV

27.0 Minimum creepage distance in mm for 33 KV PT 1116 mm

28.0 Protective creepage distance in mm for 33 KV PT 558 mm

29.0 Partial discharge test, whether will be carried out Yes / No

30.0 Weight of core 31.0 Weight of oil 32.0 Total weight 33.0 Mounting details 34.0 Overall dimensions

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Annexure –D RECOMMENDED SPARES (DATA BY SUPPLIER) List of recommended spares as following –

Sr. No. Description of spare part Unit Quality 1 2 3 4 5 6

TECHNICAL SPECIFICATIO

FOR

POLYMERIC INSULATORS

Specification No-SP-PI-Ol, RO

Reaistered Office: BSES Bhavan, Neh

Approved by I Kiran Alia

Prepared by

Reviewed by

Pronab Bairagi

Meenakshi Banerji

Rev: 00

SP-PI-01-R0

Technical Specification for Polymeric Insulator

2

Index

1.0 Scope

2.0 Code and Standards

3.0 Service Conditions

4.0 Design Feature

5.0 General Requirement

6.0 Quality Assurance

7.0 Testing and Inspection

8.0 Drawings, Data and Manuals

9.0 Shipping, Handling and Site Support

10.0 Progress reporting

11.0 Deviation

12.0 Drawings and Materials Details

13.0 GTP

Annexure-A: Scope of Supply

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3

TECHNICAL SPECIFICATIONS

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General Specifications

1.0 Scope

This specification covers the design, manufacture, testing & supply of Polymeric Insulators. 2.0 Codes and Standards

The Polymeric Insulator shall be designed, manufactured & tested in accordance with the following National / International Standards (IS/IEC). Sl No Indian Standard Title International Standard

1 IS:209-1992 Specification for zinc BS:3436 2 IS:406-1991 Method of Chemical Analysis of Slab Zinc BS:3436

3 IS:731-1991 Porcelain insulators for overhead Power lines with a nominal voltage greater than 1000 V

BS:137- (I&II) IEC:60383

4 IS:2071 Part (I) – 1993 (Part(II)- 1991, Part(III)- 1991

Methods of High Voltage Testing IEC:60060-1

5 IS:2486 Part- I-1993 Part- II-1989 Part-III-1991

Specification for Insulator fittings for Overhead Power Lines with a nominal voltage greater than 1000V General Requirements and Tests Dimensional Requirements Locking Devices

BS:3288 IEC:60120 IEC:60372

6 IS:2629-1990 Recommended Practice for Hot, Dip Galvanization for iron and steel ISO-1461 (E)

7 IS:2633-1992 Testing of Uniformity of Coating of zinc coated articles

8 IS:3188-1988 Dimensions for Disc Insulators IEC:60305

9 IS:6745-1990 Determination of Weight of Zinc Coating on Zinc coated iron and steel articles

BS:433-1969 ISO:1460-1973

10 IS:8263-1990 Methods of RI Test of HV insulators IEC:60437 NEMA Publication No.07/ 1964/ CISPR

11 IS:8269-1990 Methods for Switching Impulse test on HV insulators IEC:60506

12

Thermal Mechanical Performance test and mechanical performance test on string insulator units IEC: 60575

13 Salt Fog Pollution Voltage Withstand Test IEC:60507

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14

Composite insulators for A.C. Overhead lines with nominal voltage greater than 1000V – Definitions, test methods and acceptance criteria

IEC 61109

15

Guide for the selection of insulators in respect of polluted conditions IEC:60815

16

Tests on insulators of Ceramic material or glass or glass for overhead lines with a nominal voltage greater than 1000V

IEC:60383

17

Characteristics of string insulator units of the long rod type IEC : 60433

3.0 Service Conditions:

The Polymeric Insulator to be supplied against this specification shall be suitable for satisfactory continuous operation under the following service conditions: a) Maximum ambient temperature (Degree C) 50

b) Minimum ambient temperature (Degree C) 0

c) Relative Humidity (%) 100

d) Maximum annual rainfall (mm). 1450

e) Maximum wind pressure (Kg/Sq.m) 150

f) Maximum Altitude above mean sea level (Meters) 1000

g) Seismic level (Horizontal Acceleration) 0.30

h) Climatic Conditions : Moderately Hot and humid tropical climate conductive to rust and fungus growth

i) Ref Ambient Temperature for Temperature (Degree C) 50

4.0 Design Feature:

4.1 Details of Composite Long Rod Insulators:

• The insulators of the strings shall consist of composite long rod insulators for a three phase, 50 Hz, effectively earthed transmission system application in a very heavy polluted environment. Couplings shall be ball and socket type.

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• Bidder shall quote such composite insulators which have proven use under foggy/humid operational conditions in polluted environment combined with smoke and dust particles. The Bidder shall furnish evidence in the form of certification from the power utilities that the similar type of product supplied to them had been performing satisfactory. The Bidder shall also submit certified test report (from CPRI/ERDA) for an accelerated ageing test of 5000 hours such as that described in Appendix-C of IEC-61109.

• Insulators shall have sheds of the “open aerodynamic profile without any under ribs” with good self-cleaning properties. Insulator shed profile; spacing projection etc. shall be strictly in accordance with the recommendation of IEC-60815.

• The size of long rod insulator, minimum creepage distance, electromechanical strength and mechanical strength of insulator string along with hardware fittings up to 66 KV shall be as follows-

Sl. No Type of String

Size of Composite Insulator (mm)

Min. Creepage Distance (mm)

EM strength of Insulator Unit (KN)

Mechanical strength of Insulator string along with Hardware fittings (kN)

1 Single Suspension 20X870 2280 90 90

2 Single Tension 20X870 2280 120 120

* Note: The core dia. of composite insulators mentioned at column No.3 is minimum requirement. The bidder shall offer composite long rod insulators of suitable core dia to meet specified E&M strength requirements. However, the overall string length shall be within the limits specified in the drawing

4.2 Pin and Cap:

• Pin and cap shall be designed to transmit the mechanical stress & develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric of such design that it will not yield or distort under load conditions

• The design shall be such as to permit easy removal of replacement of either insulator units or

fittings under the live line conditions.

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4.3 Ball and Socket Designation:

The dimensions of the Ball and Socket shall be of 16 mm for 90kN & 120kN Insulators in accordance with the standard dimensions stated in IEC: 120/ IS: 2486 (Part-II).

4.4 Dimensional Tolerance of Composite Insulator:

The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed as follows: ± (0.04d+1.5) mm when d≤300 mm. ± (0.025d+6) mm when d>300 mm

Where ‘d’ is in mm being the diameter, length or creepage distance.

* Note-no negative tolerance shall be applicable to creepage distance.

4.5 Materials:

• Core- It shall be a glass-fiber reinforced (FRP rod) epoxy resin rod of high strength. Glass fibers and resin shall be optimized. The rod shall be electrical grade corrosion resistant (ECR), boron free glass and shall exhibit both high electrical integrity and high resistance to acid corrosion.

• Housing and Weather sheds- The FRP rod shall be covered by a seamless sheath of a silicone rubber compound of a thickness of minimum 3mm. The housing & weather sheds should have silicon content of minimum 30% by weight. It should protect the FRP rod against environmental influences, external pollution and humidity. It shall be extruded or directly molded on the core. The interface between the housing and the core must be uniform and without voids. The strength of the bond shall be greater than the tearing strength of the polymer. The manufacturer shall follow non-destructive technique (N.D.T.) to check the quality of jointing of the housing interface with the core. The technique being followed with detailed procedure and sampling shall be furnished along with the bid. The details for this shall be finalized during detailed engineering and finalization of MQP.

• End Fittings- End fittings transmit the mechanical load to the core. They shall be made of malleable cast iron spheroidal graphite or forged steel. They shall be connected to the rod by means of a controlled compression technique. The manufacturer shall have in-process Acoustic emission arrangement or some other arrangement to ensure that there is no damage to the core during crimping. This verification shall be in-process and done on each insulator. The gap between fitting and sheath shall be sealed by a flexible silicone rubber compound. The system of attachment of end fitting to the rod shall provide superior sealing performance between housing and metal connection. The sealing must be humidity proof and durable with time

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• Corona Ring/Grading Ring- Grading rings shall be used at both ends of each composite insulator unit for reducing the voltage gradient on and within the insulator and to reduce radio and TV noise to acceptable levels. The size and placement of the metallic grading rings shall be designed to eliminate dry band arcing/corona cutting/ exceeding of permissible electrical stress of material. The bidder shall furnish calculations along with the proposed placement and design of corona ring in support of the above. Grading rings shall be capable of installation and removal with hot line tools without disassembling any other part of the insulator assembly.

* Note:-The supply of grading rings shall be in the scope of the composite insulator supplier.

5.0 General Requirement:

5.1 Interchangeability- The composite long rod insulators inclusive of the ball & socket connection shall be standard design suitable for use with the hardware fittings of any make conforming to relevant IEC standards.

5.2 All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to excessive localized pressure. The insulator and metal parts shall be so designed and manufactured that it shall avoid local corona formation and shall not generate any radio interference beyond specified limit under the operating conditions.

5.3 The long rod insulators offered shall be suitable for employment of hot line maintenance technique so that usual hot line operation can be carried out with ease, speed and safety.

5.4 All insulators shall be designed to facilitate cleaning and insulators shall have the minimum practical number of sheds and grooves. All grooves shall be so proportioned that any dust deposit can be removed without difficulty either by wiping with a cloth or by remote washing under live line condition.

5.5 All the materials shall be of latest design and conform to the best modern practices adopted in the extra high voltage field. Bidders shall offer only such insulators as are guaranteed by him to be satisfactory and suitable for transmission lines specified and will give continued good service

5.6 The design, manufacturing process and material control at various stages shall be such as to give maximum working load, highest mobility, best resistance to corrosion, good finish and elimination of sharp edges and corners to limit corona and radio interference

5.7 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.

5.8 The core shall be free from cracks and voids which may adversely affect insulator.

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5.9 Weather sheds shall be uniform in quality. They shall be clean, sound, smooth and free from gross defects and excessive flashing at parting lines.

5.10 End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings should be effectively, sealed to prevent moisture ingress, effectiveness of sealing system must be supported by test documents. All surfaces of the metal parts shall be perfectly smooth with the projecting points or irregularities which may cause corona.

5.11 All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly.

5.12 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to 600 gm/sqmm and shall be in accordance with the requirement of ISO:1461 (E) and shall satisfy the tests mentioned in ISO:1460 (E). The zinc used for galvanizing shall be of purity of 99.95%. 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 galvanized metal parts shall be guaranteed to withstand at least six successive dips each lasting for one (1) minute duration under the standard test. The galvanizing shall be carried out only after any machining

6.0 Quality Assurance:

Vendor Quality Plan To be submitted for purchaser approval

Inspection Points To be mutually identified & agreed in quality plan

7.0 Testing and Inspection:

7.1 Type Test:

The insulators should be offered type tested from CPRI/ERDA. Type test reports should not be more than 5 (Five) years old considered from the date of bid opening in respect of all the tests carried out in CPRI/ERDA, based on ISO/IEC.

Power frequency voltage withstand test with corona control rings/grading ring and arcing horns under wet condition

IEC:383-1993 On the complete composite Long Rod Insulator String with Hardware Fittings Switching surge voltage withstand test under wet

condition

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Impulse voltage withstand test under dry condition

Corona and RIV test under dry condition

Mechanical Strength test Vibration test Salt-fog pollution withstand test Dry power frequency voltage test Sudden load release test Thermal mechanical test Water immersion test Steep front impulse voltage test

IEC: 61109 On Composite Insulator Units (Tests on interfaces and connections of metal fittings)

Dry power frequency voltage test

Determination of the average failing load of the core of the assembled unit On Composite Insulator

Units (Assembled core load time test) Control of the slope of the strength time curve of the

insulator Brittle fracture resistance test Test of housing, Tracking and erosion test

Dye penetration test Tests for the core material Water diffusion test Flammability test Recovery of Hydrophobicity test Mechanical Load Time test and test of tightness between end firings and insulator housing Silicone content test

IEC: 61109

High Pressure washing test 7.1 Acceptance Test : The following tests shall constitute the Acceptance : -

IS/IEC Reference Test Description

Verification of dimensions IEC : 61109

Verification of tightness of interface between end fittings and insulator housing and of specified mechanical load

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Tests on interfaces and connections of metal fittings (Tests to be performed on the same samples in the sequence given below)- i) Dry power frequency voltage test, ii) Sudden load release test, iii) Thermal mechanical test, iv) Water immersion test, v) Steep front impulse voltage test, vi) Dry power frequency voltage test

Galvanizing test (IS:209-1979) IEC : 60383

Verification of locking system

Recovery of Hydrophobicity

Silicone content test

Note: - 1) Test on interfaces and connection shall be carried out for a lot with qty. minimum 2000 nos.

2) Test for silicon shall be carried out for a lot with qty. minimum 2000 nos.

3) In the event of failure of the sample to satisfy the acceptance test(s) specified above, the retest procedure shall be as per clause 7.6 of IEC 61109

7.2 Routine Tests: The following tests shall constitute the

1) Visual Inspection as per IEC 61109

2) Mechanical Routine Test as per IEC 61109

7.3 Test During Manufacturing:

1) Chemical analysis of Zinc used for galvanizing.

2) Chemical analysis, mechanical, metallographic test and magnetic particle inspection for malleable castings.

3) Chemical analysis hardness tests and magnetic particle inspection for forging.

4) Tracking and erosion test on insulating material

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Inspection:

SL No. Descriptions

7.3.1 The buyer reserves the right to witness all tests specified on Polymeric Insulators

7.3.2 The buyer reserves the right to inspect Polymeric Insulators at the Seller’s works at any time prior dispatch, to verify compliance with the specifications

7.3.3 In-process and final inspection call intimation shall be given in advance to purchaser

7.3.4 In the event of any discrepancy in the test report i.e. test reports not acceptable or any type test (including special/additional test if any) not carried out, same shall be carried out without any cost implication to BSES before dispatch.

Note:

1) The routine and acceptance tests should be performed on sample chosen at random out of

every lot. 2) Three sets of complete test certificates shall be submitted along with the dispatch documents.

8 Drawing, Data and Manuals:

The seller has to submit: a) Details sectional drawing of Polymeric Insulators along with all kind of fittings b) Details of accessories and drawings

c) Complete filled GPT and QAP

e) Type Test Certificate from CPRI/ERDA

8.1 To be Submitted along with the bid

f) Complete Catalogue and manual

8.2

Within 15 days, the seller has to submit four sets of above mentioned drawings along with one set soft copy for buyer's

8.3 a) Inspection and test reports carried out in manufacturer's works Submission required prior to dispatch b) Test Certificate of all bought out items.

8.4 Drawing and Documents Size Standard size paper A0,A1,A2,A3,A4

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8.5 No of drawings/ documents required at different stages

As per Annexure A

9 Shipping, Handling and Site Support:

All insulators shall be packed in suitable PVC/ plastic tubes/any other suitable packing along with temporary wrap-on shields/shrouds for each insulator unit. The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and subsequent handling in the field Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent damage or deformation during transit and handling The items so wound will be grouped as per numbers per packet. The information like product quantity shall be mentioned on the packets Purchase order no. with SAP code shall be mentioned clearly Net weight and gross weight with packet shall be mentioned

9.1 Packing

Batch no. or lot no shall be mentioned

9.2 Shipping The seller shall give complete shipping information concerning the gross weight, size of each packing and the seller has to send the materials to buyer’s preferable store or site.

9.3 Handling & Storage

Manufacturer instruction shall be followed. Detail handling & storage instruction sheet / manual needs to be furnished before commencement of supply.

9.4 Transit damage The seller shall be responsible for any transit damage due to improper packing.

10 Progress reporting:

10.1 Outline Document To be submitted for purchaser approval for outline of production, inspection, testing, packing, dispatch, documentation programmer.


To be submitted to Purchaser once a month containing a) Progress on material procurement. b) Progress on internal stage inspection c) Reason for any delay in total program. d) Details of test failures if any in manufacturing stages e) Progress on final box up. f) Constraints / forward path

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11 Deviations:

Deviations from this Specification shall be stated in writing with the tender by reference to the Specification clause/GTP/Drawing and a description of the alternative offer. In absence of such a statement, it will be assumed by the Buyer that the Seller complies fully with this specification. 12 Drawings and Materials Details:

The bidder has to summit drawings along with bid for preliminary acceptance and for final approval before manufacturing. BRPL may insist trial installation to check dimensions and may suggest necessary changes if required. BRPL decision in this regard would be final and binding to short listed vendor without any subsequent commercial liability on purchaser. 12 Marking: The Following information shall be marked on each cross arm:

12.1 Manufacturer’s name or trade mark

12.2 Year of manufacture

12.3 BSES-BRPL, order number, date & SAP Code number

13 GTP:

Sl. No. Descriptions Unit Data to be filled by Manufacturer

1 Name & address of manufacture 2 Weight of single unit Kg 3 Size and designation of ball & socket assembly mm 4 Core diameter mm 5 Tolerance on core diameter ±mm 6 Nominal length (section length) mm 7 Tolerance on Nominal length ±mm 8 Dry arcing distance mm 9 Number of sheds nos

10 Sheds profile (type) 11 Shed spacing mm 12 Sheds profile (regular alternating) 13 Shed diameter mm 14 Tolerance on shed diameter ±mm 15 Minimum creepage distance mm 16 Tolerance on creepage distance ±mm

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17 Guaranteed mechanical strength KN 18 Routine mechanical load KN 19 Materials a FRP Rod b Weather sheds with % contents of silicon c Housing d End Fitting e Grading Ring

20 Minimum thickness of sheath covering over the core mm

21 Power frequency withstand voltage of single unit a Dry KV (rms) b Wet KV (rms)

22 Power frequency flashover voltage of single unit a Dry KV (rms) b Wet KV (rms)

23 Impulse withstand voltage of single unit (dry) a Positive KV (peak) b Negative KV (peak)

24 Impulse flashover voltage of single unit (dry) a Positive KV (peak) b Negative KV (peak)

25 Purity of zinc used for galvanizing end fittings %

26 Number of dips which the end fittings can withstand in standard preece test Nos.

27

Certified test report of accelerated ageing test of 5000 hours (enclosed) (appendix-C of IEC-61109) Yes/No

28 Drawings Enclosed Yes/No

Annexure-A: Scope of Supply 1.0 The scope of supply shall include following:

1.1 Design, manufacturing, testing at manufacturer works before dispatch, packing, delivery including unloading and stacking at Buyer’s site/store of Polymeric Insulator including all kind oh accessories for fixing e.g. fixing clump, hardwires etc as per BOQ and submission of all documents.

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1.2 BOQ as following-

Sl. No. Purchaser Equipment Tag No/ SAP no

Material Descriptions Location Unit Quantity

1 e.g. Delhi Nos. e.g. 10 2 e.g. Kolkata Nos. e.g. 10

2.0 Submission of Documents:

Along with offer


Final after approval Remarks

Detailed dimensional cross-sectional drawing along with all kind of accessories for fixing

3 copies (Typical drgs) 4 copies 6 copies + 1 soft copy in CD

Type test certificates 2 copies (Type test and sample Routine Test) 6 copies + 1 soft

copy in CD Type test and sample Routine test reports

Guaranteed technical particulars 3 copies 4 copies 6 copies + 1 soft

copy in CD

Complete catalogue and Manual 1 copy 6 copies + 1 soft

copy in CD

List of sub vendor 3 copies (typical) 4 copies 6 copies + 1 soft copy in CD

3.0 Delivery Schedule:

3.1 Delivery period start date - from date of LOI 3.2 Delivery period end date - as agreed with supplier 3.3 Material dispatch clearance - after inspection by purchaser